Welch Allyn CL-100, CL-300 Service manual

Service Manual

CL 300 Surgical Illuminator

SolarTec Source 270

CL 100 Surgical Illuminator

SolarTec Source 100

PN: LB-MAN-CLSERV Rev. A

Welch Allyn Lighting Products

4619 Jordan Road

Skaneateles Falls, NY 13153-0187

Rev. Description ECN # Date Approved

A 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.

Table of Contents

GENERAL INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

TECHNICAL HELP INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

SERVICE CENTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2

W

ARRANTY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3

S

YSTEM SYMBOL DESCRIPTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4

W

ARNINGS AND PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

Caution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

P

OWER ON/OFF SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

F

IBER PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

M

ULTI LINK™ EXPANSION PORT - INSTALLATION AND USE (OPTIONAL) - - - - - - - - - - - - - - - - - - - - - - - - - 1-7

L

IGHT ATTENUATION CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7

L

AMP LIFE INDICATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7

Principles Of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

L

IGHT SOURCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

R

EPLACEMENT LAMPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

P

OWER SUPPLY WITH CONTROL ELECTRONICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

M

ULTI LINK™ PORT AND MULTI LINK™ EXPANSION PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

S

URGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

M

ULTI LINK™ EXPANSION PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

TOOLS REQUIRED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10

T

ROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

CL 100 SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

CL 100 S

T

EST #1: BLOWN FUSES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12

T

EST #2: 100 WATT POWER SUPPLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

T

EST #3: COOLING FAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

T

EST #4: LED/OVERTEMP SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

URGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12

TEST #5: MICRO LINK® FIBER TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

T

EST #6: POWER SUPPLY CALIBRATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

CL 100 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15

POWER SUPPLY REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15

P

LATFORM REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

F

RONT BEZEL REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

F

AN DEFLECTOR REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

C

HASSIS FAN REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17

LED/O

VERTEMP HARNESS REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17

L

AMP CABLE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17

I

NTERLOCK SWITCH REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18

P

OWER ENTRY MODULE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18

CL 100 S

CL 300 S

URGICAL ILLUMINATOR REPAIR PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-19

URGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25

CL 300 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27

TEST #1: BLOWN FUSES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27

T

EST #2: AUXILIARY BOARD INPUT TERMINALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27

T

EST #3: COOLING FAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27

T

EST #4: LED OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27

T

EST #5: MICRO LINK® FIBER TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-28

CL 300 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-29

INTERNAL MODULE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-29

P

OWER SUPPLY REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-29

PCBA (

I

L

C

P

P

F

B

L

CL 300 S

PART NO. A4-10670) REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-30

GNITOR REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31

INE FILTER REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31

HASSIS FAN REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-32

OWER ENTRY MODULE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-33

LATFORM REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34

RONT BEZEL REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34

LOWER FAN REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34

AMP CABLE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-35

URGICAL ILLUMINATOR REPAIR PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-36

GLOSSARY OF TERMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-42

F

INAL INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43

CL 100 SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43

CL 300 S

URGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43

SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-45

T

HEORY OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46

LIGHT SOURCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46

R

EPLACEMENT LAMPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46

P

OWER SUPPLY WITH CONTROL ELECTRONICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46

M

ULTI LINK™ PORT AND MULTI LINK™ EXPANSION PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46

CL 100 SURGICAL ILLUMINATOR CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-47

CL 300 S

URGICAL ILLUMINATOR CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-48

GENERAL INFORMATION

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.

T

ECHNICAL HELP INFORMATION

Only fully trained and properly equipped personnel should perform all service and repairs, using genuine
replacement parts and correct procedures. Failure to do so will invalidate the product warranty and could
compromise instrument safety and performance.

Read and understand all safety warnings and service notes printed in this Service Manual and the Operating
Manuals, part number LB-MAN-100W270W. If there is any doubt about any precaution or procedure, for phone
help, or to order additional copies of the Operating Manual, contact:

Customer Service
Welch Allyn, Inc.
4619 Jordan Road, PO Box 187
Skaneateles Falls, NY 13153-0187 USA
Telephone: [phone] or

1-866-801-8428

FAX: [phone]

Techncial Assistance
Telephone: [phone], 7:00am-3:00pm(EST)

When calling, refer to the model number shown on the data label, found on the back of your Surgical Illuminator.

Technical assistance is contained in “Troubleshooting” on page 11 of this manual.

PN: LB-MAN-CLSERV Rev. A 1-1

SERVICE CENTERS

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.

BEFORE RETURNING A PRODUCT FOR REPAIR YOU MUST OBTAIN AUTHORIZATION FROM WELCH
ALLYN. AN RMA (RETURN MERCHANDISE AUTHORIZATION) NUMBER WILL BE GIVEN TO YOU BY OUR
SERVICE PERSONNEL. BE SURE TO NOTE THIS NUMBER ON THE OUTSIDE OF YOUR SHIPPING BOX.
RETURNS WITHOUT AN RMA NUMBER WILL NOT BE ACCEPTED FOR DELIVERY.

USA CUSTOMERS

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

4619 Jordan Road 160 Matheson Blvd. E., Unit #2
Skaneateles Falls, NY 13153-0187 Mississauga, Canada L4Z 1V4
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]

INTERNATIONAL CUSTOMERS

Welch Allyn, GmbH Welch Allyn, Ltd., Singapore

Zollerstrasse 2-4 300 Beach Road, #25-08
72417 Jungingen, Germany, The Concourse
Tel: [phone] Singapore 199589
Fax: [phone] Tel: [phone]

Welch Allyn, Ltd., Australia Welch Allyn, China

Metro Center Room 708, 227 Huang Pi Road, North
Unit 5 38 South Street Central Plaza
Rydalmere, NSW 2116, Australia Shanghai 200003
Tel: [phone] P.R. China
Fax: [phone] Tel: [phone]

Welch Allyn, Japan

Bon Marusan 8F, 3-5-1 Kanda
Jinbo-Cho, Chiyoda-Ku
Tokyo 101-0051
Japan
Tel: [phone]
Fax: [phone]

CANADA CUSTOMERS

Fax: [phone]

Fax: [phone]

LATIN AMERICAN CUSTOMERS

MD International

11300 N.W. 41st Street
Miami, FL 33178 USA
Tel: [phone]
Fax: [phone]

1-2 WELCH ALLYN

WARRANTY

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
within this time at no cost to the customer. It shall be the purchaser’s responsibility to return the instrument to the
authorized distributor, agent, or service representative.

Welch Allyn warrants the lamp to be free of defects in materials and workmanship for a period of 6 months from
the date of purchase. This warranty does not cover the lamp for breakage or failure due to tampering, misuse,
neglect, accidents, improper installation, modification, shipping, or from improper maintenance, service, or
cleaning procedures.

This warranty is void if the instrument is not used in accordance with manufacturer’s recommendations or if
required service is performed by other than Welch Allyn or an authorized agent. Purchase date determines
warranty requirements. No other express or implied warranty is given.

PN: LB-MAN-CLSERV Rev. A 1-3

SYSTEM SYMBOL DESCRIPTIONS

Attention: Read Operating Manual for Warnings, Precautions, and Instructions for Use

Caution – Hot Surface Area

Replace Fuse as Marked
250V, 5A

5A, 250V

WARNING – High voltage is present

Symbol on power switch indicates power is off when pressed

~

o

-20 C

95%

MAX

IPXØ

+49 C

Symbol in electrical rating signifies AC mains power

High Intensity Light

Protective Earth Ground

o

Storage Temperature Range

Maximum Storage Humidity

Type BF equipment, Class I

Not protected against the ingress of water

Manufactured in accordance with the relevant regulations and technical requirements of
Japan.

1-4 WELCH ALLYN

WARNINGS AND PRECAUTIONS

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.

• ELECTRICAL SHOCK HAZARD. Do not remove the top cover.

• Routinely examine the power cord and plug. Do not use if inspection reveals damage. Replace only
with approved hospital grade power cord and plug with appropriate electrical rating.

• Do not place the exposed distal end of the Micro Link® Fiber or fiber bundle attached to either a
headlight or other accessory. Failure to observe these precautions may result in burns to skin,
clothing, or other material inadvertently placed in front of the Micro Link® Fiber or fiber bundle.

• High energy radiated light guided through endoscopes may give rise to high temperatures in front of
the light outlet and to the tip of the instrument.

• Use care not to point the distal end of the fiber or headlight directly at the eye when unit is operating.
The brilliant light output from the unit can cause eye injury per RP-27.1 (1994-1995 Threshold Limit
Values for Chemical Substances and Physical Agent and Biological Exposure Indices, Final draft March
3,1995).

• Applied parts attached to this equipment should be approved 1) to the Medical Device Directive (93/
42/EEC) (Europe), 2) approved by a Nationally Recognized Testing Laboratory (United States), and 3) by
a Standards Council of Canada accredited laboratory (Canada) to the appropriate medical standards.
The use of non-approved components may compromise safety.

• During life threatening procedures, it is recommended to have a backup Light source and an additional
replacement lamp.

• The light source lamps are highly pressurized, any damage or improper handling may cause premature
failure or explosion of the lamp.

• The light source lamps are hot immediately after use, allow the lamp to cool for five (5) minutes after
operation. Temperatures peak in the light Sources approximately 60 seconds after the Light Source is
powered off.

CAUTION

• Do not place anything on top of the Light Source. Do not store liquid above the Light Source.

• Clogged or blocked vents may cause Light Source overheating and will result in thermal shutdown.
Keep the Light Source clear of any obstructions.

• Fully close the attenuator before turning on the Light Source or when operational but not in use.

PN: LB-MAN-CLSERV Rev. A 1-5

OPERATING INSTRUCTIONS

CONTROLS

POWER ON/OFF SWITCH

Plug hospital grade Power Cord into a grounded “Hospital Grade” or “Hospital Use” receptacle to ensure
grounding reliability.

Press Main Power Switch ON (I pressed in).

The lamp will continue to operate until the power switch is moved to the OFF position (O pressed in). If the lamp
cannot be started or stops operating see Section 8: Troubleshooting.

NOTE:

• It is normal to hear clicking (10 pulses or less) before the lamp is started.

• To insure proper operation, wait thirty (30) seconds between on/off cycles.

IBER PORT

F

To increase the versatility and applicability of use, the Light Sources are designed to use either a Micro Link® Fiber
or a fiber bundle via the Multi Link™ Port and Multi Link™ Expansion Port.

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.

1-6 WELCH ALLYN

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.

M

ULTI LINK™ EXPANSION PORT - INSTALLATION AND USE (OPTIONAL)

CAUTION: The Multi Link™ Expansion Port contains optical elements that can become damaged if dropped

or abused.

NOTE: The Multi Link™ Expansion Port must be fully engaged into the Light Source before inserting Fiber

Bundle.

To use the Multi Link™ Expansion Port perform the following operations:

1. Close the light attenuator or turn the Light Source off.

2. Remove, if any, Micro Link

®

Fiber or fiber bundle from the Multi Link™ Port.

3. Insert the Multi Link™ Expansion Port, press and turn clockwise until it locks into place.

4. Connect the fiber bundle to the instrument.

5. Insert, until fully engaged, the Light Source end of the fiber bundle into the Multi Link™ Expansion Port.

6. Turn on Light Source. Adjust the light attenuator to the required illumination level.

To remove the Multi Link™ Expansion Port perform the following operations:

1. Turn the Light Source off.

2. Remove the fiber bundle.

3. Turn Multi Link™ Expansion Port counter-clockwise until unlocked and remove.

L

IGHT ATTENUATION CONTROL

Moving the illumination wheel up + increases light output. Moving the wheel down — reduces light output.

L

AMP LIFE INDICATOR

A yellow indicator light located on the console will light when there is approximately 50 hours
remaining on the lamp. A new Replacement Lamp should be available at this point. Once the
remaining hours have been exhausted the lamp will turn off.

PN: LB-MAN-CLSERV Rev. A 1-7

PRINCIPLES OF OPERATION

LIGHT SOURCE

The Surgical Illuminators consist of an enclosure housing a high intensity lamp, proprietary optical platform, user
controls and indicators, and a power supply with control electronics. Cooling is provided via internal fans. In the
event that the fan(s) malfunctions or if adequate air flow is blocked and/or the internal temperature of the device
exceeds the engineering specifications, an internal thermal protection mechanism will automatically shut off
power to the lamp. After cooling, the Light Sources may be restarted.

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EPLACEMENT LAMPS

The lamps are high pressure, high intensity and long life Light Sources. They are mounted into a patented lamp
fixture which is designed to allow both easy and rapid exchange in the field as well as ensuring precise alignment
to the optical platform.

OWER SUPPLY WITH CONTROL ELECTRONICS

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All the electricity to the Light Source is controlled through the ON/OFF switch. Power to energize and operate the
lamp, fans, and control circuitry is provided by a custom designed, wattage regulated, switching power supply.
The operational life of the lamp and lamp life indicator are controlled by a lamp voltage monitoring circuit.

ULTI LINK™ PORT AND MULTI LINK™ EXPANSION PORT

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Internal, to both the Multi Link™ Port and Multi Link™ Expansion Port, are patented coupling optics and mechanics
designed to produce the highest output powers. Internal to the Light Sources are fans and heatsinks designed to

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reduce temperatures at the optical coupling joints thereby minimizing the possibility of damage to Micro Link
Fiber and fiber bundles.

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SERVICE

CLEANING

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.

• Routinely inspect and clean all air intakes / out flows at the rear of the chassis for lint or other debris.

• Follow the manufacturer’s instructions when Cleaning the fiber bundles or accessories used with the light

source.

3. Wipe the power cord with a cloth dampened with 10% bleach solution and water. DO NOT IMMERSE. DO
NOT RECONNECT WET.

4. DO NOT wipe down any lenses or windows.

5. DO NOT plug the power source into a wall outlet until it is thoroughly dry.

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URGICAL ILLUMINATOR

The console may be cleaned using a clean soft cloth with the following cleaning agents:

Enzymatic Solution (Enzol)

Isopropyl Alcohol

Hydrogen Peroxide 3% USP

2% Glutaraldehyde Solution

Soap and Water

10% bleach solution and water

CAUTION: Do not splash cleaning agents into any openings, seams or electrical components.

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ULTI LINK™ EXPANSION PORT

The outside surfaces may be cleaned with a soft cloth using the following:

Isopropyl Alcohol

Soap and Water

The glass surfaces may be cleaned by the following methods:

A cotton swab moistened with Isopropyl Alcohol

Blow with dry compressed air

NOTE: Use care in cleaning the optical surfaces of the Multi Link™ Expansion Port to prevent scratches.

PN: LB-MAN-CLSERV Rev. A 1-9

TOOLS REQUIRED

• Slotted screwdriver, less than 6” long

• #1 Phillips Screwdriver, less than 6” long

• #2 Phillips Screwdriver, less than 6” long

• Open end wrench set - English or 5/16”

• Needle nose pliers

• Nut Driver Set - English or 3/16”, 1/4”, 5/16”

• Nut Driver Set - Metric or 10mm

• Deep well socket set and wrench (2) - CL 100 Surgical Illuminator

• Non-conductive pot adjusting tool - CL 100 Surgical Illuminator

• 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 Illu­minator

• Calibrated RMS Digital Multimeter (DMM)

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TROUBLESHOOTING

CL 100 SURGICAL ILLUMINATOR

Symptom Cause Remedy

Lamp fails to start and
fans are not running.

Lamp fails to start and
fans are running.

Lamp shuts off after
operating for a few
minutes and restarts after
cooling.

No power to unit Check power supply cord and outlet

Line voltage is <90 VAC Refer to Hospital Engineering department

Fuses blown Inspect, replace and retest. Go to “Test #1: Blown

Fuses” on page 12.

Safety interlock open Check and tighten slotted screw on lamp fixture

access door

Power supply failure Go to “Test #2: 100 WATT Power Supply” on

page 13

Lamp not in light source
(audible clicking heard)

Defective lamp cable
(discolored, bent or broken
prongs)
(audible clicking heard)

Defective power supply
(discolored, bent or broken
prongs)
(no audible clicking heard)

Inadequate air flow for
cooling, Light Source over
temperature

Fan failure Go to “Test #3: Cooling Fan” on page 13.

Install a 100W replacement lamp, model 90133.

Replace and retest lamp cable.

Inspect wiring and if it is fine, replace and retest
power supply.

Allow 2” (51mm) clearance at back of unit; insure
that air intake-outflow vents are clean and not
blocked. Allow unit to cool and then restart

Illuminator is overheating not
due to clearance.

Lamp is at the end of life, but
amber LED is inoperative.

Indicator light on and
lamp shuts off

Replacement Lamp will
not seat into Light Source

PN: LB-MAN-CLSERV Rev. A 1-11

Lamp life exceeded. Install a 100W replacement lamp, model 90133.

Lamp cable defective. Replace if prongs are discolored, broken, or bent.

Power supply out of
calibration.

Lamp is not oriented correctly Rotate lamp 180° and re-insert

Incorrect Replacement Lamp Install a 100W replacement lamp, model 90133.

Verify operation of fans. Clean fans and internal
components of dust.

Verify LED flickers on when it is first turned on. If
not, go to “Test #4: LED/Overtemp Switch” on
page 13.

To go “Test #6: Power Supply Calibration” on
page 14.