Welch Allyn LumiView User manual

SERVICE MANUAL
Light Source Menu
Operation Manual
Int'l Operation Manual
for the
WELCH ALLYN
LX-150 LIGHT SOURCE
no.'s 45150,45250 (after 8/91),
45160, 45262, 45264, 45266, 45268
LX-150

TABLE OF CONTENTS

FORWARD - - - - - - - - - - - - - - - - - - - - - - - - - - i SAFE SERVICE - - - - - - - - - - - - - - - - - - - - - - - ii INDEX: FAILURE/CAUSE - - - - - - - - - - - - - - - - - - - 1 - 3 DIFFERENCES BETWEEN EARLY AND LATE MODELS - - - - - - - - - 3 INDEX: REMOVAL/REPLACEMENT ( R & R ) PROCEDURES - - - - - 4 REMOVAL/REPLACEMENT PROCEDURES - - - - - - - - - - - - - - 5 - 19
APPENDIX
SERVICE PARTS LIST AND EXPLODED DIAGRAM * * * * AA WIRING DIAGRAM/SCHEMATIC DIAGRAM * * * * BB REPAIR VERIFICATION TEST PROCEDURES * * * * CC SET-UP AND OPERATION ( OWNER'S MANUAL ) * * * * DD TOOLS (COMMON & SPECIAL) * * * * EE PRODUCT UP-DATES * * * * FF PRODUCT DESCRIPTION * * * * GG

FORWARD

THIS MANUAL IS FOR WELCH ALLYN TECHNICIANS WHO ARE
TRAINED AND QUALIFIED
TO PERFORM ELECTRICAL REPAIRS.
This manual provides technical assistance to Welch Allyn repair technicians for cleaning, disinfecting, diagnosing, repairing, and testing the WELCH ALLYN LX-150 LIGHT SOURCE. The manual's main content areas cover: faults/causes, step by step removal and replacement of parts, and re-test.
The repair 'TASK' procedures ( R & R .. Removal and Replacement ) are written to provide quick and easy reference for different experience levels of repair technician. Required specifications and materials are listed at each step where applicable. When reading this manual for the first time, have an LX-150 readily available for reference and practice. Read each complete repair step on what to do (task statement), plus how to do it ( technique statement ) before starting the repair or practice.
Training for the LX-150 should consist of detailed demonstrations of required repair tasks, practice using repair tooling and materials, and assessment of skill development through observation of trainee practice on actual equipment. Set up sessions to allow the trainee to practice the use of the diagnostic, repair, adjustment, and re-testing procedures found in this manual. The ability of the technician to develop and retain new skills is in great part dependent on well prepared training exercises. Each trainee must have the opportunity to practice the procedure(s) after it has been demonstrated by the instructor. More detailed background product information is found in the APPENDIX section and as such will be a critical element in a comprehensive service training program for technicians.
I M P O R T A N T :
Welch Allyn part numbers and 'M' (material) numbers appearing in this manual are for the purpose of familiarizing new technicians with Welch Allyn documentation conventions. Order replacement parts, as always, by referencing your latest bill of materials, parts catalog and assembly drawings. Part number changes, product updates, or new test procedures should be noted on the appropriate page of this manual by the manual owner. Notices announcing these changes should be attached to Appendix FF, PRODUCT UPDATES.
HOW TO FIND CURRENT PART NUMBER INFORMATION: REFER TO THE MOST RECENT ASSEMBLY DRAWING(S) FOR APPLICATION INFORMATION ON PARTS, PROCESS, AND MATERIALS. FIND THE CURRENT PART NUMBERS BY REFERRING TO THE CIRCLED NUMBERS ( 'BUBBLE' NUMBERS ) ON CURRENT ASSEMBLY DRAWINGS. FIND CORRESPONDING PART NUMBER ON THE MANUFACTURING OR REPAIR BILL OF MATERIALS.
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*** SAFE SERVICE *** WEAR approved eye protection when servicing this product. CLEAN AND DISINFECT as per normal operating procedure BEFORE
repairing, or adjusting all returned LX-150's. NEVER ASSUME IT HAS BEEN DONE!! WIPE unit off with solution of 10% Clorox, 90% water.
DISCONNECT power cord from A.C. power source before cleaning or disassembling LX-150. LET hot lamps cool before replacing them.
DO NOT OPERATE ANY UNITS UNTIL YOU HAVE DISASSEMBLED THEM AND
DETERMINED THAT THEY ARE SAFE TO TEST/OPERATE. VERIFY that the circuits are same as appropriate assembly drawings circuits before energizing the LX-150 Light Source.
COMPLY with all safety codes and practices for this product. PERFORM recommended Welch Allyn test procedures AFTER SERVICING to
assure safe and reliable product operation, ie: ground continuity testing, dielectric strength testing, leakage current testing, and air pump output pressure testing.
EXAMINE AND REPAIR OR REPLACE as required, any and all worn or questionable wiring, components, connections, connectors, warning labels, insulation and other items necessary for the continued safe operation of this product.
DO NOT TOUCH halogen lamps or nearby parts during or immediately after operation. WAIT 20 MINUTES! High temperatures can cause severe burns. Fractured or broken lamps may cause injury. Use a cloth or other protection when removing questionable lamps.
DO NOT LOOK DIRECTLY AT halogen lamps during operation.
*** QUALITY SERVICE ***
MODIFY your Repair & Training Manual frequently by notating changes
and revisions of part numbers and procedures. Enter this new data on the appropriate page and put the notice in Appendix FF.
READ AND UNDERSTAND customer comments and complaints on accompanying documentation ( P.O. or other correspondence ).
IF AN INJURY OR ILLNESS TO PATIENT OR USER, OR HAZARDOUS MALFUNCTION HAS OCCURRED OR IS SUSPECTED, DO NOT DISASSEMBLE, REASSEMBLE, ALTER OR REPAIR THE PRODUCT IN ANY WAY...INSTEAD, GIVE THE UNIT AND ALL ACCOMPANYING PAPERWORK TO YOUR REPAIR SUPERVISOR.
Appropriate action per approved Welch Allyn policy will be taken. OPEN the light source and perform complete inspection. LOOK for:
product defects, damage, tampering, unsafe condition of wiring or any component. ENTER findings and test data along with repair status in the appropriate file.
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INDEX OF FAILURES / CAUSES SEE SCHEMATIC 451536,109P370, 451605 & ASSEMBLY DRAWINGS OF LX-150. FAILURE or COMPLAINT: POSSIBLE CAUSE & CORRECTIVE ACTION: UNIT COMPLETELY INOPERATIVE ( NO LIGHT, FAN, AIR ... not plugged in...PLUG IN TO MAINS when lamp door is closed)... no voltage at MAINS (AC OUTLET). CHECK and restore voltage.
... lamp access door ajar...LATCH DOOR. ... fuse(s) blown...CHECK FOR SHORT TO
GROUND OR OTHER HIGH CURRENT DRAW CAUSE (LINE-TO-LINE SHORT.) RESTORE CIRCUIT TO SPECIFICATIONS BEFORE
ENERGIZING UNIT. REPLACE FUSES, TEST. ... defective interlock switch...REPLACE ... bent interlock switch
actuation arm...REPLACE WHOLE SWITCH. ... loose wire connection...RESTORE ... defective power switch S1...REPLACE ... defective power cord...REPLACE CORD ... unit miswired...COMPARE TO SCHEMATIC
AND RESTORE CIRCUIT TO SPECIFICATION. ... interlock switch "normally closed"
contacts used instead of required
"normally open" contacts. CHECK AND
RESTORE CORRECT CONNECTIONS.
------------------------------------------------------------------­FAN RUNS BUT NO LIGHT ... lamp loose in holder...RESEAT LAMP WARNING:: ... burned out lamp...CHECK OLD LAMP FOR
ALLOW LAMP TO CORRECT VOLTAGE RATING (21 V). COOL FOR 20 REPLACE LAMP WITH WELCH ALLYN PN04050 MINUTES BEFORE ... thermal protector over heated TOUCHING !!! (above 95 degrees C)...LET COOL
... thermal protector cooled and stuck
open...REPLACE THERMAL PROTECTOR ... open transformer winding...REPLACE ... lamp turns off after short time...
wrong or defective thermal protector
REPLACE THERMAL PROTECTOR. ... unit miswired...COMPARE TO SCHEMATIC
AND RESTORE CIRCUIT TO SPECIFICATION.
-----------------------------------------------------------------­LOW LIGHT OUTPUT ... lamp not seated...RESEAT LAMP
... bad lamp...REPLACE LAMP
WARNING:: ... lower wattage lamp installed...
ALLOW LAMP TO REPLACE WITH PNO4050 150 WATT LAMP. COOL FOR 20 ... low transformer secondary
MINUTES BEFORE voltage...check wiring...REPLACE
TOUCHING !!! TRANSFORMER.
... unit miswired (wrong transformer
tap used)...COMPARE TO SCHEMATIC
AND RESTORE CIRCUIT TO SPECIFICATION. ... dirty reflector...CLEAN. ... shutter crank loose...ALIGN, TIGHTEN.
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LX-150 INDEX OF FAILURES / CAUSES, CONTINUED.....
FAILURE OR COMPLAINT: POSSIBLE CAUSE AND CORRECTIVE ACTION: PUMP DOES NOT RUN ... defective " AIR" switch...REPLACE.
... poor electrical connection to
pump...RESTORE ELECTRICAL CONNECTION. ... defective pump...REPLACE PUMP. ... unit miswired...COMPARE TO SCHEMATIC
AND RESTORE CIRCUIT TO SPECIFICATION.
------------------------------------------------------------------­PUMP RUNS, NO/LOW OUTPUT ... loose water bottle cap...TIGHTEN.
... tubing off of connector(s)...RESTORE
CONNECTION(S). ... tubing sharply bent..STRAIGHTEN TUBE. ... cracked panel mount connector...
REPLACE PANEL MOUNT CONNECTOR. ... cracked water bottle cap air fitting
REPLACE AIR FITTING ON WATER BOTTLE
- ... wrong tubing connections...RESTORE
------------------------------------------------------------------­COOLING FAN INOPERATIVE ... bad electrical connection...RESTORE.
... defective fan motor...REPLACE FAN. ... fan obstructed...CLEAR OBSTRUCTION. ... unit miswired...COMPARE TO SCHEMATIC
AND RESTORE CIRCUIT TO SPECIFICATION.
------------------------------------------------------------------­SIGMOIDOSCOPE CONNECTOR DOES NOT PLUG IN ALL THE WAY ... ball detente jammed in down position
set screw too far in...LOOSEN SET
SCREW AND FREE UP THE BALL DETENT.
------------------------------------------------------------------­SIGMOIDOSCOPE CONNECTOR DOES NOT STAY IN THE PORT ... loose or missing ball detent or
spring...TIGHTEN SET SCREW AND PUSH
BALL INTO ITS HOLE TO CHECK FOR
SPRING.REPLACE WORN/MISSING PART.
------------------------------------------------------------------­SHUTTER DOES NOT FUNCTION... knob is loose...TIGHTEN KNOB SET SCREW.
... shutter crank is loose...TIGHTEN
SHUTTER CRANK 4-40X1/4" SET SCREW. ... bushing is broken...REPLACE BUSHING.
------------------------------------------------------------------­BRIGHTNESS KNOB RATTLES ... knob shaft is loose...INSTALL SPRING
WASHER PN106142-1.
------------------------------------------------------------------­SWITCH(S) PRODUCES ARC OR FLASH WHEN ACTUATED ... switch is defective or wiring
connections are loose or intermittent
REPLACE CONNECTORS AND OR SWITCH.
------------------------------------------------------------------­FAILS DIELECTRIC STRENGTH TEST A00166 ... transformer/power cord assembly
defective...ISOLATE AND REPLACE.
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LX-150 INDEX OF FAILURES / CAUSES, CONTINUED.....
FAILURE OR COMPLAINT: POSSIBLE CAUSE AND CORRECTIVE ACTION: FAILS GROUNDING CONTINUITY
TEST A00172 ... faulty connection in grounding
circuit between the power cord
receptacle ground pin and the
chassis. INSPECT AND TEST FOR GROUND
CONTINUITY, RESTORE AND OR REPLACE
FAULTY COMPONENT. ... if above inspection, test reveals
good circuit, then fault possible in
power cord assembly. REPLACE POWER
CORD.
------------------------------------------------------------------­FAILS LEAKAGE CURRENT
TEST A00170 ... possible defective component:
transformer, pump, fan, cord
assembly. ISOLATE AND TEST
INDIVIDUAL COMPONENTS. REPLACE.
------------------------------------------------------------------­NOTE: LX-15O UNITS MANUFACTURED AFTER JUNE 1991 INCORPORATE
FEATURES THAT DISTINGUISH THEM FROM MODELS MANUFACTURED
PRIOR TO THAT DATE. MOST NOTABLE ARE THE FOLLOWING: ITEM: BEFORE 6/91: AFTER 6/91:
POWER CORD..... PERMANENTLY ATTACHED PLUG-IN TYPE
POWER CORD.
FUSES.......... FUSES MOUNTED INSIDE EXTERNAL ACCESS
UNIT ON FUSE BLOCK. AT POWER RECEPTACLE.
TRANSFORMER
MOUNTING....... TWO PHILLIPS HEAD TWO PHILLIPS HEAD
SCREWS, TWO MACHINE SCREWS, TWO TABS.
SCREWS W/ 1/4" HEAD.
RUBBER FEET.... ADHESIVE FASTENER
PNEUMATICS..... "T" FITTING BETWEEN PUMP OUTPUT GOES
PANEL MOUNT CONNECTOR DIRECTLY TO PANEL
AND AIR PUMP. MOUNT CONNECTOR.
T E C H N I C I A N N O T E S :
____________________________________________________________
3
INDEX: REMOVAL AND REPLACEMENT ( R & R ) PROCEDURES
CAUTION : DISCONNECT LX-150 FROM A.C. POWER SOURCE
BEFORE SERVICING TO
AVOID ELECTRICAL SHOCK HAZARD Component: Page: A Lamp - - - - - 5 B.1 External fuses - - - - - 6 B.2 Internal fuses - - - - - 7 C Power cord - - - - - 8 D Power cord receptacle - - - - - 9 E Power and air switches - - - - - 10 F Fan assembly - - - - - 11 G Lamp holder - - - - - 12 - 13 H Lamp holder/heat sink assy. - - - - - 14 I Air pump - - - - - 15 - 16 J Transformer - - - - - 17 K Interlock switch - - - - - 18 L Shutter adjustment - - - - - 19
THIS MANUAL IS FOR AUTHORIZED WELCH ALLYN TECHNICIANS
WHO ARE TRAINED AND QUALIFIED TO WORK ON ELECTRICAL EQUIPMENT.
ALWAYS TEST TO VERIFY SAFE OPERATION.
4
CAUTION: DISCONNECT LX-150 FROM POWER SOURCE BEFORE SERVICING. A HALOGEN LAMP REMOVAL AND REPLACEMENT (R & R) PN04050
( GE TYPE EJA 150 WATT 21 VOLTS )
D O N O T T O U C H H O T L A M P ! WARNING: ALLOW LAMP TO COOL OFF FOR 20 MINUTES BEFORE TOUCHING. A 1. UNPLUG LX-150 AND OPEN LAMP ACCESS DOOR.
( ALSO REFER TO OPERATING INSTRUCTIONS PN451502.) REMOVE POWER CORD FROM A.C. POWER SOURCE. UNCOUPLE
AIR INPUT HOSE AND UNCLIP WATER BOTTLE AND BRACKET FROM THE SIDE OF THE UNIT. TURN THE UNIT UPSIDE DOWN. INSERT A COIN IN THE SLOT OF THE LAMP-ACCESS-DOOR LATCH ( SLOTTED SCREW HEAD ON THE SIDE OF THE DOOR OPPOSITE THE HINGE ) AND TURN THE LATCH ONE QUARTER TURN COUNTER­CLOCKWISE. OPEN LAMP ACCESS DOOR.
D O N O T T O U C H H O T L A M P ! A 2. REMOVE LAMP.
AFTER COOLING DOWN PERIOD OF 20 MINUTES, LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET AS SHOWN IN FIG. A-1. PULL THE LAMP HOLDING LEVER TOWARD THE BACK OF THE UNIT UNTIL LEVER IS ALMOST VERTICAL. REMOVE EXPIRED LAMP AS SHOWN IN FIG. A-2.
CAUTION: EXERCISE CAUTION IF THE LAMP REFLECTOR OR THE QUARTZ
ENVELOPE ITSELF IS FRACTURED, CRACKED, OR HOT. USE A CLOTH TO HOLD THE OLD LAMP WHEN PULLING OLD LAMP OUT OF SOCKET. DO NOT TWIST LAMP...THIS WILL BREAK THE PINS FROM THE LAMP. IF THE LAMP HAS FRACTURED, REMOVE ALL FRAGMENTS FROM THE LX-150.
A 3. REPLACE WITH NEW LAMP PN04050.
RETURN THE LAMP HOLDING LEVER TO ITS ORIGINAL POSITION.
AS SHOWN IN FIG. A-3. NOTE: HOLD THE LAMP ON THE OUTSIDE SURFACES ONLY. FINGER GREASE OR OTHER CONTAMINANTS WILL DARKEN THE QUARTZ ENVELOPE CAUSING DISCOLORATION AND PREMATURE FAILURE OF THE REPLACEMENT LAMP. REMOVE PROTECTIVE CAP FROM LAMP. VERIFY PROPER ALIGNMENT OF PINS IN LAMP SOCKET. PRESS DOWN INTO FULL ENGAGEMENT WITH LAMP SOCKET. SEE FIG. A-4. LAMP WILL SNAP INTO PLACE.
A 4. RESTORE LAMP ACCESS DOOR TO ORIGINAL CLOSED AND LATCHED
POSITION.
CLOSE THE LAMP ACCESS DOOR AND LATCH THE FASTENER.
THE INTERLOCK SWITCH HAS BEEN CLOSED BY THIS ACTION.
A 5. TEST TO VERIFY SAFE OPERATION.
PLACE LX-150 IN UPRIGHT POSITION AND CONNECT TO POWER SOURCE. LIGHT SHOULD COME ON. ALLOW NEW LAMP TO OPERATE AT LEAST FIVE MINUTES TO 'BURN IN'.
5
CAUTION: DISCONNECT LX-150 FROM POWER SOURCE BEFORE SERVICING. B.1 NEWER UNITS .. EXTERNAL FUSES ( TWO ) R & R. SEE TABLE IN
PARTS CATALOG FOR CORRESPONDING PART NUMBER.
CAUTION: FOR UNITS RETURNED FOR SERVICE BECAUSE OF BLOWN FUSES,
OR RE-OCCURRING FUSE BLOWING, CHECK FOR SHORT TO GROUND OR OTHER HIGH CURRENT DRAW CAUSE (LINE-TO-LINE SHORT.) INSPECT WIRING AND COMPONENTS FOR BURN AND SMOKE MARKS, AND DAMAGED INSULATION. REPLACE FAULTY COMPONENTS AND RESTORE CIRCUIT TO SPECIFICATIONS BEFORE ENERGIZING UNIT. REPLACE FUSES AND OPERATE UNIT. LOOK FOR:
1. THE FAILURE OR DEFECT WHICH CAUSED THE FUSE TO BLOW.
2. THE CAUSE OF THE FAILURE.
3. OTHER DAMAGE THAT MAY HAVE BEEN DONE BEFORE THE FUSE BLEW.
B.1 1. REMOVE FUSE DRAWER.
DISCONNECT LX-150 FROM POWER SOURCE. REMOVE POWER CORD
FROM UNIT POWER CORD RECEPTACLE. INSERT THE FLAT BLADE OF A SMALL SCREWDRIVER ( 1/8") INTO SLOT ON EITHER SIDE OF FUSE DRAWER. UN-LATCH EACH SIDE OF THE FUSE DRAWER AND REMOVE.
B.1 2. REMOVE FUSES FROM FUSE DRAWER.
PULL BOTH FUSES FROM FUSE DRAWER AND INSPECT. COMPARE
RATING ON END CAP TO CORRECT REPLACEMENT PART RATING. FUSES CAN BE CHECKED VISUALLY. A BLOWN FUSE WILL HAVE INFINITE RESISTANCE. ON DIGITAL V.O.M.'S SUCH AS BECKMAN METERS, THE SYMBOL "OL" ( OPEN LEADS ) INDICATES AN OPEN CIRCUIT, IN THIS CASE, A BLOWN FUSE.
B.1 3. INSTALL NEW FUSES IN FUSE DRAWER.
REPLACE FUSES IN MATCHED PAIRS EVEN WHEN ONE APPEARS TO
BE GOOD. ALIGN THE TAB ON THE BOTTOM OF THE FUSE DRAWER WITH THE SLOT IN THE POWER CORD RECEPTACLE.
PRESS FUSE DRAWER INTO HOUSING.
B.1 4. TEST TO VERIFY SAFE OPERATION.
CONNECT LX-150 TO POWER SOURCE AND PERFORM FULL FUNCTION
TEST.
T E C H N I C I A N N O T E S: ___________________________________________________________________ ___________________________________________________________________
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CAUTION: DISCONNECT LX-150 FROM POWER SOURCE BEFORE SERVICING. B.2 OLDER UNITS ... INTERNAL FUSES ( TWO ) R & R. SEE TABLE IN
PARTS CATALOG FOR CORRESPONDING PART NUMBERS.
CAUTION: FOR UNITS RETURNED FOR SERVICE BECAUSE OF BLOWN FUSES,
OR RE-OCCURRING FUSE BLOWING, CHECK FOR SHORT TO GROUND OR OTHER HIGH CURRENT DRAW CAUSE ( LINE TO LINE SHORT.) INSPECT WIRING AND COMPONENTS FOR BURN AND SMOKE MARKS, AND DAMAGED INSULATION. REPLACE FAULTY COMPONENTS AND RESTORE CIRCUIT TO SPECIFICATIONS BEFORE ENERGIZING UNIT. REPLACE FUSES AND OPERATE UNIT. LOOK FOR:
1. THE FAILURE OR DEFECT WHICH CAUSED THE FUSE TO BLOW.
2. THE CAUSE OF THE FAILURE.
3. OTHER DAMAGE THAT MAY HAVE BEEN DONE BEFORE THE FUSE BLEW.
B.2 1. REMOVE UNIT COVER ( ON ALL UNITS ).
DISCONNECT LX-150 FROM POWER SOURCE. UNCOUPLE AIR INPUT
HOSE AND UNCLIP WATER BOTTLE AND BRACKET FROM THE SIDE OF THE UNIT. REMOVE EIGHT ( 8 ) PHILLIPS HEAD SCREWS FROM THE SIDES OF THE UNIT. REMOVE ONE ( 1 ) PHILLIPS HEAD SCREW WITH ITS STAR WASHER ( FOR ELECTRICAL GROUNDING OF THE ENTIRE CASE ) FROM THE BACK OF THE UNIT.
B.2 2. REMOVE FUSES FROM FUSE BLOCK.
PULL BOTH FUSES FROM FUSE BLOCK AND INSPECT. COMPARE
RATING ON END CAP TO CORRECT REPLACEMENT PART RATING. FUSES CAN BE CHECKED VISUALLY. A BLOWN FUSE WILL HAVE INFINITE RESISTANCE. ON DIGITAL V.O.M.'S SUCH AS BECKMAN METERS, THE SYMBOL "OL" ( OPEN LEADS ) INDICATES AN OPEN CIRCUIT, IN THIS CASE, A BLOWN FUSE.
B.2 3. INSTALL NEW FUSES IN FUSE BLOCK.
SECURELY INSERT A PAIR OF REPLACEMENT FUSES INTO THE
RECEPTACLES IN THE FUSE BLOCK.
B.2 4. INSTALL COVER ON UNIT. (LOCKTITE IS NOT USED ON SCREWS)
CAREFULLY SLIDE THE COVER OVER CHASSIS. ALIGN HOLES IN
COVER WITH SCREW HOLES IN CHASSIS. REPLACE EIGHT ( 8 ) PHILLIPS HEAD SCREWS ON THE SIDES OF THE UNIT. REPLACE ONE ( 1 ) PHILLIPS HEAD SCREW AND STAR WASHER ON THE BACK OF THE UNIT. THE STAR WASHER ESTABLISHES ELECTRICAL CONTINUITY BETWEEN THE GROUNDED CHASSIS AND THE COVER.
B.2 5. TEST TO VERIFY SAFE OPERATION.
CONNECT LX-150 TO POWER SOURCE AND PERFORM FULL FUNCTION
TEST.
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