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.
i
*** 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 sourcebefore cleaning ordisassemblingLX-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.
ii
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
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 TOCORRECT VOLTAGE RATING (21 V).
COOL FOR 20REPLACE 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 TOREPLACE WITH PNO4050 150 WATT LAMP.
COOL FOR 20...low transformer secondary
MINUTES BEFOREvoltage...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.
1
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.
2
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:
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.
A1. 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 !
A2. 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.
A3. 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.
A4. 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.
A5. TEST TO VERIFY SAFE OPERATION.
PLACE LX-150 IN UPRIGHT POSITION AND CONNECT TO POWERSOURCE. LIGHT SHOULD COME ON. ALLOW NEWLAMP TO
OPERATE AT LEAST FIVE MINUTES TO 'BURN IN'.
5
CAUTION: DISCONNECT LX-150 FROM POWER SOURCE BEFORE SERVICING.
B.1NEWER 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.11. 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.12. 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.13. 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.14. 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:
___________________________________________________________________
___________________________________________________________________
6
CAUTION: DISCONNECT LX-150 FROM POWER SOURCE BEFORE SERVICING.
B.2OLDER 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 SMOKEMARKS,
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.21. 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.22. 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.23. 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.25. TEST TO VERIFY SAFE OPERATION.
CONNECT LX-150 TO POWER SOURCE AND PERFORM FULL FUNCTION
TEST.
7
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