Welch Allyn Solarc User manual

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Operation Manual

Welch Allyn Solarc

Light Source/Illuminator

Service Manual

Models: 49500,49502,49504,49506,

HLS-24-0,HLS-24-2,HLS-24-4,HLS24-6

Copyright 1996

Welch Allyn Inc.

4341 State Street Road

P.O Box 220

Skaneateles Falls, NY 13153-0220

P/N 495621

Rev. B

Introduction

Revision (History) Page

Rev.	Description of Change	ECN #	Date	Initial
A	New Release	5-33806	10/10/96	JSJ
B	Update, Remove section revisions,	5-34456	1/14/97	JSJ/MD
	replace fuse P/N

Light Source/Illuminator Service Manual

Page 2

Introduction

To Service Personnel:

The information in this manual is subject to change without notice and should not be construed as a commitment by Welch Allyn, Inc.

Welch Allyn assumes no responsibility for any errors that may appear in this manual. If the product and/or its operation varies significantly from any description herein, please contact the Welch Allyn Product Service Department at 4341 State Street Road, Skaneateles Falls, New York 131530220, 1 800 669-9771, [phone]

This product has been designed to provide a high degree of safety and reliability. However, we can not guarantee against the deterioration of components due to aging and normal wear.

All service and repairs must be performed by authorized Welch Allyn personnel or agents, using Welch Allyn replacement parts. Failure to do so will invalidate the product warranty.

Authorized service centers should refer to repair specification for proper test and device history record requirements.

Please refer to the product warranty for specific coverage.

Welch Allyn, Inc.

Medical Products

4341 State Street Road

Skaneateles Falls, New York 13153-0220 USA

1 800 669-9771

[phone]

Limited Warranty

Light Source/Illuminator Service Manual

Page 3

Introduction

49501Medical Light Source...Welch Allyn warrants the Welch Allyn Light Source when new, to be free of defects in material and workmanship and to perform in accordance with manufacture' specifications when subject to normal use and service for a period of three years from the 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 manufacture's specifications within this time at no cost to the customer. It shall be the purchaser's responsibility to return the instrument directly to the authorized distributor, agent, or service representative. This warranty does not cover the Solarc Lamp or breakage or failure due to tampering, misuse, neglect, accidents, improper installation, modification, shipping, or to improper maintenance, service, and cleaning procedures. This warranty is also void if the instrument is not used in accordance with manufacture's recommendations or if required or serviced by other than Welch Allyn or an authorized agent. Purchase date determines warranty requirements. No other express or implied warranty is given.

HLS24 Industrial Illuminator...Welch Allyn warrants the Welch Allyn Illuminator when new, to be free of defects in material and workmanship and to perform in accordance with manufacture' specifications when subject to normal use and service for a period ofone year from the 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 manufacture's specifications within this time at no cost to the customer. It shall be the purchaser's responsibility to return the instrument directly to the authorized distributor, agent, or service representative. This warranty does not cover the Solarc Lamp or breakage or failure due to tampering, misuse, neglect, accidents, improper installation, modification, shipping, or to improper maintenance, service, and cleaning procedures. This warranty is also void if the instrument is not used in accordance with manufacture's recommendations or if required or serviced by other than Welch Allyn or an authorized agent. Purchase date determines warranty requirements. No other express or implied warranty is given.

For service assistance or questions regarding this warranty, please call Welch Allyn Medical Technical Service Department at 1 800 669-9771, or [phone].

Light Source/Illuminator Service Manual

Page 4

Introduction

Table of Contents

SECTION 1: General Information

Basic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 2: Service
Intent of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 9
Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 10
Performance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 11
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 11
SECTION 3: Problem Solving
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12-13
SECTION 4: Disassembly and Repair
Part Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 14
Left Housing Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 15
Ballast Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 16
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 16
Fan / Secondary Wire Harness Asy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 17
Lamp Cover Safety Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 18
Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 18

SECTION 5: Maintenance

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Checking Ground Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Measuring Leakage Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22 Fuse or Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 6: Theory of Operations

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Start Up Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ballast Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Light Source/Illuminator Service Manual

Page 5

Introduction

APPENDIX A: Schematics/Diagrams

Table of Drawings (Appendix A)

Drawing Number	Description
N/A	Parts Lst/Recomended Inventory
495000	ACMI Light Box Asm
495064	Right Housing Asm
495072	Internal Chassis Asm
495078	Secondary Wire Harness Asm
495102	Interconnect Diagram
A03387	Illuminator Electrical Safety Test Secification

Drawings and specs are for reference only. Consult factory for current revisions.

Light Source/Illuminator Service Manual

Page 6

General Information

Basic System Description

Model # 49501 is a medical light source which is used in conjunction with several Welch Allyn medical instruments. This model has a built in Infrared filter to limit the heat generated by the light. It also has an external ferrite bead built into the power cord to meet Electromagnetic

Interference (EMI) requirements, as required by medical standards.

Model HLS-24-0 is an industrial illuminator which can be used in many industrial applications. The HLS-24-0 is also known at Welch Allyn as a 49501I (The I indicates that the unit is for industrial use only). This instrument is identical to the 49501 medical light source with the deletion of the Infrared filter and the Ferrite bead.

49500....Welch Allyn Light Source	HLS24-0...Welch Allyn Illuminator
100-240 VAC	100-240 VAC
50/60 Hz	50/60 Hz
U.S.A. Plug Type	U.S.A. Plug type
49502...Welch Allyn Light Source	HLS24-2...Welch Allyn Illuminator
100-240 VAC	100-240 VAC
50/60 Hz	50/60 Hz
European Plug Type	European Plug type
49504...Welch Allyn Light Source	HLS24-4...Welch Allyn Illuminator
100-240 VAC	100-240 VAC
50/60 Hz	50/60 Hz
U.K. Plug Type	U.K. Plug type
49506...Welch Allyn Light Source	HLS24-6...Welch Allyn Illuminator
100-240 VAC	100-240 VAC
50/60 Hz	50/60 Hz
Australian Plug Type	Australian Plug Type

Light Source/Illuminator Service Manual

Page 7

Section 1

General Information

Specifications

Electrical

Input Voltage: 100-240 VAC, 50-60 Hz

Input Current: 1Amp (@ 100VAC)

Output: 60VDC @.4A

Leakage Current: Less than 100 microamps

Dimensions

HxWxD: 8.2" x 3.1" x 5.2" (21cm x 8cm x 13cm)

Weight: 2.5 Pounds

Illumination System

Welch Allyn HI-Lux Lamp

Color Temperature: 5500 K

Lamp: 60 Volts, 24 Watts

Lamp Life: 300 hours average

Dimming System

Manual Shutter: 20% to 100%

Fiber Optic Bundle Interface

Standard ACMI Connector

Approvals

UL 2601-1	IEC 801-2,3,4,5
CSA C22.2 No. 601.1-M90	EN 55011
IEC 601-1	Australia AS3200
IEC 601-1-2

CE

The CE mark on this product indicates it has been tested to and conforms with the provisions noted within the 93/42/EEC Medical Device Directive.

Declarations of Conformity are held by Welch Allyn's European Representative.

European Regulatory Manager

Welch Allyn Ltd.,

Kells Road, Navan,

County Meath, Republic of Ireland.

Tel [phone]

Fax [phone]

Environment

Operating: 60 F (15 C) to 85 F (30 C)

Storage: -13 F (-25 C) to 140 F (60 C)

Equipment Classification

Class 1, Type B, Continuous Operation

Fuses

T1.0A L250V: 1.0 A, 250 V, Time Lag (Slow-Blow), Low Breaking Capacity.

Light Source/Illuminator Service Manua

Page 8

Service

Intent of Manual

The purpose of this manual is to provide Welch Allyn Inc. authorized service representatives with systematic guidelines for preventative maintenance, problem identification, and service of the Solarc Light Source/Illuminator. We have included the theory of operation schematic diagrams, simplified drawings, service tips and procedures to assist a trained service representative with board-level repairs. Should you encounter problems that are beyond the scope of this manual, please contact the Technical Service Department of Welch Allyn's Medical Products for assistance.

Required Tools for Service

1.11/32 Nut Driver

2.Screwdriver: Phillips #1

3.Long Nose Pliers

4.Wire Cutters Xcelite 54CG

5.1/16" Drill bit and Pin-Vise

Required Equipment:

1.Digital Volt/Ohm Meter with Leads (True RMS). Beckman model 310 or equivalent.

2.Soldering Iron

3.Solder Sucker or Desoldering Wick

4.Kepco Model MSK 10-10M Power Supply. Capable of 10 amps at 10VDC.

5.Hy-Pot TesterAssociated Research Inc. Model 35400D or Equivalent.

Light Source/Illuminator Service Manual

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Section 2

Service

Words of Caution:

High Voltage

Use caution when servicing. When servicing the unit, potentially dangerous high voltage levels are exposed. Disconnect the power cord whenever possible to avoid electric shock.

Static Electricity (ESD)

Adhere to standard ESD practices at all times when servicing this equipment. Many of the electronic devices in this equipment are static sensitive, and may suffer catastrophic or latent failure if handled improperly.

Heat

Lamps, power supplies, and heat sinks may emit extreme amounts of heat during and after operation. Approach and handle these and other potentially hot components with caution.

Finished Parts

Handle all finished parts with care. The finish can be easily scratched or damaged from poor or improper handling.

Light Source/Illuminator Service Manual

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Section 2

Service

Performance Checks

The following performance checks will help you (1) determine whether or not the system is operating properly, and (2) isolates a problem, if there is one.

System Set Up

Make sure the system is connected as follows:

1.Be sure that power is being provided by the wall outlet.

2.Be sure that the Lamp is installed properly.

3.Be sure that the cooling fan is turning when the unit is turned on.

4.The light source should produce a bright continuous white light with no flickering after it reaches the steady state (approx. 15-20 Sec).

If any of these conditions do not occur, see the troubleshooting section.

Calibrations

Not Applicable

Light Source/Illuminator Service Manual

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