Welch Allyn LS100 User manual

Exam/Procediure

Light

Operation

Manual

WELCH

ALLYN

LS100

HALOGEN

LIGHT

SERVICE

MANUAL

WELCH

ALLYN

4341

State

Street

Road

P.O.

Box

220

Skaneateles

Falls,

13153-0220

Technical

Service

Dept:

Telephone:

315

685-4445

Fax:

315

685-4653

SERVICE

MANUAL

FOR:

WELCH

ALLYN

LSI00

HALOGEN

LIGHT

MODELS:

44100

...

Domestic

44110...Wall/Table

mount

1994,

Welch

Allyn

Co.

4341

State

Street

Road

P.O.

Box

220

Skaneateles

Falls,

13153-0220

Originator:

Richard

Settembre

cad

file

name:440082B.WP5

ECN#

5-29487

SERVICE

MANUAL

440088

REV.B

11/94

TABLE

CONTENTS

FORWARD

--------------------------3

SAFE

SERVICE

-----------------------4

INDEX:

FAILURE/CAUSE

-------------------

INDEX:

REMOVAL/REPLACEMENT

PROCEDURES

------

REMOVAL/REPLACEMENT

PROCEDURES

--------------8-22

APPENDIX

SERVICE

PARTS

LIST

AND

EXPLODED

DIAGRAM

WIRING

DIAGRAM/SCHEMATIC

DIAGRAM

REPAIR

VERIFICATION

TEST

PROCEDURES

PACKAGING

FOR

SHIPMENT

LIST

SAFETY/ADVISORY/USE

LABELS

TOOLS

(COMMON

SPECIAL)

PRODUCT

UP-DATES

PRODUCT

DESCRIPTION

FORWARD

This

SERVICE

MANUAL

provides

technical

assistance

Welch

Allyn

repair

technicians

for

diagnosing,

repairing,

and

testing

the

WELCH

ALLYN

LS100

HALOGEN

LIGHT.

The

manual's

main

content

areas

cover:

troubleshooting,

step

repair,

adjustment,

and

re-test

procedures.

The

repair

'TASK'

procedures

Removal

and

Replacement)

are

written

provide

quick

and

easy

reference

for

repair

technicians

different

experience

levels.

Required

specifications

and

materials

are

listed

each

step

where

applicable.

When

reading

this

manual

for

the

first

time,

have

LS100

readily

available

for

reference

and

practice.

Read

each

complete

repair

step

what

(task

statement),

plus

how

(technique

statement)

before

starting

the

repair

practice.

Training

for

the

LS100

should

consist

detailed

demonstrations

required

repair

tasks,

practice

LSIOO'S

using

repair

tooling

and

materials.

Assess

skill

development

through

observation

trainee

practice

actual

equipment.

Set

sessions

allow

the

trainee

practice

the

use

the

diagnostic,

repair,

adjustment,

and

re-testing

procedures

found

this

manual.

The

ability

the

technician

develop

and

retain

new

skills

great

part

dependent

well

prepared

training

exercises.

Each

trainee

must

have

the

opportunity

practice

the

procedure(s)

after

has

been

demonstrated

the

instructor.

detailed

background

product

information

found

the

APPENDIX

section

and

such

will

critical

element

comprehensive

service

training

program

for

technicians.

IMPORTANT

Welch

Allyn

part

numbers

and

'M'

(material)

numbers

appearing

this

manual

are

for

the

purpose

familiarizing

new

technicians

with

Welch

Allyn

documentation

conventions.

Order

replacement

parts,

always,

referencing

your

latest

bill

materials,

parts

catalog

and

assembly

drawings.

Part

number

changes,

product

updates,

new

test

procedures

should

noted

the

appropriate

page

this

manual

the

manual

owner.

Notices

announcing

these

changes

should

attached

PRODUCT

UPDATES

APPENDIX.

HOW

FIND

CURRENT

PART

NUMBER

INFORMATION:

REFER

THE

MOST

RECENT

ASSEMBLY

DRAWING(S)

FOR

APPLICATION

INFORMATION

PARTS,

PROCESS,

AND

MATERIALS.

FIND

THE

CURRENT

PART

NUMBERS

REFERRING

THE

CIRCLED

NUMBERS

('BUBBLE'

NUMBERS)

CURRENT

ASSEMBLY

DRAWINGS.

FIND

CORRESPONDING

PART

NUMBER

THE

MANUFACTURING

REPAIR

BILL

MATERIALS.

WEAR

EYE

PROTECTION

WHEN

SERVICING

THIS

PRODUCT

***

SAFE

SERVICE

***

DISCONNECT

power

cord

from

A.C.

power

source

before

initial

disassembly

LS100

Light.

OBSERVE

cautions

warnings

owners

manual

and

printed

the

product

itself.

COMPLY

with

all

safety

codes

and

practices

for

this

type

product.

COMPLY

with

all

safety

regulations

your

work

place.

PERFORM

all

recommended

Welch

Allyn

service

test

procedures

assure

the

LS100

meets

all

safety,

performance

and

reliability

requirements.

EXAMINE

AND

REPAIR

REPLACE

required,

any

and

all

worn

questionable

wiring,

components,

connections,

connectors,

warning

labels,

insulation

and

other

items

necessary

for

the

continued

safe

operation

this

product.

NOT

TOUCH

halogen

lamps

nearby

parts

during

immediately

after

operation.

WAIT

LEAST

TWENTY

MINUTES

(20

MIN.)

BEFORE

TOUCHING

HALOGEN

LAMPS.

VERY

HIGH

TEMPERATURES

will

cause

severe

burns!

Fractured

broken

lamps

may

cause

injury.

prevent

cuts,

REMOVE

such

lamps

HOLDING

them

with

cloth

wear

work

gloves.

WEAR

SAFETY

GLASSES!

NOT

LOOK

DIRECTLY

TOUCH

operating

lamps!

***

QUALITY

SERVICE

***

MODIFY

your

SERVICE

Manual

notating

changes

and

revisions

part

numbers

and

procedures.

Enter

this

information

the

appropriate

page...and

include

copy

the

notification

your

Appendix

"Product

Updates".

READ

AND

UNDERSTAND

customer

comments

and

complaints

accompanying

documentation

(P.O.

other

correspondence).

INJURY

ILLNESS

PATIENT

USER,

HAZARDOUS

MALFUNCTION

HAS

OCCURRED

SUSPECTED,

NOT

DISASSEMBLE,

REASSEMBLE,

ALTER

REPAIR

THE

PRODUCT

ANY

WAY...

INSTEAD,

GIVE

THE

UNIT

AND

ALL

ACCOMPANYING

PAPERWORK

YOUR

REPAIR

SUPERVISOR.

Appropriate

action

per

approved

Welch

Allyn

policy

will

taken.

When

performing

complete

inspection,

LOOK

for

missing

parts,

product

defects,

damage,

tampering,

unsafe

condition

wiring

any

component.

ENTER

all

findings

and

test

data

along

with

repair

status

the

appropriate

file.

Most

the

repairs

can

performed

foam

covered

work

bench.

Place

the

LS100

holding

fixture

for

repairs.

Take

all

actions

prevent

scratching

the

bezel.

INDEX:

FAILURE

CAUSE

ALSO

REFER

TO:

ELECTRICAL

SCHEMATIC,

SERVICE

PARTS

DRAWING

NOS.PN

440045

AND

440120

Lamp

does

not

illuminate.

voltage

A.C.

source.

CHECK

measure

and

restore

voltage.

lamp

filament

burned,

"OPEN"

circuit.

Visually

inspect

filament.

REPLACE

open

lamp.

defective

switch,

"OPEN"

circuit

CHECK

voltage

across

switch

closed

position.

voltage

13.5

v.a.c.

15.0

+/-

0.3

V.A.C.,

then

switch

defective.

REPLACE

switch.

defective

transformer,

"OPEN"

primary

secondary

windings

defective

"failed

OPEN"

thermal

protection

device

transformer

primary

winding.

CHECKcontinuity/ohms

transformer

primary

winding.

REPLACE

'open'.

There

fuse

circuit

breaker

the

LS100.

When

the

temperature

the

transformer

primary

winding

decreases

pre-set

value

determined

the

manufacturer,

the

automatic

thermal

protection

device

will

automatically

restore

closed

'passing'

condition.

....

"OPEN"

circuit

power

cord

connecting

wires

and

connectors.

REPLACE

defective

component.

Lamp

not

bright

....

Wrong

lamp

supply

voltage

....

high

resistance

wiring

....

defective

transformer

Lamp

turns

off

after

short

time

illuminated

....

transformer

operating

high

temperature

thus

activating

internal

thermal

protection

device.

REPLACE

transformer.

....

lamp

too

high

wattage,(over

watts)

and

overloading

transformer.

INSTALL

correct

lamp.

loose

connection

wiring

lamp

loose

lamp

socket.

RESTORE

connections/REPLACE

socket.

Lamp

intermittent

when

LS100

touched

moved

INDEX:

FAILURE

CAUSE

CONTINUED

Switch

produces

arc

flash

when

operated

....

switch

defective

wiring

connections

are

not

secure.

Fails

Dielectric

strength....

replace

transformer/power

cord

assembly

....

remove

the

base

mount

plate

and

inspect

the

ground

connection

between

the

power

cord

ground

and

the

base

plate.

Test

for

Continuity.

step

above

shows

good

connection,

then

the

'open

circuit'

the

power

cord.

Replace

entire

transformer/power

cord

assembly.

....replace

the

entire

transformer/power

cord

assembly.

LSI

WALL

TABLE

MOUNT

TROUBLESHOOTING

light

output

....

broken

lamp

(broken

pins,

filament,

glass

envelope,)

REPLACE

lamp.

....

defective

switch

(failed

open),

replace

switch.

Note:

there

should

14.0

Vac

+/-.5

Vac

the

transformer

output

(no

load).

Lamp

resistance

about

one

ohm.

....

transformer

output

(defective

transformer

fuse.)

REPLACE

defective

component.

....

transformer

output

(secondary)

ohms

above

1.2

ohms..defective

winding.

REPLACE

transformer.

....

transformer

input

(primary)

ohms

above

ohms

(75

ohms

for

export

models),

defective

(open)

primary

thermal

fuse.

REPLACE

transformer.

....

cable

broken.

INSPECT

REPLACE

transformer.

load

output

transformer

than

14.0

volts.

Defective

transformer.

REPLACE

transformer.

Fails

ground

continuity

testing

Fails

leakage

current

testing

Transformer

hot

less

INDEX:

REMOVAL

AND

REPLACEMENT

PROCEDURES

CAUTION

DISCONNECT

LS100

FROM

A.C.

POWER

SOURCE

BEFORE

SERVICING

AVOID

ELECTRICAL

SHOCK

HAZARD

Component:

Page:

Halogen

Lamp

Power

Switch

Transformer/Power

Cord

Assembly-

Bezel

Reflector

Light

Cap

Hinge

'Stand-off'

Lamp

Socket

Light

Housing

Flexible

'Gooseneck'

Assembly

Pole

Wall

and

table

mount

LS100

Gooseneck

for

model

Wall/Table

Table

bracket

assembly

10-11

11-13

13-14

17-

18-

ECN#

5-29487

SERVICE

MANUAL

440088

REV.B

11/94

CAUTION:

DISCONNECT

LS100

FROM

POWER

SOURCE

BEFORE

SERVICING

HALOGEN

LAMP

PN06300

OPEN

LIGHT

CAP

PN44024

PRESS

TWO

TABS

DETENTS

OPPOSITE

SIDES

LIGHT

CAP

WHILE

THE

SAME

TIME

LIFTING

LIGHT

CAP.

PULL

OPEN

EXPOSE

LAMP

AND

LAMP

SOCKET.

REMOVE

HALOGEN

LAMP

PN06300

CAUTION:

EXERCISE

CAUTION

SINCE

LAMP

QUARTZ

ENVELOPE

MAY

BE:

FRACTURED,

CRACKED,

HOT.

USE

CLOTH

HOLD

THE

OLD

LAMP

WHEN

PULLING

OLD

LAMP

OUT

SOCKET.

NOT

TWIST

LAMP...THIS

WILL

BREAK

THE

PINS

FROM

THE

LAMP.

SUPPORT

LIGHT

CAP

WITH

ONE

HAND

AND

GENTLY

PULL

OLD

LAMP

STRAIGHT

OUT

WITH

THE

OTHER

HAND.

REMOVE

BROKEN

LAMP

PARTS

PINS

FROM

SOCKET

WITH

LONG

NOSE

PLIERS.

REPLACE

LAMP

WITH

NEW

HALOGEN

LAMP

PN06300

NOT

TOUCH

NEW

LAMP

WITH

YOUR

FINGERS.

FINGER

GREASE

OTHER

CONTAMINANTS

WILL

DARKEN

THE

QUARTZ

ENVELOPE

AND

CAUSE

DISCOLORATION

AND

PREMATURE

FAILURE

THE

REPLACEMENT

LAMP.

CLEAN

LAMP

BEFORE

PLACING

SOCKET.

USE

TISSUE

OTHER

CLEAN

CLOTH

HOLD

THE

LAMP

WITH

WHILE

INSERTING

INTO

THE

SOCKET.

SUPPORT

LIGHT

CAP

WITH

YOUR

OPPOSITE

HAND

WHILE

INSERTING

LAMP

STRAIGHT

INTO

LAMP

SOCKET.

VERIFY

PROPER

ALIGNMENT

AND

SECURE

CONNECTION

BETWEEN

LAMP

AND

LAMP

SOCKET.

RESTORE

LIGHT

CAP

ORIGINAL

CLOSED

POSITION

THE

LIGHT

CAP

AND

VERIFY

THAT

BOTH

TABS

HAVE

FULLY

ENGAGED

SECURE

THE

LIGHT

CAP

CLOSED

POSITION.

TEST

TRYING

OPEN

LIGHT

CAP

WITHOUT

DEPRESSING

TABS.

LIGHT

CAP

SHOULD

NOT

OPEN.

VERIFY

REPAIR

CONNECT

LSI0

POWER

SOURCE

AND

TURN

LIGHT

ON.

ALLOW

NEW

LAMP

OPERATE

LEAST

FIVE

MINUTES

'BURN

IN'.

TECHNICIAN

NOTES

CAUTION:

DISCONNECT

LS100

FROM

POWER

SOURCE

BEFORE

SERVICING

POWER

SWITCH

PN440029

REMOVE

SWITCH

PN44029

APPLY

SMALL

PIECE

MASKING

TAPE

ONE

END

THE

SWITCH

PROTECT

THE

LIGHT

HOUSING

TOP

FROM

MARKING

TOOLS

DURING

SWITCH

REMOVAL.

PULL

SWITCH

OUT

THE

LIGHT

HOUSING

PN440023-2

PRYING

UPWARDS

THE

END

THE

SWITCH

WITH

THIN

EDGE

SUCH

PUTTY

KNIFE.

DISCONNECT

WIRES

FROM

SWITCH

UNPLUG

BOTH

WIRES

FROM

THE

BOTTOM

THE

SWITCH.

INSTALL

NEW

SWITCH

ATTACH

WIRES

AND

PRESS

SWITCH

INTO

LIGHT

HOUSING,

MAKING

SURE

THAT

THE

"0"

LABEL

THE

TOP

THE

SWITCH

TOWARDS

THE

GOOSENECK.

SINCE

THESE

WIRES

CARRY

VOLTS

A.C.,

THE

WIRES

MAY

ATTACHED

THE

SWITCH

EITHER

POSITION.

REFER

WIRING

DIAGRAM

APPENDIX

BB.

VERIFY

REPAIR

CONNECT

LS100

POWER

SOURCE

AND

OPERATE

THE

LAMP

NUMBER

TIMES

DETERMINE

THAT

THE

SWITCH

OPERATING

PROPERLY.

CAUTION:

DISCONNECT

LS100

FROM

POWER

SOURCE

BEFORE

SERVICING

TRANSFORMER/POWER

CORD

ASSEMBLY

PN-*

part

number

for

country

use,

see

parts

list

catalog.

REMOVE

BASE

MOUNT

PLATE

PN440035-501

UNPLUG

THE

A.C.

POWER

CORD

AND

PLACE

THE

LSI0

HORIZONTAL

POSITION.

UN-SCREW

FIVE

(5)

FASTENERS

(1/4-

20)

PN10

6140-1

STARTING

WITH

THE

CENTER

FASTENER.

SECURED

WITH

LOCKTITE

262-31

(RED

M30328),

AND

WILL

REQUIRE

TORQUE

(OR

HEAT

FROM

SOLDERING

IRON

APPLIED

SCREW

HEAD)

UNFASTEN.

THE

CENTER

SCREW

THREADED

INTO

ALUMINUM

INSERT

THE

BASE

THE

POLE.

(NOT

SEPARATE

PART

NUMBER).

HOLD

THE

POLE

FIRMLY

WITH

ONE

HAND

WHILE

LOOSENING

THE

CENTER

SCREW

WITH

VISE-GRIP

LOCKING

PLIERS

(FOR

PHILLIPS

SCREWS

USE

VISE

GRIP..FOR

MODELS

THAT

HAVE

OTHER

TYPES

FASTENERS,

USE

APPROPRIATE

TOOL).

SUPPORT

THE

BASE

PLATE

WHEN

SEPARATES

FROM

THE

PLASTIC

BASE.

THIS

WILL

PROTECT

THE

WIRES

AND

CONNECTIONS

FROM

BEING

PULLED

THE

WEIGHT

THE

TRANSFORMER

AND

METAL

BASE

PLATE.

REPLACING

BASE

PLATE,

TRANSFER

MANUFACTURE

DATE

AND

LABEL

NEW

BASE.

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