Welch Allyn HLS-24-0 User 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
Light Source Menu
Operation Manual

Introduction
Light Source/Illuminator Service Manual Page 2
Revision (History) Page
Rev. Description of Change ECN # Date Initial
A New Release 5-33806 10/10/96 JSJ
B Update, Remove section revisions,
replace fuse P/N 5-34456 1/14/97 JSJ/MD

Introduction
Light Source/Illuminator Service Manual Page 3
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 responsibilityfor 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 13153-
0220, 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

Introduction
Light Source/Illuminator Service Manual Page 4
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 of one 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].

Introduction
Light Source/Illuminator Service Manual Page 5
Table of Contents
SECTION 1: General Information
BasicSystemDescription ...............................................................7
Specifications ........................................................................8
SECTION 2: Service
Intent of Manual ......................................................................9
Required Tools .......................................................................9
WordsofCaution ....................................................................10
PerformanceCheck ..................................................................11
Calibration .........................................................................11
SECTION 3: Problem Solving
Troubleshooting .................................................................. 12-13
SECTION 4: Disassembly and Repair
Part Identification ....................................................................14
LeftHousingAssy ....................................................................15
BallastBoard .......................................................................16
Power Supply .......................................................................16
Fan / Secondary Wire Harness Asy ......................................................17
LampCoverSafetyInterlockSwitch ......................................................18
PowerSwitch .......................................................................18
SECTION 5: Maintenance
Preventative Maintenance ..............................................................20
Cleaning ...........................................................................20
Checking Ground Impedance ..........................................................21
Measuring Leakage Current ......................................................... 21-22
FuseorLampReplacement ............................................................23
SECTION 6: Theory of Operations
Introduction .........................................................................24
StartUpRoutine .....................................................................24
Power Supply .......................................................................25
BallastBoard........................................................................25

Introduction
Light Source/Illuminator Service Manual Page 6
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 7
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
100-240 VAC
50/60 Hz
U.S.A. Plug Type
49502...Welch Allyn Light Source
100-240 VAC
50/60 Hz
European Plug Type
49504...Welch Allyn Light Source
100-240 VAC
50/60 Hz
U.K. Plug Type
49506...Welch Allyn Light Source
100-240 VAC
50/60 Hz
Australian Plug Type
HLS24-0...Welch Allyn Illuminator
100-240 VAC
50/60 Hz
U.S.A. Plug type
HLS24-2...Welch Allyn Illuminator
100-240 VAC
50/60 Hz
European Plug type
HLS24-4...Welch Allyn Illuminator
100-240 VAC
50/60 Hz
U.K. Plug type
HLS24-6...Welch Allyn Illuminator
100-240 VAC
50/60 Hz
Australian Plug Type

Section 1 General Information
Light Source/Illuminator Service Manua Page 8
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
FusesT1.0A L250V: 1.0 A, 250 V, Time Lag (Slow-Blow), Low Breaking Capacity.

Light Source/Illuminator Service Manual Page 9
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 Tester- Associated Research Inc. Model 35400D or Equivalent.

Section 2 Service
Light Source/Illuminator Service Manual Page 10
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.

Section 2 Service
Light Source/Illuminator Service Manual Page 11
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 Page 12
Problem Solving
Troubleshooting
Experience shows that many service calls are due to improper operator technique and poor
connections. Before taking apart the light source, make sure that setup errors are not causing
the problem. When checking voltages or signals, be sure to verify signal through the
harness wires, connectors, and on the circuit board.
Symptom Possible Cause Procedure
Lamp is not illuminated,
and the fan is running. Lamp connector is not connected well.
Lamp is blown.
Defective ballast
Remove lamp cover and
re-seat connector.
Verify unit functions with a
known good lamp or lamp
functions with a known
good unit.
Verify Voltage input and
output of the Ballast
board. Refer to wiring
diagram. Note: There is
1KV to 2KV present at
the output during
startup.

Section 3 Problem Solving
Light Source/Illuminator Service Manual Page 13
Symptom Possible Cause Procedure
Lamp not illuminated, fan
does not function (No
power is apparent).
Light Source overheating
Power line damaged or
disconnected.
Power is not turned "ON"
Lamp Door Interlock
switch is disengaged.
AC line fuses F1 and/or
F2 are open.
Open circuit connection.
Power supply circuit
defective.
Other circuits loading
down power supply.
Fan Not working properly
or blocked fan ventilation
Connect, repair, or
replace as necessary.
Turn power on.
Verify that the lamp cover
is firmly and properly in
place and that interlock
switch is functioning
properly. Verify continuity
to be sure that the switch
is working properly.
Verify and replace as
necessary.
Verify AC input through
unit to the Switching
Power Supply.
Verify DC output at J2 of
Switching Power Supply.
If the fuse is blown,
disconnect the plug from
J2 (Output of the
Switching Power Supply).
Replace the blown fuse,
and reapply power. Verify
DC output at J2. If no
voltage is present or fuse
is again blown, replace
Switching Power supply.
Verify correct voltages at
the input and output of the
power supply
(See wiring
diagram 495102).
If all
voltages are within
specification, then replace
motor/secondary wire
harness assembly.

Light Source/Illuminator Service Manual Page 14
Disassembl
y
and Re
p
air
About This Section:
This section describes how to remove and replace major sub assemblies of the
49501 (Medical Version) and 40501I (Industrial Version) Solarc Light Source.
Note: Refer to the "Bubble Number" on each drawing and the cross
reference on the Parts List to determine the correct part number.
Part
Number Description Drawing #Bubble #Start up order Qty
106087 PHPS 6-32 X.500 495000 4 20
495080 PLUG, SCREW 495000 10 50

Section 4 Disassembly and Repair
Light Source/Illuminator Service Manual Page 15
Left Housing Assy Disassembly
1. Remove the two screw plugs:
___Drill through the center of the plug with a 1/16 drill in a pin vise
and pull straight up.
2. Remove the Bottom Housing:
___ Loosen thumb screw on the back of the unit and slide the
assembly towards the back of the unit.
3. Lamp Replacement Label:
___ Peel off Label and discard.
4 Fan Guard:
___ Unscrew the two screws on the left side directly over the AC
Power inlet that hold the fan guard in place. Only remove these
two screws.
5. Light Attenuator Assembly:
___ Unscrew the two screws that hold Light Attenuator Control
Assembly, and remove the pan head screw, that was under the
attenuator control, from the left housing.
6. Left Housing Assembly:
___ Unscrew the two side screws that hold the right and left
housings together. The left housing will now come off. Make sure
to hold the switch and the AC power inlet down.

Section 4 Disassembly and Repair
Light Source/Illuminator Service Manual Page 16
Ballast Board Replacement
1. Lamp:
___ Remove the lamp from the lamp holder, and disconnect the
lamp socket.
2. Wire Tie:
___ Cut the tie wrap that holds the black and white wires that lead
to the ballast board and lift the metal chassis off to one side.
3. Ballast PCB:
___ Unscrew the four Phillips head screws that hold the ballast
board in place. Lift the board up and unplug secondary wire
harness connector from the ballast board.
4. Lamp Wires:
___ Desolder the Black and White wires from the ballast board.
5. Reassembly:
___ Reassemble in reverse order taking care to not pinch any of
the wires under the chassis plate. The chassis plate should be
between the right housing and the insulator. Be sure to place the
ballast board insulator in its original position.
Power Supply Replacement
1. Insulator Sheet:
___ Pull out insulator along side the PCB.
2. Wire Harness:
___ Unplug the secondary wire harness from the power supply
PCB. It is the plug closest to the fan.
___ Unplug the primary wire connector and the green/yellow
ground wire from the power supply board.
3. Reassembly:
___ Reassemble in reverse order. Be sure to put the insulator
back into its original position.
Make sure
that the new power
supply board is
seated
into the right housing.

Section 4 Disassembly and Repair
Light Source/Illuminator Service Manual Page 17
Fan / Secondary Wire Harness Replacement
*The fan comes as part of the secondary wire harness assembly; therefore, the
entire secondary wire harness assembly must be replaced.
1. Power Supply PCB:
___ Remove the power supply board and the ballast board as
described in earlier in section 4 of this document. Do Not desolder
the black and white wires from the ballast board as described in
the ballast board section .
2. Fan/Fan Guard:
___ Unscrew the remaining two screws that hold the fan to the
right housing. Taking care to remember how the ground wire is
connected and routed.
3. Wire Tie:
___ Cut the wire tie that holds the secondary wiring harness to the
Black & White wires leading from the ballast board.
4. Ground Wire:
___ Unscrew the top nut on the chassis ground stud, using an
11/32 nut driver, and lift off the top two ring terminals. See detail
"A"of drawing 495072 for proper assembly of ground wires to the
chassis ground stud.
5. Thermal Cut Off:
___ Loosen the screw that holds the temperature sensor to the
lamp holder assembly, and remove the sensor.
6. Harness:
___ Remove the Secondary Wiring Harness assembly.
7. Reassembly:
___ Reassemble in reverse order.
(Note)
A small amount of
thermal compound
(M11047) needs to be
applied to
the flat side
of the new temperature sensor before it is installed. See detail
"A"of drawing 495072 for
proper assembly of
g
round wires
to the
chassis ground stud.
Make sure
that the thermal cut out wire
grommets are positioned properly.

Section 4 Disassembly and Repair
Light Source/Illuminator Service Manual Page 18
Lamp Cover Safety Interlock Switch:
1. Safety Switch Assy:
___ Unscrew the two Phillips head screws that hold the switch
assembly to the chassis. Keep the outside insulators.
2. Primary Wires:
___ Disconnect the primarywires from the switch, and remove the
switch.
3. Reassembly:
___ Reassemble in reverse order. Make sure to reinstall the two
insulators that were removed in step #1. Refer to wiring diagram
for wiring of the switch.
Power Switch Replacement
1. Left Housing:
___ Remove left housing assembly as described in the left
housing disassembly section.
2. Power Switch removal:
___ Unplug the four quick connect terminals from the switch and
remove defective switch.
3. Power Switch replacement:
___ Reassemble the switch to the four quick connect terminals.
The switch should be set into the right housing with the "0" closest
to the internal chassis plate.

Section 4 Disassembly and Repair
Light Source/Illuminator Service Manual Page 19
Replacement of the Primary Wiring Harness
1. Left Housing:
___ Remove left housing assembly as described earlier in sect. 4.
2. Wire Ties:
___ Cut the two wire ties that hold the harness to the internal
chassis plate.
3. Ground Wire:
___ Unscrew the two nuts on the chassis ground lug using an
11/32 nut driver, and remove the primary ground wire.
4. Removal of the Interlock Switch:
___ Unscrew the two Phillips head screws that hold the interlock
safetyswitch assembly to the chassis. Keep the outside insulators.
5. Removal of the defective wiring harness:
___ Pull off the quick connect terminals that attach the defective
wiring harness to the power switch and to the interlock safety
switch, Remove the defective wiring harness.
6. Reassembly of the primary wire harness assembly:
___ Reassemble in reverse order. Refer to wiring diagram for
wire connections.

Light Source/Illuminator Service Manual Page 20
Maintenance
Preventative Maintenance
The purpose of preventative maintenance is to pro-actively reduce or eliminate future problems.
Keeping the Solarc Light Source in good operating condition ensures that it will perform reliably and
safely. Every six to twelve months, you should:
* Check power cable for wear.
* Ensure that, during use, the light source receives adequate ventilation.
* Ensure that the ball detent is still functioning properly.
Visual Inspection
Check for anything out of the ordinary. For instance:
- Does the light source make too much noise?
- Are there any loose parts inside the box?
- Is the power switch working properly?
- Do all components connect/disconnect easily?
- Are the ventilation holes free of obstructions?
CLEANING
Refer to Operating Manual, Welch Allyn Part Number 495003.