Welch Allyn LS200 Procedure Light User manual

SERVICE MANUAL
LS200 Procedure Light
MODELS: 44200...Domestic
44202...Europe
44204...U.K.
44206...Australia
44210...Wall Mount
44250...Mobile Stand
Copyright 1995
Welch Allyn Co.
4341 State Street Road
P.O. Box 220
Skaneateles Falls, NY 13153-0220
Originator: RJS SERVICE MANUAL 441147 REV A, 9/94
ECN# 5-29347 10/94 1

TABLE OF CONTENTS
FORWARD 3
SAFE SERVICE 4
INDEX: ELECTRICAL FAILURE/CAUSE/CORRECTIVE ACTION 5 - 7
MECHANICAL FAILURE/CAUSE/CORRECTIVE ACTION 8 - 11
INDEX: REMOVAL/REPLACEMENT (R & R) PROCEDURES 12
REMOVAL/REPLACEMENT PROCEDURES 13 - 31
APPENDIX
SERVICE PARTS LIST AND DIAGRAM AA
WIRING DIAGRAM/SCHEMATIC BB
TOOLS (COMMON & SPECIAL) CC
PRODUCT UP-DATES DD
PRODUCT DESCRIPTION EE
2

FORWARD
This SERVICE MANUAL provides technical assistance to Welch Allyn repair technicians
for diagnosing, repairing, and testing the WELCH ALLYN LS200 PROCEDURE LIGHT. The
manual’s main content areas cover: troubleshooting, step by step repair, adjustment, and re-test
procedures. The repair ‘TASK’ procedures (R & R .. Removal and Replacement) are written to
provide quick and easy reference for repair technicians of different experience levels. Required
specifications and materials are listed at each step where applicable. When reading this manual for
thefirsttime,haveanLS200readilyavailableforreferenceandpractice. Readeachcompleterepair
stepon whatto do(task statement),plus howto doit (techniquestatement) beforestarting therepair
or practice.
Training for the LS200 should consist of detailed demonstrations of required repair tasks,
practice on LS200’S using repair tooling and materials. Assess 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
replacementparts, asalways,by referencingyourlatest billofmaterials, partscatalog andassembly
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 PRODUCT UPDATES APPENDIX.
3

WEAR EYE PROTECTION WHEN SERVICING THIS PRODUCT !
*** SAFE SERVICE ***
DISCONNECT power cord from A.C. power source before initial disassembly of LS200
Light. OBSERVE cautions / warnings in owners manual and printed on the product itself.
COMPLY with all safety codes and practices for this type of product. COMPLY with all
safety regulations at your work place.
PERFORMallrecommendedWelchAllynservicetestprocedurestoassuretheLS200meets
all requirements safely and reliably.
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 AT LEAST TWENTY MINUTES (20 MIN.) BEFORE TOUCHING HALOGEN LAMPS
OR METAL NEAR THE LAMP(S). VERY HIGH TEMPERATURES will cause severe burns!
Fracturedor brokenlampsmay causeinjury. Toprevent cuts,REMOVEsuch lampsbyHOLDING
them with a cloth or wear work gloves. WEAR SAFETY GLASSES!
DO NOT LOOK DIRECTLY AT, TOUCH OR SPRAY LIT halogen lamps.
*** QUALITY SERVICE ***
MODIFY your SERVICE Manual by notating changes and revisions of part numbers and
procedures. Enter this information on the appropriate page...and include a copy of the notification
in your Appendix “Product Updates”.
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
HASOCCURREDORISSUSPECTED, DONOTDISASSEMBLE,REASSEMBLE,ALTEROR
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.
Whenperformingacompleteinspection, LOOKfor:missingparts,productdefects,damage,
tampering, unsafe condition of wiring or any component. ENTER all findings and test data along
with repair status in the appropriate file.
Most of the repairs can be performed on a foam covered work bench. Place the LS200 in
holding fixture for repairs. Take all actions to prevent scratching the bezel.
4

INDEX: FAILURE / CAUSE
LS200 ELECTRICAL
COMPLAINT / (CONDITION): CAUSE / CORRECTIVE ACTION:
__________________________ _____________________________
Less than 3 lamps light. .... lamp is burned out. REPLACE PN 06400
.... lamp not seated correctly. SEAT lamp.
(3 lamps are wired in parallel)
.... lamp socket defective. REPLACE.
None of the lamps illuminate .... no voltage at A.C. source. TRY other power outlet.
(SWITCH IS “ON”, POWER RESTORE power.
CORD PLUGGED IN) .... power cord loose. RESTORE connections
.... fuse(s) blown. CHECK for short to ground or other
highcurrentpathsuchasalinetolineshort.RESTORE
circuit to specifications prior to energizing LS200.
REPLACE fuses.
WARNING: ... burned out lamps. CHECK lamps...are they correct
ALLOW LAMPS TO COOL FOR part# for this Light. REPLACE lamp (Welch Allyn
at least 20 MINUTES. PN 06400).
.... defective (failed open) switch.
CHECK voltage across switch pole pairs in closed
position. If full transformer voltage is present, then
theswitchis“OPEN”electrically.REPLACEdefective
switch. TEST.
.... defective transformer, “OPEN”
primaryor secondarywindings ordefectiveor “failed
OPEN” thermal protection* device in transformer
primarywindingforinternationalLS200.CHECKfor
continuityintransformerprimarywinding.REPLACE
if ‘open’. *”non-resetting type” does not reset upon
cooling.
.... “OPEN” circuit in power connector.
REPLACE defective component.
.... power cord damaged. REPLACE cord.
5

INDEX: FAILURE / CAUSE
LS200 ELECTRICAL
COMPLAINT / (CONDITION): CAUSE / CORRECTIVE ACTION:
__________________________ _____________________________
Light output is very .... Wrong lamp(s) (voltage rating above low, all lamps
lit. 12 volts). REPLACE with PN 06400.
.... lamp(s) not properly aligned in holder.
INSPECT, ADJUST.
.... bezel not installed properly. CHECK AND ALIGN
three clear round sections of bezel directly over
the lamps.
.... dirty glass filters on bezel assembly. CLEAN.
.... defective transformer. MEASURE secondary
voltage. (at transformer: input:120V 60HZ/
output:12.6 VAC, +/-.2 VAC @ 5 Amps OR at
lamp holder: 12.0 +/-.3 VAC) See drawing
#441048. Low output indicates defective
transformer. However, even a good transformer will
have low output when provided with low input
voltage. MEASURE both voltages. Light intensity
is proportional to current passing through lamp
filament.
.... glass is damaged. REPLACE glass.
.... angle bracket bent. REPLACE angle bracket.
.... lamps are defective or damaged. REPLACE lamps.
6

INDEX: FAILURE / CAUSE
LS200 ELECTRICAL
COMPLAINT / (CONDITION): CAUSE / CORRECTIVE ACTION:
__________________________ _____________________________
Illumination is intermittent .... loose connections, defective wiring or lamp(s) not
(light ‘flickers’) as arm is seated fully in holder. TROUBLESHOOT /
articulated. RESTORE connections /REPLACE defective parts.
(Customer should send
LS200 to Welch Allyn
for service.)
Switch produces arc .... switch is defective or wiring connections are loose /
or flash when operated. intermittent TROUBLESHOOT, REPLACE switch,
(Customer should send connectors.
LS200 to Welch Allyn
for service.)
Fails Dielectric strength .... transformer has electrical insulation failure/current
leak. REPLACE transformer.
Lamps blow very quickly, .... transformer output voltage is too high. Find cause,
less than 30 seconds. ex.: wrong transformer, input voltage too high,
incorrect bulbs.
T E C H N I C I A N N O T E S :
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7

INDEX: FAILURE / CAUSE
LS200 MECHANICAL
D E F I N I T I O N S
To simplify text, numbers are used for the names of the joints on the LS200. See figure 1 on
page 9. This page of information is for referencing the joints on the LS200 and giving a general
description of required adjustments. This page is not service instructions.
JOINT NUMBER: DESCRIPTION:
Yoke/Housing joint ..... The crescent shaped part is the yoke. It holds the
(# 1 joint) lamp housing. This is a technician adjustable
friction joint. Adjust friction to keep lamp housing
in position when moved. Tighten/loosen lamp
housing 15/16" nut on pivot bolt. (Secure this nut
with Loctite #242, M30338.) REMOVE flakes of
Loctite which may be in lamp housing. This is the
only joint that is lubricated (Dow Corning #7
release compound, M11175)
Yoke-arm joint .... The yoke is attached to the upper (long) (# 2 joint)
arm at the ‘yoke-arm’ joint # 2. (User can adjust
this friction joint by tightening or loosening slotted
set screw in arm near joint. This set screw is secured
with Loctite #222, M30375.) To replace components
of joint # 2, remove short arm. (See sect. I.)
Arm joint .... The two arm sections are joined at the adjustable
(# 3 joint) ‘arm’ joint. (User can adjust this friction joint by
tightening or loosening the black knob.) To replace
or repair it, you must remove the lower arm and
release spring tension. (See sect.J.)
Universal connector .... The lower (short) arm attaches to the mounting
(# 4 joint) option (pole or wall mount) at the ‘universal
connector’ joint. (User can adjust this friction joint
by tightening or loosening the slotted set screw in
the arm near this joint. Do not use Loctite on this set
screw.)
Mount arm joint .... The mount arm attaches to the wall mount bracket
(# 5 joint) at the ‘mount arm’ joint. This joint is not
adjustable. Disassembled by removing 3 cap screws
underneath wall mount bracket.
8

INDEX: FAILURE / CAUSE
LS200 MECHANICAL
COMPLAINT / (CONDITION): CAUSE / CORRECTIVE ACTION:
__________________________ _____________________________
Joints are stiff.
Excessive resistance to
movement at below listed
joint(s):
#1, 2, 3, 4, 5 ..... foreign matter in joint. DISASSEMBLE, CLEAN,
REASSEMBLE, ADJUST.
#2, 4 ..... set screw too tight for #2, #4. LOOSEN and
ADJUST per instructions in owners manual.
#3 ..... arm adjustment knob is too tight.
LOOSEN to RESTORE desired holding.
#1 ..... pivot nuts too tight. LOOSEN nuts.
LS200 does not maintain
position:
Generally ..... intended joint friction (other than joint #1 which is
supposed to be lubricated) possibly compromised
by lubrication. DISASSEMBLE, CLEAN REPLACE
brake washers in affected joints and components of
joint #3. DO NOT LUBRICATE joints. Only joint #1
requires lubrication with Dow Corning #7 release
compound, Welch Allyn M#11175.
..... set screw at #2 is loose or missing. TIGHTEN / REPLACE.
..... set screw at #4 is loose or missing. TIGHTEN / REPLACE.
at #5 joint ..... wall bracket is not mounted per instructions.
CHECK with a level. REMOUNT within 2 degrees
of level per instructions in owners manual.
..... cap head screws are loose or missing.
Unit sways or wobbles: ..... mounting option attachment screw is loose or
Entire arm and light head missing. INSTALL screw and TIGHTEN.
wobbles. ..... wall bracket option is not secure. ATTACH to wall
(these are customer items) at stud with approved screws only.
..... joint #3 knob too loose. TIGHTEN.
..... pole is loose on mobile stand. REASSEMBLE
according to instructions. ALIGN the small metal
post in the stand with the hole in the pole. 10

INDEX: FAILURE / CAUSE
LS200 MECHANICAL
COMPLAINT / (CONDITION): CAUSE / CORRECTIVE ACTION:
__________________________ _____________________________
Light head wobbles. ..... clear plastic cover on front of light head is not put
on properly. REFER to lamp replacement
instructions to VERIFY that plastic cover tabs are
aligned with those on the white plastic light housing.
REMOVE and RE-INSTALL clear plastic cover.
Power supply wobbles. ..... power supply attachment points are not secure.
TIGHTEN this connection by PUSHING the power
supply housing down onto the mounting screws as
far as it will go.
Mobile stand is difficult ..... casters are locked. UNLOCK casters when moving unit.
to move.
..... wheel(s) are bound up with foreign material such as
string. CLEAR obstruction.
LS200 is noisy ..... some type of cleaning agent or solvent may have
when articulated. gotten into joint(s). ALLOW it to dry and DO NOT
LUBRICATE.
..... foreign material has built up in the joint. WIPE
material out of joints.
..... the heat shrink tubing over the spring is not in
place. REPOSITION to eliminate sound.
LS200 makes clicking sound ..... strap attached to spring is interfering with mandrel
when upper arm is raised assembly. Replace strap and any other worn parts in
and/or lowered joint #3. REASSEMBLE according to instructions
in section K.
END LS200 MECHANICAL TROUBLESHOOTING
T E C H N I C I A N N O T E S :
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11

INDEX: REMOVAL AND REPLACEMENT (R & R) PROCEDURES
CAUTION : DISCONNECT LS200 FROM A.C. POWER SOURCE
BEFORE SERVICING TO AVOID ELECTRICAL SHOCK HAZARD
Component: Page:
A Bezel assembly - - - - - - 13
B Halogen lamps - - - - - - 14
C Fuses - - - - - - 15
D IEC connector - - - - - - 16
E Power switch - - - - - - 17
F Transformer - - - - - - 18
G Lamp holder - - - - - - 19
H Lamp housing - - - - - - 20-21
I Yoke - - - - - - 22-25
J Joint #3 (Main hinge) - - - - - - 26-27
K Cable - - - - - - 28-29
L. Joint #4 (Universal connector) - - - - - - 29
M. Mobile stand - - - - - - 30
N. Wall mount - - - - - - 30-31
T E C H N I C I A N N O T E S :
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12

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
A BEZEL ASSEMBLY (R & R) PN 441145-501
CAUTION: ALLOW HOT LAMPS TO COOL FOR 20 MINUTES BEFORE REMOVING
BEZEL.
A 1. UNPLUG LS200 AND REMOVE HANDLE.
(ALSO REFER TO OPERATING INSTRUCTIONS PN 441118-1ML.)
REMOVE POWER CORD FROM A.C. POWER SOURCE. LAY LS200 DOWN
WITH HANDLE FACING UP. UNSCREW THE HANDLE COUNTER
CLOCKWISE. REMOVE HANDLE. UNSCREW THE TETHER RETAINING
NUT AND REMOVE THE TETHER.
A 2. REMOVE BEZEL.
SLIDE THE BEZEL OFF OF THE THREADED ROD.
A 3. REPLACE BEZEL.
INSPECT LAMPS, REFLECTORS, SHROUD, BEZEL, AND GLASS FOR
SMUDGES, AND DUST. CLEAN BEFORE REASSEMBLING. DO NOT USE
SOLVENTS TO CLEAN BEZEL. PUT BEZEL OVER LIGHT HOUSING
WITH THREE TABS OVER THREE RECESSES IN THE LAMP HOUSING.
ALIGN TABS ON BEZEL WITH TABS ON LAMP HOUSING. PLACE THE
TETHER ONTO THE THREADED ROD OF THE CENTRAL BRACE.
THREAD THE NUT ONTO THE THREADED ROD AND TIGHTEN HAND
TIGHT. THREAD THE HANDLE ONTO THE THREADED ROD UNTIL IT
CONTACTS THE BEZEL. TIGHTEN THE HANDLE SLIGHTLY UNTIL THE
BEZEL IS FIRMLY IN PLACE.
A 4. VERIFY REPAIR.
PLUG LS200 INTO MAINS AND TURN SWITCH TO ON POSITION.
ALL THREE LAMPS SHOULD BE LIT. TURN OFF. ALL LAMPS MUST
TURN OFF.
T E C H N I C I A N N O T E S :
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13

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
B HALOGEN LAMP REMOVAL AND REPLACEMENT (R & R) PN 06400
(OSRAM # 44860sp or 44860nsp, [ 12V/20W/12 degree spread ])
D O N O T T O U C H H O T L A M P !
WARNING: ALLOW LAMP TO COOL OFF FOR AT LEAST 20 MINUTES BEFORE
TOUCHING LAMP OR SURROUNDING METAL PARTS.
NOTE:REFER TO LAMP CHANGING DIAGRAMS IN OWNERS MANUAL #44118ML.
B 1. UNPLUG LS200 AND REMOVE BEZEL.
REMOVE POWER CORD FROM A.C. POWER SOURCE. TURN THE UNIT
FOR EASY ACCESS TO THE HANDLE AND UNSCREW HANDLE
COUNTER CLOCKWISE. LET THE BEZEL SWING AWAY TO EXPOSE
LAMPS AND LAMP SOCKETS. THE BEZEL WILL BE SUSPENDED BY
THE TETHER.
D O N O T T O U C H H O T L A M P
O R M E T A L P A R T S N E A R L A M P S !
B 2. REMOVE LAMP.
AFTER A ‘COOLING DOWN’ PERIOD OF AT LEAST 20 MINUTES,
LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE
OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET.
PULL THE LAMP HOLDING LEVER TOWARD THE BACK OF THE UNIT
UNTIL LEVER IS ALMOST VERTICAL. REMOVE THE EXPIRED LAMP
AND RETURN THE LEVER TO ITS FORMER POSITION.
CAUTION: WEAR A PROTECTIVE GLOVE WHEN REMOVING FRACTURED LAMPS.
REMOVE BROKEN LAMP FRAGMENTS FROM THE LAMP HOUSING.
B 3. REPLACE WITH NEW LAMP PN 06400.
RETURN THE LAMP HOLDING LEVER TO ITS ORIGINAL POSITION.
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. VERIFY PROPER ALIGNMENT OF PINS
IN LAMP SOCKET. PRESS DOWN INTO FULL ENGAGEMENT WITH
LAMP SOCKET. LAMP WILL SNAP INTO PLACE.
B 4. INSTALL BEZEL.
ALIGN THE TABS ON THE BEZEL WITH THE TABS ON THE LAMP
HOUSING AND MAKE SURE THAT THE THREE CLEAR WINDOWS IN
THE BEZEL LINE UP WITH LAMPS. WHILE HOLDING BEZEL IN PLACE
WITH ONE HAND, SCREW THE HANDLE ONTO THE THREADED
SHAFT. TIGHTEN THE HANDLE UNTIL IT IS FIRMLY IN PLACE.
B 5. TEST TO VERIFY SAFE OPERATION.
CONNECT TO POWER SOURCE. PLACE THE POWER SWITCH IN THE
‘ON’ POSITION. ALLOW NEW LAMPS TO OPERATE FOR FIVE
MINUTES TO ‘BURN IN’.
14

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
C FUSES (TWO) R & R. DOMESTIC: 1A,250V PN 236706-3907
INTERNATIONAL: 0.5A,250V PN 236706-3114
CAUTION: IF AN LS200 HAS BEEN RETURNED FOR FUSE REPLACEMENT,
DO NOT JUST REPLACE FUSES AND PLUG IN TO TEST. INSTEAD:
1. LOCATE AND ELIMINATE THE SHORT CIRCUIT BY TESTING
TRANSFORMER OR WIRING. DETERMINE THE CAUSE OF THE
PROBLEM IF POSSIBLE, ex.: LINE SURGE. WHAT
COMPONENT(S), IF ANY, WERE DAMAGED?
2. RESTORE THE CIRCUIT TO SPECIFICATIONS BEFORE
REPLACING FUSE AND ENERGIZING.
* LOCATE AND ELIMINATE SHORT CIRCUITS (LINE TO LINE OR
LINE TO GROUND ) BEFORE CONNECTING LS200 TO MAINS.
INSPECT WIRE INSULATION AND COMPONENTS FOR BURN
AND SMOKE MARKS. REPLACE ALL DAMAGED COMPONENTS
TO RESTORE CIRCUIT TO SPECIFICATIONS. INSPECT
TRANSFORMER ASSEMBLY FIRST.
C 1. REMOVE FUSE DRAWER.
DISCONNECT LS200 FROM POWER SOURCE. REMOVE POWER CORD
FROM UNIT POWER CORD RECEPTACLE. INSERT THE FLAT BLADE
OF A SMALL SCREWDRIVER (1/8") INTO SLOTS ON SIDES OF THE
FUSE DRAWER. PRY BOTH LATCHES AND SLIDE THE FUSE DRAWER
OUT OF THE RECEPTACLE.
C 2. REMOVE FUSES FROM FUSE DRAWER.
PULL BOTH FUSES FROM FUSE DRAWER AND VERIFY THAT ONE OR
BOTH ARE ELECTRICALLY ‘OPEN’ (BLOWN). NOTE THE FUSE
RATING. THIS IS IMPORTANT SINCE THE FUSES MAY HAVE BLOWN
BECAUSE THEIR AMP RATING WAS BELOW THE REQUIRED AMP
RATING FOR THIS PRODUCT. THUS, THE FUSES WERE AT FAULT,
NOT THE LS200 CIRCUITS. FUSES OF THE PROPER RATING CAN BE
INSTALLED AND THE LAMP TURNED ON FOR A FUNCTIONAL CHECK.
FUSES CAN BE CHECKED VISUALLY FOR OPEN FILAMENT.
CONTINUITY CAN BE CHECKED WITH AN ANALOG OR DIGITAL VOLT
OHM METER D.V.O.M.. OPEN (BLOWN) FUSES HAVE INFINITE
RESISTANCE (‘OL’ SYMBOL INDICATES “OPEN LEADS” FOR MANY
DIGITAL VOLT-OHM METERS).
C 3. INSTALL NEW FUSES IN FUSE DRAWER.
INSERT TWO FUSES IN THE RECESSES IN THE FUSE DRAWER.
REPLACE BOTH FUSES, EVEN WHEN ONE IS NOT BLOWN (MELTED
THROUGH.) ALIGN THE TAB ON THE BOTTOM OF THE FUSE DRAWER
WITH THE SLOT IN THE POWER CORD RECEPTACLE. EVENLY INSERT
THE FUSE DRAWER INTO HOUSING UNTIL ITS DETENTS LATCH.
C 4. TEST TO VERIFY SAFE OPERATION.
CONNECT LS200 TO POWER SOURCE AND VERIFY THAT ALL THREE
LAMPS ARE LIT. CONDUCT HI-POT TEST PER A-02861. 15

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
D IEC CONNECTOR R & R
D 1. REMOVE BACK HOUSING.
DISCONNECT LS200 FROM MAINS. IF MOUNTED ON MOBILE STAND,
DETACH TRANSFORMER ASSEMBLY FROM POLE. REMOVE FOUR
SCREWS AND REMOVE BACK HOUSING.
D 2. REMOVE IEC CONNECTOR.
DISCONNECT THREE WIRES FROM THE TERMINALS ON THE BACK OF
THE IEC CONNECTOR (POWER RECEPTACLE). LIFT IEC CONNECTOR
OUT OF THE FRONT HOUSING. RE-USE THE OLD FUSE TRAY IF IT IS NOT
DAMAGED. NEW FUSES OF THE CORRECT RATING SHOULD BE USED.
D 3. INSTALL REPLACEMENT IEC CONNECTOR.
ALIGN REPLACEMENT POWER RECEPTACLE WITH THE GROUND
(CENTER) TERMINAL AT THE BOTTOM OF THE HOLE IN THE CHASSIS.
PRESS RECEPTACLE INTO HOUSING CUTOUT. CONNECT WIRES PER
ASSEMBLY DRAWING. CONNECT THE BLACK WIRES TO THE IEC
CONNECTOR AT FI AND F2. THE CENTER TERMINAL IS THE GROUND
TERMINAL...CONNECT THE GREEN WITH YELLOW STRIPE (GROUND
WIRE) TO THE GROUND TERMINAL.
D 4. ATTACH BACK HOUSING OF POWER SOURCE.
MAKE SURE THE STRAIN RELIEF AND IEC CONNECTOR ARE IN THE
NOTCHES IN THE FRONT HOUSING. BE CAREFUL NOT TO PINCH
WIRES ON SECONDARY SIDE WHILE CLOSING HOUSING. POSITION
THE COVER ONTO THE POWER SUPPLY HOUSING AND FASTEN IT
WITH FOUR SCREWS.
D 5. TEST TO VERIFY SAFE OPERATION.
CONNECT LS200 TO POWER SOURCE AND VERIFY THAT ALL THREE
LAMPS ARE LIT. CONDUCT HI-POT TEST PER A-02861.
T E C H N I C I A N N O T E S :
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16

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
E POWER SWITCH R & R
NOTE: IT IS NOT NECESSARY TO DISASSEMBLE THE LAMP HOUSING TO
REPLACE THE SWITCH.
E 1. REMOVE SWITCH.
APPLY A SMALL PIECE OF MASKING TAPE TO THE LAMP HOUSING
ALONG THE EDGES OF THE SWITCH TO PROTECT THE SURFACE
FINISH OF HOUSING DURING SWITCH REMOVAL. PULL THE OLD
SWITCH OUT OF THE LIGHT HOUSING BY PRYING UPWARDS AT THE
END OF THE SWITCH WITH A THIN EDGE SUCH AS A PUTTY KNIFE.
E 2. DISCONNECT WIRES FROM SWITCH.
UNPLUG ALL FOUR (4) WIRES FROM THE BOTTOM OF THE SWITCH.
E 3. INSTALL NEW SWITCH.
ATTACH WIRES AND PRESS SWITCH INTO LAMP HOUSING, MAKING
SURE THAT THE LAMP SYMBOL ON THE TOP OF THE SWITCH IS
TOWARDS THE WORD “WELCH” OF THE WELCH ALLYN NAME ON
THE FRONT OF THE HOUSING. THESE WIRES CONDUCT A.C.
CURRENT AND AS SUCH MAY BE ATTACHED TO THE SWITCH IN
EITHER POSITION. REFER TO ASSEMBLY DRAWING NO. 441013.
E 4. VERIFY REPAIR.
CONNECT LS200 TO POWER SOURCE AND OPERATE THE SWITCH
APPROXIMATELY 5 TIMES TO DETERMINE THAT THE SWITCH IS
OPERATING PROPERLY. VERIFY THAT ALL THREE LAMPS LIGHT.
T E C H N I C I A N N O T E S :
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17

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
F TRANSFORMER ASSEMBLY R & R.
NOTE: TOCHECKFORDEFECTIVETRANSFORMER,MEASURE:input(120V)60HZ
AND OUTPUT (12.6 VAC,+/-.2 VAC @5 Amps.) SEE DWG# 441048. LOW
OUTPUTINDICATESA DEFECTIVETRANSFORMER. HOWEVER, EVENA
GOODTRANSFORMERWILLPRODUCELOWOUTPUTIFINPUTVOLTAGE
IS BELOW REQUIREMENTS. MEASURE BOTH. LIGHT INTENSITY IS
PROPORTIONALTOCURRENTPASSINGTHROUGHTHELAMPFILAMENT.
F 1. REMOVE BACK HOUSING.
DISCONNECTLS200FROMMAINS. REMOVETRANSFORMERASSEMBLY
FROM POLE OF MOBILE STAND IF SO EQUIPPED. REMOVE FOUR
SCREWS AND REMOVE BACK HOUSING.
F 2. REMOVE OLD TRANSFORMER.
DISCONNECT FIVE (5) TRANSFORMER WIRES FROM POWER
CONNECTOR AND SECONDARY CABLE (GRAY CORD). REMOVE
TRANSFORMER STRAPS BY UNSCREWING FOUR PHILLIPS HEAD
SCREWS. LIFT TRANSFORMER OUT OF FRONT HOUSING.
F 3. INSTALL REPLACEMENT TRANSFORMER.
ALIGN TRANSFORMER (WITH WIRES “DOWN”) WITH THREE (3)
PRIMARY WIRES TOWARDS THE POWER CONNECTOR. THESE WIRES
MUST PASS BETWEEN THE RIBS OF THE TRANSFORMER SUPPORT.
ALIGN STRAPS SO THAT HOLES IN STRAPS MATCH WITH HOLES IN
TRANSFORMER. SECURE THE TRANSFORMER WITH TWO STRAPS AS
SHOWN ON ASSEMBLY DRAWING #441019, AND FOUR STRAP-
HOLDING SCREWS. TIGHTEN SCREWS.
F 4. RESTORE ELECTRICAL CONNECTIONS.
CONNECT SPADE CONNECTORS OF TRANSFORMER ‘PRIMARY’ WIRES
TO TERMINALS OF POWER CONNECTOR AS SHOWN IN ASSEMBLY
DRAWING. BUNDLE THE THREE LINE SIDE WIRES TOGETHER WITH
A WIRE TIE. CONNECT SECONDARY TRANSFORMER WIRES TO CABLE.
F 5. ATTACH BACK HOUSING OF POWER SOURCE.
MAKE SURE THE STRAIN RELIEF AND IEC CONNECTOR ARE IN
PLACE. PLACE THE COVER ONTO THE POWER SUPPLY HOUSING
BEING CAREFUL NOT TO PINCH WIRES BETWEEN THE CASES.
FASTEN WITH FOUR (4) SCREWS.
F 6. TEST TO VERIFY SAFE OPERATION.
CONNECT LS200 TO POWER SOURCE AND VERIFY THAT ALL THREE
LAMPS ARE LIT. CONDUCT HI-POT TEST PER A-02861.
T E C H N I C I A N N O T E S :
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18

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
G LAMP HOLDER R & R
G 1. REMOVE BEZEL.
(ALSO REFER TO PG.8 OPERATING INSTRUCTIONS PN441118-1ML)
PUT POWER SWITCH IN OFF POSITION AND REMOVE POWER CORD
CONNECTOR FROM A.C. POWER SOURCE. LAY UNIT DOWN WITH
HANDLE UP. UNSCREW HANDLE COUNTER CLOCKWISE. REMOVE
NUT, TETHER AND BEZEL ASSEMBLY.
DANGER! D O N O T T O U C H H O T L A M P S O R H O T L A M P
H O L D E R S ! (GLASS AND METAL COMPONENTS RETAIN HEAT
EVEN AFTER LAMPS ARE OFF SEVERAL MINUTES.)
G 2. REMOVE COOL LAMP(S).
AFTER A COOLING DOWN PERIOD OF AT LEAST 20 MINUTES,
LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE
OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET. PULL
THE LAMP HOLDING LEVER TOWARD THE BACK OF THE UNIT UNTIL
LEVER IS ALMOST VERTICAL. REMOVE EXPIRED LAMP.
G 3. REMOVE OLD LAMP HOLDER FROM LAMP HOLDER.
UNSCREW THREE SCREWS. CUT THE LAMP HOLDER WIRES AS
CLOSE TO THE LAMP HOLDER AS POSSIBLE. LIFT OLD LAMP
HOLDER OUT OF LAMP HOUSING.
G 4. ATTACH REPLACEMENT LAMP HOLDER TO LAMP HOUSING.
CONNECT REPLACEMENT LAMP HOLDER WIRES TO OLD WIRES
USING BUTT SPLICES PN 488377. KEEPING WIRES OUT FROM UNDER
THE LAMP HOLDER, POSITION LAMP HOLDER OVER THREE
THREADED BOSSES IN LAMP HOUSING. MAKE SURE THAT THE
WIRES DO NOT INTERFERE WITH THE LAMP CHANGING LEVERS.
INSERT AND TIGHTEN THREE SCREWS. INSTALL LAMP.
G 5. INSTALL BEZEL ASSEMBLY.
FOLLOW INSTRUCTIONS IN SECTION B-4 PG 14 TO ATTACH THE
BEZEL ASSEMBLY TO THE LS200.
G 6. TEST TO VERIFY SAFE OPERATION.
CONNECT TO A.C. POWER SOURCE AND ILLUMINATE LAMP. LET THE
UNIT STAY ON FOR FIVE MINUTES TO VERIFY PROPER OPERATION.
T E C H N I C I A N N O T E S :
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____________________________________________________________________________
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19

CAUTION: DISCONNECT LS200 FROM POWER SOURCE BEFORE SERVICING.
H LAMP HOUSING PN 441023-1 R & R.
H 1. REMOVE BEZEL.
UNPLUG LS200 AND REMOVE HANDLE. (ALSO REFER TO OPERATING
INSTRUCTIONS PN 441118-1ML.) REMOVE POWER CORD FROM A.C.
POWER SOURCE. LAY LS200 DOWN WITH HANDLE FACING UP.
UNSCREW THE HANDLE COUNTER-CLOCKWISE. REMOVE HANDLE.
UNSCREW THE TETHER RETAINING NUT AND REMOVE THE TETHER.
REMOVE BEZEL.
DANGER! D O N O T T O U C H H O T L A M P S O R H O T L A M P
H O L D E R S ! GLASS AND METAL COMPONENTS RETAIN HEAT
EVEN AFTER THE LAMPS HAVE BEEN TURNED OFF SEVERAL MINUTES.
H 2. REMOVE COOL LAMPS.
AFTER A COOLING DOWN PERIOD OF AT LEAST 20 MINUTES,
LOCATE AND PULL THE LAMP HOLDING LEVER TO RAISE THE BASE
OF THE LAMP OUT OF ENGAGEMENT WITH THE LAMP SOCKET. PULL
THE LAMP HOLDING LEVER TOWARD THE BACK OF THE UNIT UNTIL
LEVER IS ALMOST VERTICAL. REMOVE EXPIRED LAMP.
H 3. UNSCREW TWO LAMP HOLDERS NEAR PIVOT BOLTS. (TOP HOLDERS)
MARK LAMP HOLDERS 1-2-3. (REPLACE IN SAME POSITIONS.) REMOVE
THREE SCREWS ON EACH OF THE TWO LAMP HOLDERS ADJACENT TO
THE POWER SWITCH. THESE 2 LAMP HOLDERS WILL REMAIN IN THE
LAMP HOUSING, ATTACHED TO THE WIRES, UNTIL THE LAST LAMP
HOLDER AT THE BOTTOM OF THE LAMP HOUSING (BOTTOM LAMP
HOLDER) IS REMOVED. DO NOT CUT ANY OF THE LAMP HOLDER
WIRES OR SPLICES. UNSCREW BOTH OF THE 4-WAY CONNECTORS.
H 4. REMOVE SWITCH.
UNPLUG ALL FOUR (4) WIRES FROM THE BOTTOM OF THE SWITCH
AND CUT OFF THE SPADE CONNECTORS ON THE BLACK AND WHITE
WIRES ONLY. CUT RIGHT AT THE CONNECTOR. THESE TWO WIRES
ARE THE 12 VOLT SUPPLY FOR THE LAMPS. SQUEEZE DETENTS
TOGETHER ON THE BACK OF THE SWITCH AND REMOVE SWITCH
FROM LAMP HOUSING. REMOVE FOAM RUBBER INSERT FROM THE
YOKE. INSERT A SMALL SCREWDRIVER IN THE YOKE RECESS NEAR
THE PIVOT. PUSH THE WA LOGO PLATE OUT OF THE PIVOT RECESS.
PUSH THE BLACK AND WHITE POWER WIRES OUT OF THE LAMP
HOUSING THROUGH PIVOT BOLTS.
H 5. REMOVE YOKE PIVOT BOLTS AND HARDWARE.
UNSCREW 15/16" NUTS FROM YOKE PIVOT BOLTS. (NUTS HAVE
LOCTITE #242 ON THEM.) REMOVE SPACER AND WAVE WASHER.
ALIGN FLAT OF THE PIVOT BOLT WITH THE FLAT IN THE HOLE
(“D” HOLE) IN THE BRACKET. PRESS BOLTS OUT OF LAMP
HOUSING. REMOVE LAMP HOUSING FROM YOKE. 20