Welch Allyn Stryker Quantum 2000 Light Source User manual

Light Source Menu
Operation Manual
Stryker® Quantum 2000 Light Source
Service Manual
strykep*
Welcl^Allyir
P/N 809853
Rev A.
©1997

Introduction
Revision History
Rev.
Description of Change
ECN #
Date Initial
A
New Release
11717 11/26/97 MD
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 GMBH Product Service
Department.
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 operating manual, product warranty section for specific
coverage.
Welcl^AlIyir
Welch Allyn GMBH
Product Service Center
Postfach 31
D-72417 Jungingen
Germany
Tel. [phone]
FAX [phone]
Stryker® Light Source Service Manual Page 1

Introduction
Table of Contents
SECTION 1: General Information
Basic System Description .5
Specifications .6
SECTION 2: Service
Intent of Manual .7
Required Tools .7
Words of Caution .8
Performance Check .9
Final Test.9
Calibration .9
SECTION 3: Problem Solving
Troubleshooting . 10 to 12
SECTION 4: Disassembly and Repair
Top Housing .13
Lamp Door Switch.13
Ballast Board.14
Fan .14
Thermal Cut-Out.15
Power Supply .16
SECTION 5: Maintenance
Preventative Maintenance.17
Cleaning .18
Checking Ground Impedance .18
Measuring Leakage Current.18 & 19
Fuse or Lamp Replacement .20
SECTION 6: Theory of Operations
Introduction .21
Start Up Routine .21
Power Supply .21
Ballast Board.22
Stryker® Light Source Service Manual Page 2

Introduction
Table of Reference and Drawings (Appendix A)
Parts List/Recommended Inventory. N/A
Light Box Assembly BOM (Reference Only) . 809643
Light Box Assembly Drawing (Reference Only). 809643 (Page 1 & 2)
Interconnect Diagram (Reference Only). 809744
Fan Wire Harness Assembly (Reference Only) . 809713
Note that the drawings contained within this manual are for reference only. Consult
factory for specific drawing and revision level.
Stryker® Light Source Service Manual
Page 3

Section
General Information
Introduction
Basic System Description
Power Switch
sfcryten*
0U !
QUANTUM
p QQO
Minimum
j Light Output
Maximum
Light Output
Fiber Optic
Bundle Port
Control Knob
FRONT
AC Power Inlet
(
Fuse _
Drawer
Lamp Access
Door
rr=f
BACK
Stryker® Light Source Service Manual
Page 4

Section 1
General Information
Specifications
Electrical
Input Voltage: 100 - 240 VAC, 50 - 60 Hz
Input Current: 1A (@100 VAC
Output 60 VDC @ 0.4A
Leakage Current <100^A
Dimensions
WxLxH = 11,43cm (W) x 16.5cm (L) x 6.35cm (H)
Light Source Weight
Under 5 pounds (2.25 Kilograms)
Illumination System
Welch Allyn Lamp 09500
Color temperature: 5500°K
Lamp: 60 Volts, 24 Watts
Lamp Life: 350 Hrs Average
Dimmina System
Manual Shutter: 20% to 100% full output
Fiber Optic Interface
StandardACMI Connector
Environment
Storage: Humidity: 10% to 100%
Temperature: -25°C to +60°C
Pressure: 500hPA to 1060hPA
Operating Humidity: 10% to 95% non-condensing
Temperature: +15°C to +30°C
Equipment Classification
Class 1, Type B Continuous Operation. Ordinary equipment, not suitable for use in the
presence of flammable anesthetic mixtures.
Fuses
T1.0A L250V (1 .OAmp., 250V, time lag (Slow-Blow), Low breaking capacity)
Approvals:
See Operating Manual
Stryker® Light Source Service Manual Page 5

Section
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
Stryker Light Source. 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
your local Welch Allyn Technical Service Department for assistance.
Required Tools and Equipment for Service
1. 3/8" Nut Driver
2. Screwdriver(s): Phillips #1, Phillips #2
3. Screwdriver: Flat Blade #4
4. Long Nose Pliers
5. Wire Cutters
6. Antistatic Workstation
7. Digital Volt/Ohm Meter with Leads (True RMS).
8. Soldering Iron
9. Solder Sucker or Desoldering Wick
10. DC Power Supply capable of providing 10 amps at 10VDC.
11. Hy-Pot Tester- Associated Research Inc. Model 411 Al AC Hipot Jr or Equivalent.
12. Final Production Test Spec P02760
Stryker® Light Source Service Manual
Page 6

Section 2
Service
Words of Caution:
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
[hot] 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.
Stryker® Light Source Service Manual Page 7

Section 2
Service
Performance Check
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 a warm-up period of 5-15 seconds.
If any of these conditions do not occur, see the troubleshooting section.
Final Test
1. Perform final production tests (See required tools for Final production Test P/N) as appropriate
according to model number. Consult drawings and B.O.M as needed.
2. Ignore Lightbox Data Sheet.
3) Ignore paperwork check.
COSMETICS: Note all major cosmetic defects at evaluation and include in
estimate as appropriate.
Calibrations
Not Applicable
Stryker® Light Source Service Manual Page 8

Section
8 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 the
signal through the harness wires, connectors, and on the circuit board.
Symptom
Possible Cause Procedure
Lamp does not illuminate, but
the fan is running.
Lamp connector is out of place. Remove lamp cover and reseat
the connector.
Lamp is blown.
Verify unit functions with a
known good lamp or lamp
functions with a known good
unit.
Defective ballast
Verify Voltage input and output
of the Ballast board. Refer to
wiring diagram. Note: There is
6KV to 7KV present at the
output during startup.
Defective Power supply. No
+15VDC present.
Check output of power supply
per wiring diagram.
Replace supply if no voltage is
present.
Defective or misaligned wire
harness (W006) (See
Interconnect Diagram)
Check alignment of connector
at J2B of ballast board and J2
of switched power supply.
Verify voltage from ballast
board to harness to lamp
service LED.
Defective thermal cut-out
device (Temperature clearly
does not exceed 80 °C ±5°)
Verify +15V from power supply
pin 2 at J2 to thermal cut-out to
ballast board pin 2 at J2B.
Replace if found to be
defective.
Power switch was prematurely
engaged after turning off power
switch (<30 Sec.)
Wait >30 seconds and reapply
power.
Stryker® Light Source Service Manual
Page 9

Section 3 Problem Solving
Symptom
Possible Cause
Procedure
Lamp cuts out after a short
period of operation
Fan is not functioning,
temperature has exceeded
80 °C, thermal cut-off is
engaged.
Verify correct voltages at the
input and output of the power
supply (See interconnect
diagram). If all voltages are
within specification, then
replace Ml fan assembly.
Defective ballast
Verify Voltage input and output
of the Ballast board. Refer to
wiring diagram. Note: There is
6KV to 7KV present at the
output during startup.
Lamp not illuminated, fan does
not function (No power is
apparent).
Covered or clogged air vent.
Check to see if anything is
covering the air vents, Clear as
necessary.
Power line is damaged or
disconnected.
Connect, repair, or replace as
necessary.
Power is not turned "ON"
Turn power on.
Lamp Door Interlock switch is
disengaged.
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.
AC line fuses FI and/or F2 are
open.
Verify and replace as
necessary.
Open circuit connection.
Verify AC input through unit to
the Switching Power Supply.
Power supply circuit defective.
Verify DC output at J2 of
Switching Power Supply.
Other circuits loading down
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.
Stryker® Light Source Service Manual Page 10

Section 3 Problem Solving
Symptom
Possible Cause Procedure
Low light output.
The manual shutter assy, in the
light source is set to minimum.
Adjust the shutter for maximum
light output.
Dirt on fiber optic light carrier.
Remove the fiber optic cable
from the light source and clean
both ends with alcohol and a
cotton swab.
Lamp is near end of life Replace Lamp.
Lamp is illuminated, lamp
service LED is on
Lamp is defective Replace with a known good
lamp.
Lamp is near end of life (Light
output can be purple or bluish in
nature)
Replace with a known good
lamp.
Defective or misaligned wire
harness (W006) (See
Interconnect Diagram)
Check alignment of connector at
J2 of ballast board. Verify
voltage from ballast board to
harness to lamp service LED.
Defective Ballast
Check voltage on pin 2, J1B
(See Interconnect Diagram) of
Ballast Board. It should
measure 10.5V with service
LED off, 0V with lamp service
on. Replace ballast if defective.
Stryker® Light Source Service Manual Page 11

Section
4
Disassembly and Repair
This section describes how to remove and replace major sub assemblies within the
Stryker Light Source
Top Housing Disassembly
1. Remove the top two screws (Phillips) that hold the fan guard in place.
Note not to remove the bottom fan guard screws as it will cause grounding harness
to be removed forcing you to remove the air baffle and reassemble.
2. Remove the five screws (Phillips) on the bottom of the unit and lift the top housing
assembly upwards.
Double Pole Micro Switch (Lamp Door Interlock Switch) Replacement
1. Remove and set aside the lamp door.
2. Remove the top housing as instructed in "Top Housing Removal" section.
3.
4.
Free the switch by removing the two screws (809643 #7) and disconnecting wire
harnesses W001 and W002. Note
position of wires for reassembly.
I
Replace and reassemble in reverse
, b K 0W N W I rf
order.
unmu Irv-W
Stryker® Light Source Service Manual
Page 12

Section 4
Disassembly and Repair
Ballast Board Replacement
1. Remove the top housing.
2. Remove the fan baffle (809643 #97) by removing the two Phillips head screws (809643
#60 & #89) holding the baffle in place. Note to recover and set aside the spacer (809643
#104) (809643 Section A-A) while disassembling. Remove and set aside for reassembly.
3. Remove the 4 screws (809643 #9) securing the ballast board to the chassis bottom.
4. Lift the ballast board up, so that it is resting on top of the power supply board, unplug the
two (Keyed) connectors located on the ballast board, and desolder the black and white
wires from the ballast board. Remove and replace as necessary.
5. Reassemble in reverse order.
a. Be sure to reinstall the insulating material under the ballast board.
b. The black and white wires from the lamp connector are routed through the insulator
then resoldered into the proper holes in the ballast board (refer to wiring diagram).
c. Be sure to place spacer (809643 #104) (809643 Section A-A) and cable clamps
(809643 #20 & #53 (Moderately Difficult!)) into position before reassembling the fan
baffle.
d. Take care not to over tighten the screws to avoid stripping the housing.
Fan Replacement
1 . Remove the top housing as outlined in top housing removal section.
2. Remove the fan baffle (809643 #97) by removing the two Phillips head screws (809643
#60 & #89) holding the baffle in place. Note to recover and set aside the spacer (809643
#104) (809643 Section A-A) while disassembling. Remove and set aside for reassembly.
3. Free the fan by removing the two bottom screws (809643 #31) securing the fan to the
chassis bottmm.
4. Unplug connector P2 to the DC power supply and free the connector pins from the
connector using a small screw driver or pliers.
5. Replace and reassemble in reverse order.
a. Be sure to secure the ground harness (W004) when reassembling the fan to the
chassis bottom.
b. Be sure to place spacer (809643 #104) (809643 Section A-A) and cable clamps
(809643 #20 & #53 (Moderately Difficult!)) into position before reassembling the fan
baffle.
Stryker® Light Source Service Manual Page 13

Section 4
Disassembly and Repair
Thermal Cut-out Replacement
1 . Remove the top housing as outlined in top housing removal section.
2. Remove the fan baffle (809643 #97) by removing the two Phillips head screws (809643
#60 & #89) holding the baffle in place. Note to recover and set aside the spacer (809643
#104) (809643 Section A-A) while disassembling. Remove and set aside for reassembly.
3. Free up and remove the thermal cut-out as follows:
a. Remove the finger guard shield (809643 #99) temporarily by removing the phillips
screws (809643 #95)secured to the chassis bottom in order to free the thermal cut¬
out wire harness and grommet.
b. Free the grommets and tilt the shield out of the way.
c. Remove the screw and flat washer (809643 #87 & 88) holding the thermal cut-out
to the lamp holder, and remove the thermal cut-out.
d. Unplug connector P2 to the DC power supply and P2B to the ballast.
e. Free the connector pins from the connectors using a small screw driver or pliers.
f. Remove and replace the thermal cut-out.
4. Reassemble in reverse order.
a. Be sure to apply heat sink compound to the thermal cutout before reassembly.
b. Be sure to secure the ground harness (W001) when reassembling the finger guard
shield (809643 #99).
c. Be sure to place spacer (809643 #104) (809643 Section A-A) and cable clamps
(809643 #20 & #53 (Moderately Difficult!)) into position before reassembling the fan
baffle.
Stryker® Light Source Service Manual Page 14

Section 4
Disassembly and Repair
Power Supply Replacement
1 . Remove the top housing as instructed in "Top Housing Removal" section.
2. Remove the fan baffle (809643 #97) by removing the two Phillips head screws (809643
#60 & #89) holding the baffle in place. Note to recover and set aside the spacer (809643
#104) (809643 Section A-A) while disassembling. Remove and set aside for reassembly.
3. Cut the wire ties securing the yellow thermal cutout wires (W009) to the power supply
bracket.
Unplug the keyed connector (PI) with the brown and blue wires (W002) from the power
supply, by Pulling straight up on the connector with a pair of needle-nose pliers and the
keyed Vdc output plug (P2), by Pulling straight up on the connector with a pair of needle-
nose pliers.
4. Unplug the green and yellow ground wire that attaches to the power supply.
5. Unscrew the four screws located on the four corners of the power supply board and lift
the power supply out of the bottom housing.
6. Reassemble in reverse order.
a. Be sure to put the insulator back into its original position. Take care not to over
tighten the screws, for they are only screwed into plastic.
b. Be sure to place spacer (809643 #104) (809643 Section A-A) and cable clamps
(809643 #20 & #53 (Moderately Difficult!)) into position before reassembling the fan
baffle.
Stryker® Light Source Service Manual Page 15

Section
Maintenance
Preventative Maintenance
The purpose of preventative maintenance is to proactively reduce or eliminate future problems.
Keeping the Light Source in good operating condition ensures that it will perform reliably and safely.
Every six to twelve months, you should:
* Check the power cable for wear.
* Ensure that, during use, the light source receives adequate ventilation.
* Ensure that the ball detent of the fiber optic port 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?
Stryker® Light Source Service Manual
Page 16

Section 5
Maintenance
CLEANING
Refer to Operating Manual for proper cleaning procedure.
Check Ground Continuity
1. Disconnect the power cord from the Light Source.
2. Verify the impedance between the mains ground pin of the IEC detachable ground cord and
the:
a. Recessed ground lug on the inside bottom of the light source (1 OOmQ max).
b. Fan screw located closest to the serial label (1 OOmQ max).
c. Exposed metal section of the light dimming attenuator (Isolated, >20MQ)
Measuring Leakage Current
To check the Chassis Leakage Current:
1. Connect the light source to a leakage tester (refer to figure 5-1), and measure leakage
current on leakage meter. Ensure that leakage is <100//A.
2. Open ground line, and ensure leakage current is dOO^A.
3. Reverse line polarity, and ensure that leakage current is <1 OO^A.
4. With reversed polarity, open ground line and ensure leakage is dOO^A.
CAUTION: The meter must be suitably insulated and
capable of withstanding the power line voltage.
Stryker® Light Source Service Manual
Page 17

Section 5
Maintenance
LEAKAGE CURRENT TEST SET-UP
When the light source is used in conjunction with other accessories, it may be necessary to measure
the leakage current level of the entire set-up. A typical system setup is shown in Figure 5-1. Using
a standard leakage tester, this set-up will allow the overall system leakage current to be measured.
If this value exceeds 100//A (or whatever the maximum requirements are for a particular region), an
isolation transformer should be used.
Figure 5-1: Typical Current Leakage Test Set-Up
Stryker® Light Source Service Manual
Page 18

Section 5
Maintenance
FUSE REPLACEMENT
1. Turn the power switch OFF and disconnect the power cord from the light source.
2. Open fuse drawer located as part of the power cord receptacle.
3. Remove fuse by pulling it out firmly.
4. Check fuse condition. Replace if blown. Replacement
fuse: 250V, 1.0 Amps. 5 x 20mm , Slow-Blow. Use wa
fuse only! An unqualified fuse may fail prematurely.
5. This system has two fuses. Be certain to check the
condition of both fuses.
LAMP REPLACEMENT
1. Refer to users manual for full detail.
2. Turn the power switch OFF and disconnect the power cord from the light source.
3. Wait a minimum of 5 minutes to allow the lamp to cool.
4. Remove the lamp cover by unscrewing the thumb screw on the bottom of the light source.
NOTE: Removing the cover will automatically cut off power to the Light Source.
5. Disconnect the lamp connector.
6. Remove the lamp from the holding spring assembly by pulling back and sliding up toward
yourself.
7. Acquire new replacement lamp assembly.
8. Reseat the new lamp assembly being sure the alignment pin is pointing toward the slot in the
lamp holder.
9. Slide the black connector on to lamp.
10. Secure the lamp cover, reconnect the system, and verify lamp operation.
Stryker® Light Source Service Manual
Page 19