Welch Allyn CL 300 User manual

Service Manual
CL 300 Surgical Illuminator
SolarTec Source 270
CL 100 Surgical Illuminator
SolarTec Source 100
Welch Allyn Lighting Products
4619 Jordan Road
Skaneateles Falls, NY 13153-0187
PN: LB-MAN-CLSERV Rev. A

Drawings, illustrations, and/or part numbers contained in this document are for reference purposes only. For current revisions
call the Welch Allyn Customer Service phone number listed in “Service Centers” on page 2 of this manual.
Rev. Description ECN # Date Approved
A New Release 0-1013 8/20/02 D. Rutan

Table of Contents
GENERAL INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
TECHNICAL HELP INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
SERVICE CENTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
WARRANTY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-3
SYSTEM SYMBOL DESCRIPTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
WARNINGS AND PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Caution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
OPERATING INSTRUCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
POWER ON/OFF SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
FIBER PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
MULTI LINK™ EXPANSION PORT - INSTALLATION AND USE (OPTIONAL) - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
LIGHT ATTENUATION CONTROL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
LAMP LIFE INDICATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
Principles Of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
LIGHT SOURCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
REPLACEMENT LAMPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
POWER SUPPLY WITH CONTROL ELECTRONICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
MULTI LINK™ PORT AND MULTI LINK™ EXPANSION PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
SERVICE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
CLEANING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
MULTI LINK™ EXPANSION PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
TOOLS REQUIRED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
CL 100 SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
CL 100 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
TEST #1: BLOWN FUSES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
TEST #2: 100 WATT POWER SUPPLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
TEST #3: COOLING FAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
TEST #4: LED/OVERTEMP SWITCH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13

TEST #5: MICRO LINK® FIBER TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
TEST #6: POWER SUPPLY CALIBRATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
CL 100 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
POWER SUPPLY REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
PLATFORM REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
FRONT BEZEL REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
FAN DEFLECTOR REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
CHASSIS FAN REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
LED/OVERTEMP HARNESS REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
LAMP CABLE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
INTERLOCK SWITCH REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18
POWER ENTRY MODULE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18
CL 100 SURGICAL ILLUMINATOR REPAIR PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-19
CL 300 SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25
CL 300 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27
TEST #1: BLOWN FUSES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27
TEST #2: AUXILIARY BOARD INPUT TERMINALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27
TEST #3: COOLING FAN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27
TEST #4: LED OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-27
TEST #5: MICRO LINK® FIBER TEST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-28
CL 300 SURGICAL ILLUMINATOR DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-29
INTERNAL MODULE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-29
POWER SUPPLY REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-29
PCBA (PART NO. A4-10670) REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-30
IGNITOR REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31
LINE FILTER REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-31
CHASSIS FAN REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-32
POWER ENTRY MODULE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-33
PLATFORM REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34
FRONT BEZEL REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34
BLOWER FAN REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-34
LAMP CABLE REMOVAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-35
CL 300 SURGICAL ILLUMINATOR REPAIR PARTS LIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-36

GLOSSARY OF TERMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-42
FINAL INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43
CL 100 SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43
CL 300 SURGICAL ILLUMINATOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-43
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-45
THEORY OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46
LIGHT SOURCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46
REPLACEMENT LAMPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46
POWER SUPPLY WITH CONTROL ELECTRONICS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46
MULTI LINK™ PORT AND MULTI LINK™ EXPANSION PORT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-46
CL 100 SURGICAL ILLUMINATOR CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-47
CL 300 SURGICAL ILLUMINATOR CIRCUIT DIAGRAM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-48

PN: LB-MAN-CLSERV Rev. A 1-1
GENERAL INFORMATION
The Welch Allyn CL 100 Surgical Illuminator and the Welch Allyn CL 300 Surgical Illuminator provide brilliant
illumination for the physician and surgeon. The lamps produce high intensity light nearly identical to the spectrum
of sunlight. Special features include the ability to use either a Cogent Optics Micro Link® Fiber or a conventional
fiber bundle.
T
ECHNICAL HELP INFORMATION
Only fully trained and properly equipped personnel should perform all service and repairs, using genuine
replacement parts and correct procedures. Failure to do so will invalidate the product warranty and could
compromise instrument safety and performance.
Read and understand all safety warnings and service notes printed in this Service Manual and the Operating
Manuals, part number LB-MAN-100W270W. If there is any doubt about any precaution or procedure, for phone
help, or to order additional copies of the Operating Manual, contact:
Customer Service
Welch Allyn, Inc.
4619 Jordan Road, PO Box 187
Skaneateles Falls, NY 13153-0187 USA
Telephone: [phone] or
1-866-801-8428
FAX: [phone]
Techncial Assistance
Telephone: [phone], 7:00am-3:00pm(EST)
When calling, refer to the model number shown on the data label, found on the back of your Surgical Illuminator.
Technical assistance is contained in “Troubleshooting” on page 11 of this manual.

1-2 WELCH ALLYN
SERVICE CENTERS
If you have an equipment problem that you cannot resolve, you may call the Welch Allyn Service Center nearest
you for assistance. Technical service support is available by telephone on normal business days at the phone
numbers listed below. If you are advised to return a product to Welch Allyn for repair or routine maintenance,
schedule the repair with the service center nearest you.
BEFORE RETURNING A PRODUCT FOR REPAIR YOU MUST OBTAIN AUTHORIZATION FROM WELCH
ALLYN. AN RMA (RETURN MERCHANDISE AUTHORIZATION) NUMBER WILL BE GIVEN TO YOU BY OUR
SERVICE PERSONNEL. BE SURE TO NOTE THIS NUMBER ON THE OUTSIDE OF YOUR SHIPPING BOX.
RETURNS WITHOUT AN RMA NUMBER WILL NOT BE ACCEPTED FOR DELIVERY.
USA CUSTOMERS CANADA CUSTOMERS
Welch Allyn, Inc., U.S.A. Welch Allyn, Ltd., Canada
4619 Jordan Road 160 Matheson Blvd. E., Unit #2
Skaneateles Falls, NY 13153-0187 Mississauga, Canada L4Z 1V4
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
INTERNATIONAL CUSTOMERS
Welch Allyn, GmbH Welch Allyn, Ltd., Singapore
Zollerstrasse 2-4 300 Beach Road, #25-08
72417 Jungingen, Germany, The Concourse
Tel: [phone] Singapore 199589
Fax: [phone] Tel: [phone]
Fax: [phone]
Welch Allyn, Ltd., Australia Welch Allyn, China
Metro Center Room 708, 227 Huang Pi Road, North
Unit 5 38 South Street Central Plaza
Rydalmere, NSW 2116, Australia Shanghai 200003
Tel: [phone] P.R. China
Fax: [phone] Tel: [phone]
Fax: [phone]
Welch Allyn, Japan
Bon Marusan 8F, 3-5-1 Kanda
Jinbo-Cho, Chiyoda-Ku
Tokyo 101-0051
Japan
Tel: [phone]
Fax: [phone]
LATIN AMERICAN CUSTOMERS
MD International
11300 N.W. 41st Street
Miami, FL 33178 USA
Tel: [phone]
Fax: [phone]

PN: LB-MAN-CLSERV Rev. A 1-3
WARRANTY
Welch Allyn warrants the CL 300 or CL 100 Surgical Illuminator when new, to be free of defects in material and
workmanship and to perform in accordance with manufacturer’s specifications when subject to normal use and
service for a period of one year from 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 manufacturer’s specifications
within this time at no cost to the customer. It shall be the purchaser’s responsibility to return the instrument to the
authorized distributor, agent, or service representative.
Welch Allyn warrants the lamp to be free of defects in materials and workmanship for a period of 6 months from
the date of purchase. This warranty does not cover the lamp for breakage or failure due to tampering, misuse,
neglect, accidents, improper installation, modification, shipping, or from improper maintenance, service, or
cleaning procedures.
This warranty is void if the instrument is not used in accordance with manufacturer’s recommendations or if
required service is performed by other than Welch Allyn or an authorized agent. Purchase date determines
warranty requirements. No other express or implied warranty is given.

1-4 WELCH ALLYN
SYSTEM SYMBOL DESCRIPTIONS
Attention: Read Operating Manual for Warnings, Precautions, and Instructions for Use
Caution – Hot Surface Area
5A, 250V
Replace Fuse as Marked
250V, 5A
WARNING – High voltage is present
Symbol on power switch indicates power is off when pressed
~ Symbol in electrical rating signifies AC mains power
High Intensity Light
Protective Earth Ground
Storage Temperature Range
Maximum Storage Humidity
Type BF equipment, Class I
Not protected against the ingress of water
Manufactured in accordance with the relevant regulations and technical requirements of
Japan.
+49 C
o
-20 C
o
95%
MAX
IPXØ

PN: LB-MAN-CLSERV Rev. A 1-5
WARNINGS AND PRECAUTIONS
WARNING
• Keep out of reach of patient.
• Not suitable for use in the presence of a flammable anesthetic mixture with air or with oxygen or
nitrous oxide.
• Disconnect from the patient before the discharge of a cardiac defibrillator.
• ELECTRICAL SHOCK HAZARD. Do not remove the top cover.
• Routinely examine the power cord and plug. Do not use if inspection reveals damage. Replace only
with approved hospital grade power cord and plug with appropriate electrical rating.
• Do not place the exposed distal end of the Micro Link® Fiber or fiber bundle attached to either a
headlight or other accessory. Failure to observe these precautions may result in burns to skin,
clothing, or other material inadvertently placed in front of the Micro Link® Fiber or fiber bundle.
• High energy radiated light guided through endoscopes may give rise to high temperatures in front of
the light outlet and to the tip of the instrument.
• Use care not to point the distal end of the fiber or headlight directly at the eye when unit is operating.
The brilliant light output from the unit can cause eye injury per RP-27.1 (1994-1995 Threshold Limit
Values for Chemical Substances and Physical Agent and Biological Exposure Indices, Final draft March
3,1995).
• Applied parts attached to this equipment should be approved 1) to the Medical Device Directive (93/
42/EEC) (Europe), 2) approved by a Nationally Recognized Testing Laboratory (United States), and 3) by
a Standards Council of Canada accredited laboratory (Canada) to the appropriate medical standards.
The use of non-approved components may compromise safety.
• During life threatening procedures, it is recommended to have a backup Light source and an additional
replacement lamp.
• The light source lamps are highly pressurized, any damage or improper handling may cause premature
failure or explosion of the lamp.
• The light source lamps are hot immediately after use, allow the lamp to cool for five (5) minutes after
operation. Temperatures peak in the light Sources approximately 60 seconds after the Light Source is
powered off.
CAUTION
• Do not place anything on top of the Light Source. Do not store liquid above the Light Source.
• Clogged or blocked vents may cause Light Source overheating and will result in thermal shutdown.
Keep the Light Source clear of any obstructions.
• Fully close the attenuator before turning on the Light Source or when operational but not in use.

1-6 WELCH ALLYN
OPERATING INSTRUCTIONS
CONTROLS
POWER ON/OFF SWITCH
Plug hospital grade Power Cord into a grounded “Hospital Grade” or “Hospital Use” receptacle to ensure
grounding reliability.
Press Main Power Switch ON (Ipressed in).
The lamp will continue to operate until the power switch is moved to the OFF position (Opressed in). If the lamp
cannot be started or stops operating see Section 8: Troubleshooting.
NOTE:
• It is normal to hear clicking (10 pulses or less) before the lamp is started.
• To insure proper operation, wait thirty (30) seconds between on/off cycles.
FIBER PORT
To increase the versatility and applicability of use, the Light Sources are designed to use either a Micro Link®Fiber
or a fiber bundle via the Multi Link™ Port and Multi Link™ Expansion Port.
For cables with no Multi Link™ Expansion Port required:
1. Close the light attenuator or turn the Light Source off.
Cable Compatibility Table
Multi Link™ Port Multi Link™ Expansion Port
Micro Link®Fiber
Karl Storz ACMI
Olympus Wolf, Dyonics

PN: LB-MAN-CLSERV Rev. A 1-7
2. Connect the instrument end of the Micro Link®Fiber or fiber bundle to the instrument.
3. Insert, until fully engaged (snap sound), the Light Source end into the Multi Link™ Port.
4. Turn on Light Source. Adjust the light attenuator to the required illumination level.
MULTI LINK™ EXPANSION PORT - INSTALLATION AND USE (OPTIONAL)
CAUTION: The Multi Link™ Expansion Port contains optical elements that can become damaged if dropped
or abused.
NOTE: The Multi Link™ Expansion Port must be fully engaged into the Light Source before inserting Fiber
Bundle.
To use the Multi Link™ Expansion Port perform the following operations:
1. Close the light attenuator or turn the Light Source off.
2. Remove, if any, Micro Link®Fiber or fiber bundle from the Multi Link™ Port.
3. Insert the Multi Link™ Expansion Port, press and turn clockwise until it locks into place.
4. Connect the fiber bundle to the instrument.
5. Insert, until fully engaged, the Light Source end of the fiber bundle into the Multi Link™ Expansion Port.
6. Turn on Light Source. Adjust the light attenuator to the required illumination level.
To remove the Multi Link™ Expansion Port perform the following operations:
1. Turn the Light Source off.
2. Remove the fiber bundle.
3. Turn Multi Link™ Expansion Port counter-clockwise until unlocked and remove.
LIGHT ATTENUATION CONTROL
Moving the illumination wheel up +increases light output. Moving the wheel down —reduces light output.
LAMP LIFE INDICATOR
A yellow indicator light located on the console will light when there is approximately 50 hours
remaining on the lamp. A new Replacement Lamp should be available at this point. Once the
remaining hours have been exhausted the lamp will turn off.

1-8 WELCH ALLYN
PRINCIPLES OF OPERATION
LIGHT SOURCE
The Surgical Illuminators consist of an enclosure housing a high intensity lamp, proprietary optical platform, user
controls and indicators, and a power supply with control electronics. Cooling is provided via internal fans. In the
event that the fan(s) malfunctions or if adequate air flow is blocked and/or the internal temperature of the device
exceeds the engineering specifications, an internal thermal protection mechanism will automatically shut off
power to the lamp. After cooling, the Light Sources may be restarted.
REPLACEMENT LAMPS
The lamps are high pressure, high intensity and long life Light Sources. They are mounted into a patented lamp
fixture which is designed to allow both easy and rapid exchange in the field as well as ensuring precise alignment
to the optical platform.
POWER SUPPLY WITH CONTROL ELECTRONICS
All the electricity to the Light Source is controlled through the ON/OFF switch. Power to energize and operate the
lamp, fans, and control circuitry is provided by a custom designed, wattage regulated, switching power supply.
The operational life of the lamp and lamp life indicator are controlled by a lamp voltage monitoring circuit.
MULTI LINK™ PORT AND MULTI LINK™ EXPANSION PORT
Internal, to both the Multi Link™ Port and Multi Link™ Expansion Port, are patented coupling optics and mechanics
designed to produce the highest output powers. Internal to the Light Sources are fans and heatsinks designed to
reduce temperatures at the optical coupling joints thereby minimizing the possibility of damage to Micro Link®
Fiber and fiber bundles.

PN: LB-MAN-CLSERV Rev. A 1-9
SERVICE
CLEANING
1. Prior to cleaning, turn the power switch OFF, and disconnect power source from both the Light Source and
the wall outlet.
2. Clean the external surfaces by wiping with a cloth dampened with 10% bleach solution. DO NOT IMMERSE.
• Routinely inspect and clean all air intakes / out flows at the rear of the chassis for lint or other debris.
• Follow the manufacturer’s instructions when Cleaning the fiber bundles or accessories used with the light
source.
3. Wipe the power cord with a cloth dampened with 10% bleach solution and water. DO NOT IMMERSE. DO
NOT RECONNECT WET.
4. DO NOT wipe down any lenses or windows.
5. DO NOT plug the power source into a wall outlet until it is thoroughly dry.
SURGICAL ILLUMINATOR
The console may be cleaned using a clean soft cloth with the following cleaning agents:
Enzymatic Solution (Enzol)
Isopropyl Alcohol
Hydrogen Peroxide 3% USP
2% Glutaraldehyde Solution
Soap and Water
10% bleach solution and water
CAUTION: Do not splash cleaning agents into any openings, seams or electrical components.
MULTI LINK™ EXPANSION PORT
The outside surfaces may be cleaned with a soft cloth using the following:
Isopropyl Alcohol
Soap and Water
The glass surfaces may be cleaned by the following methods:
A cotton swab moistened with Isopropyl Alcohol
Blow with dry compressed air
NOTE: Use care in cleaning the optical surfaces of the Multi Link™ Expansion Port to prevent scratches.

1-10 WELCH ALLYN
TOOLS REQUIRED
• Slotted screwdriver, less than 6” long
• #1 Phillips Screwdriver, less than 6” long
• #2 Phillips Screwdriver, less than 6” long
• Open end wrench set - English or 5/16”
• Needle nose pliers
• Nut Driver Set - English or 3/16”, 1/4”, 5/16”
• Nut Driver Set - Metric or 10mm
• Deep well socket set and wrench (2) - CL 100 Surgical Illuminator
• Non-conductive pot adjusting tool - CL 100 Surgical Illuminator
• Light output power meter with head. Coherent Lasermate 1D or equivalent (meter), Head Model 1d10 - CL
100 Surgical Illuminator
• Light output meter - Labsphere Model FIMS-400P or equivalent that measures in lumens - CL 300 Surgical Illu-
minator
• Calibrated RMS Digital Multimeter (DMM)

PN: LB-MAN-CLSERV Rev. A 1-11
TROUBLESHOOTING
CL 100 SURGICAL ILLUMINATOR
Symptom Cause Remedy
Lamp fails to start and
fans are not running.
No power to unit Check power supply cord and outlet
Line voltage is <90 VAC Refer to Hospital Engineering department
Fuses blown Inspect, replace and retest. Go to “Test #1: Blown
Fuses” on page 12.
Safety interlock open Check and tighten slotted screw on lamp fixture
access door
Power supply failure Go to “Test #2: 100 WATT Power Supply” on
page 13
Lamp fails to start and
fans are running.
Lamp not in light source
(audible clicking heard)
Install a 100W replacement lamp, model 90133.
Defective lamp cable
(discolored, bent or broken
prongs)
(audible clicking heard)
Replace and retest lamp cable.
Defective power supply
(discolored, bent or broken
prongs)
(no audible clicking heard)
Inspect wiring and if it is fine, replace and retest
power supply.
Lamp shuts off after
operating for a few
minutes and restarts after
cooling.
Inadequate air flow for
cooling, Light Source over
temperature
Allow 2” (51mm) clearance at back of unit; insure
that air intake-outflow vents are clean and not
blocked. Allow unit to cool and then restart
Fan failure Go to “Test #3: Cooling Fan” on page 13.
Illuminator is overheating not
due to clearance.
Verify operation of fans. Clean fans and internal
components of dust.
Lamp is at the end of life, but
amber LED is inoperative.
Verify LED flickers on when it is first turned on. If
not, go to “Test #4: LED/Overtemp Switch” on
page 13.
Indicator light on and
lamp shuts off
Lamp life exceeded. Install a 100W replacement lamp, model 90133.
Lamp cable defective. Replace if prongs are discolored, broken, or bent.
Power supply out of
calibration.
To go “Test #6: Power Supply Calibration” on
page 14.
Replacement Lamp will
not seat into Light Source
Lamp is not oriented correctly Rotate lamp 180° and re-insert
Incorrect Replacement Lamp Install a 100W replacement lamp, model 90133.

1-12 WELCH ALLYN
CL 100 SURGICAL ILLUMINATOR DISASSEMBLY
NOTE: For all tests, remove 9 screws from top cover.
NOTE: Do not operate unit with the top cover removed for more than 5 minutes or the unit will overheat.
T
EST #1: BLOWN FUSES
The purpose of this test is to determine the source of a short circuit causing fuses to blow. Refer to the Block
Diagram on page 47.
Replace and retest the fuses. If unit functions normally, inspect fuses that were blown. If solder is melting out of
the end of the fuse and the glass is not blackened, remove and replace the power entry module. This fault occurs
when the prong of the fuse holder makes poor contact with the fuse. The prong will look discolored and pitted
where it contacts the fuse.
Low light output Damaged Micro Link®Fiber
or fiber bundle
Check ends of Micro Link®Fiber or fiber bundle
for damage. Replace with new Micro Link®Fiber
or fiber bundle. Go to “Test #5: Micro Link® Fiber
Test” on page 13.
Fiber bundle not connected
correctly.
Re-insert fiber bundle correctly.
Lamp near end of usable life Install a 100W replacement lamp, model 90133.
Filter assembly on platform
contaminated.
Clean or replace filter assembly as necessary.
Mirrors dirty. Clean mirrors.
Broken mirrors. Replace platform.
Misaligned mirrors (possible
if unit suffers damage)
If above steps fail to improve output, replace and
retest platform.
Dirty or damaged internal
module.
Inspect, clean, and replace if necessary.
Fiber bundle will not
install in Light Source
Not a compatible fiber bundle See “Operating Instructions” on page 6
Use compatible bundle design
Install/Remove Multi Link™
Expansion Port
See “Operating Instructions” on page 6
Multi Link™ Expansion Port
installed
Remove Multi Link™ Expansion Port
Audible “clicking” or
arcing sound during the
lamp ignition process
No problem Normal operation
Symptom Cause Remedy

PN: LB-MAN-CLSERV Rev. A 1-13
If the fuse blows again, inspect the power supply and the wiring for damaged or burnt components. Remove and
replace any visually defective components.
If visual inspection does not yield any evidence of damage, remove and replace power supply and retest.
T
EST #2: 100 WATT POWER SUPPLY
Verify operating voltage is present on power supply input terminals. Connect meter and set to volts AC to J1 and
J2 terminals. When power is applied to the unit, verify the operating voltage is displayed on the meter. NOTE:
Verify the lamp access door is closed.
If voltage is present, replace and retest power supply.
If voltage is not present, inspect the fuses, wiring, power entry module, line filter, and interlock switch.
T
EST #3: COOLING FAN
The purpose of this test is to verify the operation of the lamp cooling fan.
Visually inspect for a broken fan. When the unit is powered up, look for a fan not turning. If found, remove top
cover and inspect fan. Replace any broken fans.
If fan is inoperative and not broken, measure using DMM set for Volts DC for 12VDC on fan connector.
• If voltage is present, replace and retest fan.
• If voltage is not present, replace and retest power supply.
T
EST #4: LED/OVERTEMP SWITCH
The purpose of this test is to verify proper operation of the LED.
Visually inspect that LED/overtemp switch harness is connected to the power supply. Verify continuity of wiring
and LED with DMM set to the Diode Scale. DMM should read ≈.7VDC.
• If the DMM reading does not match, replace and retest the LED harness.
• If DMM reading matches above, replace and retest the power supply.
T
EST #5: MICRO LINK® FIBER TEST
The purpose of this test is to verify the operation of the Micro Link® Fiber.
With the illuminator on, connect the fiber and the headlight. Over a distance of at least five feet, adjust the spot
diameter to the largest size.
• If the intensity of light is not consistent throughout the light spot and rotating the distal end connector does
not cause the shape to change, the headlight is the most likely cause of the fault.
• If the intensity is not consistent with alternating light and dark rings present, the fiber is broken at the distal
end.
Over the same distance, adjust the headlight to the smallest diameter spot. At this adjustment, the headlight is
focused. If any spot irregularities are present, hold the headlight steady while rotating the distal end (black)
connector.

1-14 WELCH ALLYN
• If the location of the defects move, remove the fiber, clean the end with distilled water, reconnect the unit, and
test. Replace the fiber if defects are still present.
• If the location of the defects remain stationary, the fault is within the headlight.
T
EST #6: POWER SUPPLY CALIBRATION
The purpose of this test is to verify the operation of the power supply.
Apply power to unit, once the lamp lights, connect the DMM (set to volts DC) to the lamp cable wires on the
power supply. The positive lead of DMM to the HV+ terminal on the power supply and the negative lead of the
DMM to the Lamp Return - terminal on the power supply. WARNING: Do not connect DMM to wires prior to
turning the unit on. When the lamp ignites, there is approximately 25kV on the terminals which could damage the
DMM. Monitor the voltage displayed on the fluke when the LED first turns on. Verify the voltage is between 17.00
and 18.00v.
• If the voltage is less than 17.00VDC, remove and replace the power supply or return the unit for recalibration.
If the voltage is between 17.00VDC and 18VDC, remove and replace the lamp fixture.
• If the voltage is more than 18.00DC, contact the Welch Allyn Technical Services Department at
1-315-685-2993 or 1-315-685-4233, 7:00am-3:00pm(EST).