Exam Light III Service Manual Rev B Dec 2009

Part# 488061 488061

Revision A B

Description New service manual Page 24, Bubble 81, 488119 changed to new 714160

ECN# 5-45435 D*

Date 01/20/03 08/12/09

Approved DK D*

D*: See SAP DIR for change number, approver name, and date of approval.

Drawings and/or 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 Section 1 page 3.

Service Manual 488061 Rev. B

Welch Allyn Exam Light III i

Table Of Contents Section 1: General Information About the Exam Light... 1 Features ... 1 Agency Approvals ... 1 Cautions and Warnings... 2 Help Information ... 3

Section 2: Incoming Inspection Incoming Inspection ... 1 Required Tools ... 1

Section 3: Troubleshooting Initial Screening... 1 Light Pipe ... 1 Focusing Sleeve ... 1 Electrical Troubleshooting ... 1

Section 4: Disassembly and Repair Cover Removal ... 1 EMI Shield Removal ... 1 Lamp Clip Removal ... 1 Lamp Removal ... 2 Lamp Holder Removal... 2 Lamp Baffle Removal... 2 Light Pipe Connector Assembly Removal ... 3 Transformer Removal ... 3 Illuminated On/Off Switch Removal ... 4 Fan Removal ... 4 Rectifier Board Removal... 5 Light Pipe Connector Assembly Dissassembly... 6 Focusing Sleeve Assembly ... 8

Appendix A: Repair Part Numbers Appendix B: Expoded View Drawings/Photos Appendix C: Electrical Schematic ii

Welch Allyn Exam Light III

Service Manual 488061 Rev. B

Service Manual 488061 Rev. B

Welch Allyn Exam Light III iii

iv

Welch Allyn Exam Light III

Service Manual 488061 Rev. B

General Information

Section 1

About the Exam Light III Welch Allyn’s Exam Light IIITM takes flexible illumination to a new level. It mounts easily to fit on a wall, stand, or on an examination table. The Exam Light III delivers bright, white, fiber optic illumination for better visibility and more accurate diagnosis.

Features • Durable fiber optic pipe provides cool illumination and is bendable to almost any position. • Easy to position, small, non-obstrusive head does not block view for task areas. • Light weight focusing sleeve optics are sealed for less dust. • Provides homogenous spot and variable spot size. • Easy to maintain dichronic halogen lamp provides brighter, whiter light (3,200°F). • Multiple mounting options for greater flexibility. • Special UV filters provide safe trans illumination of neonates to detect pneumothorax conditions and intacranial hemorrhaging, perform infant venipuncture, and locate blood vessels (Model 48760 only).

Agency Approvals

The CE mark on this product indicates that it has been tested to and conforms with the provisions noted within the 89/336/ECC Electromagnetic Compatibility Directive.

Australia EMC Framework Compliance

N344 Service Manual 488061 Rev. B

Welch Allyn Exam Light III 1

Section 1

General Information

Cautions and Warnings

Intense Light: Lamp is extremely bright. Do not stare at the lamp when in use. May be harmful to eyes.

Caution: Remove power cord from electrical outlet and allow lamp to cool 10 minutes before replacing with a Welch Allyn lamp.

Danger: Electrical shock hazard. Refer servicing to qualified service personnel.

Caution: Risk of explosion if used in the presence of flammable anesthetics.

Hot Surface: Lamp is hot. May be harmful to skin if touched.

NOTE: This product complies with the current required standards for electromagnetic interference and should not interfere with other equipment or be affected by other compliant devices. As a precaution, avoid using this device in close proximity to other equipment.

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Welch Allyn Exam Light III

Service Manual 488061 Rev. B

General Information

Section 1

Help Information To assure correct operation and performance all service and repairs must be performed by fully trained and properly equipped personnel, using genuine replacement parts and correct procedures. Failure to do so will also invalidate the product warranty. Welch Allyn Inc. State Street Plant /Corporate Headquarters 4341 State Street Road Skaneateles Falls, NY 13153-0220, USA tel:

1-800-535-6663 315-685-4100 fax: 315-685-3361 www.welchallyn.com/medical/support/tech Welch Allyn GMBH Zollerstrasse 2-4 72417 Jungingen, Germany tel: fax:

(011) 49-7477-927186 (011) 49-7477-927193

Welch Allyn UK Ltd St. Georges House Vernon Gate, Derby England DE1 1UQ tel: fax: mob:

(011) 44-01332-206208 (011) 44-01332-206209 (011) 44-0467-301814

MD International 11300 N.W. 41st Street Miami, FL 33178 USA tel: fax:

Welch Allyn France SARL 814 rue Charles de Gaulle 77100 Mareuil les Meaux France tel: Fax:

300 Beach Road, #25-08 The Concourse Singapore 199589, Singapore tel: fax:

(011) 65-291-0882 (011) 65-291-5780

( 011) 33 1.6009.3366 (011) 33 1 .6009.6797

Welch Allyn Australia Pty The Metro Centre Unit 5 38-46 South Street Rydalmere NSW 2116, Australia Postal address: PO Box 132 Rydalmere NSW 1701, Australia tel: fax:

Welch Allyn Singapore Ltd

305-669-9003 305-669-1971

(011) 612 9638-3000 (011) 612 9638-3500

China Service Center Room 708 Central Plaza No. 277 Huang Pi Bei Rd. Huang Pi District Shanghai 200003 China tel: fax:

(011) 86-21-63279631 (011) 86-21-63279632

Welch Allyn Japan K.K. Bon Marusan 8F, 3-5-1 Kanda Jinbo-Cho, Chiyoda-Ku Tokyo 101-0051 Japan tel: fax:

(011) 813-5212-7391 (011) 813-3261-7372

Service Manual 488061 Rev. B

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Service

Section 2

Incoming Inspection NOTE: Use the following guidelines when unpacking the Exam Light III from its shipping carton. 1. Before opening the Exam Light shipping carton, check for damage. 2. If damage is apparent, stop unpacking the carton and contact the shipping company for further instructions. If the carton is intact, unpack the Exam Light. 3. With the Exam Light out of its carton, check to see that all the items listed on the packing slip are in the shipping carton. 4. If an item is missing, first check the carton, then check with your receiving department. If necessary contact Welch Allyn at the Address and phone number shown in Section 1. 5. Clean and disinfect by following the instructions printed in the Operator Manual.

NOTE: Perform all functional tests before and after servicing. 6. Operate the Exam Light to verify the customer complaint before making any changes to the unit. Call the customer if the complaint is unclear. 7. If the unit has caused or is suspected of having caused an injury of any type:

DO NOT DISASSEMBLE OR REPAIR THE UNIT IN ANY WAY. Contact Welch Allyn Customer Service immediately.

Required Tools Phillips Screw Driver Flat Head Screw Driver Standard Needle Nose Pliers 11/32 Nut Driver 5/64 Nut Driver 3/8 Nut Driver 5/64 Hex wrench Digital MultiMeter

Service Manual 488061 Rev. B

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Troublshooting

Section 3

Initial Screening 1. Inspect the Exam Light for physical damage - cracked cover, etc. 2. Attempt to confirm reason for return. 3. If reason can not be determined, contact the sender.

Light Pipe 1. Flex the light pipe at each bend and replace any that: A. Have noisy monocoils. B. Show signs of not holding position. C. Have excessive springback when positioned in a “U” position.

NOTE: When the light pipe is placed in the “U” shape, at the center bend, the pipe should not spring back by more than 8 to 9 inches. When the light pipe is bent in a “U” shape at the light source bend, the spring back should not be more than 4 to 5 inches.

Focusing Sleeve 1. Check for cracks or damage. 2. Check for smooth operation of the lens when the sleeve is turned. 3. Replace any lens that have scratches.

Electrical Troubleshooting WARNING: Turn off and unplug unit between each of the next steps.

1. Lamp does not light and the green rocker switch does not light. A. Pull fuses out and check fuses with ohm meter. B. Attach a known good power cord. C. Replace the green rocker switch. D. Check the AC connector for damage and cracks. Service Manual 488061 Rev. B

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Section 3

Troubleshooting

2. Green rocker switch light is illuminated but the lamp does not light. A. Check for proper lamp. It should be 12 volt 35 watt, Welch Allyn #04200.

NOTE: If the lamp is replaced, burn the unit in for at least one hour to confirm there are not other issues. B. Check transformer output. It should measure 12vac. C. Lift lamp out of bracket and check filter and gasket.

NOTE: The gasket should not be blocking the light. The filter should not be cracked, chipped or dirty.

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Welch Allyn Exam Light III

Service Manual 488061 Rev. B

Disassembly and Repair

Section 4

Observe All ESD Precautions! Turn unit off. Unplug the power cord from the outlet and from the light box! 1. Cover Removal Unscrew the captured screw at the bottom of the main housing. Push the cover up and forward.

NOTE: Take extreme care when removing the cover. The tabs on the cover may break if you do not push the cover all the way up before removal. 2. EMI Shield Removal Remove the 5 phillips head screws.

NOTE: Notice manufactured date stamp on the EMI shield.

3. Lamp Clip Removal For first time lamp removal, grasp the wire clip at the top of the lamp. Rotate the clip toward the base of the unit it pops out.

NOTE: Discard the clip. It is used only for shipping.

Service Manual 488061 Rev. B

Welch Allyn Exam Light III 1

Section 4

Disassembly and Repair

4. Lamp Removal Grasp the lamp connector and pull the lamp straight out of its holder.

5. Lamp Holder Removal Remove the two nuts.

6. Lamp Baffle Removal

Remove the one phillips head screw.

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Service Manual 488061 Rev. B

Disassembly and Repair

Section 4

7. Light Pipe Connector Assembly Removal With a 5/64 hex wrench, slightly back the hex nut off the pipe connector assembly. Slide the pipe connector assembly out. The pipe connector assembly can only be removed from the inside of the main housing

8. Transformer Removal Remove the 4 phillips head screws.

NOTE: Note the wire orientation and wire color on the illuminated off/on switch. The wires must be removed from the illuminated switch before the illuminated switch can be removed.

Light Blue

Blue

The photo shows the wiring as wired for domestic 120V. See the wiring diagram in Appendix C for the wiring in your local area.

Black

Service Manual 488061 Rev. B

Brown

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Section 4

Disassembly and Repair

9. Illuminated Switch Removal Squeeze the outer tabs on the switch and push outward.

NOTE: Notice the orientation of the switch when properly installed.

10. Fan Removal Use a 3/16 driver on the hex nut and a flat bed screw driver on the screw and remove all four fasteners. Disconnect the fan connector from the PCB.

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Service Manual 488061 Rev. B

Disassembly and Repair

Section 4

NOTE:

C

A. Notice how the wires are secured to the chassis. B. Notice how wires are routed through the channel with rubber grommets.

A

C. Notice wire ties on brown wires.

B

Note: Notice the wiring orientation to the IEC connector and wire colors

Green

Blue

Brown

11. Rectifier board removal Remove all four phillips head screws.

Service Manual 488061 Rev. B

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Section 4

Disassembly and Repair

12. Light Pipe Connector Assembly Disassembly. A. Remove the retaining ring.

B. Remove the square heat filter.

C. Remove the heat filter gasket.

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Service Manual 488061 Rev. B

Disassembly and Repair

Section 4

D. Remove the two hex set screws that secure the insulator to the retaining collar.

E. Pull the retaining collar from the insulator.

F. Remove the brake from the inside of the insulator.

Service Manual 488061 Rev. B

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