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ASTOTHERM 200 - 260 Infusion Pump Service Manual

1. C devices 46 0 C 1 C heater bimetal cut off 65 C 5 C inadequate temperature alarm 4 C 0 5 C below operation temperature Page 10 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 1 5 Terminal connecting plan Mains Heating Heat exchanger voltage cable No PE Mm LA LNPE EP ASTOLINE F2 F1 e F 4 Voltage jumpers Primary or solder strap fuses Voltage jumpers O F3 or solder straps n 20V n Secondary fuses 7902 nin 100V nin be 115V 1 vy vy O F4 ar PIT TRANSFORMER BOARD gt CETTE O oM E oC oC OPERATING BOARD Fig 2 Connections between electronic components Revision 6 03 2010 OPTIONAL EQUIPOTENTIAL BONDING 3 OPTIONAL ASTOLINE Y o o oo ASTOLINE socket connection ASTOLINE BOARD Page 11 ASTOTHERM PLUS Repair Instructions 1 6 ASTOTHERM PLUS spare parts Fig 3 Cross section of the ASTOTHERM PLUS Page 12 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions Fig 4 Cross section of bottom part assembly with optional components Revision 6 03 2010 ASTOTHERM PL
2. WAF 12 open the hasp of the union nut and take it off Carefully push the cable into the plug housing and evenly pull out the plug insert at the same time Check the solder points for break e Attaching device f Using a suitable cross head screwdriver undo the four screws of the device fixing and remove the washers Lift off the bottom part and remove the O rings Replace the sealing rings before reassembling Further procedure for dismantling is described in Section 6 5 Caution the two bolts are not secured and may easily fall out Page 32 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 6 3 Dismantling the top part assembly When handling the top part ensure that the bolts are not put under lateral strain this can lead to fracture of the bolts or of the housing domes e Operating board a Place the top part on its front Using a suitable cross head screwdriver remove the two top screws on the operating board Slightly lift the operating board by the connecting cable until it slides out of the bottom screw retainer Take the board out upwards without tilting If necessary loosen the two bottom mounting screws Defective operating boards can only be repaired by the manufacturer Handle b Using a suitable cross head screwdriver unscrew the screws of the handle and remove the washers Remove the handle and the O rings on the outside Front panel C Loosen the front panel with a knife or a needle and re
3. knowledge and experience and are familiar with the relevant technologies standards and local rules and regulations Personnel who have to assess safety must be able to recognise any consequences and dangers caused by devices which do not comply with the requirements The measuring equipment must comply with the relevant standards All repair activities all tests carried out and their results must be recorded The pattern approval is invalidated if the device is no longer in its original state You must therefore use only original spare parts Due to the safety risks electronic PWBs must only be repaired by the manufacturer If they are faulty they must always be replaced in their entirety Any heat exchanger cylinder is an individual item from a heat engineering point of view due to its complex production and the large number of influencing variables production tolerances in the manufacture of the heating system NTCs etc For this reason every electronic temperature control needs to be specifically matched to its heat exchanger cylinder in order to achieve sufficiently small control fluctuation later on The NTCs form the core of the blood warmer Their sensitivity means that it is prohibited to change their position or replace them When dismantling or assembling the device ensure that the NTCs their connecting wires are not damaged Defective NTCs may be replaced only by the manufacturer The complete heat exchanger cylinder trans
4. 21 3 21 4 21 5 21 6 21 7 21 8 21 9 22 22 1 22 2 22 3 22 4 22 5 22 6 22 7 22 8 22 9 23 23 1 23 2 23 3 23 4 23 5 23 6 23 7 23 8 23 9 24 24 1 24 2 24 3 24 4 24 5 24 6 24 7 24 8 24 9 25 25 1 25 2 25 3 25 4 25 5 25 6 25 7 25 8 25 9 26 26 1 26 2 26 3 26 4 26 5 26 6 26 7 26 8 26 9 kQ 5 83372682 5 81104614 5 78846694 5 76598869 5 74361089 5 72133303 5 69915461 5 67707512 5 65509406 5 63321094 5 61142527 5 58973655 5 5681443 5 54664803 5 52524726 5 5039415 5 48273029 5 46161314 5 4405896 5 41965917 5 39882141 5 37807584 5 35742201 5 33685945 5 31638772 5 29600635 5 27571489 5 2555129 5 23539993 5 21537554 5 19543929 5 17559073 5 15582943 5 13615496 5 11656688 5 09706477 5 07764821 5 05831675 5 03906999 5 01990751 5 00082888 4 98183369 4 96292153 4 94409199 4 92534466 4 90667914 4 88809501 4 86959189 4 85116937 4 83282705 4 81456453 4 79638144 4 77827737 4 76025193 4 74230475 4 72443543 4 70664359 4 68892886 4 67129086 4 65372921 C 27 27 3 27 2 27 3 27 4 27 5 27 6 27 7 27 8 27 9 28 1 28 2 28 3 28 4 28 5 28 6 28 7 28 8 28 9 29 1 29 2 29 3 29 4 29 5 29 6 29 7 29 8 29 9 30 1 30 2 30 3 30 4 30 5 30 6 30 7 30 8 30 9 31 1 31 2 31 3 31 4 31 5 31 6 31 7 31 8 31 9 32 1 32 2 32 3 32 4 32 5 32 6 32 7 32 8 32 9 KO 4 63624353 4 61883346 4 60149863 4 58423866 4 56705319 4 54994187 4 5329
5. 6003 03 OUTER CARTON FOURFOLD AP TEST EQUIPMENT 9950 9000 02 POWER RESISTORS SET 4Pieces 15 Ohm 10 W 5 1Piece 100 Ohm 10 W 5 9950 9000 03 CD ROM AP Calibration Software 1 Interface 230 VAC 1 Instructions AP Cala Program 1 Instructions Eliminating microprocessor faults 9950 9000 35 Test Thermistor tip 3 5 mm to measure the temperature dependent on the resistance with multimeter and table Important details Because of the different variants and changes due to technical improvement it is absolutely necessary to indicate the model number REF and the serial number SN Only then it is ensured that the desired spare part is delivered in the right configuration 1 An exchange of this part requires an adjusting of temperature and display see chapter 4 of the Repair Instructions An exact adjustment can only be made by using the interface and the AP Calibration Software or by the manufacturer 2 Operating boards only for Glass NTCs from Rev 3 1 can be used alternatively for 40 C or for 41 C or for 43 C devices by uploading an corresponding data file to do this the interface and the AP Calibration Software is necessary I Operating boards from Rev 3 1 can be used alternatively for M841 NTC or Glass NTC devices by switching a solder jumper Because of the different characteristics of M841 NTCs and Glass NTCs transformer boards cannot be used alternatively They must be ordered and built in for the specific NT
6. and tighten up the nut Page 40 ASTOTHERM PLUS Repair Instructions Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 7 5 Final assembly of assemblies Once the individual assemblies are prepared they can be joined to form a complete ASTOTHERM PLUS device e Heat exchanger assembly and top part assembly a If necessary insert new sealing rings in the end face grooves of the heat exchanger b Check whether the connecting wires of the NTCs are correctly located inside the heat exchanger so they are not damaged c Insert the top part with the bolts ahead into the heat exchanger d Plug the operating board plug onto the transformer board e Guide the transformer board into the lateral guide rails in the top part Be careful with the connecting wires f Align the heat exchanger with the device to prevent twisting and carefully press onto the housing g Push the intermediate ring plus lateral guide grooves onto the transformer board and bolts Be careful with the NTC connecting wires h Screw the four spacing bolts onto the bolts Align the intermediate ring with the top groove to match the bore in the heat exchanger Hand tighten the spacing bolts i Push the cable tie through the top bore in the intermediate ring and place loosely around the heating cable and earth wire Align the cables exactly as shown in Fig h slightly tighten the cable tie and cut off the excess Warning correct routi
7. by this guarantee This also applies to interventions by persons other than those authorised by the manufacturer or if the original condition is changed If damage occurs during the guarantee period please clean the device and send it to a sales location near you or directly to STIHLER ELECTRONIC The costs of transport and packaging are for the sender s account 2 3 Liability The manufacturer shall only be liable for the safety reliability and performance of the device if all operating maintenance and testing procedures comply with the procedures communicated by the manufacturer and are carried out by properly trained and qualified personnel if when necessary only original spare parts are used to replace components if assembly and repairs are only carried out by authorised personnel or an authorised service centre if the electrical systems comply with the locally applicable instructions and regulations and the IEC requirements and if the device is used in keeping with the instructions of use for the intended purpose and at a suitable location not imply any authorisation on the part of the manufacturer to open or N The fact that technical documents or spare parts are made available does repair the device Revision 6 03 2010 Page 19 2 4 Page 20 ASTOTHERM PLUS Repair Instructions Important instructions Alltests must be carried out by properly qualified staff i e staff who have the relevant expert professional training
8. eV en Ext eR YR o RETIRER E DE Ra aa eeu 43 9 CONTINOUS DUTY TEST MER 44 10 RETURN AND OR DISPOSAL OF DEVICES OR ASSEMBLIES eene 44 11 APPENDIX e 45 Revision 6 03 2010 Page 3 ASTOTHERM PLUS Repair Instructions User information Test results which must be achieved to ensure safe operation are outlined by a frame The description for dismantling covers every possible assembly group and step If a defective component or an assembly group are to be replaced only the steps necessary for this should be performed Page4 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 1 Technical description 1 1 General Applications The ASTOTHERM PLUS allows fluids supplied to patients to be heated either to avoid or reduce hypothermia or to increase well being Applications include transfusions infusions dialysis haemofiltration and apheresis The warmer works in accordance with the principle of flow heating i e the heat is transmitted by the heat exchanger via the sterile infusion extension to the fluid flowing within it If the full heating capacity is not required two infusion extensions can also be inserted into the first and second halves of the heat exchanger A check on heat exchanger temperature at the inlet and outlet avoids fluids being overheated even if they have different inlet temperatures The patented heat protection sleeve i
9. selected state in the event of a brief power failure Automatic start is effected in the event of a power failure lasting up to 5 seconds 30 seconds at most e ASTOLINE active insulation ASTOLINE is an auxiliary heating system controlled by current and voltage If voltage or current are above or below the permissible limit values an alarm is activated The board is operated with low voltage power Safety cut off at warmer outlet Heater u Controller A Safety cut off at warmer inlet V Heizung amp ASTOLINE RESET ASTOLINE Watch Dog Power supply electronic Fig 1 Electronics block diagram Page 8 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 1 4 Technical Data 1 4 1 ASTOTHERM PLUS 200 and 200S ASTOTHERM PLUS 200 S AP200 S EU AP200 S UK AP200 S CH AP200 S DK AP200 S NA Line voltage 230 240 VAC 10 100 115 VAC 10 47 63 Hz 47 63 Hz Power supply cord SCHUKO BS plug Schweiz plug DK plug Hospital Grade Plug plug 13A Fuse H 05 VVF DK2 la DK2 NEMA 5 15P H 05 VVF H 05 VVF 3x1 3x0 75 5a SJO SJT 18 3 3x0 75 H 05 VVF 3x0 75 Impedance of protective earth lt 0 2 Ohm lt 0 2 Ohm Insulation resistance gt 2 MOhm gt 2 MOhm Primary Fuses 2x4A 2500 Selfstart after mains power failure 5 to 30 sec ES ES Dimensions height width depth Weight 2 9 kg Permissible ambient temperature for operat
10. splashes of physiological saline or blood from the surface of the housing use a soft cloth with a mild soap solution or a special plastic cleaner Commercially available cotton buds are suitable for cleaning the circumferential heat exchanger groove Never immerse device completely in fluid or bring into contact with steam Disinfecting For disinfecting use 4 sodium hypochlorite solution or alcohol based disinfectants of the ready to use spray disinfectant type containing low quantities 0 2 96 of aldehydes For disinfecting the ASTOTHERM PLUS and the ASTOLINE we recommend Bacillol plus from Bode Chemie in Hamburg Meliseptol from B Braun in Melsungen and Mikrozid Liquid or Mikrozid Pumpspray from Sch lke amp Mayr in Hamburg The operator should not use any cleaning or decontamination methods other than those recommended If using other methods check with the manufacturer that these will not damage the device N Under no circumstances sterilise with steam hot air or thermo chemically On the dismantled device ensure that the NTCs their connecting wires are not damaged or brought into contact with fluid If metal parts connecting wires printed circuits of electronic components on the boards are contaminated or corroded then replace the electronics for safety reasons Corroded metal parts inside the device suggest the use of non approved cleaning agents and disinfectants and the destruction of seals 4 Functional ch
11. 0432 4 51594019 4 49904911 4 48223074 4 46548472 4 4488107 4 43220832 4 41567725 4 39921712 4 38282761 4 36650836 4 35025904 4 3340793 4 31796882 4 30192725 4 28595426 4 27004951 4 25421269 4 23844346 4 2227415 4 20710648 4 19153807 4 17603597 4 16059984 4 14522937 4 12992425 4 11468415 4 09950878 4 08439781 4 06935094 4 05436786 4 03944827 4 02459185 4 00979832 3 99506736 3 98039868 3 96579198 3 95124696 3 93676333 3 9223408 3 90797907 3 89367786 3 87943687 3 86525583 3 85113443 3 83707241 3 82306948 3 80912535 3 79523976 3 78141241 3 76764304 3 75393136 3 74027712 3 72668002 Page 47 Page 48 C 33 33 1 33 2 33 3 33 4 33 5 33 6 33 7 33 8 33 9 34 1 34 2 34 3 34 4 34 5 34 6 34 7 34 8 34 9 35 1 35 2 35 3 35 4 35 5 35 6 35 7 35 8 35 9 36 1 36 2 36 3 36 4 36 5 36 6 36 7 36 8 36 9 37 1 37 2 37 3 37 4 37 5 37 6 37 7 37 8 37 9 38 1 38 2 38 3 38 4 38 5 38 6 38 7 38 8 38 9 kO 3 71313981 3 69965621 3 68622896 3 67285779 3 65954244 3 64628264 3 63307812 3 61992864 3 60683392 3 59379372 3 58080777 3 56787582 3 55499762 3 54217291 3 52940144 3 51668296 3 50401723 3 49140399 3 47884301 3 46633402 3 4538768 3 4414711 3 42911668 3 41681329 3 4045607 1 3 39235869 3 380207 3 36810539 3 35605365 3 34405154 3 33209881 3 32019526 3 30834064 3 29653473 3 2847773 3 27306814 3 261407 3 24979368 3 23822794 3 22670958 3 215
12. 23836 3 20381407 3 1924365 3 18110543 3 16982064 3 15858191 3 14738905 3 13624183 3 12514004 3 11408348 3 10307194 3 0921052 3 08118307 3 07030533 3 05947179 3 04868224 3 03793648 3 02723431 3 01657552 3 00595993 C 39 39 1 39 2 39 3 39 4 39 5 39 6 39 7 39 8 39 9 40 1 40 2 40 3 40 4 40 5 40 6 40 7 40 8 40 9 41 1 41 2 41 3 41 4 41 5 41 6 41 7 41 8 41 9 42 1 42 2 42 3 42 4 42 5 42 6 42 7 42 8 42 9 43 1 43 2 43 3 43 4 43 5 43 6 43 7 43 8 43 9 44 1 44 2 44 3 44 4 44 5 44 6 44 7 44 8 44 9 kQ 2 99538732 2 98485751 2 9743703 2 96392549 2 95352289 2 94316231 2 93284355 2 92256642 2 91233074 2 90213632 2 89198296 2 88187047 2 87179869 2 86176741 2 85177645 2 84182564 2 83191478 2 82204371 2 81221222 2 80242016 2 79266733 2 78295356 2 77327868 2 7636425 2 75404485 2 74448557 2 73496446 2 72548137 2 71603612 2 70662854 2 69725846 2 68792571 2 67863012 2 66937153 2 66014976 2 65096466 2 64181606 2 63270379 2 62362769 2 6145876 2 60558335 2 59661479 2 58768176 2 5787841 2 56992164 2 56109424 2 55230173 2 54354396 2 53482077 2 52613201 2 51747752 2 50885716 2 50027077 2 49171819 2 48319929 2 4747139 2 46626188 2 45784308 2 44945735 2 44110455 ASTOTHERM PLUS Repair Instructions C 45 45 1 45 2 45 3 45 4 45 5 45 6 45 7 45 8 45 9 46 46 1 46 2 46 3 46 4 46 5 46 6 46 7 46 8 46 9 47 47 1 47 2 47 3 47
13. 2620 FERRIT RING 9950 2100 20 FIXING STRIP 9750 8230 00 ASTOLINE ACTIVE INSULATION 4 MM 9750 8231 00 ASTOLINE ACTIVE INSULATION 6 8 MM FO 9850 5100 10 KNURLED SCREW 9750 5103 00 CLAMP LEFT 1Clamp left 1Rectangular nut left 1Pad 9750 5104 00 HAND WHEEL 1Hand wheel with Nut M8 1Grip cover 1Head screw M4x8 1Washer A4 3 9750 5101 00 DEVICE FIXING AP COMPLETE 9750 8230 17 PROTECTION CAP for ASTOLINE device socket 1Protection cap 1Crimp connector 9750 8230 02 ASTOLINE DEVICE SOCKET 1AL device socket 1AL arrow sticker 1Counter nut 9750 8220 03 ASTOLINE BOARD 1AL Board 2Pan head tapping screw EET 9750 8240 04 AL INSULATION PLATE 9750 4184 00 EQUIPOTENTIAL RETROFITTING SET 1Earth conductor 150mm 1Connector dia 6 mm 2Nut M6 2Washer R6 4 1Serrated lock washer V6 4 10 ring 5x1 1Assembly plan 1Drilling gauge 1Sticker Revision 6 03 2010 Page 17 ASTOTHERM PLUS Repair Instructions When ordering please indicate always model number and serial number DEI 9750 8230 20 AL PLUG for soldering 1 AL arrow sticker 9750 4201 14 SET O RINGS 4x1 MM 4 for housing screws 2 for handle 2Cable tie 90mm 9750 5101 11 SET O RINGS 5x1 MM 4 for device fixing AP 1 for equipotential bonding plug 2Cable tie 9850 6001 00 PACKAGE AP COMPLETE 1Internal carton 1EPS insert botton 1EPS insert top 1Outer carton 1Sticker package AP blank DEW 6003 01 OUTER CARTON SINGLE AP M 9850 6003 02 OUTER CARTON DOUBLE AP Ing 9850
14. 4 47 5 47 6 47 7 47 8 47 9 48 48 1 48 2 48 3 48 4 48 5 48 6 48 7 48 8 48 9 49 49 1 49 2 49 3 49 4 49 5 49 6 49 7 49 8 49 9 50 kQ 2 43278453 2 42449714 2 41624225 2 4080197 2 39982935 2 39167106 2 38354468 2 37545009 2 36738713 2 35935566 2 35135555 2 34338667 2 33544886 2 32754199 2 31966593 2 31182055 2 3040057 2 29622125 2 28846707 2 28074302 2 27304898 2 2653848 2 25775037 2 25014555 2 2425702 2 23502421 2 22750743 2 22001975 2 21256104 2 20513117 2 19773 2 19035743 2 18301332 2 17569755 2 16840999 2 16115052 2 15391903 2 14671538 2 13953946 2 13239114 2 12527031 2 11817684 2 11111062 2 10407153 2 09705945 2 09007427 2 08311586 2 07618411 2 06927891 2 06240014 2 05554768 Revision 6 03 2010
15. 5 0 C Toispla 42 1 to 42 9 C 42 1 to 42 9 C 45 1 to 46 9 C Teut off Page 26 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions Functional check of devices with ASTOLINE active insulation Models 200S 2208 2608 only 4 8 Measuring resistance of ASTOLINE active insulation Using a resistance measuring device measure the electrical resistance T Ss between Pin 1 and Pin 3 on the plug of the flexible silicone groove see pe Fig 13 In cold condition ASTOLINE temperature ambient temperature Fig 13 Pin assignment on the ASTOLINE plug The cold resistance of the ASTOLINE active insulation must be 54 3 5 ohms at an ambient temperature of 20 C add 0 26 ohms 1K higher ambient temperature 4 9 Testing ASTOLINE connection For the test a set of power resistors is required order no 9950 9000 02 The power resistors should have the following values 4 pieces with 15 Ohm 10W 5 1 piece with 100 Ohm 10W 5 They should be connected to the circuit according to the table below and Fig 14 triggering the appropriate reaction on the device Resistance Rx Q Reaction required white AL Plug Pin 1 R Pin 3 x Measurement of voltage Un U 20 8 21 4 VDC brown Fig 14 Test circuit for devices with an ASTOLINE After an alarm reaction the device must be restarted before further tests can be performed Revision 6 03 2010 Page 27 ASTOTHERM PLUS Repai
16. ARTH RES ABLEITSTROM LEAKAGE CURRENT mA GETESTED VON DATUM TESTED BY DATE Ll das gepr fte Ger t hat alle geforderten Pr fungen bestanden the tested unit has fulfilled all required tests BEMERKUNGEN NOTES Page 46 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions b Table Resistance Temperature of Test Thermistor C 15 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 16 16 1 16 2 16 3 16 4 16 5 16 6 16 7 16 8 16 9 17 17 1 17 2 17 3 17 4 17 5 17 6 17 7 17 8 17 9 18 18 1 18 2 18 3 18 4 18 5 18 6 18 7 18 8 18 9 19 19 1 19 2 19 3 19 4 19 5 19 6 19 7 19 8 19 9 20 20 1 20 2 20 3 20 4 20 5 20 6 20 7 20 8 20 9 Revision 6 03 2010 kO 7 40155109 7 37172128 7 34202981 7 31247595 7 28305898 7 2537782 7 22463287 7 1956223 7 16674578 7 13800261 7 1093921 7 08091354 7 05256626 7 02434956 6 99626278 6 96830522 6 94047623 6 91277513 6 88520125 6 85775394 6 83043253 6 80323639 6 77616485 6 74921726 6 722393 6 69569142 6 66911189 6 64265377 6 61631643 6 59009927 6 56400164 6 53802295 6 51216257 6 48641989 6 46079432 6 43528524 6 40989206 6 38461419 6 35945102 6 33440198 6 30946648 6 28464393 6 25993376 6 23533539 6 21084825 6 18647177 6 16220538 6 13804853 6 11400065 6 09006119 6 06622959 6 04250531 6 0188878 5 99537651 5 97197091 5 94867046 5 92547462 5 90238286 5 87939466 5 85650949 C 21 21 1 21 2
17. ASTOTHERM plus Blood and Infusion Warmer Models AP200 AP220 and AP260 Models AP200S AP220S and AP260S with ASTOLINE Repair Instructions REVISION 6 03 2010 STIHLER ELECTRONIC GmbH Julius Hoelder Strasse 36 D 70597 Stuttgart Phone 49 0 711 720670 Fax 49 0 711 7206757 Part No 9950 9000 12 ASTOTHERM PLUS Repair Instructions Table of Contents 1 TECHNICAL DESCRIPTION ER 5 1 1 Generali ur ten hee dtr e doe E oret leihen 5 iea SO tetur cium doe eerte babeat emm ei eue 6 1 3 Description of the electronics seen 7 1 4 Technical Data o eene Oe CBE PS 9 1 52 Terminalic ninecting plari J C ehe da de me andre ipe 11 1 6 ASTOTHERM PLUS Spare parts iic eei d creen La Lnd e due qe d av ned e ua d ad enr viene 12 2 GENERAL GUIDELINES AND PRINCIPLES FOR THE REPAIR OF ASTOTHERM PLUS BLOOD AND INFUSION WARMERS 19 2 1 Technical Service and Ordering Spare Parts usine 19 2 2 Guarantee Tepalls 5nd dene i tq oie dle iiie e e oed erben siehe desc aa aaa deest dpa dte Fu de 19 PR San ET 1 11T EE T 19 24 ImportantinstructiOns i ierit es ance er lee ed doa ree ERI a pee e ete nes Pere Lean 20 2 5 Procedure for ASTOTHERM PLUS repairs issues 21 3 CLEANING AND DISINFECTING nn enne nnnnnnn in nn nnne inii tenes nint n sind n tnn nsns n nnns natns snae nennen 22 4 FUNCTIONAL CHECK dc LE 22 4 1 Check display devices LCD and L
18. C type Because of the different excessive temperature cut offs transformer boards cannot be used alternatively for 40 41 C or for 43 C devices Because of the different position of the NTCs heat exchanger cannot be used alternatively for 40 41 C or for 43 C devices 7 Heat exchanger with M841 NTCs are no longer available Page 18 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 2 General guidelines and principles for the repair of ASTOTHERM PLUS blood and infusion warmers 2 4 Technical Service and Ordering Spare Parts STIHLER ELECTRONIC GmbH Tel 49 0 711 720670 Julius Hoelder Str 36 Fax 49 0 711 7206757 70597 Stuttgart www stihlerelectronic de Germany E mail info stihlerelectronic de When making requests or ordering spare parts please state the reference and serial number of the device in question You can find them on the device rating plate C A C o124 ASTOTHERM plus ASTOLINE Typ 1 U 24U VP Moro KR end STIHLER ELECTRONIC GmbH 50 60Hz 450W IPX4 DC 8W 70597 Stuttgart Germany cmo Joch Fig 6 Information on the rating plate 2 2 Guarantee repairs A 12 month guarantee is granted During the guarantee period the manufacturer will remedy all defects due to material or manufacturing faults free of charge either by repair or replacement This guarantee does not cover any other damage Damage due to misuse or improper handling excessive force or regular wear is not covered
19. E SOCKET 1Bottom part with drill hole for ASTOLINE socket connector and equipotential bonding 1AL Device Socket 1AL arrow sticker 1Sticker ASTO 2Buffer 2Cable tie 90mm 1Protective cap 1Crimp connection Fe 9750 4300 01 INTERMEDIATE RING 5 8750 5100 08 THREADED SHAFT 9750 5102 00 CLAMP RIGHT 1Clamp right 1Rectangular nut right 1Pad 17 9750 5100 01 BASEPLATE 1Base plate 1ldentification label Ip 1 9750 4300 02 SPACING BOLT 1 Piece ss 9720 3725 02 O RING 114 02 x 1 78 2 Pieces 9750 8100 00 HEAT PROTECTION SLEEVE AP 2Half part Heat protection sleeve 1Axle 2Sticker ASTOTHERM PLUS 1Fixing cord Page 16 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions When ordering please indicate always model number and serial number 9750 3132 00 41 HEAT EXCHANGER COMPLETE GROOVE 4 MM AP200 220 40 41 C 09 1Earth conductor 200mm mounted Alnsulating cover 1Ferrit Ring 2Cable tie 90mm 9750 3132 00 43 HEAT EXCHANGER COMPLETE GROOVE 4 MM AP220 43 C 09 1Earth conductor 200mm mounted Alnsulating cover 1Ferrit Ring 2Cable tie 90mm 9770 3132 00 41 HEAT EXCHANGER COMPLETE GROOVE 6 7 MM AP260 41 C 09 1Earth conductor 200mm mounted Alnsulating cover 1Ferrit Ring 2Cable tie 90mm 9770 3132 00 43 HEAT EXCHANGER COMPLETE GROOVE 6 7 MM AP260 43 C 09 1Earth conductor 200mm mounted Alnsulating cover 1Ferrit Ring 2Cable tie 90mm ian 9750 8110 01 FIXING CORD HEAT PROTECTION SLEEVE Ing 9524
20. ED eeseeeeeeeetetee nennen nennt nsns 23 42 Check heating UP timers 2234 toe terio m d RE do te a ge it eerie 23 4 3 Check display temperature fluctuations 23 4 4 Check temperature in control state issues 24 4 5 Test temperature overshoot on heating see 24 4 6 Alarm test TunctionS i od rea I IE i sur E tie LG Pere eto a 25 4 7 Checking Safety Cutonts 2 5 iori m P de tem UP epi rn M p RU TRA nt p eit 25 4 8 Measuring resistance of ASTOLINE active insulation ssse mem emm 27 4 9 Testing AS TOLINE GCOnnectioh intor cric RUP UR I PUn ER Sii 27 5 TROUBLESHOOTLTING 22 en ae ann retur ann ann Dore ES 28 6 DISMANTLING 22 02 30 6 1 Dismantling for troubleshooting in assemblies nnne 30 6 2 Dismantling bottom part assembly sise 31 6 2 Dismantling bottom part assembly sise 32 6 3 Dismantling the top part assembly sise 33 6 4 Dismantling the heat exchanger cylinder assembly 33 6 5 Dismantling the device fixing assembly sens 34 2 ASSEMBLING THE DEVICE ricette rene noces temp eee teer ERRANA A raiz mn ent een a Rene nra eR RO HERR AANA ARASA A BENK 35 7 1 Assembling the device fixing assembly ses 35 7 2 Assembling the heat exchanger assembly sin 35 7 3 Assembly of the top part assembly siens 37 7 4 Assembling the bottom part assembly siens 39 7 5 Final assembly of assemblies seen 41 8 ELECTRICAL SAFETY TEST ne ne nt Den
21. ERM PLUS KUNDE CUSTOMER AUSF HRUNG MODEL Li AP200 CIAP220 LIAP260 O S ASTOLINE 040 C 041 C 043 C FEHLERBESCHREIBUNG KUNDE DEFECT DESCRIPTION CUSTOMER TATS CHLICHE FEHLER REALLY DEFECTS AUSGEF HRTE ARBEITEN WORK PERFORMED DEMONTAGE DISMANTLING SICHTPR FUNG VISUAL CHECK Ok defekt defective REPARATUR REPAIR Geh use Housing n o Aufschriften Labeling MONTAGE ASSEMBLY Frontplatte Front panel Netzanschlu leitung power supply cord ASTOLINE ASTOLINE FUNKTIONSPR FUNG FUNCTIONAL TEST SONSTIGES OTHER Anzeigeeinrichtungen Indicators Funktion Function Alarmtest t1 t2 Temperature alarms t1 t2 Temperatur berschwinger Thermal overshoot Temperaturregelung Temperature control Thermometer Thermometer Temperaturanzeige Displayed temperature Abschaltung Warmereintritt Safety cutoff warmer inlet Abschaltung W rmeraustritt Safety cutoff warmer outlet ASTOLINE Test ASTOLINE Test ANZEIGEEINRICHTUNGEN INDICATORS ek ANZEIGE DISPLAY THERMOMETER ALARWTEST ti 2 TEMPERATURE ALARWS ec THERMOMETER THERMOMETER Siehe rechts ABWICKLUNG TRANSACTION see rignt side ANZEIGETEMPERATUR DISPLAYED TEMPERATURE gt GARANTIE GUARANTEED ABSCHALTUNG W EINTRITT SAFETY CUTOFF W INLET KULANZ FAIR DEAL ABSCHALTUNG W EINTRITT SAFETY CUTOFF W OUTLET ASTOLINE TEST SCHUTZLEITERWIDERSTAND PROTECTIVE E
22. NTC wire insulation tested 9750 2101 01 Glas TRANSFORMER BOARD for glass NTCs 41 C 9 white NTC wire insulation tested 0450 2101 43 TRANSFORMER BOARD 43 C 9 white NTC wire insulation tested 8510 0305 01 BUFFER 2 Pieces 9750 4100 09 CABLE GLAND PG9 1Cable gland 1Counter nut Order number oO Revision 6 03 2010 Page 15 ASTOTHERM PLUS Repair Instructions When ordering please indicate always model number and serial number 9750 4100 10 POWER SUPPLY CORD SCHUKO 1Power supply cord SCHUKO 1Cable tie 90mm 9750 4100 12 POWER SUPPLY CORD GREAT BRITAIN 1Power supply cord GREAT BRITAIN 1Cable tie 90mm 9750 4100 16 POWER SUPPLY CORD SWITZERLAND 1Power supply cord SWITZERLAND 1Cable tie 90mm 9750 4100 17 POWER SUPPLY CORD USA 1Power supply cord USA 1Sticker GROUNDING 1Cable tie 90mm 9750 4100 00 BOTTOM PART OF HOUSING AP 200 220 260 1Bottom part 1Sticker ASTO 2Buffer 2Cable tie 90mm 9750 4101 00 BOTTOM PART OF HOUSING AP 200 220 260 PA 1Bottom part with drill hole for equipotential bonding 1Sticker ASTO 2Buffer 2Cable tie 90mm 9750 4102 10 BOTTOM PART OF HOUSING AP 200S 220S 260S WITH ASTOLINE DEVICE SOCKET 1Bottom part with drill hole for ASTOLINE socket connector 1AL Device Socket 1AL arrow sticker 1Sticker ASTO 2Buffer 2Cable tie 90mm 1Protective cap 1Crimp connector 9750 4103 10 BOTTOM PART OF HOUSING AP 200S 220S 260S PA WITH ASTOLINE DEVIC
23. US Repair Instructions Fig 5 Cross section of top part assembly with optional components Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions ASTOTHERM PLUS spare parts When ordering please indicate always model number and serial number Name consist of 9751 4205 00 TOP PART OF HOUSING AP 200 complete with handle bolts and front pane 9750 4205 00 TOP PART OF HOUSING AP 220 260 complete with handle bolts and front pane 9751 4202 00 TOP PART OF HOUSING AP 200S complete with handle bolts and front pane 9750 4202 00 TOP PART OF HOUSING AP 220S complete with handle bolts and front pane 9770 4202 00 TOP PART OF HOUSING AP 260S complete with handle bolts and front pane 9750 8240 00 AL Holder 4 mm only from SN BSEU1017 BSUK1021 BSCH1012 BSNA1001 with fastening material DSEU1323 DSUK1043 DSCH1012 DSNA1054 9750 8241 00 AL Holder 6 8 mm only from SN HSEU1015 HSUK1018 HSCH1001 HSNA1015 with fastening material CS CE with fastening material 3 9750420078 DISPLAYCOVER o O FRONT BANEU AP Zaos o 9750 4200 02 FRONT PANEL AP 220S 260S 9750 2201 01 M841 OPERATING BOARD for M841 NTCs red or black NTC wire insulation tested and adjusted for Type 9750 2201 01 Glas OPERATING BOARD for glass NTCs white NTC wire insulation tested and adjusted for Type 6 9750 2200 14 KEY EXTENSION 1 Piece 9750 2101 01 M841 TRANSFORMER BOARD for M841 NTCs 41 C 99 red or black
24. acing downwards Revision 6 03 2010 Page 37 f 9 h ASTOTHERM PLUS Repair Instructions Operating board Fit the key extensions to the keys of the operating board The key extensions must lie level on the keys Push operating board into the lateral guide rails of the housing at an angle and suspend behind the bottom mounting screws If necessary undo the bottom mounting screws slightly and suspend the operating board Move the washers towards the operating board using a fine screwdriver and tighten back up Screw the operating board firmly in the housing Place the top part on the bolts and check that the key extensions do not project beyond or drop behind the openings in the surface of the front panel Adjusting the height of keys The distance from the surface of the front panel can be slightly altered by moving the washers of the bottom mounting screws To do so undo the screws and push the washers towards the operating board with a fine screwdriver This leads to the key extensions projecting out of the surface of the front panel Be sure that the front panel does not keep a key permanently depressed Front panel Do not stick a front panel back on once it has been removed as this does not guarantee permanently leak tight adhesion j k m n Remove old parts of adhesive Clean and degrease carefully the opening in the top part for the front panel with alcohol Do not use agents which attack plast
25. d relay optocoupler triac control LED Device activates alarm during Electronics defective after fall water damage or heating up use of non permitted disinfectants NTC defect NTC1 NTC2 NTC3 External effect sunlight heating air conditioning too hot a medical solution used Bimetal thermal cut off defective Device in alarm state device Bimetall thermal cut off has switched off cannot be started until display temperatures are below 30 C Display temperature above the External effect sunlight heating air tolerance of the control conditioning too hot a medical solution used temperature set in the control state Control NTC NTC1 is incorrectly adjusted or defective Display NTC NTC2 is incorrectly adjusted or defective Display temperature above the Models with ASTOLINE internal heating up due tolerance of the control to heat from transformer with ASTOLINE swit temperature set in the control state ched on and not enough heat being taken away at the heat exchanger Software alarm after connecting to Program fault microprocessor the mains alarm LED and alarm sound only available at manufacturer Revision 6 03 2010 Remedy Measure resistance of heating system In event of deviation from specified value see Section 6 4 Change heat exchanger and calibrate the unit Adjust it if necessary Change operating board and calibrate and adjust it if necessary Change transformer boa
26. e inlet NTC1 and outlet NTC2 cf Fig 1 Block Diagram e Temperature display The actual temperature is displayed in the LCD as a mean value At a temperature below 15 C only three bars at the bottom are shown and above 50 C only three bars at the top The three small displays on the 220 S and 260 S models show the user selectable temperatures The frame outlines the current selection according to which the temperature of the heat exchanger is being controlled On the model 200 S the temperature of the heat exchanger is fixed e Safety cut off at warmer inlet heat exchanger rear side The safety cut off at the warmer inlet is a device independent of the microcontroller It checks whether NTC1 is hotter than the alarm limit temperature value of second excessive temperature cut off see Section 1 4 In the event of an alarm the safety cut off switches off relay K1 This interrupts the heating current and the power supply for K1 and K2 Drop out of the relay is indicated by the flashing alarm LED and the alarm tone If the heat exchanger cylinder cools to below the alarm limit the device can be re started manually NTC1 cannot be affected by any conceivable defect of the safety cut off at the warmer outlet or of NTC3 e Safety cut off at warmer outlet heat exchanger front side The safety cut off at the warmer outlet works according to the same principle as the safety cut off at the inlet though it checks NTC3 temperature va
27. e operating board to be disconnect ed Disconnect the connection between the transformer board and the operating board Do not remove the fixing strip which retains the transformer board in the heat exchanger Prevent the heat exchanger transformer board assembly from rolling away The device is now dismantled into individual groups Fig 15 ASTOTHERM PLUS and ASTOLINE dismantled into assemblies Revision 6 03 2010 Page 31 ASTOTHERM PLUS Repair Instructions 6 2 Dismantling bottom part assembly e Mains cable and screw connection a Undo the union nut of the cable gland until the mains cable can be pulled out Place the bottom part on the fixing unit b Should the cable gland have to be completely dismantled the nut on the inside needs to be undone using a double cranked hex ring spanner WAF 22 If an equipotential bonding plug is attached to the device this must be removed beforehand e ASTOLINE electronics c Undo the screws on the left and right of the ASTOLINE board Take out the board far enough for the connection to the device socket to be accessible d Disconnect the connecting cable of the device socket to the ASTOLINE board e ASTOLINE active insulation e Note only the plug can be dismantled The described test according chapter 4 8 should be performed before dismantling To dismantle the plug using an open ended spanner WAF 10 open the cable clamp completely Using an open ended spanner
28. eck The functional check must be performed with the device assembled Note the following ambient conditions e avoid external effects on the device no draughts e constant room temperature 20 to 26 C keep out of direct sunlight keep away from strong light sources All Tests must be passed If any errors are found the warmer must be repaired before using it on patients The results of the functional check can be entered in the repair report template in appendix Page 22 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 4 1 Check display devices LCD and LED Connect the device to the mains at room temperature All the display devices should come on for a brief period cf Figs 8 and 9 O0 c C O0 0 mat rr LEIDEN 7 sag Bag a e e e e e e Model 200S only iie Do Fig 8 Display elements of model 200 S Fig 9 Display elements of models 220 S and 260 S 4 2 Check heating up time Switch on the device and start the warmer cf operating instructions Section COMMISSIONING without selecting a temperature Watch the temperature display during heating up Temperature increases rapidly at first then more slowly Heating up time 20 C to 35 C 4 3 Check display temperature fluctuation better with heat protection sleeve After a few minutes the displayed temperature is reaching the set temperature and is then deviating only marginally Fluct
29. ed when putting on the bottom part Warning correct routing of the cables is essential for EMC and safety reasons Place the bottom part on the heat exchanger exerting slight pressure The bottom part must be in place all but a small gap without the use of great force Fit the four housing screws with new O rings and place in the bores Tighten up screws evenly with minimum force until the gap closes Push the mains cable back into the bottom part a little way Tighten up the cable gland by hand until the sealing grommet abuts on all sides Using a suitable tool turn another half turn It should now only be possible to move the mains cable using considerable force Once the device has been assembled a complete functional check as described in Section 4 must be performed The results of the functional check must be entered in a repair report template in appendix Page 42 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 8 Electrical safety test The following checks are to be performed and recorded after any repair or modification to electrical medical equipment For exact testing guidelines see EN 62353 All checks must be passed according to the limit values Before conducting the tests ensure that test equipment is calibrated and in perfect condition Limit values according to EN 62353 Protective earth resistance 0 3 Ohm Insulation resistance gt 2 MOhm Equipment leaka
30. erated exclusively with low voltage power Depending on model type the heat exchanger cylinder has either 11 models 200 S and 220 S or 9 windings model 260 S Approximately 40 cm of infusion extension are required for one winding The heating system is attached to the inner surface of the aluminium heat exchanger cylinder The three temperature sensors for temperature control display and safety cut offs are located in the end faces of the cylinder The transformer board is inserted in the heat exchanger cylinder On this board are the fuses the connections for the mains cable and the heating and the heating control LED WARNING This board is live 100 V AC to 240 V AC The transformer board is secured in the heat exchanger cylinder by the intermediate ring and the fixing strip A universal mounting is fitted to the bottom part of the housing allowing the device to be attached to an infusion stand dia 12 mm to dia 35 mm or to a standard medical rail Warmers with ASTOLINE active insulation models 200S 220S and 2605 have the board and the device socket for the ASTOLINE fitted in the bottom part Page 6 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 1 3 Description of the electronics Temperature control The temperature at the heat exchanger cylinder is controlled by a control unit consisting of a microprocessor an A D converter and a triac unit The actual temperature is determined by two NTC sensors at th
31. f at the warmer inlet Using a hot air blower or hairdryer on the lowest temperature setting heat up the heat exchanger in the area below of the rear temperature measuring bore bottom right on bottom part of housing see mark in Fig 11 until the device activates the alarm Allow the device to cool down and keep pressing the Start key until it can be re started In the moment when the warmer can be re started the temperature display should be within the range of values given in the table Fig 11 Testing safety cut off at warmer inlet Safety cut off temperature AP 200 S at warmer inlet backside Ts 40 C Tset 41 C Tset 43 C Nominal value warmer display 41 5 to 42 0 C 42 0 to 42 5 C 43 8 to 44 7 C Toispla real value T 43 1 to 43 9 C 43 1 to 43 9 C 44 6 to 46 4 C Cut off Safety cut off at the warmer outlet Allow the device to cool down to the set temperature and repeat the measurement as carried out above below the front temperature measuring bore bottom left on top part of housing see mark in Fig 12 The temperature in the moment when the warmer can be re started should be within the range of values given in the table when the alarm occurs Fig 12 Testing safety cut off at warmer outlet Safety cut off temperature AP 200 S AP 220 260 S AP 220 260 S at warmer outlet frontside Tset 40 C Tset 41 C Tset 43 C Nominal value warmer display 41 0 to 41 7 C 41 5 to 42 2 C 44 0 to 4
32. former board operating board unit needs to be returned for this purpose For all thermal test work pay attention to room temperature and ambient effects As the control temperature is set accurate to a few tenths of a C note the following points avoid external effects on the heat exchanger unit electronics to be measured no draughts constant room temperature 20 to 26 C keep out of direct sunlight keep away from strong light sources Section 9 must be performed after any repair to the device A functional check see Section 4 and a continuous duty test see Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 2 Procedure for ASTOTHERM PLUS repairs Cleaning Section 3 Functional check Section 4 Troubleshooting Section 5 Dismantling Section 6 Replace individual parts of the housing and housing assemblies appliance fixing mains cable Replace ASTOLINE board socket Replace heat exchanger transformer and operating board assembly Assembly Section 7 l Functional check Section 4 Electrical safety test Section 8 o Continous duty test Section 9 Fig 7 Flow chart for repairs Revision 6 03 2010 Page 21 ASTOTHERM PLUS Repair Instructions 3 Cleaning and disinfecting N Always disconnect from the mains before cleaning and disinfecting Cleaning To remove
33. g Note NTC3 is positioned differently in 40 C 41 C devices and in 43 C devices g Route the connecting wires of NTCs 2 and 3 in a slight inward curve push through the soldering eyes and solder in place Page 36 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions h Turn the unit round Connect the earth wire and the heating cable to the transformer board in accordance with mains voltage see printed information on the transformer board 7 3 Assembly of the top part assembly When handling the top part ensure that the bolts are not put under lateral strain This can lead to the bolts or the housing domes fracturing Steps a to i can also be performed with the front panel glued in place Handle a Put washers on the screws of the handle and push them through the relevant top bores in the housing b Secure the screws against falling out with the o ring seals c The handle should not have any burr on the end faces If necessary remove burr with a knife Carefully place the handle on the screws Tighten up the screws loosely with a suitable cross head screwdriver to a gap of approx 5 mm Ensure that the O rings are not damaged by the screw thread d Turn the housing so that the handle points downwards Align the O rings on the handle Push the handle against the housing The seals must lie cleanly inside the depressions Tighten up screws evenly e Putthe pre assembled top part down with the front f
34. ge current Alternative method On the top of the back of the heat exchanger cylinder is a small point for contacting with the test probe when measuring protective earth resistance At this point the anodised aluminium coating of the heat exchanger has already been penetrated by the manufacturer s test The standard EN 62353 regulates no limit value the stated value is given by the manufacturer Fig 17 Contact point for protective earth resistance test On devices with equipotential bonding plugs earth wire resistance must likewise be measured with the test probe at the plug No electrical tests are carried out on ASTOLINE and the ASTOLINE device socket these parts are double insulated The results of the test for electrical safety must be entered in a repair report template in appendix Revision 6 03 2010 Page ASTOTHERM PLUS Repair Instructions 9 Continous duty test Once the functional check of the ASTOTHERM PLUS blood and infusion warmer is complete a continuous duty test needs to be carried out in conclusion In this test note room temperature and ambient effects As the control temperature is set accurate to a few tenths of a C note the following points avoid external effects on the heat exchanger unit electronics to be measured no draughts e constant room temperature 20 to 26 C keep out of direct sunlight keep away from strong light sources The continuous duty test co
35. ic for degreasing Ensure that no fluid gets through the openings onto the board Blow off dust particles on the LCD display or remove with a soft lint free cloth If using a new display cover remove the protective film Clean the display cover with alcohol Blow off dust particles or remove with a soft lint free cloth Insert the display cover in the opening satin side to front panel Ensure that it does not project beyond the front panel opening Experimentally position the front panel plus protective film onto the top part and align in accordance with the LEDs Observe the intervals from the edge of the front panel opening Pull the protective film off the adhesive back of the front panel Stick the front panel down on one side according to the previous alignment Slowly unroll the front panel and smooth onto the housing without trapping any air Do not take the front panel off again Page 38 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 7 4 Assembling the bottom part assembly e Device fixing a Place the preassembled device fixing as per Section 7 1 on the clamps so that the handwheel points to the left b Insert o ring seals in the depressions of the base plate at the screw bores c Place the bottom part on the device fixing and align in accordance with the bores Note the rating plate must point in the direction of the inlet retainer towards the top of the device d Putthe screws plus washers
36. in Fig 16 Ensure that the base plate with the depression for the rating plate is facing upwards Arrange the two clamps so that they can be suspended in a medical rail system The lug needs to be on top of the clamp for this purpose b Insert the left hand rectangular nut left hand thread into the opening on the underside of the left hand clamp and the right hand rectangular nut right hand thread into the right hand one c Turn the two clamps on the threaded shaft and ensure that the two clamps meet in the centre of the threaded shaft at the same time The groove of the threaded shaft must be precisely between the two clamps If necessary unscrew one clamp and turn the nut through 90 or 180 Screw on again until the clamps are central in relation to the groove of the shaft d Push the clamps and the shaft into the guide on the base plate e Push the two bolts with the retaining washers into the bores of the base plate from underneath f Screw the hand wheel and the washer very firmly onto the thin end of the thread of the shaft by hand and likewise screw very firmly to the cylindrical bolt and the washer Secure the bolt with a drop of adhesive g Press the grip cover flush onto the hand wheel h Screw the knurled screw into the thread of the left hand clamp 7 2 Assembling the heat exchanger assembly When handling this assembly ensure that itis reliably disconnected from the mains the fitted transformer board is p
37. in the bores and tighten up using a suitable cross head screwdriver e Cable gland e Push the cable gland into the bore of the bottom part from the outside The hexagon of the cable gland must engage in the flanks of the bottom part prevents twisting f Place the nut on the cable gland from inside and tighten up using a suitable tool For devices with ASTOLINE e ASTOLINE Board g Connect the board plug of the device socket to the ASTOLINE board h Route the cable of the device socket around the top left screw dome Warning correct routing of the cables is essential for EMC and safety reasons heating the shrink tube makes the cable more flexible i Insert board in the guide journals and align to suit the bores The cables may not be damaged in the process The board must lie level Tighten up the mounting screws and check that the board is firmly seated Revision 6 03 2010 Page 39 e Devices with equipotential bonding plug j Push the O ring seal over the thread of the equi potential bonding plug and insert this in the housing bore from the outside k Puton the washer and tighten the nut with an open ended spanner WAF 10 The plug must be held steady with an identical open ended spanner The o ring may not be forced out in the process Put on the serrated lock washer and the cable eye of the EP cable and tighten the second nut up slightly Align the cable eye front right at 45 hold steady
38. ion 16 C to 30 C for storage 40 C to 70 C Ambient operating humidity 10 to 90 Operation temperature 40 C 0 5 C 1 safety cut off 42 5 C 0 5 C 2 safety cut off 43 5 C 0 5 C heater bimetal cut off 65 C 5 C inadequate temperature alarm below 32 C Revision 6 03 2010 Page 9 ASTOTHERM PLUS Repair Instructions 1 4 2 ASTOTHERM PLUS 220 220S and 260 260S ASTOTHERM PLUS 220 S AP220 S EU AP220 S UK AP220 S CH AP220 S DK AP220 S NA ASTOTHERM PLUS 260 S AP260 S EU AP260 S UK AP260 S CH AP260 S DK AP260 S NA Line voltage 230 240 VAC 10 100 115 VAC 10 47 63 Hz 47 63 Hz Power supply cord SCHUKO BS plug Swiss plug DK plug Hospital Grade Plug plug 13A Fuse H 05 VVF DK2 la DK2 5a NEMA 5 15P H 05 VVF H 05 VVF 3x1 3x0 75 H 05 VVF SJO SJT 18 3 3x0 75 3x0 75 l Protection class Dimensions height width depth Weight 2 9 kg Warm up time approx 1 min 20 C to 35 C Permissible ambient temperature for operation 16 C to 30 C for storage 40 C to 60 C Ambient operating humidity 10 96 to 90 Operation temperature 37 C 0 5 C 39 C 0 5 C 41 C 0 5 C up to SN lt 5000 or 39 C 0 5 C 41 C 0 5 C 43 C 0 5 C from SN 2 5001 1 safety cut off 41 C devices 42 5 C 0 5 C 43 C devices 45 5 C 1 C 41 C devices 43 5 C 0 5 C 2 safety cut off a 43
39. ions 6 5 Dismantling the device fixing assembly Dismantling for cleaning purposes a Push the bolts out of the base plate using a drift b Push the base plate off the clamps c Unscrew the clamp on the right of the threaded shaft Remove the rectangular nut on the right and unscrew the knurled screw Clean the fixing unit as dismantled thus far with the cleaning agents disinfectants mentioned in Section 3 To do so turn the threaded shaft to and from in the clamp up to the ends Complete dismantling Further assembly may lead to destruction of the grip cover d Lever out the grip cover with a fine screwdriver e Turn the hand wheel so that it is flush with the left hand clamp Using a suitable screw driver undo the cylinder bolt and unscrew it it is secured with adhesive Remove the washer f Hold the threaded shaft with pliers in the cylindrical area and unscrew the hand wheel Remove the big washer g Unscrew the threaded shaft from the left hand clamp and take out the rectangular nut on the left Fig 16 Device fixing assembly disjointed completely Page 34 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 7 Assembling the device The safety information in Section 6 applies to assembly of the ASTOTHERM PLUS device Procedure for assembly assembly steps are described in individual sections by assembly group 7 1 Assembling the device fixing assembly a Prepare all the parts as shown
40. ions Section CONTROL PANEL Checking excessive temperature alarms Test 1 Start device at middle selected temperature Keep Start key depressed for three seconds to start the internal test cycle LCD display alternately displays t1 and actual temperature After a brief time the device should react with the excessive temperature alarm Re start the device by pressing the Start key Test 2 Start device at upper selected temperature Keep Increase key top Test function key depressed for three seconds to start the internal test cycle LCD display alternately displays t2 and actual temperature After a brief time the device should react with the excessive temperature alarm Re start the device by pressing the Start key Checking low temperature alarm Test 3 Start device at bottom selected temperature Remove heat protection sleeve Keep Decrease key bottom Test function key depressed for three seconds to start the internal test cycle LCD display alternately displays t3 and actual temperature Once the device has cooled down about approximately 4 C AP220 260 respective to 32 C AP200 the device should react with the low temperature alarm Switch off the device using the Device On Off key After this test the device cannot be restarted by pressing the Start key 4 7 Checking safety cut offs Note the temperature display reflects the mean value of the temperature of the heat exchange
41. lue of the first excessive temperature cut off see Section 1 4 located atthe outlet and controls relay K2 NTC3 cannot be affected by any conceivable defect of the control system the safety cut off at the warmer inlet NTC1 or NTC2 The drop out of the relay is indicated by the flashing alarm LED and the alarm tone If the heat exchanger cylinder cools to below the alarm limit the device can be re started manually Test devices Pressing the Start key checks whether relays K1 and K2 reliably cut power if so required A fault signal is sent to the safety cut off at the warmer inlet followed by the safety cut off at the warmer outlet The safety cut offs react with an audible click Following a successful test the device switches on the heating With alarm tests 1 and 2 the safety cut offs at the warmer inlet and outlet can be tested individually cf operating instructions Section PERIODICALLY RECURRING TEST MEASURES EEPROM memory An EEPROM is provided to store constants and operating states Calibration data are also stored here Revision 6 03 2010 Page 7 ASTOTHERM PLUS Repair Instructions Watchdog device The microprocessor is continuously monitored by a so called watchdog circuit If the microprocessor becomes defective due to a malfunction the watchdog circuit emits a signal and the device goes to stand by mode e Mains power failure bridging This is used to restart the device automatically in the previously
42. move the display cover 6 4 Dismantling the heat exchanger cylinder assembly When handling this assembly ensure that itis reliably disconnected from the mains the fitted transformer board is prevented from moving by the fixing strip the heat exchanger is prevented from rolling away a Disconnect the electrical plug connections between the heat exchanger and the transformer board heating and earth wire cable Measure heating system resistance between the numbered heating cables Specified values 1 2 125 to 145 ohm 1 3 62 5 to 72 5 ohm 1 4 lt 1 ohm 2 3 62 5 to 72 5 ohm b Turn the heat exchanger cylinder so that the secured transformer board is accessible from underneath c Heat the soldering points of the NTC lines using a soldering iron and pull them out with tweezers One NTC is attached at the inlet side of the heat exchanger mains side of the transformer board and two NTCs at the outlet side plug connection for the operating board d Turn the heat exchanger round again take hold of the top centre of the fixing strip and pull it out e Take hold of the transformer board in the area of the plug connector to the operating board and lift upwards Push the board through the heat exchanger f If polluted remove the sealing rings in both end faces of the heat exchanger using tweezers or another suitable tool and clean the groove Revision 6 03 2010 Page 33 ASTOTHERM PLUS Repair Instruct
43. ng of cables is essential for EMC and safety reasons j Check whether the sealing ring is properly seated in the groove of the heat exchanger and whether the heating cables are connected in accordance with mains voltage Revision 6 03 2010 Page 41 k m n 0 p q r ASTOTHERM PLUS Repair Instructions Bottom part assembly Push mains cable through the cable gland in the prepared bottom part from the outside Push mains cable and if necessary the equipotential bonding cable EP cable through the opening of the transformer board from underneath Connect mains cable to the mains terminals according to the printed information cf Fig 2 Guide cable tie through the small bore next to the opening around the mains cable from underneath and tighten If appropriate plug EP cable onto free earth wire connection cf Fig 2 Do not secure this cable with the cable tie Models with ASTOLINE only place insulating plate on heating cables and intermediate ring Note to make it easier to assemble the bottom part one corner of the cut away of the insulating plate can be engaged in the mains cable opening of the transformer board Carefully align the bottom part on the spacing bolts pulling the mains cable out of the cable gland and pushing the EP cable through the transformer board after it On bottom parts of housings with an ASTOLINE board ensure that the plug connection of the boards is not damag
44. nplug the ASTOLINE active insulation Place the device on the front top and handle a Undo the cable gland with a suitable tool until the mains cable can be moved b Undo the four housing screws with a screwdriver and remove these and the O rings c Remove the lower part in an upward direction pushing the mains cable after it Caution the housing has a plastic pin to prevent twisting which reaches into the heat exchanger cylinder Therefore never twist the bottom part against the heat exchanger d Models with ASTOLINE only remove insulating plate e Undo mains cable connections on the transformer board and remove cable tie Models with equipotential bonding plug only pull plug of earth wire cable off the transformer board and take out through the bore of the board Page 30 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions f 9 h i Unscrew the four spacing bolts of the bolts undo the cable tie of the heating cable and take off the intermediate ring Take the heat exchanger cylinder off the top part Caution the housing has a plastic pin to prevent twisting which rises up into the heat exchanger Therefore take the top part in both hands and using your thumbs push the heat exchanger cylinder upwards against the outlet side and remove Never twist the top part and the heat exchanger Push the parts only far enough apart to allow the electrical connection between the transformer board and th
45. nsulates the heat exchanger cylinder and the infusion extension against the effects of ambient cold e g air conditioning systems and thus increases the degree of efficiency There is an opening in the centre of the heat protection sleeve for use of a second infusion extension This is where extensions can be routed in and out and secured with the hand grips Overheating is reliably prevented by the following measures e 2 separate temperature sensors for temperature control temperature display and excessive temperature cut off e an additional independent temperature sensor for excessive temperature cut off optical and acoustic alarms On models 220 S and 260 S the temperature of the ASTOTHERM PLUS can be set alternatively at three fixed temperature steps up to 43 C On the model 200 S the temperature is fixed at 40 C The temperature display always shows the current mean temperature of the heat exchanger Heating of the medium is based on flow speed and inlet temperature For an optimum heat transfer we recommend the original infusion extension ASTOTUBE see outlet temperature diagrams in the operating instructions If on the models 220 S and 260 S the displayed temperature of the heat exchanger drops by more than 4 C below the selected set temperature the inadequate temperature alarm is activated On the model 200 S the inadequate temperature alarm is fixed at 32 C Revision 6 03 2010 Page 5 ASTOTHERM PLUS Re
46. ntling Generally applicable safety conditions and precautions apply to dismantling the ASTOTHERM PLUS All electrical installations must comply with the applicable national standards and regulations in each case During dismantling ensure that the device is reliably disconnected from the mains Electronic components can contain a residual current even after the device is switched off If a mains connection is required with the device dismantled e g for test purposes ensure that no conducting parts can be touched Procedure for dismantling The description follows the assembly structure of the device Once the cause of the fault has been localised the relevant assembly can be dismantled into smaller units The section heading indicates the assembly in question If potential dismantling is not described then this is either because there is no point or because the unit should not be dismantled any further Once the device is dismantled ensure that the electronics and the NTCs their connecting wires are not damaged or brought into contact with fluid If metal parts connecting wires printed circuits of the boards and the electronic components are contaminated or corroded then the electronics should be replaced for safety reasons Corroded metal parts inside the device suggest the use of non approved cleaning agents and disinfectants or defective seals 6 1 Dismantling for troubleshooting in assemblies Disconnect device from the mains U
47. pair Instructions There are ASTOTHERM PLUS in the following variations Order no Heat exchanger Temperature Power ASTOLINE groove consumption actively heated insulation up to the patient AP 200 4mm 40 C fixed 250 W AP 200 S 4 mm 40 C fixed 250 W v 37 C 39 C 41 C selectable AP 220 4mm or 450 W 39 C 41 C 43 C selectable 37 C 39 C 41 C selectable AP 220 8 4 mm or 450 W v 39 C 41 C 43 C selectable 37 C 39 C 41 C selectable AP 260 6 8 mm oder 450 W 39 C 41 C 43 C selectable 37 C 39 C 41 C selectable AP 260 S 6 8 mm oder 450 W v 39 C 41 C 43 C selectable no more in the actual sales program Description of ASTOLINE optional accessory Using the active ASTOLINE insulation it is possible to limit cooling of the fluid en route from the warmer to the patient The heated flexible silicone body surrounds the infusion extension over a distance of up to 130 cm ensuring that the part of the infusion line which would otherwise be exposed to the cool ambient air is both insulated and heated Its special shape also enables infusions and transfusions to be observed all the way to the patient 1 2 Structure In the top part of the housing underneath the front panel is the board with the components for electronic control the keys for operation and the associated LEDs and LCD for actual and selected temperature displays The board is op
48. r between front and rear side By testing the safety cut off of warmer rear side or warmer front side the heat exchanger is only heated up only at a small area In this condition the display shows not the real temperature of the small heated area it shows the mean value of the heated and unheated area The formula below shows the background Tpisplay Tintet Toutiet 2 or Tcut off TDispiay X 2 Tset Tpipay actual temperature which is indicated on the display Tinet actual temperature inside the heat exchanger in the area of the rear measuring bore Toutet actual temperature inside the heat exchanger in the area of the front measuring bore Tcut or real temperature in the moment of switching off Tset selected temperature on the side which will not be warmed up from external Revision 6 03 2010 Page 25 ASTOTHERM PLUS Repair Instructions Please observe the following instructions 1 Warmer has to be calibrated and if necessary to be adjusted 2 Warmer needs to work in the control state for a few minutes to ensure that the heat exchanger is heated through evenly N 3 Immediately before testing the display of the warmer should indicate 40 C 0 1 C AP200 41 C or 43 C 0 1 C respectively AP220 260 4 Between the tests of safety cut off warmer inlet backside and safety cut off warmer outlet frontside you have wait until the temperature has dropped to the set temperature see 3 Safety cut of
49. r Instructions 5 Troubleshooting If one or more items of the functional check are failed then troubleshooting will be required Compare the activities of the display devices with the operating and alarm states also described in the operating instructions Section CONTROL PANEL The table below is intended to assist in troubleshooting and help eliminate faults Renewal of individual components of the heat exchanger cylinder unit including transformer board and operating board requires calibration and if necessary adjusting of the calibration values with the interface An exact adjustment can only carried out with the interface and the accompanying software or by the manufacturer A modified device may not be commissioned without calibration and testing If a fault has been found on a component and there is no interface available the complete device should be returned to the manufacturer with a brief description of the fault Fault Possible causes Remedy Display devices LED LCD do not Lack of incorrect power supply Check socket fuse compare mains voltage light up after plugging in device with details on rating plate cannot be started Mains connection cable or mains plug defective Change mains connection cable Primary fuse defective impact short circuit in Measure resistance of heating system see heating system in mains transformer or on Section 6 4 board If heating system OK change primary fuse if device still no
50. rd and calibrate the unit Adjust it if necessary Change operating or transformer board and calibrate the unit Adjust it if necessary Change heat exchanger and calibrate the unit Adjust it if necessary Select a different location Do not use overheated medical solutions Change heat exchanger and calibrate the unit Adjust it if necessary Check whether device got too hot approx 65 C if due to external thermal effects thermal cut off OK if not due to external effects thermal cut off defective Change heat exchanger and calibrate the unit Adjust it if necessary Select a different location Do not use overheated medical solutions Check whether actual temperature of heat exchanger corresponds with display If so Adjust control temperature NTC1 Change heat exchanger and calibrate the unit Adjust it if necessary If not see next line Adjust temperature display NTC2 Change heat exchanger and calibrate the unit Adjust it if necessary Take off heat protection sleeve Switch off ASTOLINE unless in sole use Unplug device restart after approx 1 minute Reset device keep Decrease and Increase keys both test keys depressed for approx 5 seconds then disconnect from and connect to the mains Transfer the original data file Change operating board and calibrate the unit Adjust it if necessary Page 29 ASTOTHERM PLUS Repair Instructions 6 Disma
51. revented from moving by the fixing strip the heat exchanger is prevented from rolling away a Check whether the jumpers for voltage selection correspond to mains voltage and the details on the rating plate cf Fig 2 b Check whether the solder bridges for NTC tolerance class selection only glass type NTCs are set correct c Push the heating cables and the NTC wires of the heat exchanger slightly outwards When fitting the transformer board ensure that they are not trapped or damaged Push the transformer board into the heat exchanger from the back side with the heating system cables and one NTC with the front side with the plug connection to the operating board tilted slightly upwards Insert the rectangular flanks of the board into the two grooves of the heat exchanger and drop Revision 6 03 2010 Page 35 ASTOTHERM PLUS Repair Instructions d Clamp the fixing strip on the correct side on the front between the edge of the heat exchanger and the transformer board The fixing strip has an opening for the bimetallic switch of the heating system e Turn round the heat exchanger cylinder so that the secured transformer board is accessible from underneath Prevent the unit from rolling away f Push the connections of NTC1 into the designated solder eyes with tweezers and solder in place The connecting wires must be bent close to the transformer board so that they are not subsequently damaged by the intermediate rin
52. rresponds to the Check temperature in control state as described in Section 4 This test is carried out 3 times over a period of 24 hours The measured value of the thermometer and the temperature display must be entered in a repair report template in appendix 10 Return and or disposal of devices or assemblies If the device or an assembly has been in contact with blood or bodily fluids it needs to be carefully cleaned and disinfected In view of the risk of contamination with viruses and other pathogens adequate precautions should always be taken to prevent contact with such pathogens We recommend placing the device in a plastic bag and sealing this tightly before returning it The device should be packed in either the original packaging or equivalent to avoid transport damage This likewise applies to individual assemblies It is the customer s responsibility to pack and mark correctly the product for return STIHLER ELECTRONIC can dispose of your old device cheaply and properly To make use of this service return the cleaned and disinfected device with a note to this effect Page 44 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 11 Appendix a Form Repair Report Rev 2 02 05 b Table Resistance Temperature of Test Thermistor order no 9950 9000 35 Revision 6 03 2010 Page 45 ASTOTHERM PLUS Repair Instructions Reparaturbericht Seite 1 von Repair report Page 1 PRODUKT PRODUCT ASTOTH
53. set temperature Tse and then switch off the device Insert the test thermistor into the rear measuring bore on the side of the heat exchanger see Fig 10 and connect it with the ohmmeter Allow heat exchanger cylinder to cool down by 1 C 0 2 K If the device is switched back on the temperature of the heat exchanger can be read off on the display The alarm should sound continuously Fig 10 Measuring control temperature and Start the warmer when the Tse 1 C cooling limit is temperature overshoot reached Look at the display of the ohmmeter and jot down the lowest measured resistance Take the corresponding temperature out of the table and compare it with the following values AP200 AP220 260 AP220 260 40 C 41 C 43 C Start at circa Tse 1 C 38 8 39 2 C 39 8 40 2 C 41 8 42 2 C max set temperature max allowed temperature overshoot 40 7 C 42 2 C 43 5 C Page 24 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions 4 6 Alarm test functions The ASTOTHERM PLUS is fitted with alarm test functions These simulate the failure of temperature sensors and thus lead to activation of alarm cut offs The description which follows relates to ASTOTHERM PLUS 220 S and 260 S models with adjustable selected temperature For the ASTOTHERM PLUS 200 S models there are no keys for changing temperature In this case the key names in brackets apply cf Figs 8 and 9 and operating instruct
54. t OK transformer board return complete electronics system with heat exchanger If heating system not OK return complete electronics system with heat exchanger Device switched on device cannot Secondary fuses defective Change secondary fuses on transformer be started board Operating board defective Change operating board and calibrate and adjust it if necessary Transformer board defective Change transformer board and calibrate the unit Adjust it if necessary NTC 1 2 or 3 defective Change heat exchanger and calibrate the unit Adjust it if necessary On models with ASTOLINE Switch off ASTOLINE if warmer can be started check the following ASTOLINE On Off key pressed but ASTOLINE Connect ASTOLINE not connected ASTOLINE device socket defective Check resistance Replace device socket ASTOLINE board defective Replace ASTOLINE board ASTOLINE defective Check resistance Replace ASTOLINE if necessary Device switched on device cannot Control NTC NTC1 or Display NTC NTC2 Change heat exchanger and calibrate the be started bars only on defect unit Adjust it if necessary temperature display Device is colder than 0 C place device in a warmer location Page 28 Revision 6 03 2010 ASTOTHERM PLUS Repair Instructions Fault Possible causes Device can be started but heat Heating system defective exchanger cylinder does not get hot Operating board defective Defect on transformer boar
55. uation of the display temperature due to control may not exceed 0 2 C in load free mode Revision 6 03 2010 Page 23 ASTOTHERM PLUS Repair Instructions 4 4 Check temperature in control state better with heat protection sleeve The test thermistor order No 9950 9000 35 a calibrated ohmmeter and the table of resistance temperature in the appendix of these repair instructions are required for this purpose Insert the test thermistor into the rear measuring bore on the side of the heat exchanger see Fig 10 and connect it with the ohmmeter Wait until the indicated value is stable Then read the indicated value and take the corresponding temperature out of the table Deviation of the control temperature measured with the test thermistor from the set control temperature may not exceed 0 4 C The displayed temperature of the warmer may not exceed more than 0 4 C from the selected and the measured temperature Example Set temperature 41 C 41 C 41 C measured temperature 40 8 C 41 2 C 40 5 C ok ok not ok displayed temperature of 40 6 41 2 C 40 7 C 40 8 C the warmer ok not ok ok 4 5 Test temperature overshoot on heating without heat protection sleeve The test thermistor order No 9950 9000 35 a calibrated ohmmeter and the table of resistance temp erature in the appendix of these repair instructions are required for this purpose Operate warmer with the highest

ASTOTHERM 200 - 260 Infusion Pump Service Manual

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