Model WT-5200
Patient Warming System
Service Manual
To obtain information about a warranty, if any, contact Nellcor’s Technical Services Department
(1.800.635.5267, press 3), or your local Nellcor representative.
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Figuree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Warnings ...................................... ....... ...... ....... ...... ... ....... ...... ....... ...... ...... ....... .....1
Cautions .................................... ...... ....... ...... ....... ... ...... ....... ...... ....... ...... ....... ...... ..2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intended Use ............................... ... ................................................. ... ... ... ............3
Manual Availability ................................................................................................3
Background Information ........................................................................................3
Safety Features ..........................................................................................4
Customized Warming Therapy ........ ..................................................4
Automatic Temperature Stepdown ........................ ............................4
Automatic Shutdown ......................................................................... 4
Warning Light ....................................................................................4
HEPA Filter .......................................................................................4
Wheel Locks ......................................................................................4
Symbols .................................... ................................................................ ............ 6
The WarmTouch Warming System Description .................. .......... ......... .......... .....7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HEPA Filter Replacement ...... ...............................................................................9
Hose Replacement .............................................................................................11
Power Cord Replacement ...................................................................................13
Nozzle Replacement ...........................................................................................15
Cleaning the WarmTouch Patient Warming System ..........................................15
Performance Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Thermostat Protection Check ............................................................. ... ... .... ... ...17
Output Temperature Check ................................................................................20
Safety Tests ........................................................................................................22
Disassembly Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Filter Cover Assembly Replacement ..................................................................23
Separating the Warming Unit Front and Rear Covers ........................................25
Front Cover Assembly Replacement ........................ .......................................... 28
Universal PCB Replacement ..............................................................................37
Heater Assembly Replacement ..........................................................................46
Duct Adapter Assembly Replacement ................... ... ... .... ... ... ... .... ... ... ... ... .... ... ...62
Rear Cover Assembly Replacement ............................ .......... .......... ......... ..........66
Spare Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Ordering Information ...........................................................................................85
WarmTouch Replacement Parts and Accessories .............................................87
Manual Availability ..............................................................................................87
Packing for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Introduction .................................. ................................................................. ......89
Returning the WT-5200 ......................................................................................89
General Instructions ............................... ... ... .... ................................................ ...89
WT-5200 i
Contents
Repacking in Original Carton ..............................................................................89
Repacking in a Different Carton ..........................................................................91
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
WarmTouch Patient Warming System Specifications ........................................93
Transport and Shipping in Shipping Container ............................ ... .... ... ...93
Ground Integrity Test ................................................................................94
Earth Leakage Current Test .....................................................................94
Enclosure Leakage Current Test ..............................................................94
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Control Panel ......................................................................................................95
Main Circuit Board ..............................................................................................96
DC Power Supply Circuit ....................................... ... ... ... .... ... ... ... ... .... ... ...96
Control Logic Circuit .................................................................................97
Automatic Temperature Stepdown ........................... ................................97
Temperature Control Circuit .............................. ....................................... 97
LCD Hour Meter .......................................................................................98
AC Power Section ..................................... ... .... ... ... ... ... .... ... ... ... ..........................98
Blower ....................................... ................................... .................................... ... 99
Heater .................................... ................................................................ ............. 99
Thermostat Protection .............................. ... .... ... ... ... ... .... ... ................................99
Over-Temperature Test Port ...............................................................................99
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
ii
Figuree
Contents
Figure 1: Cart Wheel Lock .............................................................................5
Figure 2: Model WT-5200 Front View ............................................................7
Figure 3: Model WT-5200 Back View ............................................................8
Figure 4: Operating Hours Meter ...................................................................9
Figure 5: Rear Panel Screws .......................................................................10
Figure 6: HEPA Filter ...................................................................................11
Figure 7: Back of Case ................................................................................12
Figure 8: Hose Retaining Wire .....................................................................13
Figure 9: Power Cord Routing .....................................................................14
Figure 10: Over-Temperature Test Port .........................................................18
Figure 11: WarmTouch High Temperature Setting ........................................19
Figure 12: Warning Light ................................................................................19
Figure 13: Output Temperature Setup ...........................................................21
Figure 14: Temperature Selection .................................................................21
Figure 15: Ground Stud .................................................................................22
Figure 16: Power Cord ...................................................................................24
Figure 17: Rear Panel Screws .......................................................................24
Figure 18: Power Cord ...................................................................................25
Figure 19: Power cord Removal ....................................................................26
Figure 20: Cover Screw Locations .................................................................27
Figure 21: Separated Covers .........................................................................27
Figure 22: Cable Harness Cable Ties-downs ................................................29
Figure 23: Front Cover Assembly ..................................................................29
Figure 24: Power Switch Removal .................................................................30
Figure 25: Cable Disconnect ..........................................................................30
Figure 26: Universal PCB Screws ..................................................................31
Figure 27: Universal PCB Lights ....................................................................32
Figure 28: Universal PCB Screws ..................................................................32
Figure 29: Cable Connections .......................................................................33
Figure 30: Power Switch Clips .......................................................................33
Figure 31: Front cover Assembly Component Locations ...............................34
Figure 32: Equipotential Ground ....................................................................35
Figure 33: Cable Harness Cable Ties-downs ................................................35
Figure 34: Cover Screw Locations .................................................................36
Figure 35: Power Cord Retaining Bracket .....................................................37
Figure 36: Universal PCB Connections .........................................................38
Figure 37: Universal PCB Screws ..................................................................39
Figure 38: Universal PCB Solid State Relay Assembly .............. ... ... ... .... ... ...40
Figure 39: Part of Universal PCB ...................................................................41
Figure 40: Universal PCB Alarm Jumper .......................................................42
Figure 41: Universal PCB Lights ....................................................................42
Figure 42: Universal PCB Screws ..................................................................43
Figure 43: Cable Connections .......................................................................43
Figure 44: Cable Harness Cable Ties-downs ................................................44
Figure 45: Cover Screw Locations .................................................................45
WT-5200 iii
Contents
Figure 46: Power Cord Retaining Bracket .....................................................46
Figure 47: Filter Removal ...............................................................................47
Figure 48: Blower Assembly Screws .............................................................48
Figure 49: Cable Harness Cable Ties-downs ................................................48
Figure 50: Front Cover Assembly ..................................................................49
Figure 51: Cable Disconnect ..........................................................................50
Figure 52: Duct Adapter Placement ...............................................................51
Figure 53: Blower Motor Removal .................................................................52
Figure 54: Blower Assembly Clips .................................................................52
Figure 55: Rubber Washer .............................................................................53
Figure 56: Heater Assembly ..........................................................................53
Figure 57: Heater Assembly Installation ........................................................54
Figure 58: Rubber Washer .............................................................................55
Figure 59: Blower Assembly Clips .................................................................55
Figure 60: Blower Assembly Screws .............................................................56
Figure 61: Duct Adapter Placement ...............................................................57
Figure 62: Cable Connections .......................................................................57
Figure 63: Front Cover Assembly ..................................................................58
Figure 64: Equipotential Ground Stud Wiring ......... .... ... ... ... .... ... ... ... ... .... ... ...59
Figure 65: Cable Harness Cable Ties-downs ................................................59
Figure 66: Cover Screw Locations .................................................................60
Figure 67: Filter Installation .................................. .......................... ................60
Figure 68: Filter Cover Installation .................................................................61
Figure 69: Power Cord Retaining Bracket .....................................................61
Figure 70: Thermistor Silicone .......................................................................63
Figure 71: Thermistor Removal .....................................................................63
Figure 72: Duct Adapter Removal ..................................................................64
Figure 73: Duct Adapter Placement ...............................................................64
Figure 74: Thermistor Position Within Duct Adapter ................................ ... ...65
Figure 75: Cover Screw Locations .................................................................66
Figure 76: Filter Removal ...............................................................................68
Figure 77: Warming Unit Mounting Clamps ................................................... 68
Figure 78: Separated Covers .........................................................................69
Figure 79: Front Cover Assembly ..................................................................70
Figure 80: Cable Disconnect ..........................................................................71
Figure 81: Thermistor Cable Removal ...........................................................71
Figure 82: Blower Assembly Screws .............................................................72
Figure 83: Blower Capacitor ..........................................................................73
Figure 84: Blower Motor Removal .................................................................74
Figure 85: Blower Assembly Clips .................................................................74
Figure 86: Rubber Washer .............................................................................75
Figure 87: Heater Assembly ..........................................................................75
Figure 88: Warming Unit Mounting Brackets .................................................76
Figure 89: Heater Assembly Installation ........................................................76
Figure 90: Rubber Washer .............................................................................77
Figure 91: Blower Installation ............................... .......................... ................77
Figure 92: Blower Screws ..............................................................................78
Figure 93: Thermistor Cable Installation ........................................................ 78
iv
Contents
Figure 94: Capacitor Installation ....................................................................79
Figure 95: Cable Connections .......................................................................79
Figure 96: Front Cover Assembly ..................................................................80
Figure 97: Equipotential Ground Stud Wiring ......... .... ... ... ... .... ... ... ... ... .... ... ...81
Figure 98: Cable Harness Cable Ties-downs ................................................81
Figure 99: Cover Screw Locations .................................................................82
Figure 100: Filter Installation ............................... .......................... ...................82
Figure 101: Filter Cover Installation .................................................................83
Figure 102: Power Cord Retaining Bracket .....................................................83
Figure 103: Spare Parts (Sheet 1) ...................................................................86
Figure 104: Spare Parts (Sheet 2) ...................................................................87
Figure 105: Packing .........................................................................................90
Figure 106: Keyboard Assembly ......................................................................95
Figure 107: Warning Light ................................................................................95
Figure 108: Remove Screws to Open Case ....................................................97
Figure 109: Hour Meter ....................................................................................98
Figure 110: 5200 Schematic Diagram ...........................................................101
WT-5200 v
Tables
Tables
Table 1: WT-5200 Symbols ........................ ... ... ... ... .... .....................................6
Table 2: HEPA Filter Replacement Equipment Required ...............................9
Table 3: Hose Replacement Equipment Required ........................................12
Table 4: Power Cord Replacement Equipment Required .............................13
Table 5: Equipment Required for Thermostat Protection Check ............. ... ...17
Table 6: Equipment Required for Output Temperature Check ......................20
Table 7: Replacement Parts and Accessories ..............................................85
Table 8: Model WT-5200 Blower Specifications ...........................................93
Table 9: Model WT-5200 Cart Specifications ...................... ..........................93
vi
Safety Information
Warnings
WARNING: Possible explosion haz ard. Do not use the WarmTouch® Model
WT-5200 Patient Warming System in the presence of flammable anesthetic
agents.
WARNING: Possible electrical shock hazard. To reduce electrical shock do
not remove back case. Servicing is only to be done by qualified personnel.
WARNING: Possible electric shock hazard. Grounding reliability can be
achieved only when the Warming System is connected to an equivalent socket
marked “HOSPITAL ONLY” or “HOSPITAL GRADE.”
WARNING: Possible fire hazard. Prevent the blanket material from coming
into contact with a laser or an electrosurgical active electrode; rapid
combustion could result.
WARNING: Possible burn hazar d. Do not apply heat directly to open
wounds. All patient’s wounds should be covered while using the warming
system.
WARNING: Possible patient bur ns . Us e caution and consider discontinuing
use on patients during vascular surgery when an artery to an extremity is
clamped. Do not apply the warming system to ischemic limbs. This could
possibly cause the patient to be burned.
WARNING: Possible patient bur ns . Us e caution and monitor closely if used
on patients with severe peripheral vascular disease. This could possibly cause
the patient to be burned.
WARNING: If a malfunction occurs in the warming system, discontinue use.
Notify your sales/service center of the malfunction. The unit must be serviced
by an authorized service technician.
WT-5200 1
Safety Information
WARNING: Possible patient burns. Do not warm patients with the warming
system hose only. Thermal injury may result. Always attach the hose to a
WarmTouch blanket before providing warming therapy.
WARNING: WarmTouch, CareDrapeTM, and CareQuilt® blankets are for
single patient use only.
WARNING: The warming system should not be operated in the presence of
electromagnetic fields that are greater than 3 volts/meter. This could cause
shutdown of the warming system by the fail-safe function within the
equipment.
WARNING: The warming system is not suitable for use during magnetic
resonance imaging (MRI) scanning. The warming system may affect the MRI
image.
Cautions
Caution: Federal (U.S.A.) law restricts the use of the warming system to sale by or
on the order of a physician.
Caution: Continuously monitor the patient's temperature. Reduce the air
temperature or discontinue therapy when normothermia is reached.
Caution: The warming system is fitted with an air filter; however, airborne
contamination should be considered when using the warming system.
Caution: If the warming system is mounted on the intravenous (IV) pole, it should
be installed with the top of the unit’s handle less than 76 cm (30 inches) ab ove the
floor to prevent the IV pole from tipping over.
Caution: If a malfunction occurs in the warming system, discontinue use. Notify
your sales/service center of the malfunction. Servicing is only to be done by
qualified personnel.
Caution: Ensure that the patient is dry or the warming system may be ineffective.
2
Introduction
Intended Use
The WarmTouch Model WT-5200 Patient Warming System (warming unit and
blanket) is intended for prevention and treatment of hypothermia. For example,
with the surgical patient, the patient in the pre-operative holding area, the
pregnant woman who shivers during epidural anesthesia, or any patient who is
uncomfortable in the cold critical care environment.
Manual Availability
The most recent revision of this manual is available on the Internet at:
http://www.mallinckrodt.com/respiratory/resp/serv_supp/productmanuals.html
Background Information
There are numerous ways of warming your patient, from cotton blankets to water
mattresses. Research has shown that low temperatures surrounding the patient are
a major factor contributing to hypothermia
patient with warm air and actively transfers heat across the skin. The result is to
achieve normal thermia.
In creating this warm customized pocket of air around the hypothermic patient,
Stagnant air, even if it is warm, does not work as an effective heat transfer
medium. Stagnant air acts as an insulator, preventing the boundary layer of
molecules next to the skin surface from transferring heat.
Forced air warming causes warmed air molecules to flow over cooler skin surface.
It is this active flow of warmed molecules that acts as a heat transfer medium.
With the warming system, air is warmed and delivered into a lightweight blanket
(CareQuilt or CareDrape Blanket) that rests over or under the patient. The
CareQuilt and CareDrape blankets have many small perforations on the
underside that allow air to exit the blanket and surround the patient.
1), 2)
. The warming system covers the
1) Morris RH, Wilkey BR. "The Effects of the Ambient Temperature on Patient Temperature
During Surgery Not Involving Body Cavities.” Anesthesiology 32:102-107, 1970.
2) Morris RH. “Influence of Ambient Temperature on Patient Temperature During Intraabdominal Surgery.” Annals of Surgery 173:230-233, 1971.
WT-5200 3
Introduction
Safety Features
The warming system is designed to give healthcare professionals more control
over patients' core body temperature. Several safety features of the warming
system make it safe and appropriate for such use. These features are described
below.
Customized Warming Therapy
Clinicians select temperature range setting at the onset of warming therapy to help
ensure the appropriate setting is selected for every patient.
Automatic Temperature Stepdown
The warming system provides a 45-minute temperature stepdown feature. When
the unit is operating in the high mode, air temperature will automatically drop to
medium after 45 minutes of continuous use. The temperature may be reset to high
mode by selecting high temperature on the unit front panel.
Automatic Shutdown
Warning Light
HEPA Filter
The automatic temperature controller and two back-up systems help to ensure
temperature will not reach excessive levels. If necessary, the back-up systems
automatically turn off the heater and illuminates the warning light. The warming
system heater will start producing heat when the warming system temperature
drops to approximately 34ºC to 37ºC.
When the warning light on the control panel is illuminated, it indicates that one of
the two thermostats has turned off the heater. The reason for the heater turn-off
should be investigated as soon as possible after use.
The system's High Efficiency Particulate Air Filter is 99.97% efficient at
0.3-micron particle size.
Wheel Locks
4
The cart is equipped with two wheel locks. The wheel locks prevent the cart from
moving while in use. The wheel locks must be released when moving the cart.
Introduction
Press the wheel lock arm down to lock the wheel. Lift the wheel lock arm to
release the wheel lock. See Figure 1.
Figure 1: Cart Wheel Lock
WT-5200 5
Introduction
Symbols
The symbols identified in Table 1 are the symbols used on the WT-5200 and all
WT-5200 labeling.
Table 1: WT-5200 Symbols
Attention symbol, consult
accompanying documentation
Temperature Control
Ambient Air
Temperature Control
Low
° C)
(30-34
Temperature Control
Medium
(36-40
° C)
Temperature Control
High
° C)
(42-46
I Power On
0 Power Off
Protection Class I
Protection Type BF
6
The WarmTouch Warming System Description
The warming system (Figure 2 and Figure 3) and CareQuilt and CareDrape
blankets are intended to prevent and treat hypothermia. For example, with the
surgical patient, the patient in the pre-operative holding area, the preg nant woman
who shivers during epidural anesthesia, or any patient who is uncomfortable in the
cold critical care environment.
Introduction
1 — Hose 4 — Power Cord
2 — Main Power Switch 5 — Hour Meter
3 — Nozzle 6 — Control Panel
Figure 2: Model WT-5200 Front View
WT-5200 7
Introduction
1 — Over-Temperature Test Port 4 — Warning Label
2 — Bed Hook Bracket 5 — Nozzle Strap with Clip
3 — Filter Cover 6 — Instruction Label
Figure 3: Model WT-5200 Back View
8
Routine Maintenance
Caution: The institution should follow local governing ordinances and recycling
instructions regarding disposal or recycling of filter and device components or end
of life of the product.
HEPA Filter Replacement
The warming system filter should be replaced after every 2000 hours of use.
Contact Nellcor’s Customer Service Department (1.800.635.5267, press 3) or
your local Nellcor representative to purchase new filters. The correct filter will be
sent to your hospital for installation.
Caution: Only qualified hospital personnel should replace the air filter.
The warming system total operating hours and the date of installation should be
recorded on the new filter label and on the unit label when the filter is installed.
See Figure 4 for the location of the Hour Meter on the warming system.
Note: The warming system must be operating to read the total operating hours
meter.
Table 2: HEPA Filter Replacement Equipment Required
Equipment Description/Use
Phillips Screwdriver #2, removing screws
1 — Operating Hours Meter
Figure 4: Operating Hours Meter
WT-5200 9
Routine Maintenance
Warning: Do not operate the warming system with the back cover removed.
1. Write the date and total hours of operation of the warming system on the new
filter label and unit label.
2. Unplug the warming system.
3. Lay the warming system on the front cover.
4. Unwrap the power cord from the rear of the warming system.
5. Remove the three screws from the rear of the warming system. See Figure 5.
10
Figure 5: Rear Panel Screws
6. Remove the warming system back panel.
Routine Maintenance
1 — HEPA Filter 2 — Power Cord Stain Relief
Figure 6: HEPA Filter
7. Remove the filter. See Figure 6.
8. Place the new filter into the warming system.
9. Ensure that the power cord’s female connector is fully seated into the
10. Place the warming system back panel on the case and insert the power cable
11. Align the back case with the three screw holes in the filter and install the three
Hose Replacement
If the warming system hose is damaged, contact Nellcor’s Technical Services
Department (1.800.635.5267, press 3) or your local Nellcor representative to
obtain a replacement hose. The hose for the warming system is made of plastic
reinforced with wire.
warming system case.
into the power cable slot on the bottom of the case.
screws holding the back case to the unit.
Warning: Only qualified hospital personnel should replace the hose.
WT-5200 11
Routine Maintenance
Table 3: Hose Replacement Equipment Required
Equipment Description/Use
Phillips Screwdriver #2, removing screws
Needle-Nose Pliers Bending hose wire
1. Unplug the warming system.
2. Place the warming system on a workbench with the back of the unit facing
you.
3. Remove the 7 screws holding the case together. See Figure 7.
12
Figure 7: Back of Case
4. Open the top of the case assembly far enough to access the hose and the hose
retaining wire. See Figure 8.
1 — Hose Retaining Wire
Figure 8: Hose Retaining Wire
Routine Maintenance
5. Straighten the hose retaining wire.
6. Remove the hose from the warming system.
7. Install the new hose. Ensure that the hose retaining wire is threaded through
the hose retaining wire hole.
8. Bend the hose retaining wire to ensure that the hose does not detach from the
warming system.
9. Close the warming system case.
10. Install the 7 screws to hold the case together. See Figure 7.
Power Cord Replacement
The warming system is equipped with a detachable power cord. If the power cord
is damaged, contact Nellcor’s Technical Services Department (1.800.635.5267,
press 3) or your local Nellcor representative.
Caution: Only qualified hospital personnel should replace the power cord.
Table 4: Power Cord Replacement Equipment Required
Equipment Description/Use
Allen Wrench 3/32 inch, loosening retaining bracket
WT-5200 13
Routine Maintenance
1. Unplug the warming system power cord from the AC outlet.
2. Place the warming system unit on a workbench with the bottom of the unit
facing you.
3. Unwind the power cord from the warming unit case.
Caution: The power cord retaining bracket screws have retaining nuts. Do not
unscrew the screws enough to damage the retaining nuts or screws.
4. Loosen the power cord retaining bracket screws enough to pull the bracket
away from the power cord connector. See Figure 9.
14
1
— Power Cord Retaining Bracket Screws 3 — Power Cord Connector
— Power Cord Retaining Bracket 4 — Power Cord Routing
2
Figure 9: Power Cord Routing
5. Disconnect the power cord connector from the warming unit.
6. Remove the power cord from the power cord routing bracket.
7. Connect the new power cord connector to the warming unit.
8. Insert the power cord into the power cord routing bracket. It may be necessary
to use a screwdriver to pry apart the power cord routing bracket, to aid
insertion.
9. Tighten the power cord retaining bracket screws.
Nozzle Replacement
If the nozzle is damaged, contact Nellcor’s Technical Services Department
(1.800.635.5267, press 3) or your Nellcor representative. The nozzle is held in
place by four clips on the hose assembly. Pu ll and twist the nozzle to remove it. To
replace the nozzle, push the new nozzle over the clips on the hose assembly.
Cleaning the WarmTouch Patient Warming System
Caution: Do not spray, pour, or spill any liquid on the warming system, its
accessories, connectors, switches, or openings in the case.
For surface-cleaning and disinfecting, follow your institution's procedures or:
• The warming system may be surface-cleaned by using a soft cloth
dampened with either a commercial, nonabrasive cleaner or a solution of
70% alcohol in water, and lightly wiping the surfaces of the monitor.
Routine Maintenance
• The warming system may be disinfected using a soft cloth saturated with
a 10% solution of chlorine bleach in tap water.
WT-5200 15
Blank Page
Performance Verification
Thermostat Protection Check
This procedure checks to ensure that the thermostat protection controls are
working properly. This procedure should be performed before returning the
warming system into service. Table 5 lists the equipment required for the
thermostat protection check.
No calibration of the thermostat protection is required or possible. If the test time
or temperatures are outside the allowable range, factory service is required.
Contact Nellcor’s Technical Services Department (1.800.635.5267, press 3) or
your local Nellcor representative.
Table 5: Equipment Required for Thermostat Protection Check
Equipment Description/Use
Temperature Probe
Tape To hold the temperature probe in place
Stopwatch Manual or electronic
Jumper wire with alligator
clips
Phillips Screwdriver #2
WarmTouch CareDrape
Lower Body Blanket
1. Lay the temperature probe beside the warming system nozzle at the end of the
hose and bend approximately 1.5 inches (4 centimeters) of the temperature
probe into the nozzle opening.
2. Position the tip of the temperature probe so that it is centered in the middle of
the nozzle opening and is inside the nozzle approximately 1 to 2 inches (2.5 to
5 centimeters).
3. Tape the probe in place.
Mon-a-Therm
probe, or equivalent, and temperature
monitor with an accuracy of ±0.2 degrees C
3 to 12 inches (8 to 30 centimeters) long,
alligator clip at each end, 12 gauge minimum
To complete patient warming system
®
subcutaneous temperature
4. Connect the probe to the temperature monitor.
5. Connect the nozzle to the blanket.
6. Unplug the warming system.
WT-5200 17
Performance Verification
7. Loosen the over-temperature test port screw. See Figure 10.
8. Slide the over-temperature test port cover to the side.
1 — Over Temperature Test Port
Figure 10: Over-Temperature Test Port
WARNING: Possible Patient Injury. Connecting the jumper wire disables
(shorts out) the thermistor that is part of the temperature control system and
is only for use by qualified personnel.
9. Connect the jumper wire across the two terminals in the over-temperature test
port.
10. Plug in the warming system and turn it on.
18
Performance Verification
11. Select the high temperature setting. See Figure 11.
1 — High T emperature Setting
Figure 11: WarmTouch High Temperature Setting
12. When the monitored temperature exceeds 46 degrees C, start the stopwatch.
1 — Warning Light
Figure 12: Warning Light
13. When the Warning Light indicator lights, stop the stopwatch. See Figure 12.
14. The stopwatch should indicate 10 minutes or less, and the temperature
monitor should not exceed 66 degrees C.
15. Turn off the warming system and unplug it.
WARNING: Possible Patient Injury. Connecting the jumper wire disables
(shorts out) the thermistor that is part of the temperature control system and
only for use by qualified personnel. The jumper wire must be removed.
16. Remove the jumper wire from the over-temperature test port. See Figure 10.
17. Close the over-temperature test port and tighten the screw.
18. Disconnect the warming system from the blanket.
19. Allow the warming system to cool for 30 minutes before using the unit on a
patient.
WT-5200 19
Performance Verification
Output Temperature Check
This procedure measures the warming system output air temperature at the input
to the blanket. The output temperature should be measured before returning the
Warming System into service. Table 6 lists the equipment required for the
thermostat protection check.
No calibration of the temperature control circuit is required or possible. If the test
temperatures are outside the allowable range, factory service is required. Contact
Nellcor’s Technical Services Department (1.800.635.5267, press 3) or your local
Nellcor representative.
Table 6: Equipment Required for Output Temperature Check
Equipment Description/Use
T emperature Probe Mon-a-Therm subcutaneous temperature probe,
or equivalent, and temperature monitor with an
accuracy of ±0.2 degrees C
Tape To hold the temperature probe in place
WarmTouch CareDrape
Lower Body Blanket
1. Lay the temperature probe alongside the warming system nozzle at the end of
the hose and bend approximately 1.5 inches (4 centimeters) of the temperature
probe into the nozzle opening.
2. Position the tip of the temperature probe so that it is centered in the middle of
the nozzle opening and is inside the nozzle approximately 1 to 2 inches (2.5 to
5 centimeters).
3. Tape the probe in place.
4. Connect the probe to the temperature monitor.
5. Connect the nozzle to the blanket.
6. Extend the warming system hose to the configuration shown in Figure 13.
To complete patient warming system
20
1 — 14 to 16 inches 2 — 32 to 34 inches
Figure 13: Output Temperature Setup
7. Turn on the warming system.
Performance Verification
8. Select the low temperature range. See Figure 14.
1 — High Temperature 3 — Low Temperatu re
2 — Medium Temperature 4 — Ambient T e mp erature
Figure 14: Temperature Selection
9. Allow the temperature to stabilize. The temperature monitor should indicate
30.0 ºC to 35.0 ºC.
10. Select the medium temperature range.
11. Allow the temperature to stabilize. The temperature monitor should indicate
36.0 ºC to 41.5 ºC.
12. Select the high temperature range.
13. Allow the temperature to stabilize. The temperature monitor should indicate
42.0 ºC to 48.0 ºC.
WT-5200 21
Performance Verification
Safety Tests
14. Turn off the warming system.
15. Disconnect the warming system nozzle from the blanket.
16. Remove the temperature probe from the warming system nozzle.
The warming system is provided with a ground stud to allow safety testing
without opening the case.
1 - Ground Stud
Figure 15: Ground Stud
The warming system meets the standards of CSA C22.2 No. 125 (Risk Class 2)
and UL 544.
Applicable tests for these standards are listed below. Technicians should be
familiar with the standards applicable to their institution and country. Test
equipment and its application must comply with the applicable standard.
• Ground Integrity. See page 94 for test values.
• Earth Leakage Current. See page 94 for test values.
• Enclosure Leakage Current. See page 94 for test values.
22
Disassembly Guide
Warning: Before attempting to open or disassemble the warming unit,
disconnect the power cord from the AC power source.
Caution: Observe ESD (electrostatic discharge) precautions when working within
the warming unit.
Caution: Repairs to the warming unit should only be accomplished by trained
service technicians.
Follow local government ordinances and recycling instruct ions regarding the
disposal of the warming unit and/or parts.
Filter Cover Assembly Replacement
The replacement Filter Cover Assembly is delivered assembled with:
• 1 — filter cover
• 1 — bed hook
• 1 — foot, filter cover, short
• 4 — 8-32 truss HD screws
The tools required for this procedure are:
Tool Parameter/Use
Phillips screw driver #2
Torque driver 8 in./lbs to 12 in./lbs (20 cm/kg to 30 cm/kg)
Use the following procedure to replace the filter cover assembly.
1. Unplug the warming system power cord from the AC outlet.
2. Place the warming system unit on a workbench with the bottom of the unit
facing you.
3. Unwind the power cord from the warming unit case. See Figure 16.
WT-5200 23
Disassembly Guide
4. Disconnect the power cord connector from the warming unit.
1 — Power Cord
Figure 16: Power Cord
5. Remove the 3 rear panel screws from the warming unit. See Figure 17.
24
Figure 17: Rear Panel Screws
6. Slide the filter cover assembly from the warming unit.
7. Place the new filter cover assembly on the warming unit and install the 3
screws. The screws should be torqued to 8 in./lbs to 12 in./lbs (20 cm/kg to 30
cm/kg). See Figure 17.
8. Install the power cord on the warming unit. See Figure 16.
Separating the Warming Unit Front and Rear Covers
This procedure requires:
Phillips screw driver, #2
Socket wrench, 10 mm
Use the following procedure to separate the warming unit covers.
1. Unplug the warming system power cord from the AC outlet.
Disassembly Guide
2. Place the warming system unit on a workbench with the bottom of the unit
facing you.
3. Unwind the power cord from the warming unit case. See Figure 18.
1 — Power Cord
Figure 18: Power Cord
WT-5200 25
Disassembly Guide
4. Loosen the power cord retaining bracket (Figure 19, item 2) by loosening the
retainer bracket screws (item 1).
1 — Retaining bracket screws 3 — Power cord connector
2 — Retaining bracket
Figure 19: Power cord Removal
5. Disconnect the power cord connector from the warming unit. See Figure 19,
item 3.
26
Disassembly Guide
6. Remove the seven screws holding the front and rear covers together. See
Figure 20.
Figure 20: Cover Screw Locations
Caution: Separate the front and rear covers very carefully. The wires connected
between the covers are short and may be damaged if too much pressure is applied
to them.
7. Carefully separate the front and back covers. See Figure 21.
Figure 21: Separated Covers
WT-5200 27
Disassembly Guide
Front Cover Assembly Replacement
The replacement front cover assembly comes assembled with:
• 1 — front enclosure
• 1 — key pad
•1 — lens
• 1 — ground symbol label
• 1 — cable tie mount
• 1 — cable tie
• 1 — ground equipotential label
• 1 — 6.5 mm (0.25 inch) hole for equipotential ground pin
The tools required for this procedure are:
Tool Parameters/Use
Phillips screwdriver #2
Torque driver/wrench 4 in./lbs to 12 in./lbs (10 cm/kg to 30 cm/kg7)
36 in./lbs to 40 in./lbs (91 cm/kg to 112 cm/kg)
Wire cutter Cutting cable tie-downs
Socket wrench 10 mm
Use the following procedure to replace the front cover assembly.
1. Separate the front and rear cover assemblies. See Separating the Warming
Unit Front and Rear Covers on page 25.
28
2. Cut the cable harness cable tie-down. See Figure 22, item 1.
Figure 22: Cable Harness Cable Ties-downs
Disassembly Guide
3. Disconnect the 9-pin connector from the universal PCB. See Figure 23, item
1.
1 — 9-pin connector 4 — Cable tie-down
2 — Equipotential ground terminal 5 — Power switch
3 — AC power connector
Figure 23: Front Cover Assembly
WT-5200 29
Disassembly Guide
4. Disconnect the equipotential ground stud and remove it from the front cover
assembly. See Figure 23, item 2.
5. Remove the AC power connector from the front cover assembly. See Figure
23, item 3.
6. Remove the cable tie-down from the front cover assembly. See Figure 23,
item 4.
Caution:Write down the color code of each wire connected to the power switch.
This will ensure that the wires will be reconnected properly.
7. Disconnect the four wires from the power switch. See Figure 23, item 5.
8. Depress the four clips on the power switch and push the power swit ch through
the front cover assembly. See Figure 24.
Figure 24: Power Switch Removal
9. Cut the cable tie. See Figure 25, item 1.
Figure 25: Cable Disconnect
30
Disassembly Guide
10. Remove the ground screw. See Figure 25, item 2.
11. Cut the cable tie-down holding the thermistor cable to the connector. See
Figure 25, item 3.
12. Disconnect the thermistor cable connector. See Figure 25, item 3.
13. Disconnect the ribbon cable connector. See Figure 25, item 4.
14. Remove the four screws holding the universal PCB onto the front cover
assembly. See Figure 26.
Figure 26: Universal PCB Screws
15. Carefully lift the universal PCB out of the front cover assembly.
16. Discard the old front cover assembly.
WT-5200 31
Disassembly Guide
Caution: Carefully align the five lights on the universal PCB with the control
panel key pad push buttons. Failure to do so coul d damage the key pad or the
universal PCB lights. See Figure 27.
Figure 27: Universal PCB Lights
17. Carefully place the universal PCB into the replacement front cover assembly
and install the four mounting screws. The screws should be torqued to 4 in./
lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure 28.
32
Figure 28: Universal PCB Screws
18. Connect the ribbon cable connector. See Figure 29, item 4.
Figure 29: Cable Connections
Disassembly Guide
19. Connect the thermistor cable connector. See Figure 29, item 3.
20. Install cable tie-down around the thermistor cable connector and universal
PCB connector. See Figure 29, item 2.
21. Connect the key pad grounding strap and blower ground wire . The screw
should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure
29, item 2.
22. Install the cable tie around the blower ground cable and the cable tie-down
mount. See Figure 29, item 1.
23. Slide the power switch through the front of the front cover assembly until the
four clips on the power switch click into place. Ensure that the “0”, marked on
the front of the power switch, is towards the bottom of the front cover
assembly. See Figure 30.
Figure 30: Power Switch Clips
WT-5200 33
Disassembly Guide
24. Connect the four wires to the power switch. Refer to the wire colors recorded
in accordance with the Caution before Step 7. See Figure 31, item 5.
Figure 31: Front cover Assembly Component Locations
25. Install the cable tie around the power switch cables. The screw should be
torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure 31, item 4.
26. Install the AC power connector into the front cover assembly. The screws
should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure
31, item 3.
34
Disassembly Guide
27. Install Equipotential Ground (Figure 31, item 2) and the ground wires to the
equipotential ground. The nuts should be torqued to 36 in./lbs to 44 in./lbs (91
cm/kg to 112 cm/kg). See Figure 32.
1 — Blower Housing Ground
2 — Blower Motor Ground
3 — AC Power Connector Ground
Figure 32: Equipotential Ground
28. Connect the 9-pin connector to the universal PCB. See Figure 31, item 1.
29. Install the cable harness cable tie-down. See Figure 33, item 1.
Figure 33: Cable Harness Cable Ties-downs
Caution: Ensure that the cable harness between the two cover halves is not
pinched by the covers when joining the front and rear cover assemblies.
WT-5200 35
Disassembly Guide
30. Carefully align the front and rear cover assemblies and install the seven
screws. The screws should be torqued to 7 in./lbs to 10 in./lbs (18 cm/kg to 25
cm/kg). See Figure 34.
Figure 34: Cover Screw Locations
31. Attach the AC power cord to the warming unit.
32. Install the power cord retaining bracket (Figure 35, item 2), by tightening the
bracket screws (item 1).
36
Disassembly Guide
33. Perform the following checks/test to verify proper operation of the warming
unit prior to returning the warming unit into service:
• Thermostat Protection Check on page 17
• Output Temperature Check on page 20
• Safety Tests on page 22
Universal PCB Replacement
The replacement universal PCB comes fully assembled except for the solid state
relay assembly.
The tools required for this procedure are:
Tool Parameter/Use
Figure 35: Power Cord Retaining Bracket
Phillips screwdriver #2
Torque driver 4 in./lbs to 20 in./ lbs (10 cm/kg to 51 cm/kg)
Wire cutter Cut cable tie-downs and jumpers
Use the following procedure to replace the universal PCB assembly.
WT-5200 37
Disassembly Guide
1. Separate the front and rear cover assemblies. See Separating the Warming
Unit Front and Rear Covers on page 25.
2. Disconnect the 9-pin connector from the universal PCB. See Figure 36, item
1.
1 — 9-pin connector
2 — Key pad and blower ground 4 — Key pad ribbon cable connector
Thermistor cable connector
3 —
Figure 36: Universal PCB Connections
3. Remove the thermistor cable co nnector cable tie-down. S ee Figure 36, item 3.
4. Disconnect the thermistor cable connector. See Figure 36, item 3.
5. Disconnect the ribbon cable connector. See Figure 36, item 4.
38
Disassembly Guide
6. Remove the four screws holding the universal PCB onto the front cover
assembly. See Figure 37.
Figure 37: Universal PCB Screws
7. Carefully lift the universal PCB out of the front cover assembly.
WT-5200 39
Disassembly Guide
8. Remove the solid state relay assembly from the removed universal PCB. See
Figure 38, item 1.
Figure 38: Universal PCB Solid State Relay Assembly
40
Disassembly Guide
9. Cut and remove transformer voltag e selection jumpers S1 and S3 on the
replacement universal PCB. See Figure 39, items 2 and 3.
1 — Transformer T1 4 — Relay Mounting Hole
2 — Transformer Jumper S1 5 — Relay Mounting Hole
2 — Transformer Jumper S2
Figure 39: Part of Universal PCB
10. Install the removed solid state relay assembly onto the replacement universal
PCB. The small screws should be torqued to 7 in./lbs to 10 in./lbs (18 cm/kg
to 25 cm/kg). The larger screws should be torqued to 17 in./lbs to 20 in./lbs
(43 cm/kg to 51 cm/kg). See Figure 38.
WT-5200 41
Disassembly Guide
11. Ensure the alarm jumper is connected between connector J4, pins 2 and 3. See
Figure 40.
1 — J4, Pin-1 2 — J4, Pin-3
Figure 40: Universal PCB Alarm Jumper
Caution: Carefully align the five lights on the universal PCB with the control
panel key pad push buttons. Failure to do so coul d damage the key pad or the
universal PCB lights. See Figure 41.
Figure 41: Universal PCB Lights
42
Disassembly Guide
12. Carefully place the replacement universal PCB into the front cover assembly
and install the four mounting screws. The screws should be torqued to 4 in./
lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure 42.
Figure 42: Universal PCB Screws
13. Connect the ribbon cable connector. See Figure 43, item 4.
Figure 43: Cable Connections
14. Connect the thermistor cable connector. See Figure 43, item 3.
15. Attach a cable tie-down around the thermistor cable connector and the
universal PCB connector. See Figure 43, item 3.
WT-5200 43
Disassembly Guide
16. Connect the 9-pin connector to the universal PCB. See Figure 43, item 1.
17. Install the cable harness cable tie-down. See Figure 44, item 1.
Figure 44: Cable Harness Cable Ties-downs
Caution: Ensure that the cable harness between the two cover halves is not
pinched by the covers when joining the front and rear cover assemblies.
44
Disassembly Guide
18. Carefully align the front and rear cover assemblies and install the seven
screws. The screws should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15
cm/kg). See Figure 45.
Figure 45: Cover Screw Locations
19. Attach the AC power cord to the warming unit.
20. Install the power cord retaining bracket (Figure 46, item 2), by tightening the
bracket screws (item 1).
WT-5200 45
Disassembly Guide
Figure 46: Power Cord Retaining Bracket
21. Perform the following checks/test to verify proper operation of the warming
unit prior to returning the warming unit into service:
• Thermostat Protection Check on page 17
• Output Temperature Check on page 20
• Safety Tests on page 22
Heater Assembly Replacement
The replacement heater assembly comes assembled with:
• 1 — heater, 230 volt
• 2 — pins, 16 - 18 GA, 13 A
The tools required for this procedure are:
46
Tool Parameter/Use
Phillips screwdriver #2
Wire cutter Cut cable tie-downs
Socket 10 mm
Disassembly Guide
Tool Parameter/Use
Contact removal tool AMP 305783 or equivalent
Torque driver/wrench 4 in./lbs to 12 in./lbs (10 cm/kg to 30 cm/kg)
36 in./lbs/44 in./lbs (91 cm/kg to 112 cm/kg)
Use the following procedure to replace the heater assembly.
1. Remove the filter cover assembly from the rear cover assembly. See Filter
Cover Assembly Replacement on page 23.
2. Remove the filter assembly from the rear cover assembly. See Figure 47, item
1.
Figure 47: Filter Removal
3. Separate the front and rear cover assemblies. See Separating the Warming
Unit Front and Rear Covers on page 25.
Note: The blower assembly is held onto the rear cover assembly by four screws
and four clips. It is easier for two people to release the clips and lift the
blower assembly from the rear cover assembly.
WT-5200 47
Disassembly Guide
4. Remove the four screws holding the blower assembly to the rear cover
assembly. See Figure 48.
Figure 48: Blower Assembly Screws
5. Separate the warming unit front and rear cover assemblies. See Separating the
Warming Unit Front and Rear Covers on page 25.
6. Cut the cable harness cable tie-down. See Figure 49, items 1 and 2.
48
Figure 49: Cable Harness Cable Ties-downs
Disassembly Guide
7. Disconnect the 9-pin connector from the universal PCB. See Figure 50, item
1.
1 — 9-pin connector 4 — Cable tie-down
2 — Equipotential ground terminal 5 — Power switch
3 — AC power connector
Figure 50: Front Cover Assembly
8. Disconnect the equipotential ground stud wires. See Figure 50, item 2.
9. Remove the AC power connector from the front cover assembly. See Figure
50, item 3.
10. Remove the cable tie-down from the front cover assembly. See Figure 50,
item 4.
Note: Write down the color code of each wire connected to the power switch.
This will ensure that the wires will be reconnected properly.
11. Disconnect the four wires from the power switch. See Figure 50, item 5.
WT-5200 49
Disassembly Guide
12. Cut the cable tie. See Figure 51, item 1.
Figure 51: Cable Disconnect
13. Remove the ground screw. See Figure 51, item 2.
14. Cut the cable tie-down from the thermistor cable connector. See Figure 51,
item 3.
15. Disconnect the thermistor cable connector. See Figure 51, item 3.
16. Place the front cover assembly in a safe place.
Caution: Care must be taken when moving the duct adapter. The thermistor
connection to the duct adaptor is fragile and will become disconnected if too much
pressure is applied to it.
50
Disassembly Guide
17. Carefully lift the duct adapter and lay the duct adapter on the rear cover
handle. See Figure 52.
1 — Duct adapter 2 — Thermistor connection
Figure 52: Duct Adapter Placement
WT-5200 51
Disassembly Guide
18. Rotate the blower motor assembly clockwise to disengage two of the four
clips. See Figure 53 and Figure 54.
Figure 53: Blower Motor Removal
Figure 54: Blower Assembly Clips
52
19. Slide the blower motor assembly away from the engaged clips to disengage
the last two clips.
20. Lay the blower motor assembly beside the rear cover assembly. Do not over
stress the wires.
Disassembly Guide
21. Remove the rubber washer from the rear cover assembly. See Figure 55, item
1.
Figure 55: Rubber Washer
Caution: Do not touch the heater coil. Oil from your fingers may cause damage to
the heater coil when it is in use.
22. Lift the heater assembly out of the rear cover assembly. See Figure 56, item 1.
Figure 56: Heater Assembly
Note: For the next four steps, use an AMP 305183 contact removal tool or
equivalent.
WT-5200 53
Disassembly Guide
23. Remove the heater black wire and pin from pin-2 of the 9-pin connector. See
Figure 56, item 3.
24. Remove the heater red wire (may be white in some assemblies) and pin from
pin-8 of the 9-pin connector. See Figure 56, item 2.
25. Install the new heater red wire and pin into pin-8 of the 9-pin connector. See
Figure 56, item 2.
26. Install the new heater black wire and pin into pin-2 of the 9-pin connector. See
Figure 56, item 3.
Note: Ensure that the heater thermostat (Figure 57, item 3) is at the top of the
heater when the heater is installed in the rear cover assembly.
27. Slide the new heater into the rear cover assembly. See Figure 57, item 1.
54
Figure 57: Heater Assembly Installation
28. Orient the heater with the heater thermostat (item 3) is nearest the rear cover
assembly handle (item 2). See Figure 57.
29. Route heater black and red wires through the cut-outs in the rear cover
assembly. See Figure 57, item 4.
Disassembly Guide
30. Place the rubber washer into the rear cover assembly with the wire
indentations over the heater wires. See Figure 58, item 1.
Figure 58: Rubber Washer
31. Place the blower assembly into the rear cover assembly and ensure that the
four blower assembly clips attach over the edges of the blower assembly. See
Figure 59.
Figure 59: Blower Assembly Clips
WT-5200 55
Disassembly Guide
32. Install the four blower assembly mounting screws into the rear cover
assembly. The screws should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to
15 cm/kg). See Figure 60.
Figure 60: Blower Assembly Screws
Caution: Care must be taken when moving the duct adapter. The thermistor
connection to the duct adaptor is fragile and will become disconnected if too much
pressure is applied to it.
56
Disassembly Guide
33. Carefully insert the duct adapter into the blower assembly. See Figure 61.
1 — Duct adapter 2 — Thermistor connection
Figure 61: Duct Adapter Placement
34. Connect the thermistor cable to the universal PCB assembly. See Figure 62,
item 3.
Figure 62: Cable Connections
WT-5200 57
Disassembly Guide
35. Install the cable tie around the thermistor cable. See Figure 62, item 1.
36. Connect the key pad ground strap and the blower ground wire. The screw
should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure
62. item 2.
37. Connect the four wires to the power switch. See Figure 63, item 5.
Figure 63: Front Cover Assembly
38. Install the tie-down around the four power switch wires. The screw should be
torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure 63, item 4.
39. Install the AC power connector into the front cover assembly. The screws
should be torqued to 7 in./lbs to 10 in./lbs (18 cm/kg to 25 cm/kg). See Figure
63, item 3.
58
Disassembly Guide
40. Connect the ground wires to the equipotential ground stud (Figure 63, item 2).
The nuts should be torqued to 36 in./lbs to 44 in./lbs (91 cm/kg to 112 cm/kg).
See Figure 64.
1 — Blower Housing Ground
2 — Blower Motor Ground
3 — AC Power Connector Ground
Figure 64: Equipotential Ground Stud Wiring
41. Connect the 9-pin connector to the universal PCB. See Figure 63, item 1.
42. Install the cable harness cable tie-down. See Figure 65, items 1 and 2.
Figure 65: Cable Harness Cable Ties-downs
Caution: When placing the front and rear cover assemblies together ensure that
the wires are not pinched between the covers.
43. Carefully place the front and rear cover assemblies together.
WT-5200 59
Disassembly Guide
44. Install the seven screws into the rear cover assembly to attach it to the front
cover assembly. The screws should be torqued to 7 in./lbs to 10 in./lbs (18 cm/
kg to 25 cm/kg). See Figure 66.
Figure 66: Cover Screw Locations
45. Place the filter assembly into the rear cover assembly. See Figure 67, item 1.
Figure 67: Filter Installation
60
Disassembly Guide
46. Install the filter cover assembly on the rear cover assembly. The screws
should be torqued to 8 in./lbs to 12 in./lbs (20 cm/kg to 30 cm/kg). See Figure
68.
Figure 68: Filter Cover Installation
47. Attach The AC power cord to the warming unit.
48. Install the power cord retaining bracket (Figure 69, item 2), by tightening the
bracket screws (item 1).
Figure 69: Power Cord Retaining Bracket
WT-5200 61
Disassembly Guide
49. Perform the following checks/test to verify proper operation of the warming
unit prior to returning the warming unit into service:
• Thermostat Protection Check on page 17
• Output Temperature Check on page 20
• Safety Tests on page 22
Duct Adapter Assembly Replacement
The replacement duct adapter assembly come assembled with:
• 1 — duct adapter
• 1 — screen
The tools required for this procedure are:
Tool Parameter/Use
Phillips screwdriver #2
Wire cutter Cut cable tie-downs
Knife Removal of silicone RTV
Silicone RTV Thermistor connection
Torque driver/wrench 7 in./lbs to 12 in./lbs (18 cm/kg to 30 cm/kg)
Use the following procedure to replace the duct adapter assembly.
1. Separate the warming unit front and rear cover assemblies. See Separating the
Warming Unit Front and Rear Covers on page 25.
Caution: The thermistor is very delicate and easily damaged. Use extreme care
when handling, removing, or replacing the thermistor.
62
Disassembly Guide
2. Remove the silicone RTV from the thermistor connection on the duct adapter
assembly. See Figure 70, item 1.
Figure 70: Thermistor Silicone
3. Carefully slide the thermistor out of the duct adapter assembly . See Figure 71,
item 1.
Figure 71: Thermistor Removal
WT-5200 63
Disassembly Guide
4. Lift the duct adapter assembly out of the rear cover assembly. See Figure 72,
item 1.
Figure 72: Duct Adapter Removal
5. Connect the three wires on the removed duct adapter onto the replacement
duct adapter, ensuring the same connection points.
6. Slide the new duct adapter assembly into the blower housing. See Figure 73,
item 1.
64
Figure 73: Duct Adapter Placement
Disassembly Guide
Caution: The thermistor is very delicate and easily damaged. Use extreme care
when handling, removing or replacing the thermistor.
7. Carefully insert the thermistor into the duct adapter assembly. See Figure 71,
item 1.
8. The thermistor (item 1) should be positioned as shown in Figure 74.
Figure 74: Thermistor Position Within Duct Adapter
9. Apply a small amount of silicone RTV to the thermistor rivet cap and the
adapter housing. See Figure 70.
Caution: When placing the front and rear cover assemblies together ensure that
the wires are not pinched between the covers.
WT-5200 65
Disassembly Guide
10. Carefully align the front and rear cover assemblies and install the seven
screws. The screws should be torqued to 7 in./lbs to 10 in./lbs (18 cm/kg to 25
cm/kg). See Figure 75.
Figure 75: Cover Screw Locations
11. Attach the AC power cord to the warming unit.
12. Perform the following checks/test to verify proper operation of the warming
unit prior to returning the warming unit into service:
• Thermostat Protection Check on page 17
• Output Temperature Check on page 20
• Safety Tests on page 22
Rear Cover Assembly Replacement
The replacement rear cover assembly comes assembled with:
• 1 — rear enclosure
• 1 — cable tie mount
66
• 1 — cable tie
• 3 — lag bolts, 3¼ inches
• 1 — test cover
• 1 — screw
• 1 — heater cone insert
• 1 — heater screen
• 1 — attention label
• 1 — model/serial number label
The tools required for this procedure are:
Tool Parameter/Use
Disassembly Guide
Phillips screwdriver #2
Wire cutter Cut cable tie-downs
Socket 10 mm
Torque driver/wrench 4 in./lbs to 12 in./lbs (10 cm/kg to 30 cm/kg)
36 in./lbs to 44 in./lbs (91 cm/kg to 112 cm/kg)
Use the following procedure to replace the rear cover assembly.
1. Unplug the warming system power cord from the AC outlet.
2. Place the warming system unit on a workbench with the bottom of the unit
facing you.
3. Remove the filter cover assembly, see Filter Cover Assembly Replacement on
page 23.
4. Separate the front and rear cover assemblies. See Separating the Warming
Unit Front and Rear Covers on page 25.
5. Slide the filter cover assembly from the warming unit.
WT-5200 67
Disassembly Guide
6. Remove the filter assembly from the rear cover assembly. See Figure 76, item
1.
Figure 76: Filter Removal
7. Remove the three warming unit mounting clamps from the rear cover
assembly. See Figure 77.
68
Figure 77: Warming Unit Mounting Clamps
Caution: Separate the front and rear covers very carefully. The wires connected
between the covers are short and may be damaged if too much pressure is applied
to them.
Disassembly Guide
8. Separate the front and rear cover assemblies. See Separating the Warming
Unit Front and Rear Covers on page 25.
9. Cut the two cable ties. See Figure 78, items 1 and 2.
Figure 78: Separated Covers
WT-5200 69
Disassembly Guide
10. Disconnect the 9-pin connector from the universal PCB. See Figure 79, item
1.
1 — 9-pin connector 4 — Cable tie-down
2 — Equipotential ground terminal 5 — Power switch
3 — AC power connector
Figure 79: Front Cover Assembly
11. Disconnect the equipotential ground stud wires. See Figure 79, item 2.
12. Remove the AC power connector from the front cover assembly. See Figure
79, item 3.
13. Remove the cable tie-down from the front cover assembly. See Figure 79,
item 4.
Note: Write down the color code of each wire connected to the power switch.
This will ensure that the wires will be reconnected properly.
14. Disconnect the four wires from the power switch. See Figure 79, item 5.
70
15. Cut the cable tie. See Figure 80, item 1.
Figure 80: Cable Disconnect
Disassembly Guide
16. Remove the ground screw. See Figure 80, item 2.
17. Cut the cable tie from the thermistor cable connector. See Figure 80, item 3.
18. Disconnect the thermistor cable connector. See Figure 80, item 3.
19. Place the front cover assembly in a safe place.
Caution: The thermistor is very delicate and easily damaged. Use extreme care
when handling, removing or replacing the thermistor.
20. Remove the thermistor cable terminal board. See Figure 81, item 2.
Figure 81: Thermistor Cable Removal
WT-5200 71
Disassembly Guide
21. Cut the cable tie on the thermistor cable. See Figure 81, item 1.
Note: The blower assembly is held onto the rear cover assembly by four screws
and four clips. It is easier for two people to release the clips and lift the
blower assembly from the rear cover assembly.
22. Remove the four screws holding the blower assembly to the rear cover
assembly. See Figure 82.
Figure 82: Blower Assembly Screws
72
Disassembly Guide
23. Loosen the nut holding the capacitor to the rear cover assembly. See Figure
83, item 1.
Figure 83: Blower Capacitor
24. Lift the capacitor free of the rear cover assembly.
WT-5200 73
Disassembly Guide
25. Rotate the blower motor assembly clockwise to disengage two of the four
clips. See Figure 84 and Figure 85.
Figure 84: Blower Motor Removal
Figure 85: Blower Assembly Clips
74
26. Slide the blower motor assembly away from the engaged clips to disengage
the last two clips.
Disassembly Guide
27. Remove the rubber washer from the rear cover assembly. See Figure 86, item
1.
Figure 86: Rubber Washer
Caution: Do not touch the heater coil. Oil from your fingers may cause damage to
the heater coil when it is in use.
28. Lift the heater assembly out of the rear cover assembly. See Figure 87, item 1.
Figure 87: Heater Assembly
29. Discard the old rear cover assembly.
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Disassembly Guide
30. Install the three warming mounting brackets on the replacement rear cover
assembly. See Figure 88.
Figure 88: Warming Unit Mounting Brackets
Note: Ensure that the heater temperature sensor (Figure 89, item 1) is at the top of
the heater when the heater is installed in the rear cover assembly.
31. Slide the heater into the replacement rear cover assembly. See Figure 89, item
2.
76
Figure 89: Heater Assembly Installation
32. Route heater black and red (in some units the wire is white, not red) wires
through the cut-outs in the rear cover assembly. See Figure 89, item 3.
Disassembly Guide
33. Place the rubber washer into the rear cover assembly with the wire
indentations over the heater wires. See Figure 90, item 1.
Figure 90: Rubber Washer
34. Place the blower assembly into the rear cover assembly and ensure that the
four blower assembly clips attach over the edges of the blower assembly. See
Figure 91.
Figure 91: Blower Installation
WT-5200 77
Disassembly Guide
35. Install the four blower assembly mounting screws into the rear cover
assembly . The screw should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15
cm/kg). See Figure 92.
Figure 92: Blower Screws
36. Attach the cable tie around the thermistor cable. See Figure 93, item 1.
Figure 93: Thermistor Cable Installation
37. Install the thermistor cable terminal board. The screw should be torqued to 4
in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure 93, item 2.
78
Disassembly Guide
Caution: Do not over tighten the capacitor nut. Over tightening the capacitor nut
will cause the plastic rib to crack.
38. Install the capacitor in the rear cover assembly and tighten the nut. The nut
should be torqued to 7 in./lbs to 10 in./lbs (18 cm/kg to 25 cm/kg). See Figure
94, item 1.
Figure 94: Capacitor Installation
39. Install the cable tie around the capacitor. See Figure 94, item 2.
40. Connect the thermistor cable to the universal PCB assembly. See Figure 95,
item 3.
Figure 95: Cable Connections
41. Connect a cable tie-down around the thermistor cable connector. See Figure
95, item 3.
WT-5200 79
Disassembly Guide
42. Connect the key pad ground strap and the blower ground wire. The screw
should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure
95, item 2.
43. Install the cable tie around the thermistor cable. See Figure 95, item 1.
44. Connect the four wires to the power switch. See Figure 96, item 5.
Figure 96: Front Cover Assembly
45. Install the tie-down around the four power switch wires. See Figure 96, item
4.
46. Install the AC power connector into the front cover assembly. The screws
should be torqued to 4 in./lbs to 6 in./lbs (10 cm/kg to 15 cm/kg). See Figure
96, item 3.
47. Connect the 9-pin connector to the universal PCB. See Figure 96, item 1.
80
Disassembly Guide
48. Connect the ground wires to the equipotential ground stud (Figure 96, item 2).
The nuts should be torqued to 36 in./lbs to 44 in./lbs (91 cm/kg to 112 cm/kg).
See Figure 97.
1 — Blower Housing Ground
2 — Blower Motor Ground
3 — AC Power Connector Ground
Figure 97: Equipotential Ground Stud Wiring
49. Install the cable harness cable tie-down. See Figure 98, items 1 and 2.
Figure 98: Cable Harness Cable Ties-downs
Caution: When placing the front and rear cover assemblies together ensure that
the wires are not pinched between the covers.
50. Carefully place the front and rear cover assemblies together.
WT-5200 81
Disassembly Guide
51. Install the seven screws into the rear cover assembly to attach it to the front
cover assembly. The screws should be torqued to 7 in./lbs to 10 in./lbs (18 cm/
kg to 25 cm/kg). See Figure 99.
Figure 99: Cover Screw Locations
52. Place the filter assembly into the rear cover assembly. See Figure 100, item 1.
Figure 100: Filter Installation
82
Disassembly Guide
53. Install the filter cover assembly on the rear cover assembly. The screws
should be torqued to 8 in./lbs to 12 in./lbs (20 cm/kg to 30 cm/kg). See Figure
101.
Figure 101: Filter Cover Installation
54. Attach the AC power cord to the warming unit.
55. Install the power cord retaining bracket (Figure 102, item 2), by tightening the
bracket screws (item 1).
Figure 102: Power Cord Retaining Bracket
56.
WT-5200 83
Disassembly Guide
57. Perform the following checks/test to verify proper operation of the warming
unit prior to returning the warming unit into service:
• Thermostat Protection Check on page 17
• Output Temperature Check on page 20
• Safety Tests on page 22
84
Spare Parts and Accessories
Ordering Information
The warming system and blankets may be ordered from Nellcor’s Customer
Services Department (1.800.635.5267, press 3) or your local Nellcor
representative. See W a rmTouch Replacement Parts and Accessories below for the
Internet reference to part numbers for replacement parts and accessories.
Table 7: Replacement Parts and Accessories
Description Part Number
Cart 502-2900 5
Duct Adapter Assembly 168-0205SP 14
Filter Cover Assembly 168-0202SP12 8
Front Cover Assembly 168-0201SP1 2 2
Fuse, 0.32 amps 169-5800 13
Heater Assembly 168-5203SP 15
Hepa Filter 502-2200 9
Hose 502-2000 1
I.V. Clamp and Foot 168-0203SP 4
I.V. Clamp Knob 168-2005SP 5
Nozzle 502-2100 11
Nozzle Adapter, Augustine Medical
BairHugger, Models 200, 250, and
500
502-1600
Item
Figure 103
Item
Figure 104
Nozzle Strap, with Alligator Clip 312-0070 12
Power Cord 502-2400 7
Rear Cover Assembly 168-0200SP12 6 6
Shipping Carton 346-5849
Strap, Velcro 168-2023 10
Universal PCB 169-0217SP12 16
WT-5200 85
Spare Parts and Accessories
Figure 103: Spare Parts (Sheet 1)
86
Spare Parts and Accessories
Figure 104: Spare Parts (Sheet 2)
WarmTouch Replacement Parts and Accessories
Warming system replacement parts and accessories are listed on the Internet at:
http://www.mallinckrodt.com/respiratory/resp/Serv_Supp/Apartweb/Main/
PartAcceMenu.html
Manual Availability
The most recent revision of this manual is available on the Internet at:
http://www.mallinckrodt.com/respiratory/resp/serv_supp/productmanuals.html
WT-5200 87
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Packing for Shipment
Introduction
To ship the monitor for any reason, follow the instructions in this section.
Returning the WT-5200
Contact Nellcor’s Technical Services Department or your local Nellcor
representative for shipping instructions, including a Returned Goods
Authorization (RGA) number. Pack the WT-5200 in its original shipping carton.
If the original carton is not available, use a suitable carton with appropriate
packing material to protect it during shipping.
Return the WT-5200 by any shipping method that provides proof of delivery.
General Instructions
Pack the WT-5200 carefully . Fa ilure to follow the instructions in this section may
result in loss or damage not covered by any applicable Nellcor warranty. If the
original shipping carton is not available, use another suitable carton; North
American customers may call Nellcor’s Technical Services Department to obtain
a shipping carton.
Prior to shipping the WT-5200, contact your supplier or local Nellcor office
(T echnical Services Department) for a returned goods authorization number . Mark
the shipping carton and any shipping documents with the returned goods
authorization (RGA) number. Return the WT-5200 by any method that provides
proof of delivery.
Repacking in Original Carton
If available, use the original carton and packing materials. See Figure 105. Pack
the monitor as follows:
1. Place the WT-5200 in the original packaging.
WT-5200 89
Packing for Shipment
90
1 — Place cut outs over cart handle and blower handle.
2 — Route nozzle and hose under cart handle and place nozzle behind insert in
basket.
3 — Use ty-wrap to hold insert to cart while packing.
4 — Mount blower onto mounting pins on cart. Cart pins fit into lower blower case
screw holes.
Notes:
1 — Cart handle must be in the fully down position.
2 — Tape or staples may be used on the inserts to ensure the insert retains its form.
3 — Ensure nozzle clip is placed away from basket and insert. Place as shown.
Figure 105: Packing
2. Seal carton with packing tape.
3. Label carton with shipping address, return address, and RGA number, if
applicable.
Repacking in a Different Carton
If the original carton is not available, use the following procedure to pack the
WT-5200:
1. Locate a corrugated cardboard shipping carton with a bursting strength of at
least 200 pounds per square inch (psi).
2. Fill the bottom of the carton with at least 2 inches of packing material.
Packing for Shipment
3. Place the WT-5200 on the layer of packing material and fill the box
completely with packing material.
4. Seal the carton with packing tape.
5. Label the carton with the shipping address, return address, and RGA number,
if applicable.
WT-5200 91
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