Stihler Astotherm Service manual
®
ASTOTHERM
Blood and Infusion Warmer
Models 200, 220 und 260
Models 200S, 220S and 260S with ASTOLINE
plus
Repair Instructions
REVISION 5, 02/2005
Stihler Electronic GmbH
Julius-Hölder-Str. 36
70597 Stuttgart
Germany
Phone: +49-711-72067-0
Fax: +49-711- 72067-57
Part-No. 9950.9000.12
ASTOTHERM PLUS Repair Instructions
Table of Contents
1 TECHNICAL DESCRIPTION...............................................................................................................................5
1.1 General............................................................................................................................................................5
1.1.1 Structure......................................................................................................................................................6
1.1.2 Description of the electronics ......................................................................................................................7
1.2 Technical Data..............................................................................................................................................10
1.2.1 ASTOTHERM PLUS 200 and 200S..........................................................................................................10
1.2.2 ASTOTHERM PLUS 220, 220S and 260, 260S........................................................................................11
1.3 Terminal connecting plan ...........................................................................................................................12
1.4 ASTOTHERM PLUS spare parts .................................................................................................................13
2 GENERAL GUIDELINES AND PRINCIPLES FOR THE REPAIR OF ASTOTHERM PLUS BLOOD AND
INFUSION WARMERS......................................................................................................................................20
2.1 Responsibility of the manufacturer............................................................................................................21
2.2 Procedure for ASTOTHERM PLUS repairs................................................................................................22
3 CLEANING AND DISINFECTING .....................................................................................................................23
4 FUNCTIONAL CHECK......................................................................................................................................24
5 TROUBLESHOOTING.......................................................................................................................................31
6 DISMANTLING ..................................................................................................................................................34
6.1 Dismantling for troubleshooting in assemblies........................................................................................34
6.2 Dismantling bottom part assembly............................................................................................................36
6.3 Dismantling the top part assembly ............................................................................................................37
6.4 Dismantling the heat exchanger cylinder assembly ................................................................................38
6.5 Dismantling the device fixing assembly....................................................................................................39
6.6 Dismantling the heat protection sleeve.....................................................................................................39
7 ASSEMBLING THE DEVICE.............................................................................................................................40
7.1 Assembling the device fixing assembly....................................................................................................40
7.2 Assembling the heat exchanger assembly ...............................................................................................40
7.3 Assembly of the top part assembly ...........................................................................................................42
7.4 Assembling the bottom part assembly......................................................................................................44
7.5 Fitting the heat protection sleeve...............................................................................................................46
7.6 Final assembly of assemblies ....................................................................................................................46
8 ELECTRICAL SAFETY TEST...........................................................................................................................49
9 CONTINOUS DUTY TEST.................................................................................................................................50
10 RETURN AND/OR DISPOSAL OF DEVICES OR ASSEMBLIES....................................................................51
11 APPENDIX.........................................................................................................................................................51
Revision: 5 – 02/2005 Seite 3
ASTOTHERM PLUS Repair Instructions
Index of Figures
Fig. 1 Electronics block diagram........................................................................................... 9
Fig. 2 Connections between electronic components .......................................................... 12
Fig. 3 Cross-section of the ASTOTHERM PLUS................................................................ 13
Fig. 4 Cross-section of bottom part assembly with optional components........................... 14
Fig. 5 Cross-section of top part assembly .......................................................................... 15
Fig. 6 Flow chart for repairs................................................................................................22
Fig. 7 Display elements of Model 200(S)............................................................................24
Fig. 8 Display elements of models 220(S) und 260(S) ....................................................... 24
Fig. 9 Measuring control temperature and temperature overshoot..................................... 26
Fig. 10 Testing safety cut-off at warmer inlet........................................................................28
Fig. 11 Testing safety cut-off at warmer outlet...................................................................... 28
Fig. 12 Pin assignment on the ASTOLINE plug.................................................................... 29
Fig. 13 Test citrcuit for devices with an ASTOLINE.............................................................. 30
Fig. 14 Lifting off bottom part of housing .............................................................................. 35
Fig. 15 Lifting off heat exchanger ......................................................................................... 35
Fig. 16 ASTOTHERM PLUS and ASTOLINE dismantled into assemblies ........................... 36
Fig. 17 Device fixing assembly............................................................................................. 39
Fig. 18 Inserting fixing strip................................................................................................... 41
Fig. 19 Routing NTC1 connecting wires............................................................................... 41
Fig. 20 NTC2 and NTC3 connecting wires ........................................................................... 42
Fig. 21 Aligning the bottom part on the device fixing............................................................ 44
Fig. 22 Fitting the ASTOLINE board..................................................................................... 45
Fig. 23 Equipotential bonding plug ....................................................................................... 45
Fig. 24 Aligning equipotential bonding plug.......................................................................... 45
Fig. 25 Cable routing in heat exchanger - Plug in heating cables to suit mains voltage. ...... 47
Fig. 26 Attach mains cable and cable tie.............................................................................. 47
Fig. 27 ASTOLINE models: insert insulating plate................................................................ 47
Fig. 28 Contact point for grounding impedance test ..............................................................49
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 and step. If a defective
component or an assembly are to be replaced, only the steps necessary for this should be
performed.
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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 insulates 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:
C 2 separate temperature sensors for temperature control, temperature display and
excessive temperature cut-off,
C an additional independent temperature sensor for excessive temperature cut-off,
C 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.
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ASTOTHERM PLUS Repair Instructions
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.
There are the following versions of the ASTOTHERM PLUS which can be delivered:
Order no Heat exchanger
groove
AP 200*
AP 200 S*
AP 220
AP 220 S
AP 260
AP 260 S
*no more in the actual sales program
4 mm 40°C (fixed) 250 W
4 mm 40°C (fixed) 250 W
4 mm
4 mm
6,8 mm
6,8 mm
Temperature Power
consumption
37°C, 39°C, 41°C (selectable)
or
39°C, 41°C, 43°C (selectable)
37°C, 39°C, 41°C (selectable)
or
39°C, 41°C, 43°C (selectable)
37°C, 39°C, 41°C (selectable)
oder
39°C, 41°C, 43°C (selectable)
37°C, 39°C, 41°C (selectable)
oder
39°C, 41°C, 43°C (selectable)
450 W
450 W
450 W
450 W
ASTOLINE
actively-heated
profile up to the
patient
-
U
-
U
-
U
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.
1.1.1 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 operated 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.
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ASTOTHERM PLUS Repair Instructions
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 260S) have the board and the device socket
for the ASTOLINE fitted in the bottom part.
1.1.2 Description of the electronics
C 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 the inlet (NTC1) and outlet (NTC2) (cf. Fig. 1, Block Diagram).
C 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.
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ASTOTHERM PLUS Repair Instructions
C 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 1.2) 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.
C 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 value of the first excessive
temperature cut-off, see Section 1.2) located at the 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 restarted manually.
C 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”).
C EEPROM memory:
An EEPROM is provided to store constants and operating states. Calibration data are also
stored here.
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ASTOTHERM PLUS Repair Instructions
C 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.
C Mains power failure bridging:
This is used to restart the device automatically in the previously 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.
C 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.
Fig. 1 Electronics block diagram
Revision: 5 – 02/2005 Page 9
1.2 Technical Data
1.2.1 ASTOTHERM PLUS 200 and 200S
ASTOTHERM PLUS 200(S)
Line voltage
Power supply cord
Impedance of protective earth
Insulation resistance
AC leakage current
Primary Fuses
Secondary Fuses
Power input
Selfstart after mains power failure
Protection class
Protection level (IEC 601-1)
Humidity protection
Classification as per appendix IX
UMDNS Code
Dimensions
height
width
depth
Weight
Warm- up time
Operating mode
Permissible ambient temperature
for operation
for storage
Ambient operating humidity
Operation temperature
1. safety cut-off
2. safety cut-off
heater bimetal cut-off
inadequate temperature alarm
AP200(S) EU AP200(S) UK
SCHUKO -
plug
H 05 VVF
3x0,75
H 05 VVF 3x1
AP200(S) CH AP200(S) DK
230-240 VAC "10%
47-63 Hz
BS - plug
13A Fuse
defibrillation-proof applied part of type B
Schweiz plug
H 05 VVF
3x0,75
#0,2 Ohm #0,2 Ohm
>2 MOhm
#0,2 mA
2 x 4 A
2 x 0,63 A
250 W
5 to 30 sec.
I
IPX4
IIb (Rule 9)
10-447
145 mm
135 mm
295 mm
2,9 kg
approx. 1 min (20 °C to 35 °C)
continous operation
+16 °C to +30 °C
-40 °C to +70 °C
10 % to 90 %
40 °C (" 0,5 °C)
42,5 °C (" 0,5 °C)
43,5 °C (" 0,5 °C)
65 °C (" 5 °C)
below 32 °C
DK2-Ia, DK2-
ASTOTHERM PLUS Repair Instructions
AP200(S) NA
100-115 VAC "10%
47-63 Hz
DK - plug
5a
H 05 VVF
3x0,75
Hospital Grade Plug
NEMA 5-15P
SJO, SJT 18/3
>2 MOhm
Page 10 Revision: 5 – 02/2005
ASTOTHERM PLUS Repair Instructions
1.2.2 ASTOTHERM PLUS 220, 220S and 260, 260S
ASTOTHERM PLUS 220(S)
ASTOTHERM PLUS 260(S)
Line voltage
Power supply cord
Impedance of protective earth
Insulation resistance
AC leakage current
Primary Fuses
Secondary Fuses
Power input
Selfstart after mains power failure
Protection class
Protection level (IEC 601-1)
Humidity protection
Classification as per appendix IX
UMDNS Code
Dimensions
height
width
depth
Weight
Warm- up time
Operating mode
Permissible ambient temperature
for operation
for storage
Ambient operating humidity
Operation temperature
1. safety cut-off
2. safety cut-off
heater bimetal cut-off
inadequate temperature alarm
AP220(S) EU
AP260(S) EU
SCHUKO-
plug
H 05 VVF
3x0,75
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)
43°C-devices: 46,0 °C (" 1 °C)
AP220(S) UK
AP260(S) UK
230-240 VAC "10%
BS - plug
13A Fuse
H 05 VVF 3x1
37 °C (" 0,5°C) / 39 °C (" 0,5 °C) / 41 °C (" 0,5 °C)
39 °C (" 0,5°C) / 41 °C (" 0,5 °C) / 43 °C (" 0,5 °C)
47-63 Hz
#0,2 Ohm
>2 MOhm
defibrillation-proof applied part of type B
approx. 1 min (20 °C to 35 °C)
4 °C (" 0,5 °C) below operation temperature
AP220(S) CH
AP260(S) CH
Swiss plug
H 05 VVF
3x0,75
#0,2 mA
2 x 4 A
2 x 0,63 A
450 W
5 to 30 sec.
I
IPX4
IIb (Rule 9)
10-447
145 mm
135 mm
295 mm
2,9 kg
continous operation
+16 °C to +30 °C
-40 °C to +60 °C
10 % to 90 %
or
65 °C (" 5 °C)
AP220(S) DK
AP260(S) DK
DK-plug
DK2-Ia, DK2-5a
H 05 VVF
3x0,75
AP220(S) NA
AP260(S) NA
100-115 VAC "10%
47-63 Hz
Hospital Grade Plug
NEMA 5-15P
SJO, SJT 18/3
#0,2 Ohm
>2 MOhm
Revision: 5 – 02/2005 Page 11
1.3 Terminal connecting plan
Fig. 2 Connections between electronic components
ASTOTHERM PLUS Repair Instructions
Page 12 Revision: 5 – 02/2005
ASTOTHERM PLUS Repair Instructions
1.4 ASTOTHERM PLUS spare parts
20
8
9
33
23 18
31
34
Fig. 3 Cross section of the ASTOTHERM PLUS
1
22
7
21
19 14 10
12
Revision: 5 – 02/2005 Page 13
30
13
28
13a
29
35 17
25
16
Fig. 4 Cross-section of bottom part assembly with optional compoents
ASTOTHERM PLUS Repair Instructions
(27)
32
11
24 15
26
27
Page 14 Revision: 5 – 02/2005
ASTOTHERM PLUS Repair Instructions
4
2
Fig. 5 Cross-section of top part assembly with optional compoents
3
1
(2)
6
5
Revision: 5 – 02/2005 Page 15
ASTOTHERM PLUS Repair Instructions
ASTOTHERM PLUS spare parts
When ordering please indicate always model number and serial number!
No.
1
n.g.
n.g.
2
3
4
5
6
7
8
9
*
calibration is required, see section 4 of this repairing instructions; an exact setting can only carried out
with the interface and the accompanying software or by the manufacturer!
Comment: Operating boards (only for glass NTCs) can used for 41°C or 43°C devices by transferring a
corresponding data file. Because of different temperatures of the safety cut-offs (hardware) it is not
possible to change transformer boards between 41°C and 43°C devices!
Order number
9751.4205.00
9750.4205.00
9751.4202.00
9750.4202.00
9770.4202.00
9750.8240.00
9750.8241.00
9750.4202.14
9750.4200.13
9751.4200.05
9751.4200.02
9750.4200.05
9750.4200.02
9750.2201.01-M841
9750.2201.01-Glas
9750.2200.14
9750.2101.01-M841
9750.2101.01-Glas
0450.2101.43
9750.8100.02
9750.8100.03
Name
consist of
TOP PART OF HOUSING AP 200
complete with handle, bolts and front panel
TOP PART OF HOUSING AP 220/260
complete with handle, bolts and front panel
TOP PART OF HOUSING AP 200S
complete with handle, bolts and front panel
TOP PART OF HOUSING AP 220S
complete with handle, bolts and front panel
TOP PART OF HOUSING AP 260S
complete with handle, bolts and front panel
AL-Holder 4 mm
with fastening material
AL-Holder 6,8 mm
with fastening material
HANDLE
with fastening material
DISPLAY COVER
FRONT PANEL AP 200
FRONT PANEL AP 200S
FRONT PANEL AP 220/260
FRONT PANEL AP 220S/260S
*OPERATING BOARD for M841 NTCs
(red or black NTC wire insulation)
tested and adjusted for Type
*OPERATING BOARD for glass NTCs
(white NTC wire insulation)
tested and adjusted for Type
KEY EXTENSION (1 Piece)
*TRANSFORMER BOARD for M841 NTCs
(red or black NTC wire insulation)
tested
*TRANSFORMER BOARD for glass NTCs
(white NTC wire insulation)
tested
*
TRANSFORMER BOARD for glass NTCs (43°C)
(white NTC wire insulation)
tested
AXLE HEAT PROTECTION SLEEVE
only from SN: SN: BSEU1017, BSUK1021, BSCH1012, BSNA1001,
DSEU1323, DSUK1043, DSCH1012, DSNA1054
only from SN: HSEU1015, HSUK1018, HSCH1001, HSNA1015
HEAT PROTECTION SLEEVE AP HALF PART
1Half Heat protection sleeve
1Sticker ASTOTHERM PLUS
Page 16 Revision: 5 – 02/2005
ASTOTHERM PLUS Repair Instructions
When ordering please indicate always model number and serial number!
10
11
12
13
13a
14
15
16
17
8510.0305.01
9750.4100.09
9750.4100.10
9750.4100.12
9750.4100.16
9750.4100.17
9750.4100.00
9750.4101.00
9750.4102.10
9750.4103.10
9750.4300.01
9750.5100.04
9750.5102.00
9750.5100.01
BUFFER (2 Pieces)
CABLE GLAND PG9
1Cable gland
1Counter nut
POWER SUPPLY CORD SCHUKO
1Power supply cord SCHUKO
1Cable tie 90mm
POWER SUPPLY CORD GREAT BRITAIN
1Power supply cord GREAT BRI T AIN
1Cable tie 90mm
POWER SUPPLY CORD SWITZERLAND
1Power supply cord SWITZERLAND
1Cable tie 90mm
POWER SUPPLY CORD USA
1Power supply cord USA
1Sticker GROUNDING
1Cable tie 90mm
BOTTOM PART OF HOUSING AP 200/220/260
1Bottom part
1Sticker ASTO
2Buffer
2Cable tie 90mm
BOTTOM PART OF HOUSING AP 200/220/260 - PA
1Bottom part with drill-hole for equipotential bonding
1Sticker ASTO
2Buffer
2Cable tie 90mm
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
BOTTOM PART OF HOUSING AP 200S/220S/260S - PA WITH
ASTOLINE DEVICE 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
INTERMEDIATE RING
THREADED SHAFT
CLAMP RIGHT
1Clamp right
1Rectangular nut right
1Pad
BASEPLATE
1Base plate
1Identification label
Revision: 5 – 02/2005 Page 17
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