Stihler Astotherm AP200-260 Service manual
®
ASTOTHERM
Blood and Infusion Warmer
Models AP200, AP220 and AP260
Models AP200S, AP220S and AP260S with ASTOLINE
plus
Repair Instructions
REVISION 6, 03/2010
STIHLER ELECTRONIC GmbH
Julius-Hoelder-Strasse 36
D-70597 Stuttgart
Phone: +49 (0)711-720670
Fax: +49 (0)711- 7206757 Part-No. 9950.9000.12
ASTOTHERM PLUS Repair Instructions
Page 2 Revision: 6 – 03/2010
ASTOTHERM PLUS Repair Instructions
Table of Contents
1 TECHNICAL DESCRIPTION...............................................................................................................................5
1.1 General ............................................................................................................................................................5
1.2 Structure ..........................................................................................................................................................6
1.3 Description of the electronics...........................................................................................................................7
1.4 Technical Data.................................................................................................................................................9
1.5 Terminal connecting plan...............................................................................................................................11
1.6 ASTOTHERM PLUS spare parts...................................................................................................................12
2 GENERAL GUIDELINES AND PRINCIPLES FOR THE REPAIR OF ASTOTHERM PLUS BLOOD AND
INFUSION WARMERS......................................................................................................................................19
2.1 Technical Service and Ordering Spare Parts ................................................................................................19
2.2 Guarantee repairs ..........................................................................................................................................19
2.3 Liability ...........................................................................................................................................................19
2.4 Important instructions.....................................................................................................................................20
2.5 Procedure for ASTOTHERM PLUS repairs ...................................................................................................21
3 CLEANING AND DISINFECTING .....................................................................................................................22
4 FUNCTIONAL CHECK......................................................................................................................................22
4.1 Check display devices (LCD and LED):.........................................................................................................23
4.2 Check heating-up time...................................................................................................................................23
4.3 Check display temperature fluctuation...........................................................................................................23
4.4 Check temperature in control state................................................................................................................24
4.5 Test temperature overshoot on heating.........................................................................................................24
4.6 Alarm test functions .......................................................................................................................................25
4.7 Checking safety cut-offs.................................................................................................................................25
4.8 Measuring resistance of ASTOLINE active insulation ...................................................................................27
4.9 Testing ASTOLINE connection......................................................................................................................27
5 TROUBLESHOOTING.......................................................................................................................................28
6 DISMANTLING ..................................................................................................................................................30
6.1 Dismantling for troubleshooting in assemblies ..............................................................................................30
6.2 Dismantling bottom part assembly.................................................................................................................31
6.2 Dismantling bottom part assembly.................................................................................................................32
6.3 Dismantling the top part assembly.................................................................................................................33
6.4 Dismantling the heat exchanger cylinder assembly.......................................................................................33
6.5 Dismantling the device fixing assembly .........................................................................................................34
7 ASSEMBLING THE DEVICE.............................................................................................................................35
7.1 Assembling the device fixing assembly .........................................................................................................35
7.2 Assembling the heat exchanger assembly ....................................................................................................35
7.3 Assembly of the top part assembly................................................................................................................37
7.4 Assembling the bottom part assembly...........................................................................................................39
7.5 Final assembly of assemblies........................................................................................................................41
8 ELECTRICAL SAFETY TEST...........................................................................................................................43
9 CONTINOUS DUTY TEST.................................................................................................................................44
10 RETURN AND/OR DISPOSAL OF DEVICES OR ASSEMBLIES....................................................................44
11 APPENDIX.........................................................................................................................................................45
Revision: 6 – 03/2010 Page 3
ASTOTHERM PLUS Repair Instructions
User information:
Test results which must be achieved to ensure safe operation are outlined by a frame.
The description for dismantling covers every possible assembly group and step. If a defective
component or an assembly group are to be replaced, only the steps necessary for this should
be performed.
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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.
Heating of the medium is based on flow speed and inlet temperature. For an optimum heat transfer we
recommend the original infusion extension ASTOTUBE. (see outlet temperature diagrams in the operating
instructions).
If on the models 220(S) and 260(S) the displayed temperature of the heat exchanger drops by more than
4 C below the selected set temperature, the inadequate temperature alarm is activated. On the model
200(S), the inadequate temperature alarm is fixed at 32 C.
Revision: 6 – 03/2010 Page 5
There are ASTOTHERM PLUS in the following variations
ASTOTHERM PLUS Repair Instructions
Order no Heat exchanger
groove
AP 200* 4 mm 40°C (fixed) 250 W
AP 200 S* 4 mm 40°C (fixed) 250 W
AP 220
AP 220 S
AP 260
AP 260 S
*no more in the actual sales program
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
insulation 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.
1.2 Structure
In the top part of the housing underneath the front panel is the board with the components for electronic
control, the keys for operation and the associated LEDs and LCD for actual and selected temperature
displays. The board is 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.
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.
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ASTOTHERM PLUS Repair Instructions
1.3 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.
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 1.4) In
the event of an alarm, the safety cut-off switches off relay K1. This interrupts the heating current and the
power supply for K1 and K2. Drop-out of the relay is indicated by the flashing alarm LED and the alarm tone.
If the heat exchanger cylinder cools to below the alarm limit, the device can be re-started manually. NTC1
cannot be affected by any conceivable defect of the safety cut-off at the warmer outlet or of NTC3.
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 1.4) 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 re-started 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.
Revision: 6 – 03/2010 Page 7
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.
Safety cut-off at
warmer outlet
Safety cut-off at
warmer inlet
Heater
Watch-Dog
Power supply
electronic
Fig. 1 Electronics block diagram
Page 8 Revision: 6 – 03/2010
ASTOTHERM PLUS Repair Instructions
1.4 Technical Data
1.4.1 ASTOTHERM PLUS 200 and 200S
ASTOTHERM PLUS 200(S)
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 AP200(S) NA
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-
DK - plug
5a
H 05 VVF
3x0.75
100-115 VAC "10%
47-63 Hz
Hospital Grade Plug
NEMA 5-15P
SJO, SJT 18/3
> 2 MOhm
Revision: 6 – 03/2010 Page 9
1.4.2 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) up to SN ≤ 5000
39 C (" 0.5°C) / 41 C (" 0.5 °C) / 43 C (" 0.5 °C) from SN ≥ 5001
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)
ASTOTHERM PLUS Repair Instructions
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
Page 10 Revision: 6 – 03/2010
ASTOTHERM PLUS Repair Instructions
1.5 Terminal connecting plan
Fig. 2 Connections between electronic components
Revision: 6 – 03/2010 Page 11
1.6 ASTOTHERM PLUS spare parts
20
8
33
23 18
31
34
Fig. 3 Cross section of the ASTOTHERM PLUS
ASTOTHERM PLUS Repair Instructions
1
22
7
21
19 14
10
12
Page 12 Revision: 6 – 03/2010
ASTOTHERM PLUS Repair Instructions
30
13
28
13a
29
35 17
25
16
Fig. 4 Cross-section of bottom part assembly with optional components
(27)
32
11
24 15
26
27
Revision: 6 – 03/2010 Page 13
4
2
Fig. 5 Cross-section of top part assembly with optional components
ASTOTHERM PLUS Repair Instructions
3
1
(2)
6
5
Page 14 Revision: 6 – 03/2010
ASTOTHERM PLUS Repair Instructions
When ordering please indicate always model number and serial number!
No.
1
Order number
9751.4205.00
9750.4205.00
9751.4202.00
9750.4202.00
9770.4202.00
n.g.
n.g.
2
3
4
5
6
7
8
10
11
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
8510.0305.01
9750.4100.09
ASTOTHERM PLUS spare parts
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 (41°C)
(red or black NTC wire insulation)
tested
TRANSFORMER BOARD for glass NTCs (41°C)
(white NTC wire insulation)
tested
TRANSFORMER BOARD (43°C)
(white NTC wire insulation)
tested
AXLE HEAT PROTECTION SLEEVE
BUFFER (2 Pieces)
CABLE GLAND PG9
1Cable gland
1Counter nut
only from SN: BSEU1017, BSUK1021, BSCH1012, BSNA1001,
DSEU1323, DSUK1043, DSCH1012, DSNA1054
only from SN: HSEU1015, HSUK1018, HSCH1001, HSNA1015
1) 4) 5)
1) 2) 3)
1) 2) 3)
1) 4) 5)
1) 4) 5)
Revision: 6 – 03/2010 Page 15
12
13
13a
14
15
16
17
18
19
20
ASTOTHERM PLUS Repair Instructions
When ordering please indicate always model number and serial number!
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
9750.4300.02
9720.3725.02
9750.8100.00
POWER SUPPLY CORD SCHUKO
1Power supply cord SCHUKO
1Cable tie 90mm
POWER SUPPLY CORD GREAT BRITAIN
1Power supply cord GREAT BRITAIN
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
SPACING BOLT (1 Piece)
O-RING 114.02 x 1,78 (2 Pieces)
HEAT PROTECTION SLEEVE AP
2Half part Heat protection sleeve
1Axle
2Sticker ASTOTHERM PLUS
1Fixing cord
Page 16 Revision: 6 – 03/2010
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