Heater cooler-Sorin-3T-Service Manual

Heater-Cooler System 3T
Service Manual
Heater-Cooler System 3T • Service Manual
Copyright © 2002 - 2011

SORIN GROUP DEUTSCHLAND GMBH
Lindberghstrasse 25
D-80939 München, Germany
Tel.: +49 - 89 - 32301-0

Fax: +49 - 89 - 32301-777
All rights, particularly the right to reproduce, distribute and translate this manual, are reserved. No part of this
publication may be reproduced, stored electronically, processed, duplicated or distributed in any form – by
photocopy, microfilm or by any other means – without the written approval of SORIN GROUP DEUTSCHLAND GMBH.
Service Manual
Version 11/2011 – SM-16-XX-XX.03 ENG
Valid for Heater-Cooler Systems with the firmware version 1.XX (1.08 and newer)
SM-16-XX-XX.03 ENG
Heater-Cooler System 3T • Table of Contents
Table of Contents
1 Introduction
1.1 About this Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1.1 Symbols Used in this Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1.2 The Chapters in this Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2 Safety
2.1 Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2 Regulations and Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.2.1 Usage in Accordance with Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.2 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2.3 Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.4 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.5 Safety Instructions for Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.6 Disposal in accordance with environmental regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3 Safety Features of the Heater-Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
3 System Description
3.1 Heater-Cooler System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1.1 Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2 Structure of the Heater-Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

3.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2.2 Overview of the Modules in the Patient Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.2.3 Overview of the Modules in the Cardioplegia Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.2.4 Overview of the Modules in the Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.2.5 Overview of the System Electronics Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
3.2.6 Overview of the System Electronics Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Mains AC board (UL 507). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
CPU Board (UL 508). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Keyboard and Display Board (UL 509) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Distributor Board (UL 510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
Level Board (UL 459) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
3.2.7 Functional Diagram of the Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Cold C-Plegia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Warm C-Plegia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
SM-16-XX-XX.03 ENG 1
4 Service Mode and Software

4.1 The Service Mode of the Heater-Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1
4.1.1 Calling Service Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2
4.1.2 Overview of the Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4
4.2 Calibrating the Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11

4.2.1 Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
4.2.2 Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
Calibrating the Temperature Sensors in the Patient Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
Calibrating Temperature Sensors in the Cardioplegia Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
4.3 Software Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15

4.3.1 Preparing for Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
4.3.2 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
Loading the Flash Kernel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
Updating the Operating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
5 Error Messages and Error Diagnosis

5.1 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2 Error Diagnosis on the Cooling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
6 Replacing Modules and Components

6.1 Accessing the Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.1.1 Opening the Heater-Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Opening the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Opening the Side Panels and the Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3
System Electronics Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
6.2 Tank Bridges, Stirring mechanism and Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7

6.2.1 Removing the Tank Bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Patient Tank Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Cardioplegia Tank Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
6.2.2 Removing the Stirring Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
6.2.3 Removing the Floats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
6.3 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
2 SM-16-XX-XX.03 ENG
7 Appendix
7.1 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.1 Dimensions, Weights, Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.3 General Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.4 Information about Global Warming Potentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2 Labelling and tagging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.5 Part Numbers of Service Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.5.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.5.2 Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.5.3 System Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.5.4 Tank Bridges and Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Patient Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
Cardioplegia Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.6 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
SM-16-XX-XX.03 ENG 3
4 SM-16-XX-XX.03 ENG
Heater-Cooler System 3T • Introduction
1 Introduction
1.1 About this Service Manual
This Service Manual (in addition to the training courses run by

SORIN GROUP DEUTSCHLAND GMBH) is the basis for the maintenance and repair of your
Heater-Cooler System. This manual is intended only for suitably qualified service technicians.
In the interest of the safety of patients and all operators:
!
Only service technicians trained and authorised by SORIN GROUP DEUTSCHLAND GMBH may
service the Heater-Cooler System.
Please refer to the operating instructions for any information you need on operating the Heater-
Cooler. This Service Manual contains references to the corresponding chapters in the operating
instructions (if required).
1.1.1 Symbols Used in this Service Manual
The symbols used in this manual are intended to help you find special text passages. The
meaning of the symbols is as follows:
! Danger! Failure to pay attention may endanger the patient’s and/or

the operator’s life.
! Warning! Failure to pay attention may cause damage to the machine

or other equipment.
✓ A check list for a quick and safe follow up on whether operational

steps have been carried out completely.
◗ Primary list (main groups)
➜ Secondary list (subgroups)
SM-16-XX-XX.03 ENG 1.1

Heater-Cooler System 3T • Introduction
1.1.2 The Chapters in this Service Manual
In Chapter... you will find the following information:
1 Introduction ➜ Symbols used in the Service Manual

➜ Overview of chapters (this table)
2 Safety ➜ Important safety instructions for the

operation and maintenance of the Heater-
Cooler System
3 System Description ➜ A brief description of all the service-

relevant components
4 Service Mode and Software ➜ Working in Service mode

➜ Calibrating the temperature sensors
➜ Software updates
5 Error Messages and Error Diagnosis ➜ A list of all error messages and
information on locating errors
6 Replacing Modules and Components ➜ Information and instructions for adding

and removing components
7 Appendix ➜ Technical data on all the components

➜ Order numbers/spare parts
1.2 SM-16-XX-XX.03 ENG

Heater-Cooler System 3T • Safety
2 Safety
2.1 Approvals
Just like development and production, the system must also be serviced in accordance with the
following standards and legal regulations.
– Declaration of Conformity
◗ IEC 60601-1 – Medical Electrical Equipment: General

Requirements for Safety
◗ IEC 60601-1-2 – EMC (Electro-Magnetic Compatibility)
◗ MDD – Medical Device Directive 93/42 EEC
◗ DIN EN ISO 13485 – Quality Management System
◗ UVV – Regulations for the Prevention of
Accidents
The Heater-Cooler System is a medical device, class IIb (MDD 93/42). A Declaration of
Conformity has been issued for the Heater-Cooler.
2.2 Regulations and Safety Instructions
2.2.1 Usage in Accordance with Regulations
!
◗ In accordance with applicable regulations, the Heater-Cooler is used with a Stöckert/Sorin
Heart-Lung Machine (S3/SC/S5/C5) for the controlled heating/cooling of 3 water circuits
during extracorporeal perfusion. The water circuits are used for cooling/heating blood (in
the oxygenator), hypothermia blankets or cardioplegic solutions. The use of the Heater-
Cooler for any other purposes is not in accordance with the regulations.
SORIN GROUP DEUTSCHLAND GMBH assumes no liability whatsoever for damages arising
from such usage. Usage in accordance with regulations also includes compliance with the
operating instructions as well as repair and maintenance according to the maintenance
instructions.
◗ Relevant accident prevention measures according to existing local policy and employees’
health and safety regulations must be complied with. SORIN GROUP DEUTSCHLAND GMBH
will not assume any liability for damage due to non-compliance with these regulations.
◗ SORIN GROUP DEUTSCHLAND GMBH will not assume any liability for injuries and/or
damage caused by failure to observe the safety instructions or by the operator not taking
due care. This applies even if the operator’s duty to take due care has not been specifically
expressed to the user.

2.2.2 General Safety Instructions
◗ The Heater-Cooler has been designed according to current state-of-the art technology and
accepted safety standards. Although this may be the case, danger may arise for the patient,
the user or for other equipment during operation.
◗ The Heater-Cooler must be operated by trained and qualified personnel only.
◗ The Heater-Cooler must not be operated near explosive materials.

!
◗ The Heater-Cooler may only be used when in fully operational condition and according to Usage in accordance
regulations and the operating instructions. Be sure to take note of any cautions or with regulations: see
warnings. chap. 2.2.1 on page 2.1
◗ The operating instructions must be available close to the Heater-Cooler at all times.
Incomplete or illegible operating instructions must be replaced immediately.
◗ According to the European Directive 93/42 and the national standards based on this
directive, the Heater-Cooler must be subjected to a regular maintenance check by an
authorised service representative. The maintenance check must be performed after every
1000 operating hours or at least once every 12 months (whichever comes first).
◗ In addition to the operating instructions, the relevant legal, general and binding
regulations concerning the prevention of accidents must be observed.
◗ In order to take situations into account which are clinic-specific and outside of normal
routines, e.g. certain working procedures, the operating instructions must be
supplemented with relevant instructions (supervision and registration requirements, etc).
◗ Personnel operating the Heater-Cooler must have acquainted themselves thoroughly with
the operating instructions prior to working with the machine!
◗ If you discover any safety-relevant modifications to the Heater-Cooler or its operating

behaviour (outside of OP mode): Do not use the Heater-Cooler and have it checked out by
authorised service personnel.
◗ Do not perform any modifications or extensions to the Heater-Cooler, unless they have been
tested and approved by SORIN GROUP DEUTSCHLAND GMBH.
SORIN GROUP DEUTSCHLAND GMBH cannot assume liability or responsibility for
unauthorised modifications or changes.
◗ Keep the Heater-Cooler clean! Doing so will prevent possible contact errors and faults due
to dirt.

2.2.3 Operating Safety
◗ Prior to working with the Heater-Cooler, you must have thoroughly read the operating
instructions and have become familiar with the machine functions!
◗ Ensure that the Heater-Cooler is placed on a horizontal surface and the castor brakes have
been locked prior to operation.
◗ Only use decalcified water (no distilled or de-ionised water) to fill the Heater-Cooler tanks.
◗ Check the water level of the tanks prior to each operation. Only operate the Heater-Cooler if
the water level is sufficient, i.e., is above the minimum water level (one segment of the bar
graph display).
◗ Empty the water tank completely at least once a week in order to prevent the growth of
bacteria and algae inside the tank.
!
◗ Prior to operation, check all cables, tubing, connectors and other accessories to ensure
correct connections, seals and proper function. Replace all damaged components
immediately.
◗ Check the actual temperature displays on the Heater-Cooler regularly.
!
◗ Check the patient’s blood temperature with an appropriate temperature measurement
system regularly, independently of the displays on the Heater-Cooler (e.g. on the HLM).
!
◗ For emergencies, e.g. in case of a total failure, ensure that a replacement with compatible
connectors is ready for operation.
◗ Activate the pumps of the primed and filled system prior to its first operation. Watch the
water level display on the Heater-Cooler control panel and monitor the connected heat
exchanger (e.g. oxygenator, cooling/heating blanket). A leakage in a water circuit will
influence the water level in the connected tank.
◗ Do not use self-closing connectors. Compared to “open connectors”, they reduce the water
flow.
◗ Ensure that the tubing is straight and do not bend or twist it. Apart from occluding the water
flow, bent or twisted tubing can pose a hazard for the personnel (causing them to stumble).
◗ Ensure optimum ventilation at the ventilation grills and the fan. Insufficient ventilation may
result in excessive heating of the Heater-Cooler.
◗ Modifications or extensions to the machine, as well as the use of spare parts, which have
not been tested and approved by SORIN GROUP DEUTSCHLAND GMBH, may have negative
effects on the safety and function of the machine. SORIN GROUP DEUTSCHLAND GMBH
cannot accept any liability or responsibility.
◗ Accessories and supplementary devices, which have not been tested and approved by
SORIN GROUP DEUTSCHLAND GMBH, must prove that their use does not pose a safety
hazard (see chap. 7.4 “Accessories” on page 7.6).

2.2.4 Electrical Safety
◗ The electrical installation must be in compliance with DIN VDE 0107 (for Germany) or the
corresponding, equivalent, local regulations and guidelines. Hereby, refer to the technical
specifications.
◗ Check the functional safety of all electrical connections, cables and sockets regularly!
◗ Mains power quality should be that of a typical commercial or hospital environment.
2.2.5 Safety Instructions for Routine Maintenance
◗ Routine maintenance work must only be performed by qualified personnel.
◗ The water tanks must be disinfected prior to operating the heater-cooler for the first time. In
order to prevent germal growth, the disinfection cycle must be repeated at regular intervals
after the initial operation. For detailed information, please refer to the Operating
Instructions.
!
◗ Disconnect the Heater-Cooler from the power supply completely before carrying out
maintenance and cleaning work.
◗ Please adhere to the instructions for maintenance and care given in these operating
instructions as well as the recommended maintenance intervals.
◗ Ensure that no liquids or cleaning agents enter the machine housing through the vents or
other openings.
◗ Use recommended cleaning agents.
◗ Repair work may only be carried out by authorised service technicians. Only original spare
parts from SORIN GROUP DEUTSCHLAND GMBH may be used in order to guarantee the
proper functioning of the Heater-Cooler.
◗ The repair work of the cooling circuit of the refrigerant must only be performed by an expert
for refrigerant systems.
2.2.6 Disposal in accordance with environmental regulations
◗ The heater-cooler is not subject to disposal according to the EC directive 2002 96 EG WEEE
and/or the derivative German ordnance ElektroG, since after the elapse of the device's
lifespan, it is to be regarded as potentially infectuous.
◗ All single-use articles used in conjunction with the heater-cooler must be disposed of in
accordance with local policies and environmental regulations. Observe the hospital
regulations when discarding these articles.
◗ The cooling circuit of the heater-cooler is filled with a CFC-free HFC-(hydrofluorocarbons)

refrigerant. Please see the device label to obtain further information about the type and
volume of the refrigerant to be used. The disposal of the refrigerant must only be performed
by an expert for refrigerant systems.

2.3 Safety Features of the Heater-Cooler System
◗ The Heater-Cooler performs a self-test during power-up. Check that all the LEDs, the 7-
segment displays and the beep alarm function correctly.
◗ Visual and audible alarms indicate when an internal error has occurred.
◗ If the water level is too low, the water pumps will stop. The latter will be indicated by a
corresponding alarm.


Heater-Cooler System 3T • System Description
3 System Description
3.1 Heater-Cooler System
The Heater-Cooler contains all the components required for operation. The remote control
modules for operation with the S3/SC system are not required for full functioning (but are
recommended for clinical usage). The following pages provide an overview of the installation
location and the function of each of the modules.
3.1.1 Modules
The Heater-Cooler comprises the following modules:
◗ Patient circuits ➜ 2 pumps for 2 separate circuits

➜ 2 heaters
➜ Stirring mechanism to guarantee a
consistent tank temperature
➜ Floats for monitoring the water level
◗ Cardioplegia ➜ 2 pumps for the warm and cold tanks

circuit ➜ 1 heater
➜ Valve block for electro-mechanical
switching between the warm and cold
tank
➜ Float for monitoring the water level
◗ Cooling unit ➜ Condenser

➜ Liquefier with a controlled fan
➜ Collector
➜ Filter drier
➜ 2 magnetic valves
➜ 2 return valves
➜ FCKW-free cooling agent R 134 A
◗ System electronics ➜ Ring core transformer

➜ Mains safety switch
➜ “Mains” printed circuit board
➜ “CPU” board with a serial interface
➜ “Keyboard and Display” board
➜ “Distributor” board
➜ Two “Level” pc boards for monitoring the
float gauges in the patient and warm
c-plegia tanks

3.2 Structure of the Heater-Cooler System
3.2.1 Overview
B D
Fig. 1: Overview

Mod. = Module
A Patient circuits
B Cardioplegia circuit
C Cooling unit
D System electronics

3.2.2 Overview of the Modules in the Patient Circuits
A 11 D7 A2
A 10
A5
A 11
A 10 A9
A8
A3
A 12
A1
A6
A7
A5 A4 A8 A5
A9
Fig. 2: Overview of the modules in the patient circuits

Mod. Pos. Description Number ET number
A Patient circuit bridge (complete), UD 488-E 96-410-725

(frequency motors)
Patient circuit bridge (complete), UD 488-PE (230 V) 96-410-726

(PWM motors) UD 688 (120 V) 96-410-824
A 1 Pump for patient circuit 1 (complete) BPS 083P 96-410-716
A 2 Pump for patient circuit 2 (complete) BPS 083P 96-410-716
A 3 Stirring mechanism (complete) consists of
stirrer motor EM 109 96-410-719
stirrer pump head UD 485 96-410-720
drive shaft extension HSA 038 96-410-721
set screws M3 x 4 (2 pcs.) DGI 002 96-410-722
A 4 Float assembly (mech. complete) HX 339 96-410-710
A 5 Heaters UH 176 (230 V) 96-410-743

EH 2224 (120V) 96-410-818
A 6 Suction tube for pump RKJ 103
A 7 Pressure tube for pump RKJ 102
A 8 Patient tank safety system temperature sensors ETP 042 96-410-738
A 9 Patient tank control system temperature sensors ETP 042 96-410-738
A 10 Patient circuit inlet EOA 006 96-410-032
A 11 Patient circuit outlet 16-02-58
A 12 Opening for reference temperature sensors (cali- EZV 016 96-410-545

bration)

3.2.3 Overview of the Modules in the Cardioplegia Circuit
B 17
B 15
B 13
B9 B 10
D7
B1
B3
B 14
B 12
B2
B 11
B5 B 16
B 15
B 10
B9
B6 B8 B5 B6 B4
Fig. 3: Overview of the modules in the cardioplegia circuit

B Cardioplegia circuit bridge (complete), UD 489-E 96-410-730

(frequency motors)
Cardioplegia circuit bridge (complete), UD 489-PE (230 V) 96-410-731

(PWM motors UD 689 (120V) 96-410-825
B 1 Cold tank pump (complete) BPS 082P 96-410-715
B 2 Warm tank pump (complete) BPS 082P 96-410-715
B 3 Valve block (complete)
B 4 Floats HX339 96-410-710
B 5 Heaters UH 176 (230 V) 96-410-743

EH 2224 (120 V) 96-410-818
B 6 Suction tube for pump (warm tank) RKJ 103
B 7 Suction tube for pump (cold tank) RKJ 037
B 8 Pressure tubing for pump RKJ 102
B 9 Cold tank safety system temperature sensors ETP 042 96-410-738
B 10 Cold tank control system temperature sensors ETP 042 96-410-738
B 11 Warm tank safety system temperature sensors ETP 042 96-410-738
B 12 Warm tank control system temperature sensors ETP 042 96-410-738
B 13 Cardioplegia circuit inlet EOA 006 96-410-032
B 14 Cardioplegia circuit outlet 16-02-58
B 15 Opening for reference temperature sensors in EZV 016 96-410-545

the cold tank
B 16 Opening for reference temperature sensors in EZV 016 96-410-545

the warm tank
B 17 Water inlet (all tanks) HXO 216 (Part of 96-410-730)

3.2.4 Overview of the Modules in the Cooling Unit
C 16 C 13
C 14
C 18 C 15
C 17
C8
C5 C7
D 12
C6
C 12
C 10
C 11
C9 D 10
D9
C3 C2 C4 D 11
Fig. 4: Overview of the modules in the cooling unit

C 1 Cooling unit (complete) EMK 213
C 2 Compressor
C 3 Hot-gas line to the liquefier
C 4 Suction pipe (condenser inlet)
C 5 Liquefier
C 6 Fan with a Hall sensor,

Fan motor for cooling unit EML 037 (230V) 96-410-763
EML 066 (120V) 96-410-820
C 7 Liquid separator/collector
C 8 Filter drier
C 9 Magnetic valve in the patient circuit
C 10 Magnetic valve in the cardioplegia circuit
C 11 Expansion valve in the patient circuit
C 12 Expansion valve in the cardioplegia circuit
C 13 Return valve in the patient circuit
C 14 Return valve in the cardioplegia circuit
C 15 Outlet to the patient tank evaporator
C 16 Inlet from the patient tank evaporator
C 17 Outlet to the cardioplegia cold tank evaporator
C 18 Inlet from the cardioplegia cold tank evaporator

3.2.5 Overview of the System Electronics Modules
D5
D2
D3
D7
D1
D6
D4
D7
D8
Fig. 5: System electronics
3.10 SM-16-XX-XX.03 ENG

D 1 Ring core transformer EIT 128 96-410-744
D 2 Mains safety switch EST 102 (230 V) 96-410-748

EST 118 (120 V) 96-410-822
D 3 Mains AC board UL 507 96-410-701
D 4 CPU board UL 508 96-410-702
D 5 Keyboard and Display board UL 509 96-410-703
D 6 Distributor board UL 510 96-410-704
D 7 Level pc board UL 459 96-410-705
D 8 Hall sensor (on the fan motor) UD 491 96-410-740
D 9 Junction box for the compressor and fan see Fig. 4: “Overview
of the modules in the
D 10 Starter for the compressor cooling unit” on page
3.8
D 11 Start and run capacitors for the compressor
D 12 Temperature sensor for the condenser US 073 96-410-739
SM-16-XX-XX.03 ENG 3.11

3.2.6 Overview of the System Electronics Components
Mains AC board (UL 507)
D 13
D 14
D 15
D 21
D 20
D 31
D 16
D 17
D 18
D 19
D 27 D 28
D 22
D 23
D 24
D 25
D 26
D 29 D 30
Fig. 6: Mains board
3.12 SM-16-XX-XX.03 ENG

Mod. Pos. Description Number Remark
Mains AC board UL 507 96-410-701
D 13 24V DC output X 21
D 14 Ring core transformer input for secondary wind- X 61

ing
D 15 Ring core transformer output for primary wind- X 44

ing
D 16 Cardioplegia warm tank heating output X 43
D 17 Output from the condenser/fan to the junction X 42

box D 9
D 18 Patient tank heating output X 41
D 19 Power input from the mains safety switch D 2 X 40
D 20 Magnetic valve cooling output (both circuits) X 60
D 21 Distributor board connection X 20
D 22 Triac LED for the magnetic valve in the cardiople- H 1

gia tank
on = valve open
D 23 Triac LED for the magnetic valve in the patient H2

tank
on = valve open
D 24 Safety relay LED for patient tank heating H3

on = heating on
D 25 Triac LED for heating patient tank 1 H4

on = heating on
D 26 Triac LED for heating patient tank 2 H5

on = heating on
D 27 Safety relay LED for the condenser H6

on = condenser on
D 28 Safety relay LED for heating the cardioplegia H7

tank
on = heating on
D 29 Press switch/excess temperature switch LED H8

Normal state:
Off when cooling unit is running
On when cooling unit is switched off
D 30 Triac LED for heating the cardioplegia tank H9

on = heating on
D 31 6.3-amp primary fuse, slow
SM-16-XX-XX.03 ENG 3.13

CPU Board (UL 508)
D 32
D 42
D 33
D 43
D 45
D 41
D 40
D 39
D 38
D 34
D 35
D 36
D 37
D 46
D 44
Fig. 7: CPU board
3.14 SM-16-XX-XX.03 ENG

CPU board UL 508 96-410-702
D 32 RS232 programming interface X2
D 33 Mains board connection X 20
D 34 Connection for programming adapter (program- X 81 Switched off in

ming the control system Flash memory) normal operation
D 35 CAN interface connection X3
D 36 Hall sensor connection D 8 (fan speed) X 64
D 37 Distributor board connection X 23
D 38 Connection for programming adapter (program- X 83 Switched off in

ming the safety system Flash memory) normal operation
D 39 Temperature sensor connection for the cardio- X 63

plegia tanks
D 40 Temperature sensor connection for the patient X 62

tank
D 41 Keyboard and Display board connection X 22
D 42 Temperature sensor connection for the X 65

liquefier D 12
D 43 Control system Reset key S2
D 44 Safety system Reset key S1
D 45 Control system microprocessor D6
D 46 Safety system microprocessor D2
SM-16-XX-XX.03 ENG 3.15

Keyboard and Display Board (UL 509)
D 50 D 51
D 48
D 47
D 53
D 52
D 49
D 69 D 63
D 61
D 57 D 54
D 62
D 59
D 55
D 56
D 71
D 64
D 65
D 70 D 66
D 60 D 67
D 68 D 58
Fig. 8: Keyboard and Display board
3.16 SM-16-XX-XX.03 ENG

Keyboard and Display Board UL 509 96-410-703
D 47 CPU board connection
Patient circuits
D 48 7-segment “Actual temp.” display
D 49 7-segment “Set temp.” display
D 50 LED alarm
D 51 Fill level LEDs
D 52 “Start/Stop Circuit 1” key
D 53 “Start/Stop circuit 2” key
D 54 “Standby” key
D 55 “Raise set temperature” key
D 56 “Lower set temperature” key
Patient circuit
D 57 7-segment “Actual temp.” display (warm tank)
D 58 7-segment “Set temp.” display (warm tank)
D 59 7-segment “Actual temp.” display (cold tank)
D 60 7-segment “Set temp.” display (cold tank)
D 61 LED alarm (warm tank)
D 62 LED alarm (cold tank)
D 63 Fill level LEDs
D 64 “Standby” key
D 65 “Raise set temperature” key (warm tank)
D 66 “Lower set temperature” key (warm tank)
D 67 “Raise set temperature” key (cold tank)
D 68 “Lower set temperature” key (cold tank)
D 69 “Start/Stop circuit” key (warm tank)
D 70 “Start/Stop circuit” key (cold tank)
All circuits
D 71 “Audio alarm off” key
SM-16-XX-XX.03 ENG 3.17

Distributor Board (UL 510)
D 85
D 72
D 84
D 83
D 82
D 81
D 73
D 80 D 74
D 75
D 79
D 76
D 77
D 78
Fig. 9: Distributor board
3.18 SM-16-XX-XX.03 ENG

Distributor Board UL 510 96-410-704
D 72 24 V DC input X 21
D 73 24 V DC connection for small fans X 70
D 74 Pump connection for patient tank 2 X 68
D 75 Stirring mechanism connection for the patient X 69

tank
D 76 Level pc board connection for the patient tank X 42
D 77 CPU board connection X 23
D 78 Pump connection for patient tank 1 X 67
D 79 Pump connection for the cardioplegia cold tank X 72
D 80 Magnetic valve connection for cardioplegia X 73

tanks (on the valve block, to equalise the tem-
perature)
D 81 Magnetic valve LED for the cardioplegia tank H1

on = valve open
D 82 Stepping motor connection for the cardioplegia X 75

cold tank
D 83 Stepping motor connection for the cardioplegia X 74

warm tank
D 84 Pump connection for the cardioplegia warm tank X 71
D 85 Level pc board connection for cardioplegia tanks X 25
SM-16-XX-XX.03 ENG 3.19

Level Board (UL 459)
D 87
D 86
D 88
Fig. 10: Level Board and Float
Level Board UL 459 96-410-705
D 86 Distributor board connection X1
D 87 Hall sensors
D 88 Floats (complete)
3.20 SM-16-XX-XX.03 ENG

3.2.7 Functional Diagram of the Valve Block
Both pumps in the cardioplegia circuit run provided the circuit is not switched to Standby
mode. The valve block controls the flow of water (warm c-plegia, cold c-plegia or Off).
Cold C-Plegia
B 18
B 19
B 22
B 21
B 20
Fig. 11: Sectional view of the valve block (cold c-plegia)
B 18 Valve block outlet
B 19 Valve block inlet
B 20 Inlet from the pump for the cold tank
B 21 Outlet to the pump for the cold tank
B 22 Slide valve for the cold tank
Starting the cardioplegia cooling circuit (on the Heater-Cooler control panel) opens the slide
valve B 22, which is driven by the relevant stepping motor
◗ The water now flows Pump B 1 see Fig. 2:

➜ from the pump’s pressure chamber B 1 “Overview of the mod-
➜ via the inlet B 20 and the open channel ules in the patient cir-
cuits” on page 3.4
➜ to the outlet B 18 of the valve block.
◗ The reflux water flows
➜ from the inlet B 19 and the reflux channel, which is also open,
➜ via the outlet B 21 directly to the pump’s suction chamber B 1.
SM-16-XX-XX.03 ENG 3.21

Warm C-Plegia
B 25 B 24 B 18
B 19
B 23
Fig. 12: Sectional view of the valve block (warm c-plegia)
B 23 Inlet from the pump for the warm tank
B 24 Outlet to the pump for the warm tank
B 25 Slide valve for the warm tank
Starting the cardioplegia heating circuit opens the slide valve B 25, which is driven by the
relevant stepping motor.
◗ The water now flows Pump B 2 see Fig. 4:

➜ from the pump’s pressure chamber B 2 “Overview of the mod-
➜ via the inlet B 23 and the open channel ules in the cooling unit”
on page 3.8
➜ to the outlet B 18 of the valve block.
◗ The reflux water flows
➜ from the inlet B 19 and the reflux channel, which is also open,
➜ via the outlet B 24 directly to the pump’s suction chamber B 2.
3.22 SM-16-XX-XX.03 ENG

Heater-Cooler System 3T • Service Mode and Software
4 Service Mode and Software

4.1 The Service Mode of the Heater-Cooler System
The Service mode allows you to set and display various system parameters. These include:
◗ Calibrating the temperature sensors

◗ Displaying the fan speed, temperatures, etc.
◗ Basic settings, such as the CAN address, power consumption, etc.
The pumps are deactivated (for the user) in Service mode for safety reasons. To start a pump,
you must therefore exit Service mode.
Note: If you are not completely familiar with the operation of the Heater-Cooler System 3T, you
will find all the necessary information in the separate operating instructions.

4.1.1 Calling Service Mode
Before you start the Service Mode:

◗ Exit any Standby mode you may have activated (i.e. both control panels must be ready).
◗ Switch off any active circuits.
◗ Do not press any keys apart from those mentioned below while activating the Service mode.
The Service mode can be called by entering a special key combination on the patient circuit
control panel.
5 °C 37 °C 37.6 °C
1 2
20 °C 20 °C 20.1 °C
b c d
Fig. 13: Calling the Service menu
Starting Service mode

◗ Press and hold down the “Standby” key d.
◗ Also, press and hold down the “Lower set temperature” b and “Raise set temperature”
c arrow keys.
◗ Then release the “Standby” key.

◗ Keep pressing the arrow keys.
➜ After around 5 seconds, all the displays flash (except for “Set temp. patient circuits” a).
➜ The “Set temp. patient circuits” a now shows “(al”
➜ Service mode is now activated.
➜ Now, release the arrow keys.

Working in Service mode

In Service mode, menu functions and parameters are displayed on the 7-segment “Set
temp.” display a. The other 7-segment displays flash while Service mode is active.
The “Standby” d, “Lower set temperature” b and “Raise set temperature” c keys on the
Heater-Cooler are redefined as follows in Service mode:
◗ d “Select/Enter” key
➜ Use this key to activate the currently displayed menu function or
➜ to confirm an entry or selection using the up/down arrow keys.
◗ b “Up Arrow” und c “Down Arrow” key

➜ Use this key to choose the function you want in a menu or
➜ to change the displayed parameters.
Note: Some menu functions have a timeout, which prevents them from being pressed
inadvertently. To activate these menu functions, press and hold down the Select/Enter key
for at least 3 seconds.
Exiting Service mode

The main menu for the Service mode contains a command that allows you to exit Service
mode. The Heater-Cooler is then ready for normal operation. If a person who is not qualified
for service activities inadvertently activates the Service mode, you can exit this mode by
powering down the Heater-Cooler and then powering it up again.
Please note that changes you make to individual parameters are only retained permanently
if they are written to EEPROM using the relevant function (bAC). Otherwise, the Heater-
Cooler reverts to the last saved status the next time you power it down and then up again.
!

4.1.2 Overview of the Service Menu
The Service menu, as shown below, is divided into a number of individual menus.
(AL (d
Calibration 1 Set Defaults 2
End End
(XA
Change (Basic Setup) 3
End
SX0
Show Values 4
End
Main
I0 coo
I/O Check 5 Check Cooling Unit 6
End End
Backup
bA( (Save to EEPROM)
Restore
rES (from EEPROM)
Defaults
dEf
Fig. 14: Overview of the Service menu

Menu 0: “Start” menu
Function
➜ “Calibrate menu” See “Calibrating the

(AL You can calibrate the temperature sensors for the control and safety Temperature Sen-
sors” on page 4.11.
system in this menuPlease note the sequence of the individual
calibrations specified at the corresponding position.
➜ “Change menu”
(XA This menu contains all the basic settings for configuring the Heater-
Cooler (e.g. CAN address, max. power consumption, etc.).
➜ “Show menu”
SX0 You can display currently entered measurement values
(temperatures, fan speed) in this menu.
➜ “I/O menu”
I0 This menu allows you to control all the functions of the cooling unit
manually (magnetic valves, condensers, etc.).
“Backup”
bA( Back up currently set parameters in EEPROM. Use this command to
store a permanent backup of correctly implemented settings.
“Done“
don Display when parameters are successfully saved.
“Restore”
rES Read stored parameters from EEPROM. Use this command to reset
incorrect or experimental settings to the last stored value.
“Defaults”
dEf Load the factory settings for standard parameters and required
values. Use this command for every software update in order to
activate any parameters that may have changed. Then, store the
newly loaded parameters in EEPROM using the “bAC” command.
➜ End of Service mode, normal operation

End

Menu 1: Calibrate menu
Function
➜ Default calibration (resetting each calibration setting individually)
(d
calibrate H/C (patient tank) control system,
(X lower measurement point (5 AC)
Calibration of lower measurement point complete
(Xv
calibrate H/C (patient tank) control system,
(X upper measurement point (40 AC)
Calibration of upper measurement point complete
(X
calibrate warm c-plegia, control system (40 AC)
(h
calibrate cold c-plegia, control system (10 AC)
(c
calibrate sensors on the condenser
((o
calibrate H/C (patient tank), safety system (40 AC)
(SX
calibrate warm c-plegia, safety system (40 AC)
(Sh
calibrate cold c-plegia, safety system (10 AC)
(Sc
➜ back to “Cal”
End

Menu 2: Calibrate Default menu
Default values for H/C (patient tank), control system

dX
Default values for warm c-plegia, control system
dh
Default values for cold c-plegia, control system
dc
Default values for sensors on the condenser
d(o
Default values for H/C (patient tank), safety system
dSX
Default values for warm c-plegia, safety system
dSh
Default values for cold c-plegia, safety system
dSc
Default values for all temperature sensors
dAL
➜ back to “Cd”
End
Menu 3: Change menu (basic settings)
Parameters to be changed
FrE
Specification of mains frequency (from software version V2.06):
➜ 50/60 Hz
CAN device address: 0/1 for operating a number of similar devices on
Adr a Stöckert Heart-Lung machine
Required H/C temperature (patient tank) for calibration
SX
Maximum power consumption
(vr
H/C (patient tank) standby: On/Off
01X
Volume configuration:
U0L ➜ 9 litres = 10
➜ 6 litres = 0
Pump selection:
Pv PWM = 0 (old pump), Frequency = 1 (new pump)
Hyst. cooler, cold c-plegia
Xc
Hyst. cooler, economy range
XXE
Hyst. cooler, other range
XX

Menu 3: Change menu (basic settings) Continued
Parameters to be changed
H/C (patient tank), control parameter 0
rX0
rX1
rX2
rX3
rX4
rX5
rX6
rX7
H/C (patient tank), control parameter 7 (from software version V2.06)
rh0
Warm c-plegia, control parameter 0
rh1
rh2
rh3
rh4
rh5
rh6
rh7
Warm c-plegia, control parameter 7 (from software version V2.06)

Menu 3: Change menu (basic settings) Continued
rc0
Cold c-plegia, control parameter 0
rc1
rc2
rc3
rc4
rc5
rc6
rc7
Cold c-plegia, control parameter 7 (from software version V2.06)
➜ back to “CHA”
End
Menu 4: Show Values menu
current power consumption from mains

IEF
Control system sensor temperature in H/C (patient tank)
tX
Safety system sensor temperature in H/C (patient tank)
tSX
Control system sensor temperature for warm c-plegia
th
Safety system sensor temperature for warm c-plegia
tSh
Control system sensor temperature for cold c-plegia
tc
Safety system sensor temperature for cold c-plegia
tSc
Liquefier temperature
t(o
Fan speed on the liquefier (x 100)
n(o
➜ back to “SHO”
End

Menu 5: I/O Check
➜ Service Cooler (menu 6)

coo Controlling the cooling unit manually
➜ back to “IO”
End
Menu 6: Test Cooling Unit
Function
Compressor On/Off
P
H/C magnetic valve (patient tank) On/Off
UX
Cold c-plegia magnetic valve On/Off
Uc
Fan Off (0), Normal (1), Max. (2)
Fon
➜ back to “coo”
End
4.10 SM-16-XX-XX.03 ENG

4.2 Calibrating the Temperature Sensors
Fig. 15: Openings for reference sensors
The openings for the reference sensors are located at the positions marked with arrows. When
inserting the sensors, make sure not to inadvertently push the plastic caps into the tanks (by
using too much force).
SM-16-XX-XX.03 ENG 4.11

4.2.1 Preparing for Calibration
To calibrate the temperature sensors, you need a suitable reference thermometer and a
corresponding temperature sensor.
◗ Power on the Heater-Cooler (with the lid open) and set the following required temperature
values:
➜ Cardioplegia cold tank 5 AC
➜ Cardioplegia warm tank 40 AC
➜ Patient tank (H/C) 40 AC
◗ Wait until the heat-up process is complete.
4.12 SM-16-XX-XX.03 ENG

4.2.2 Calibrating
Calibrating the Temperature Sensors in the Patient Tank
◗ Insert the reference thermometer into the patient tank.

◗ Open the Service menu and choose menu 1 “CAL”.
Calibrate the safety system first.

(SX
Enter the value shown on the reference thermometer using the arrow
keys. Confirm your entry by pressing “Enter”.
Then calibrate the control system’s upper measurement point.

(X
keys.
Confirm your entry by pressing “Enter”. The display indicates that

(X the calibration of the upper measurement point is complete.
➜ Go back to menu 0.
End
➜ Switch to menu 3.
(XA
Enter the required temperature value of 5 AC.
SX
➜ Go back to menu 0.
End
➜ Switch to menu 1 (Calibrate) again and wait until the cooling-down
(AL process is complete.
Then calibrate the control system’s lower measurement point.

(X
keys.
Confirm your entry by pressing “Enter”. The display indicates that

(Xv the calibration of the lower measurement point is complete.
or
(Xo
The temperature sensors in the patient tank are now calibrated.
SM-16-XX-XX.03 ENG 4.13

Calibrating Temperature Sensors in the Cardioplegia Tanks
Insert the reference thermometer into the cardioplegia warm tank.
Calibrate the warm tank’s safety system (40 AC).

(Sh
Calibrate the warm tank’s control system (40 AC).

(h
Insert the reference thermometer into the cardioplegia cold tank.
Calibrate the cold tank’s safety system (5 AC).

(Sc
Calibrate the cold tank’s control system (5 AC).

(c
➜ back to menu 0
End
Save the calibration.
bA(
➜ Calibration successfully saved.
don
➜ Exit the Service Menu.
End
The calibration process is now complete. Compare all the displays on the Heater-Cooler with
the display on the reference thermometer again.
4.14 SM-16-XX-XX.03 ENG

4.3 Software Update
The installed software version of the Heater/Cooler will be displayed in the "Set Temperature"
display of the patient tank during the self-test performed upon powering up.The Heater-Cooler
software comprises two parts:
◗ The kernel, which is created in the Heater-Cooler’s Flash program memory and provides the
CPU’s basic communication capability with the update software. As a rule, the kernel
(unlike the operating software) is not reloaded or updated.
◗ The actual operating software of the Heater-Cooler System. This is loaded via the serial
interface (RS232) of the CPU board. An update software package (Updater) for Windows is
available for this purpose.
You need the following to carry out the programming:
For every software update:

◗ A PC or laptop with the Microsoft® Windows operating system (a program version of the
update program is available for Windows 95/98/NT and a version for Windows 2000/ME).
◗ A serial cable (9-pin D-Sub, 1:1 wiring, no null modem cable).
◗ The current version of the update program (Updater.exe/Updater.msi).
◗ The current version of the operating software, consisting of 2 files with the file name
extension “*.a20” (e.g. HP_R108.a20). One of these files contains the software for the
control system, while the other contains the software for the safety system.
To load the Flash kernel, you also need:

◗ the programming adapter (see Fig. 17: “Programming adapter connection” on page 4.17).
◗ The current version of the Flash program (Flash.exe)
◗ The current version of the Flash kernel, consisting of one file with the file name extension
“*.a20” (e.g. KHP_15.a20).
Important Programming Information:
!
Always take the time to read the “ReadMe” files supplied on the software diskettes! These files
always contain the latest information on installing and using the update software as well as
information about the update files.
!
Please make sure that you only use update files belonging to the Heater-Cooler System 3T. You
will recognise the correct files by their file names. The names of the update files created as
follows:
Operating software: [device type] _ [controller] [version number] . [extension]

Flash kernel : K [device type] _ [version number] . [extension]
◗ The device type must be either “HP” (for the German “Hypothermie-/Plegiegerät”, meaning
Heater-Cooler/Plegia System) or “HPU” (for “Heater-Cooler/Plegia System, USA version”).
◗ The letter under controller indicates either the control system (R) or the safety system (S).
◗ The version number is either a three-digit number (operating software, e.g. 108 for version
1.08) or a two-digit number (Flash kernel, e.g. 11 for version 1.1), always without the point.
◗ The file name extension is always *.a20.
SM-16-XX-XX.03 ENG 4.15

4.3.1 Preparing for Programming
D4
Fig. 16: Accessing the system electronics
◗ Power off the Heater-Cooler and open the lid (see chap. 6.1.1 on page 6.2)
◗ To access the CPU board D 4, remove the plate covering the system electronics.
4.16 SM-16-XX-XX.03 ENG

4.3.2 Programming
Loading the Flash Kernel
As mentioned earlier in the previous section, this step is only necessary in the following cases:
◗ The Heater-Cooler is part of a product batch that does not yet have a Flash kernel,
◗ the kernel has to be loaded because a pc board was replaced or
◗ there is a service instruction to update the kernel.
Only the operating software needs to be updated in all other cases.
B
A
Fig. 17: Programming adapter connection
!
Please note the sequence of the descriptions given below!
On the CPU board:

◗ Connect the programming adapter (with the Heater-Cooler powered off):
➜ Connect “Control/D6” to the connection D 34 (X81)
➜ Connect “Safety/D2” to the connection D 38 (X83)
◗ Leave the serial cable plugged out!
On the programming adapter

(the next setting is used for programming the control system):
◗ Move switch A to the “PGM” setting.
◗ Move switch B (safety) to the “Reset” setting.
◗ Move switch C (control) to the “Run” setting.
SM-16-XX-XX.03 ENG 4.17

On the computer:
◗ Start the “Flash.exe” program.
◗ Select the command Connect }> Boot }> Connect }> OK in the Command menu.
◗ You get an error message regarding failed communication. Confirm this by pressing OK.
On the Heater-Cooler:
◗ Connect the serial cable to the RS232 interface.
◗ Power on the Heater-Cooler.
On the computer:
◗ Click Open in the File menu. Select the current Flash kernel file (e.g. “khp_11.a20”) in the
next file selection dialog box.
◗ Select the command Connect }> Boot }> Connect }> OK in the Command menu.
◗ Use Command }> Change Baud }> 38400 }> OK to change the speed of the serial interface.
◗ Choose the Program Flash command in the Command menu. Confirm the start of the
programming operation by clicking OK.
◗ Wait until the display indicates that the programming operation is finished.
◗ Choose the Disconnect command in the Command menu.

(the next setting is used for programming the safety system):
◗ Move switch B (safety) to the “Run” setting.
◗ Move switch C (control) to the “Reset” setting.
On the computer:
◗ Select the command Connect }> Boot }> Connect in the Command menu and confirm your
selection with OK.
◗ Choose the Program Flash command in the Command menu. Confirm the start of the
programming operation by clicking OK.
◗ Wait until the display indicates that the programming operation is finished.
◗ Choose the Disconnect command in the Command menu.

◗ Move switch B (safety) to the “Reset” setting.
◗ Move switch A to the “Run” setting.
◗ Move both switch B (safety) and switch C (control) to the “Run” setting at the same time.
The Flash kernel is now programmed and the Heater-Cooler starts. Remove the programming
adapter and continue updating the operating software.
4.18 SM-16-XX-XX.03 ENG

Updating the Operating Software
Updating the operating software (in contrast to loading the Flash kernel) is one of the routine
service tasks.
Install the update software on your PC, if you have not already done this, and copy the update
files into the desired folder. The default path in the “Updater” program is:
Programs\Updater\Data. Of course, you can define any other folder, which you must then
select when you start the program.
!
Make sure that both update files have the same version number. Otherwise, you cannot
perform an update!
Fig. 18: Serial cable connection
On the Heater-Cooler:
◗ Connect the serial cable to the RS232 interface.
◗ Power on the Heater-Cooler (if you have not already done so).
SM-16-XX-XX.03 ENG 4.19

On the computer
Fig. 19: Update program
◗ Start the “Updater.exe” update program.

◗ Click Start Update.
◗ Select the first file to be transferred (e.g. HP_R108.a20) in the next file selection dialog box.
Start the update operation by clicking OK.
◗ The second related file (e.g. HP_S108.a20) is then selected and transferred automatically.
◗ Wait until the transfer is complete and leave the device switched on. The Heater-Cooler
restarts automatically following a successful update.
◗ Exit the update program and disconnect the serial cable.
4.20 SM-16-XX-XX.03 ENG

Heater-Cooler System 3T • Error Messages and Error Diagnosis
5 Error Messages and Error

Diagnosis
The Heater-Cooler is subjected to continual monitoring by the control and safety system. Errors
that occur (e.g. a component breaks down) are displayed as E(rror) codes on the 7-segment
displays.
5.1 Error Messages
Error Description Corrective Measures

Display is Defective fuse D 31 (F3) on the “Mains” – Replace the fuse.
dark printed circuit board
Defective mains transformer – Replace the mains transformer.
Defective power pack – Replace the “Mains” board.
Ring main to the display drivers defective – Replace the “Display” board. See also E37
– Replace the “CPU” board.

Control system is no longer working – Replace the “CPU” board. See also E44
E00 Short circuit: – Eliminate the short circuit.

Temperature sensors, control system, – Replace the temperature sensors.
warm c-plegia/cold c-plegia/patient tank – Replace the “CPU” board.
E01 Interruption: – Eliminate the interruption.
Temperature sensors, control system, – Replace the temperature sensors.
E02 Short circuit: – Eliminate the short circuit
Temperature sensors, safety system, – Replace the temperature sensors.
Temperature sensors, safety system, – Replace the temperature sensors.
E04 The temperature difference of the – Calibrate both temperature sensors.
temperature sensors in the control/safety – Replace the temperature sensors.
system is too big, – Replace the “CPU” board.
warm c-plegia/cold c-plegia/patient tank


E05 Pump 1 (in the patient circuit: stirring – Check the plug-in connections (pump
mechanism) will not start (does not take in and “Distributor” board).
enough power) – Make the stirring mechanism or pump
warm c-plegia/cold c-plegia/patient tank easier on power/clean or replace them,
if necessary.
– Replace the “Distributor” board.
E06 Pump 1 uses too much power – Check the plug-in connections (pump
warm c-plegia/cold c-plegia/patient tank and “Distributor” board).
– Make the stirring mechanism or pump
easier on power/clean or replace them,
if necessary.
E07 Pump 1 is blocked (too slow) – Clean the pump or stirring mechanism.
warm c-plegia/cold c-plegia/patient tank – Replace the pump or stirring
mechanism.
E08 Pump 1 is not immersed in liquid – Check or replace the floats.
– Top up the water.
There is still air in the external circuit – Wait until the circuit removes the air
automatically.
Incorrect pump configuration – Service menu:
➜ “CHA” (menu 3)
➜ Enter the “Pu” correctly
➜ Store using “bAC”
E09 The set temperatures of the control system – Change the set temperature.
and safety system are not identical – Power the system down/up.
E16 Pump 2 is not working – Check the plug-in connections (pump
(if this is in the patient circuit: Circuit 1) and “Distributor” board).
– Incorrect pump configuration, Service
menu:
➜ Enter the “Pu” correctly.
➜ Store using “bAC”.
– Clean or replace the pump.
(if this is in the patient circuit: Circuit 1) and “Distributor” board).
– Replace the pump.
E18 Pump 2 is blocked – Clean the pump.
(if this is in the patient circuit: Circuit 1) – Replace the pump.
E19 Pump 2 is not immersed in liquid (if this is – Check the floats.
in the patient circuit: Circuit 1) – Top up the water.
automatically.

E20 Pump 3 is not working – Check the plug-in connections (pump

(patient circuit: Circuit 2) and “Distributor” board).
– Incorrect pump configuration, Service
menu:
➜ Store using “bAC”.
– Clean or replace the pump.
(patient circuit: Circuit 2) and “Distributor” board).
– Replace the pump.
E22 Pump 3 is blocked – Clean the pump.
(patient circuit: Circuit 2) – Replace the pump.
E23 Pump 3 is not immersed in liquid (patient – Check the floats.
circuit: Circuit 2) – Top up the water.
automatically.


E24 Short circuit: – Eliminate the short circuit.
Temperature sensors on the liquefier – Replace the temperature sensors.
Temperature sensors on the liquefier – Replace the temperature sensors.
E26 Cooler: defective fan
– Fan: defective motor
– Fan is not running or is too – Replace the fan.
slow
– Fan voltage ≥ mains voltage
– Hardware activation: error (e.g. triac)
– Fan is not running or is too – Replace the Mains board.
slow
– Fan voltage < mains voltage
– No/ or incorrect speed checkback: (e.g.
Hall sensor)
– Defective Hall sensor – Check Hall sensor connection, replace
– Fan speed too high Hall sensor if necessary
(1300 ... 1500 rpm) – Check connection/magnet position
E27 Cooler: – Wait, allow the cooler to cool down.
Press switch tripped – Clean the liquefier.
– Reset the machine (heat
accumulation).
– Check the fan.
– Check the press switch.
E28 Cooler: – Wait, allow the cooler to cool down.
Excess temperature switch tripped – Clean the liquefier.
(Klixon, in the condenser’s junction box) – Reset the machine (heat
accumulation).
– Check the fan.
– Check the line voltage.
– Check the supply frequency.
E29 Start test: Key hangs because it is – Replace the “Display” board.
defective
Start test: Key hangs because the foil – Replace the “Display” board.
exerts too much pressure – Replace the metal frame.
E30 Safety system: Program run error – Check supply voltage for disturbances
Communication problems between the – Check supply frequency
control and safety systems – Check emergency power supply system
– Check “CPU” circuit board, replace
“CPU” circuit board if necessary (REV
UL508k or later)
– Check software, update software if
necessary (software version V2.06 or
later)

E31 Start test: No supply synchronisation – Check the line voltage for faults.
possible – Check the supply frequency.
E32 EEPROM module: – Replace the “CPU” board.
Defective or cannot be accessed
E33 Start test (control system): – Calibrate at least 1 of the temperature
Data in the EEPROM is defective sensors in the control system, load the
factory settings (dEF), store the
changes (bAC) and power the machine
down/up.


E34 Start test (safety system): Data in the – Calibrate at least 1 of the temperature
EEPROM is defective sensors in the safety system and power
the machine down/up.
E35 Safety system: EEPROM write test failed – Power the system down/up.
Calibrate at least 1 of the temperature
sensors in the safety system and power
the machine down/up again.
E36 Start test: Cannot access CAN controller – Replace the “CPU” board.
E37 Start test: Cannot access display drivers – Check the plug-in connection.
– Replace the “Display” board.
– Replace the “Mains” board
E38 Start test (control system): – Replace the “CPU” board.
ROM checksum error
E39 Start test (control system):
RAM error
E40 Start test (control system):
CPU error
E41 Start test (safety system):
ROM checksum error
RAM error
CPU error
E44 Safety system: Control system does not – Replace the “CPU” board.
respond
E45 Safety system: 5 V control system not – Replace the “Mains” board.
within the tolerated range – Replace the “CPU” board.
E46 Control system: Safety system does not – Replace the “CPU” board.
respond
E47 Control system: 5 V safety system is not – Replace the “Mains” board.
within the tolerated range – Replace the “CPU” board.
E48 Start test: All relays and triacs are open, – Check the line voltage and the supply
current too high frequency, replace the “Mains” board,
if necessary.
– Check the fan.
– Check and replace the transformer.


E49 Start test (warm c-plegia): – Check the line voltage, replace the
Relay does not open “Mains” board, if necessary.
E50 Start test (warm c-plegia):
Triac does not open
E51 Start test (warm c-plegia):
Relay or triac does not close
Start test for warm c-plegia heating – Check the warm c-plegia heaters (by
interrupted measuring the resistance) and replace
them if necessary.
E52 Start test (warm c-plegia): – Check the warm c-plegia heaters (by
Heating uses too much power measuring the resistance) and replace
them if necessary.
E53 Start test (patient tank): – Check the line voltage, replace the
Relay does not open “Mains” board, if necessary.
E54 Start test (patient tank):
Triac 1 does not open
Relay or triac 1 does not close
Start test (patient tank): – Check the heaters in patient tank 1 (by
Heating process 1 interrupted measuring the resistance) and replace
them if necessary.
E56 Start test (patient tank): – Check the heaters in patient tank 1 (by
Heating process 1 uses too much power measuring the resistance) and replace
them if necessary.
E57 Start test (patient tank): – Check the line voltage, replace the
Triac 2 does not open “Mains” board, if necessary.
Relay or triac 2 does not close
Start test (patient tank): – Check the heaters in patient tank 2 (by
Heating process 2 interrupted measuring the resistance) and replace
them if necessary.
E59 Start test (patient tank): – Check the heaters in patient tank 2 (by
Heating process 2 uses too much power measuring the resistance) and replace
them if necessary.
Pumps operate with a continually – Incorrect pump configuration, Service

fluctuating rotational speed menu:
– Store using “bAC”.

5.2 Error Diagnosis on the Cooling Unit
Repairs to the cooling unit, particularly in the coolant circuit, cannot be carried out as part of an
on-site service. Mobile service personnel cannot check either the pressure in the system or the
water-tightness. As a result, the cooling unit can only be replaced as a complete unit. The next
section provides an overview of possible error sources so that you can correct minor errors
yourself (e.g. problems caused by dirt and dust) or so that you can at least locate the error
accurately.
C8
C5 C7
C 10
C9
C3 C2 C4
Fig. 20: Error diagnosis on the cooling unit

Description of the Error Possible Causes

Generally reduced cooling capacity ➜ The condenser is dirty
➜ Heat accumulation (installation site)
➜ Defective fan
➜ Magnetic valve does not open
➜ Expansion valve moved
➜ Control error
Test Options
C5 Liquefier temperature
(Service menu <SHO>, Parameter <tCo>):
Normally around 10-20 K above the
ambient temperature for compressor
operation.
➜ The condenser is dirty
– If the temperature is higher: ➜ Heat accumulation (installation site)
➜ Fan is defective
➜ Magnetic valve does not open

– If the liquefier temperature = ambient ➜ Loss of coolant
temperature:
C2 Compressor temperature
Normally hand-hot... in other words:
– If cold, wet (dew) or frosty: ➜ Expansion valve moved

C3 Hot-gas line temperature
(compressor outlet):
Normally around 50-70AC for compressor
operation and approx. 15 K above the
liquefier temperature.
– If the temperature is higher: ➜ The condenser is dirty

➜ Heat accumulation (installation site)
➜ Defective fan
➜ Possible loss of coolant
– If cold (ambient temperature): ➜ Defective compressor

C4 Suction pipe temperature
(compressor inlet, insulated pipe):
Temperature is about 1-4 K below the
temperature of the tempered tank for
compressor operation.
➜ Expansion valve moved
– If the temperature is different:

C5 Temperature of individual components

C7 for compressor operation:
C8 The temperatures of the filter drier,
C9 magnetic valves, collectors and liquefiers
C 10 are around 10 – 20 K above the ambient
temperature.
– If cold: ➜ Component is clogged
5.10 SM-16-XX-XX.03 ENG

Heater-Cooler System 3T • Replacing Modules and Components
6 Replacing Modules and

Components
6.1 Accessing the Modules
The Heater-Cooler System 3T can be opened at several places to facilitate easy access to all the
modules.
◗ Opening the hinged cover allows you to access

➜ all the printed circuit boards that make up the system electronics (having first removed
the cover plate),
➜ the pumps and
➜ the valve block.
◗ Opening the right-hand panel allows you to access

➜ parts of the cooling unit (magnetic valves, expansion valves, collector, filter drier) and
➜ the water tank’s overflow outlet (6/9-litre configuration).
◗ Opening the left-hand panel allows you to access

➜ the power supply connections,
➜ the fan connections and
➜ parts of the cooling unit (compressor).
◗ Opening the back panel allows you to access

➜ parts of the cooling circuit (compressor, expansion valves).

6.1.1 Opening the Heater-Cooler
Opening the Cover
Fig. 21: Opening the Heater-Cooler (1)
To open the cover:
◗ Unscrew the six screws at the top of the side panels.

◗ Hold the back of the cover and lift it forward carefully.
◗ Hold the cover until it is in the required position (90°, see Fig. 21:).

Opening the Side Panels and the Back Panel
To open the side panels:
◗ Unscrew the remaining three screws and remove the side panel carefully.

Opening the rear panel will be performed using one of two different methods, depending on the
date of manufacture.
Equipment manufactured prior to 2002
◗ The venting valves of the patient circuits can be removed as follows:

As the venting valves have been mounted using an adhesive sealant for safety reasons, use
a hot-air gun to heat the sleeve nut (and thereby the sealant). Twist the venting valve slowly
off the threads of the outlet The adhesive sealant is still very stiff. Removing the valve
quickly could damage the threads of the outlet.
◗ Disconnect the wiring of the small fan.
◗ Remove the six screws holding the rear panel in place, and then carefully remove the rear
panel.

Equipment manufactured since 2002
Heater/Coolers manufactured since 2002 are equipped with a two-part rear panel. The venting
valves do not have to be removed in order to remove the rear panel or to remove the patient
tank bridge.
◗ Remove the four screws of the lower rear panel to access the cooling aggregate.
◗ Remove the four screws of the upper rear panel to remove the patient tank bridge.

System Electronics Cover Plate
If you remove the cover plate, you can access the Mains (D 3), CPU (D 4) and Entry/Display
(D 5) pc boards.
Fig. 25: System electronics cover plate

6.2 Tank Bridges, Stirring mechanism and Float
To remove the tank bridges, the top cover must be opened, and: The upper rear panel must be
removed (manufacture dates as of 2002). The venting valves and rear panel must be removed
as described on 6.4 (manufacture dates prior to 2002). Removing the left side panel of the unit
facilitates the removal of the internal tubing of the cardioplegia circuit.
Basically, the tank bridges must be removed in the following cases:

◗ When you replace the stirring mechanism
◗ When you replace or clean float thoroughly
◗ When you replace a heater
You do not need to remove the tank bridges in order to replace a temperature sensor.
Note on replacing pumps:
!
The pumps should not be opened or dismantled on site. The pumps should always be replaced
as complete units as the centring of pump motor, shaft and pump mechanics on site is not
possible.
When ordering a replacement pump, you should always quote the correct type designation, and
mention the installation site (patient tank/cardioplegia tank) so that the tubing set included in
the delivery is correct. The tubing lengths differ depending on the installation site.
Note on replacing the valve block:
!
The valve block should not be opened or dismantled on site. The valve block is always replaced
as a complete unit.

250
366
190
Fig. 26: Support block
If you need to work on the tank bridges, we recommend that you create a support block on
which you can safely place the bridges that you remove without putting pressure on the
heaters, pumps, floats or temperature sensors.

6.2.1 Removing the Tank Bridges
Patient Tank Bridge
Fig. 27: Tank bridge cabling in the patient tank
◗ To dismantle the tank bridge, remove all the plug-in connectors marked with arrows.
◗ Open the cable harnesses, where necessary (e.g. temperature sensor cable).

Fig. 28: Dismantling the patient tank support
◗ Remove all the screws marked with arrows.

◗ Lift the tank bridge out of the tank.
◗ Place the tank bridge you remove on the support block (see Fig. 26: “Support block” on
page 6.8) so as not to damage the components underneath.
6.10 SM-16-XX-XX.03 ENG

Cardioplegia Tank Bridge
Fig. 29: Tank bridge cabling in the cardioplegia tanks
◗ To dismantle the tank bridge, remove all the plug-in connectors marked with arrows.
◗ Open the cable harnesses, where necessary (e.g. temperature sensor cable).
SM-16-XX-XX.03 ENG 6.11

B 13
B 14
Fig. 30: Dismantling the patient tank bridge
◗ Remove all the screws marked with arrows.

◗ Remove the two tube clamps at the inlet and outlet of the cardioplegia circuit.
◗ Heat up the ends of the tubing at the joint using hot air and remove the two tubes.
◗ Lift the tank bridge out of the tank.
◗ Place the tank bridge you remove on the support block (see Fig. 26: “Support block” on
page 6.8) so as not to damage the components underneath.
6.12 SM-16-XX-XX.03 ENG

6.2.2 Removing the Stirring Mechanism
In the interest of clarity, the pumps have been omitted from the illustration.
A 15
A 14 A 13
A 16
A 17
A 17
Fig. 31: Removing the stirring mechanism motor
SM-16-XX-XX.03 ENG 6.13

A 13 Pump motor in the stirring mechanism EM 109 96-410-719
A 14 M4 oval-head screws (Philips) x 16
A 15 A4.3 fan washers
A 16 M3 x 4 set screw DGI 002 96-410-722
A 17 Axle extension HSA 038 96-410-721
A 18 M3 flat-head screws (slit) x 16
The entire stirring mechanism structure comprises two parts that are fixed separately to the
tank bridge:
◗ Motor with shaft

◗ Stirring mechanism (pump chamber) with holding rods
The two parts are connected by the axle extension A 17, secured by two threaded pins. You
must therefore release this connection first before removing the motor.
Removing the motor:
◗ Loosen the two threaded pins A 16 (do not screw them out fully).
◗ Remove the four screws A 14 with the fan washers A 15.
◗ Pull the motor up and out.
Installing a new motor involves the same steps, in reverse order.
Stirring mechanism (removing the pump chamber):
◗ Loosen the two threaded pins A 16 (do not screw them out fully).
◗ Remove the three screws A 18.
◗ Pull the stirring mechanism down.
Installing a new stirring mechanism involves the same steps, in reverse order.
6.14 SM-16-XX-XX.03 ENG

6.2.3 Removing the Floats
A 19
A 20
Fig. 32: Removing floats
A 19 M3 oval-head screws (Philips) x 16
A 20 A3.2 fan washers
◗ Remove the three screws A 19 with the fan washers A 20 on the top of the float socket.
◗ Take off the float components by pulling them up and down.
!
Warning: The magnets a are horizontal to the rod. During assembly, you should ensure that the
rod is inserted into the guide bush in the same direction as before removal!
SM-16-XX-XX.03 ENG 6.15

6.3 Control Panel
D4
D 89
D 90
D5
D 92
D 90
D 91
D 93
D 94
Fig. 33: Dismantling the control panel
6.16 SM-16-XX-XX.03 ENG

D 89 SD8 M4 spacing bolt x 10 ELZ 012
D 90 M4 hexagon nut
D 91 A4.3 fan washer
D 92 Spacer
D 93 Foamed rubber gasket RDP 019
D 94 Front plate HPF 189
To remove the “Keyboard and Display” board:
◗ Unplug all the plug-in connectors from the “CPU” board D 4.

◗ Remove the support brackets for the spacing bolts D 89 by pressing the barbed hooks
together while lifting the board slightly.
◗ Remove the “CPU” board.
◗ Remove the hexagon nuts D 90 and the spacing bolts D 89 that are used to hold the
“Keyboard and Display” D 5 board.
◗ Remove the “Keyboard and Display” board.
To remove the front plate:
◗ Remove the eight hexagon nuts D 90 and fan washers D 91 that are used to secure the front
plate.
◗ Pull the front plate D 94 and the foamed rubber gasket D 93 forward.
To install the front plate and pc board:
Installing the front plate and the board involves the same steps as described above for
removing them, but in the reverse order.
Caution: During installation, screw on all the nuts equally and “gently” (max. 0.4 Nm torque per
nut). Otherwise, the front plate will buckle and apart from looking bad, the key functions may
!
no longer work!
SM-16-XX-XX.03 ENG 6.17

6.18 SM-16-XX-XX.03 ENG

Heater-Cooler System 3T • Appendix
7 Appendix
7.1 Technical Data
7.1.1 Dimensions, Weights, Operating Conditions
Heater-Cooler System
Width 500 mm
Height 840 mm
Depth 550 mm
Weight 101.5 kg
Remote Control Modules

Width 200 mm
Height 55 mm
Depth 35 mm
Weight 0.3 kg
Operating Conditions
Operating Temperature +10 AC … + 35 AC
Storage Temperature 0 AC … + 40 AC
Relative Humidity (Operation and Storage) from 30% to 75%

7.1.2 Electrical Specifications
Heater-Cooler System
Drip-proof IPX1
Input current 16 A
Input voltage Allowed voltage tolerance: ± 10% max.
230 V ~ / 50 Hz
(Max. demand power: 3.6 kW)
240 V ~ / 60 Hz
208 V ~ / 60 Hz
200 V ~ / 50/60 Hz (for Japan)
127 V ~ / 60 Hz (for Mexico)
120 V ~ / 60 Hz
Remote Control Modules
Input voltage 5 VDC via control panel/expansion system
Power consumption max. 3 W

7.1.3 General Performance Data
General Data
Heating Performance (2 x pat., 1 x c-plegia) 3 x 1,250 W (input voltage 230 V ~)
(country-specific) 3 x 1,200 W (input voltage 240 V ~)
3 x 1,000 W (input voltage 208 V ~)
3 x 900 W (input voltage 200 V ~)
Cooling performance 2.1 kW at an ambient and tank temperature
of 20 AC
Noise Level M 56 dB (A)
Volume and Flow

Minimum Fill Level (Patient Circuit) 4.5 l (11.6 l total volume)
Maximum Fill Level (Patient Circuit) 6.5 l (13,8 l total volume)
Water Flow (Patient Circuit) 15 –17 LPM
Water Flow (Cardioplegia Circuit) 9-11 LPM
Water Pressure in the Circuit max. 0.7 bar
min. -0.3 bar
Temperature Ranges
Normal Range (Patient Circuit) from 2 AC to 41 AC
Normal Range (Cardioplegia Cooling from 2 AC to 20 AC
Circuit)
Normal Range (Cardioplegia Heating from 25 AC to 41 AC
Circuit)
7.1.4 Information about Global Warming Potentials
The cooling circuit of the heater-cooler is filled with a CFC-free HFC-(hydrofluorocarbons)

refrigerant. Please see the device label and chapt. 7.2 to obtain further information about the
type and volume of the refrigerant.
Global warming potentials (abbreviation: GWP)

Refrigerant R-134/HFC-134a
The mixture of the refrigerant may vary.
GWP 1,300 GWP (according to IPCCIII (2001/
Appendix I):
baseline data in EU F-gas regulation
Active life span 100 years
according to IPCCII (1996) source document
for the Kyoto protocol

7.2 Labelling and tagging
Symbols:
Attention! Please refer to documentation.
Degree of protection against electrical

shock: type B
IPX1 Drip proof (vertical)
Potential equalization point
Drain valve of the patient circuits,

Drain valve of the cardioplegia circuit
Tagging on the additional label:
This cooling system contains fluorinated This cooling system contains fluorinated
greenhouse gases covered by the Kyoto greenhouse gases covered by the Kyoto
protocol: protocol:
Refrigerant R 134a Refrigerant (R 134a)
(Hydrofluorocarbons)
Filling charge: Filling charge
PS high pressure: PS high pressure
PS low pressure: PS low pressure

7.3 Part Numbers
Heater-Cooler System 3T (various designs):

Heater-Cooler System 3T (220/230/240 V ~ ; 50/60 Hz) 16-02-80
Heater-Cooler System 3T (240 V ~ / 60 Hz) (USA/Canada) 16-02-81
Heater-Cooler System 3T (127 V ~ / 60 Hz) (for Mexico) 16-02-83
Heater-Cooler System 3T (200 V ~ ; 50/60 Hz) (for Japan) 16-02-95
Remote control modules patient circuits 16-30-10

Remote control modules cardioplegia circuit 16-30-20
SC Modular Expansion System (SC MODES) 55-91-00
Accessories
CAN connection cable for the S3/SC System 45-11-01
CAN connection cable for the S5/C5 System 45-12-16
Adapter cable for CAN connection cable 45-12-01 45-12-91
Adapter cable for CAN connection cable 45-12-16 45-12-92
Ice container 16-02-60
Cooling/heating blanket for adults 55 x 150 cm 16-10-50
Cooling/heating blanket for children 55 x 90 cm 16-10-51
Tubing set for cooling/heating blankets 16-10-55
1 set of adapters for cooling/heating blankets 16-10-10
Tubing connector 1/2", 90° angle, with venting valve 16-10-17
Tubing connector 1/2", straight 73-300-19
Optional: Blow valve 16-02-90
Optional: Hansen coupling for oxygenator, straight, 73-300-089
3/8" with 1/2" tubing insert
Optional: Hansen coupling for oxygenator, 90° offset, 73-300-090
Optional: Short-circuit bridge for 3/8" Hansen couplings, 73-300-160
Overflow bottle 96-410-765
Holder for overflow bottle 96-410-766
Telescope mast, complete 16-09-20
Potential equalization cable 5m 45-10-50
Maranon canister (6l) 74-400-607

Micropur MT 10 package of 40 74-400-606
tablets
LimCalc descaler 74-400-605

7.4 Accessories
Compatibility of the Heater-Cooler System 3T with the products listed in the table below has
been tested by SORIN GROUP DEUTSCHLAND GMBH and is thus guaranteed.
The disposables listed must be used in compliance with their separate operating
instructions:
Product Manufacturer
Heating/cooling blanket dim. 55 x 150 cm Cincinnati Sub-Zero
(21.65 x 59.06 in.)
Oxygenator Sorin
Heat exchanger for cardioplegic solutions Sorin
Ice container Sorin
Tubing set/cardioplegia tubing set Sorin
SORIN GROUP DEUTSCHLAND GMBH assumes no responsibility for the use of components
other than those listed above; any other use or combination of use with other
componenents is not covered by our warranty or garantee.

7.5 Part Numbers of Service Components
These part numbers refer to parts and components that are used exclusively for service
purposes.
7.5.1 Housing
Description Number ET number

Fan screen, front HGW388 96-410-759
Wheel, d=125, with brake 73-501-051
Wheel, d=125, without brake 73-501-052
7.5.2 Power Pack

Mains AC board UL 507 96-410-701
Ring core transformer EIT 128 96-410-744
Mains safety switch 18 A EST 102 (230 V) 96-410-748
EST 118 (120 V) 96-410-822
7.5.3 System Electronics

CPU board UL 508 96-410-702
Keyboard and Display board UL 509 96-410-703
Distributor board UL 510 96-410-704
Level pc board UL 459 96-410-705
Hall sensor (on the fan motor) UD 491 96-410-801
Temperature sensor for the condenser US 073 96-410-739
Fan motor for cooling unit, 220 - 240 V EML037 96-410-763

Fan motor for cooling unit, 120 V EML066 96-410-820
Ribbon cable, UL508 <==> UL510 EKS051 96-410-741
Ribbon cable, UL508 <==> UL507 EKS050 96-410-742
Cable, internal for CAN socket RCE125 96-410-819
CAN socket cap 96-410-532

7.5.4 Tank Bridges and Pumps
Patient Circuits

Patient circuit bridge (complete), UD 488-E 96-410-725
(frequency motors)
Patient circuit bridge (complete), UD 488-PE (230 V) 96-410-726
(PWM motors) UD 688 (120 V) 96-410-824
Stirring mechanism (complete) consists of

Stirrer motor EM 109 96-410-719
Stirrer pump head UD 485 96-410-720
Drive shaft extension HSA 038 96-410-721
Set screws M3 x 4 (2 pcs.) DGI 002 96-410-722
Float assembly (mech. complete) HX 339 96-410-710

Heaters UH 176 96-410-743
Heaters, 120V / 600W EH2224 96-410-818
Patient tank temperature sensors ETP 042 96-410-738
Temperature sensors, double, new ETP071 96-410-750
Patient circuit inlet EOA 006 96-410-032
Patient circuit outlet, with ventilation valve 16-02-58
Opening for reference temperature sensors EZV 016 96-410-545
(calibration)
Water drain valve for tank UD084 96-410-800

Cardioplegia Circuit

Cardioplegia circuit bridge (complete), UD 489-E 96-410-730
(frequency motors)
Cardioplegia circuit bridge (complete), UD 489-PE (230 V) 96-410-731
(PWM motors) UD 689 (120 V) 96-410-825
Float assembly (mech. complete) HX 339 96-410-710

Heaters UH 176 96-410-743
Heaters, 120V / 600W EH2224 96-410-818
Cardioplegia tanks temperature sensors ETP 042 96-410-738
Temperature sensors, double, new ETP071 96-410-750
Cardioplegia circuit inlet EOA 006 96-410-032
Cardioplegia circuit outlet, with ventilation 16-02-58
valve
Opening for reference temperature sensors EZV 016 96-410-545
(calibration)
Water drain valve for tank UD084 96-410-800
Magnetic valve for cardioplegia circuit EVZ770 96-410-770
Note on assembling the magnetic valve:
!
Always use the preinstalled holder. Only replace the holder when damaged.

SM-16-XX-XX.03 ENG 7.10
E1
X41 X41
1 x1
2 x2
HYPO
E2 3 x3
Heaters
4 x4
x5 x5
6 x6 X20 X21
x1 1
x2 2
+/– 24VDC
X43 X43
1 x1
E3 2 x2
x3 x3
Heater
4 x4
X20 X20
x1 x1
WARM PLEGIA
x2 x2
x3 x3
x4 x4
x5 x5
x6 x6
for example mains 230 V x7 x7
X44
240 V x8 x8
230 V
220 V
208 V
200 V
127 V
120 V
x9 x9
red blue
0V 0V x10 x10
x11 x11
x12 x12
1
green x13 x13
blue
blue
blue
blue
blue
blue
blue
mains connection
120 V x14 x14

X44 X44 x15 x15
brown
1 x1 x16 x16
127 V 2 x2 x17 x17
white
2
T1 3 x3 x18 x18
200 V 4 x4 x19
black
violet
white
x19
green
brown
yellow
orange 5 x5
208 V x20 x20
6 x6 x21 x21
yellow x7
7 x22 x22
220 V
3 violet
8 x8 x23
x24
x23
x24
green
orange yellow
230 V
x25 x25
white black
20 V/16.5 A 240 V x26 x26
U0=21.25 V x27 x27
4
x28 x28
x29 x29
green
yellow orange
yellow orange
orange
yellow orange
yellow orange
yellow orange
X61 X61 x30 x30
1 x1 x31 x31
2 x2 x32 x32
5
x33 x33
x34
violet
violet
violet
violet
violet
violet
x34
green
x35 x35
x36 x36
x37 x37
6
x38 x38
x39 x39
black
black
black
black
black
black
green
x40 x40
x41 x41
x42
chill
X60 X60 x42
HYPO
x43
7
1 x1 x43
x44 x44
green
brown
brown
brown
brown
brown
brown
2 x2 x45
3 x3 x45
x46 x46
4 x4
x47 x47
8
x48 x48
x49 x49
white
white
white
white
white
white
green
chill
x50 x50
COLD PLEGIA
+/– 24VDC
7.6 Wiring diagrams

7.11 SM-16-XX-XX.03 ENG
X22 X22 X22 X20 X20
A2
x1 x1 x1 x1 x1
x2 x2 x2 x2 x2
x3 x3
A3
x3 x3 x3
x4 x4
+/– 24VDC
x4 x4 x4
x5 x5 x5 x5 x5
x6 x6 x6 x6 x6
x7 x7 x7 x7 x7
x8 x8 x8 x8 x8
x9 x9 x9 x9 x9
x10 x10 x10 x10 x10
x11 x11 x11 x11 x11
CPU WKS/3/P
x12 x12 x12 x12 x12

x13 x13 x13 x13 x13
x14 x14 x14 x14 x14
x15 x15 x15 x15 x15
x16 x16 x16
DISPLAY WKS/3/P
x16 x16
x17 x17 x17 x17 x17
x18 x18 x18 x18 x18
x19 x19 x19 x19 x19
x20 x20 x20 x20 x20
x21 x21 x21 x21 x21
x22 x22 x22 x22 x22
x23 x23 x23 x23 x23
x24 x24 x24 x24 x24
x25 x25 x25 x25 x25
x26 x26 x26 x26 x26
x27 x27 x27 x27 x27
x28 x28 x28 x28 x28
x29 x29 x29 x29 x29
x30 x30 x30 x30 x30
x31 x31
X28 x32 x32
x1 x33 x33
x2 x34 x34
x3 x35 x35
x4 x36 x36
x5 x37 x37
Boot Mode
flash control
x6 x38 x38
x39 x39
X29 x40 x40
x1 x41 x41
x2 x42 x42
x3 x43 x43
x4 x44 x44
x5 x45 x45
Boot Mode
flash safety
x6 x46 x46
X2 x47 x47
x48 x48
x1 x49 x49
x2 x50 x50
x3
x4
x5 X23 X23
x6 x1 x1
RS232
x7 x2 x2
x8 x3 x3
x9 x4 x4
x5 x5
x6 x6
X3 X3 X3 x7 x7
1 1 x1 x8 x8
2 2 x2 x9 x9
CAN
3 3 x3 x10 x10
x11 x11
x12 x12
x13 x13
x14 x14
X64 X64 x15
1 green x15
1 x1 x16 x16
U1
2 brown 2 x2
3 white x17 x17
3 x3 x18
fan speed
x18
x4 x4 x19 x19
x20 x20
x21 x21
x22 x22
X65 X65 x23 x23
1 x1 x24 x24
2 x2 x25 x25
condenser
x26
temperature
B4 x26
x27 x27
X66 x28 x28
x1 x29 x29
x2 x30 x30
x31 x31
x32 x32
white X63 x33 x33
1
white/blue x34
warm
2
x34
B1 red x35 x35
3
control saftey
red/blue x36 x36
4 x37
white x37
5
PLEGIA
white/blue x38 x38
6 x39
red x39
7 x40
red/blue x40
8
cold
x41 x41
B2
x42 x42
x43
control saftey
x43
x44 x44
white X62 x45 x45
1 x46
white/blue x46
2 x47
red x47
3
control
red/blue x48 x48
4 x49 x49
x50 x50
HYPO
B3
saftey
+/– 24VDC
SM-16-XX-XX.03 ENG 7.12
Q1
200 V ... 240 V
X1
A1
L2 (blue) blue 11 20 X40 X40

L1 (brown) grey
green/yellow green/yellow 1 x1
21 22 x2
2
3 x3
4 x4
mains
120 V ... 127 V
NEMA 5-20P
Hospital Grade (transparent)
mains WKS/3/P
X1
Silver (neutral) L2
Brass (hot) Messing L1
green/yellow
Green (grounding)
for example mains
200 V; 50/60 Hz
0V
<T X45 X45
X45
withe 1 1 x1
200 V black
X45
2 2 x2
blue
T2
208 V 3 3 x3
240 V; 60 Hz
127 V; 60 Hz
120 V; 60 Hz
230 V; 60 Hz
220 V; 60 Hz
208 V; 60 Hz
220 V
200 V; 50/60 Hz
230 V; 50/60 Hz
mains connection
220 V/ 230 V/ 240 V; 50 Hz
240 V
1
white
white
white
white
red
brown
yellow
red
3
2
1
black
x4
brown
yellow
X101
blue
blue
blue
blue
M10
200 V ... 240 V
X42 X42
1 x1
2 x2
M11
3 x3
4 x4
x5 x5
6 x6
M10
120 V ... 127 V
X42
1
2
3
M11
4
x5
6
P>
F55
7.13 SM-16-XX-XX.03 ENG
x8
x7
x6
x5
x4
x3
x2
x1
A5
X23 X23
level
X1
X24 X24 x1 x1
x1 x1 x2 x2
x8
x7
x6
x5
x4
x3
x2
x1
x2 x2 x3 x3
x3 x3 x4 x4
x4 x4 x5 x5
x5 x5 x6 x6
A4 splitter WKS/3/P
x6 x6 x7 x7
x7 x7 x8 x8
x8 x8 x9 x9
x10 x10
x11 x11
x12 x12
X67 X67 x13 x13
1 x1 x14 x14
2 x2 x15 x15
M1
M=
3 x3 x16 x16
pump 1
4 x4 x17 x17
x18 x18
x19 x19
X68 X68 x20 x20
1 x1 x21 x21
2 x2 x22 x22
M=
3 x3
M2
x23 x23
4 x4
pump 2
x24 x24
HYPO
x25 x25
X69 X69 x26 x26
1 x1 x27 x27
x28 x28
2 x2 x29
M3
M=
x29
mixer
3 x3 x30 x30
x31 x31
x32 x32
X70 X70 x33 x33
1 x1 x34 x34
x35
M=
x35
fan
M4
2 x2 x36 x36
x37 x37
x38 x38
x39 x39
x40 x40
X71 X71 x41 x41
1 x1 x42 x42
2 x2 x43 x43
M=
M5
warm 3 x3 x44 x44

pump 4 x4 x45 x45
x46 x46
x47 x47
x48 x48
X72 X72 x49 x49
1 x1 x50 x50
2 x2
M= x3
M6
3
cold
pump
4 x4
X73 X73
1 x1
Y1
2 x2
mix
X74 X74
1 x1
2 x2
M
3 x3
M7
warm
4 x4
stepper
X21 X21
x5 x5
PLEGIA
x1 1
x6 x6 x2 2
+/– 24VDC
X75 X75
1 x1
2 x2
M8
3 x3
cold
x4
stepper
4
x5 x5
x6 x6
X25 X25
x1 x1
x2 x2
x3 x3
x4 x4
x5 x5
x6 x6
x7 x7
x8 x8
x8
x7
x6
x5
x4
x3
x2
x1
X1
A6
level
x8
x7
x6
x5
x4
x3
x2
x1
7.14 SM-16-XX-XX.03 ENG

SM-16-XX-XX.03 ENG 7.15

Heater-Cooler System 3T SM-16-XX-XX.03 ENG

Heater cooler-Sorin-3T-Service Manual

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Heater-Cooler System 3T

Copyright © 2002 - 2011

Tel.: +49 - 89 - 32301-0

2.2 Regulations and Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.3 Safety Features of the Heater-Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

3.2 Structure of the Heater-Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

4 Service Mode and Software

4.2 Calibrating the Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.11

4.3 Software Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15

5 Error Messages and Error Diagnosis

5.2 Error Diagnosis on the Cooling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

6 Replacing Modules and Components

6.2 Tank Bridges, Stirring mechanism and Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7

6.3 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16

7.2 Labelling and tagging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.5 Part Numbers of Service Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.6 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

This Service Manual (in addition to the training courses run by

1.1.1 Symbols Used in this Service Manual

! Danger! Failure to pay attention may endanger the patient’s and/or

! Warning! Failure to pay attention may cause damage to the machine

✓ A check list for a quick and safe follow up on whether operational

◗ Primary list (main groups)

➜ Secondary list (subgroups)

SM-16-XX-XX.03 ENG 1.1

1.1.2 The Chapters in this Service Manual

In Chapter... you will find the following information:

1 Introduction ➜ Symbols used in the Service Manual

2 Safety ➜ Important safety instructions for the

3 System Description ➜ A brief description of all the service-

4 Service Mode and Software ➜ Working in Service mode

6 Replacing Modules and Components ➜ Information and instructions for adding

7 Appendix ➜ Technical data on all the components

1.2 SM-16-XX-XX.03 ENG

◗ IEC 60601-1 – Medical Electrical Equipment: General

2.2 Regulations and Safety Instructions

2.2.1 Usage in Accordance with Regulations

SM-16-XX-XX.03 ENG 2.1

2.2.2 General Safety Instructions

◗ The Heater-Cooler must be operated by trained and qualified personnel only.

◗ The Heater-Cooler must not be operated near explosive materials.

◗ If you discover any safety-relevant modifications to the Heater-Cooler or its operating

2.2 SM-16-XX-XX.03 ENG

2.2.3 Operating Safety

◗ Check the actual temperature displays on the Heater-Cooler regularly.

SM-16-XX-XX.03 ENG 2.3

2.2.4 Electrical Safety

◗ Mains power quality should be that of a typical commercial or hospital environment.

2.2.5 Safety Instructions for Routine Maintenance

◗ Routine maintenance work must only be performed by qualified personnel.

◗ Use recommended cleaning agents.

2.2.6 Disposal in accordance with environmental regulations

◗ The cooling circuit of the heater-cooler is filled with a CFC-free HFC-(hydrofluorocarbons)

2.4 SM-16-XX-XX.03 ENG

2.3 Safety Features of the Heater-Cooler System

SM-16-XX-XX.03 ENG 2.5

2.6 SM-16-XX-XX.03 ENG

The Heater-Cooler comprises the following modules:

◗ Patient circuits ➜ 2 pumps for 2 separate circuits

◗ Cardioplegia ➜ 2 pumps for the warm and cold tanks

◗ Cooling unit ➜ Condenser