MR860AEU Technical Manual Rev B May 2011

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HumiGard™

Surgical Humidifier Technical Manual

REF MR860AEU

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Revision

Description of Technical Manual Change

Date Issued

A

First release technical manual

February - 2011

B

Revision to Spare Parts List §17

May - 2011

Note:

This technical manual covers software version 3.0.x, and updated Printed Circuit Board (PCB) set with control

board 347042519 Rev A and power board 347042520 Rev A or later

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1. About this Manual

This manual is intended for qualified service personnel who will perform maintenance and servicing on the

MR860AEU Surgical Humidifier and 900ST100 Adaptor. This manual covers the product specifications and

maintenance schedule, and provides the necessary information required for servicing.

Maintenance procedures should be carried out at regular intervals, as recommended in the maintenance

schedule, to ensure that the humidifier and its accessories are working correctly.

If a fault should occur with the humidifier, follow the troubleshooting guide (Section 14) in order to find the

most likely cause. If the unit requires servicing, make sure the servicing procedures are carefully followed

in order to prevent damage to the humidifier. After service, or as part of the maintenance schedule, a

humidifier performance check should be completed.

Due to the nature of the electronics contained within this humidifier, it is not recommended that the Printed

Circuit Boards (PCBs) are serviced at a component level. Instead, if the PCBs are found to be malfunctioning,

they should be replaced.

For instructions on how to operate the F&P HumiGard™ Surgical Humidification System please refer to the relevant

instructions for use.

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2. Glossary

Adaptor

900ST100 Adaptor is comprised of four components: heater-wire plug, chamber probe,

ambient sensor and humidifier plug.

Humidification chamber

Chamber that holds water used to humidify and warm the insufflation gas.

Chamber set point

The temperature that the humidifier attempts to maintain at the chamber probe port.

Chamber probe

Part of the adaptor which measures the chamber outlet temperature and flow rate of

the gas travelling through the humidified insufflation tube.

Humidified insufflation tube

Tubing used to deliver humidified warm gas for insufflation.

Heater-wire

Wire inside the humidified insufflation tube used to heat the gas.

Heater-wire plug

Part of the adaptor which provides electrical connection from the adaptor to the

humidified insufflation tube heater-wire.

Humidifier plug

Part of the adaptor which provides electrical connection between the humidifier and

the Adaptor.

PCB

Printed Circuit Board.

Thermistor

A temperature sensitive resistor placed inside the chamber probe.

ST310

Laparoscopic Humidification Kit.

RT350

Laparoscopic Humidified Insufflation Kit.

ST300

Open surgery Humidification Kit.

F&P HumiGard™ Surgical

Humidification System

MR860AEU Surgical Humidifier used with one of the consumable kits

(RT350, ST310, ST300) and a 900ST100 Adaptor.

3. Definitions

NOTE: A NOTE provides important information or explanation of procedures or conditions which may otherwise be

misinterpreted or overlooked.

PRECAUTION: A PRECAUTION statement designates the possibility of damage to this or other equipment if a procedure is

not followed exactly.

WARNING: A WARNING statement refers to conditions with a possibility of personal injury if a procedure is not followed

exactly.

4. Intended Use

For use in warming and humidifying surgical insufflation gas.

Laparoscopic Procedures

Intended for patients of all ages undergoing laparoscopic procedures where carbon dioxide (CO2) insufflation gas is used.

Open surgery Procedures

Intended for patients of all ages undergoing open abdominal or cardiothoracic surgical procedures where CO2 insufflation

gas is used.

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5. Warnings

5.1 General Warnings

• The ST310 Laparoscopic Humidification Kit, RT350 Humidified Insufflation Kit and the ST300 Open Surgery

Humidification Kit are intended for single use. Reuse may result in transmission of infectious substances,

interruption of treatment, serious harm or death. Incinerate consumables after use.

• To ensure sterility of the humidified insufflation tube, inspect sterile packaging for damage before use. Discard if

damaged.

• To avoid the risk of electric shock, this equipment must be connected to a mains supply with protective earth.

To avoid excess energy in the output gas do not:

• Use the system with preconditioned CO2 gas.

• Fill the humidification chamber with water in excess of 37 °C.

• Place surgical drapes over the humidified insufflation tube.

• Coil the humidified insufflation tube.

• Do not use gases other than CO2.

5.2 Warnings for Laparoscopic Procedures

• To prevent air embolism, purge the system of air using CO2 before insufflation.

• For safe and effective use do not exceed the insufflator maximum set flow rate (≤ 45 L/min).

• To avoid inaccurate pressure readings on the insufflator, ensure insufflators used are regularly serviced and/or

calibrated according to the manufacturer’s instructions.

5.2.1 ST310 Laparoscopic Humidification Kit Only

• To ensure stable and accurate pressure readings on the insufflator when using the Veress needle, ensure that the

humidification chamber is filled to the recommended water level ~ 180 mL.

5.2.2 RT350 Humidified Insufflation Kit Only

• To ensure stable and accurate pressure readings on the insufflator when using the Veress needle, use the Veress

bypass connector.

• To prevent any pressure fluctuations with the Conmed-Linvatec GS1002 insufflator, use conventional insufflation

tubing for initial creation of pneumoperitoneum when using the Veress needle.

5.3 Warnings For Open Procedures

• To ensure efficient de-airing of the wound only use the system with an approved gas diffuser. The VITA-diffuser™

manufactured by Cardia Innovation AB is approved for use with the ST300 Open Surgery Humidification Kit.

• For correct use of the VITA-diffuser™ refer to the VITA-diffuser™ Instructions for Use

(REF VdBXYYYYMM) or the CarbonVITA™ Instructions for Use (CVBXYYYMM).

• For safe and effective use do not exceed the maximum flow rate (≤ 15 L/min).

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6. General Precautions

To ensure patient safety, optimal therapy and performance:

• Only use accessories approved by Fisher & Paykel Healthcare.

• Do not use the serial port when the humidifier is in patient use as this may cause electromagnetic interference with

other equipment.

• Always disconnect the power supply before servicing. Failure to do so may compromise electrical safety.

• Do not touch the glass tip of the chamber probe or the heater-plate during use or directly after use as this may result

in minor skin burns.

• Do not use the 900ST100 Adaptor if there is visible damage to the adaptor as this may compromise system

performance.

• Do not use the humidification chamber if the seal is not intact or the humidification chamber has been dropped.

Broken seal or cracks may result in water and gas leaks.

• Mount the humidifier so that the heater-plate is on a horizontal plane to prevent water spillage.

• Do not obstruct ventilation slots on the humidifier as this may cause overheating.

• Ensure the 900ST100 Adaptor connectors are dry at all times. Failure to do so may damage the device.

• Operate the F&P HumiGard™ Surgical Humidification System within the recommended operating conditions.

• Connect to output of a source delivering CO2.

• Do not exceed the maximum set flow rate.

• Do not modify the humidifier or accessories.

• Do not use the humidifier in the vicinity of high-frequency surgical apparatus and shortwave or microwave

equipment which adversely affects the humidifier’s function. If this occurs, the humidifier should be removed from

the vicinity of such devices.

• Do not use excessive force when refastening screws and bolts which have been removed during servicing.

• Follow anti-static procedures when servicing this product.

• Fisher & Paykel Healthcare does not currently support connections to the Surgical Humidifier via the serial port for

data-logging purposes.

7. Symbol Definitions

Do not use if package is damaged

C-Tick for EMC

Use sterile water

Caution - Hot Surface

STANDBY/ON Button

Use only carbon dioxide gas

Resistant to vertical falling drips

Peel the sterile bag open in

direction indicated

Do not use oxygen gas

Fragile.

Handle With Care

Excess water in the chamber

Prior to gas flow,

Preheat mode will

heat the water

This Way Up

Correct water level in the chamber

Serial port

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8. Approved Accessories

Using non-approved accessories or spare parts could be unsafe.

Use only the following approved products from your Fisher & Paykel Healthcare supplier:

General Accessories

900ST100 Adaptor

900MR880 Reference Probe

Laparoscopic Accessories

ST310 Laparoscopic Humidification Kit

RT350 Humidified Insufflation Kit

Open Surgery Accessories

ST300 Open Surgery Humidification Kit

VITA-diffuser™ manufactured by Cardia Innovation AB

CarbonVITA™ manufactured by Cardia Innovation AB

VITA-diffuser™ and CarbonVITA™ are registered trademarks of Cardia Innovation AB

NOTE: Accessories may not be available in all countries. Contact your local Fisher & Paykel Healthcare office or distributor

for more information.

9. Device Description

F&P HumiGard™ Surgical Humidifier

Finger-guard:

Prevents touching the

hot heater-plate and

keeps chamber in place

MR860AEU

Temperature display:

Indicates the humidification chamber

outlet temperature when the

temperature display button is pressed

Temperature display

button:

Displays the temperature

on the temperature

display when pressed

Heater-plate:

Heats water to supply

heat and humidity to

the insufflation gas

Standby/ON button:

Toggles the heaterbase between ON and

Standby mode

Operational indicators:

Indicates incorrect

connections, humidity

level and hardware

faults

Adaptor port:

Attaches the adaptor to

the humidifier

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10. Accessory Description

10.1 900ST100 Adaptor

Heater-wire plug:

Provides electrical

connection from

the adaptor to the

humidified insufflation

tube heater wire

Chamber probe:

Measures the chamber

outlet temperature

and flow rate of gas

traveling through the

humidified insufflation

tube

Ambient sensor:

Measures ambient

temperature

Humidifier plug:

Provides electrical

connection between

the humidifier and the

adaptor

10.2 900MR880 Reference Probe

Black plug:

Used to complete

humidifier calibration

check number 2

Grey plug:

Used to complete

humidifier calibration

check number 1

NOTE:

The 900MR880 Reference Probe is to be replaced every three years. Please contact your Fisher & Paykel Healthcare

office or distributor to arrange for the replacement of the probe.

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11. Mode of Operation

The F&P HumiGard™ Surgical Humidification System is used to deliver humidified CO2 to patients undergoing laparoscopic

and open surgery. The gas is passed through a humidification chamber where it is warmed and humidified by the humidifier.

The temperature of the gas is then maintained as it travels along the humidified insufflation tube to the patient.

The F&P HumiGard™ Surgical Humidification System has two heating systems. The first is a heater-plate, which heats

the water contained in the humidification chamber, humidifying the CO2 passing through it. The humidifier monitors the

temperature of the CO2 at the chamber outlet with the chamber probe, and controls the amount of power delivered to the

heater-plate, to maintain the chamber set point. The second heating system is the heater-wire encapsulated within the

humidified insufflation tube. Humidified gas from the humidification chamber travels through the humidified insufflation

tube, where the temperature is maintained to prevent the generated humidity from condensing in the humidified insufflation

tube. The humidifier maintains the temperature along the humidified insufflation tube by controlling the power delivered to

the heater-wire.

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12 Specifications

12.1

F&P HumiGard™ Surgical Humidifier

Dimensions (without chamber fitted):

140 mm x 173 mm x 135 mm

Mass (without chamber fitted):

2.8 kg

Supply voltage:

230 V ~

Supply frequency:

50 Hz

Supply current:

1 A @ 230 V ~

Rated Input:

230 W

Heater-plate:

150 W

Heater-wire:

22 V ~, 60 W MAX

93/42/EEC Class IIb Medical Device

Recommended operating environment: 18 °C to 24 °C

IP rating:

IPX1

Humidity performance (0 to 10 L/min):

> 33 mg/L

Humidity (Min):

20% RH

Humidity (Max):

60% RH

Sound Pressure Level:

Audible tomes exceed 50 dBA @ 1 m

Transport and storage conditions:

-10 °C to +50 °C

Standards and approvals:

IEC 60601-1, EN 60601-1, IEC 60601-1-2

Heater-plate high temperature cut-out:

118 ± 6 °C

If you are considering operating the system outside the recommended temperature range first consult your local

Fisher & Paykel Healthcare office or distributor.

NOTE: This device is latex free.

DISPLAY

Three-digit 14 mm 7-segment LED

Display range:

10 °C to 70 °C

Display accuracy: (25 °C to 45 °C )

+/- 2 °C

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12.2

Laparoscopic Procedures – ST310 Laparoscopic Humidification Kit

Maximum gas pressure:

30 mmHg

Input set flow rate:

≤ 45 L/min

Maximum achieved flow rate:

15 L/min

Resistance to flow: @ 1 L/min

0.6 mmHg

@ 2 L/min

1.4 mmHg

@ 5 L/min

4.4 mmHg

Leakage (@ 30 mmHg):

< 50 mL/min

Warm-up time:

≤ 10 mins

Humidification chamber reservoir

~180 mL (Use sterile water)

Luer fittings conform to ISO 594-1:1986 and ISO 594-2:1998

12.3

Laparoscopic Procedures – RT350 Humidification Kit

Maximum gas pressure:

30 mmHg

Input set flow rate:

≤ 45 L/min

Maximum achieveable flow rate:

15 L/min

Resistance to flow: @ 1 L/min

0.5 mmHg

@ 2 L/min

1.2 mmHg

@ 5 L/min

3.9 mmHg

Leakage (@ 30 mmHg):

< 50 mL/min

Warm-up time:

≤ 10 mins

Humidification chamber reservoir

~30 mL (Use sterile water)

Luer fittings conform to ISO 594-1:1986 and ISO 594-2:1998

12.4

Open Procedures – ST300 Open Surgery Humidification Kit

Maximum achieved flow rate:

≤ 15 L/min

Maximum Input set flow rate:

≤ 15 L/min

Recommended flow rate

10 L/min

Warm-up time:

≤ 10 mins

Humidification chamber reservoir

~180 mL (Use sterile water)

Luer fittings conform to ISO 594-1:1986 and ISO 594-2:1998

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13. Maintenance Procedures

To keep the F&P HumiGard™ Surgical Humidification System in good working order, it is necessary for qualified service

personnel to perform maintenance at regular intervals. The maintenance schedule below is designed to ensure testing is

carried out on the various components of the F&P HumiGard™ Surgical Humidification System at appropriate intervals.

13.1 Maintenance Schedule

13.1.1 Surgical Humidifier

Annually:

a. Check the humidifier for physical damage:

• Check the mains cable for damage; replace if necessary.

• Check the heater-plate for deep scratching and damage; replace if necessary.

b. Carry out a full performance test. This procedure is detailed in Section 16 Performance Testing.

NOTE: A maintenance check sheet is given in Appendix A.

13.1.2 900ST100 Adaptor

Every six months:

a. Visually check the adaptor for physical damage:

1. Check that the chamber probe’s glass thermistor has not been damaged. Replace adaptor if required.

2. Inspect the chamber probe’s glass thermistor for deposits or foreign material. Clean the chamber probe as

required.

3. Check the adaptor cable for kinks and abrasions and damaged connectors.

4. Check that the adaptor’s connectors couple with the humidifier sockets.

b. Check the adaptor’s accuracy:

• Carry out a temperature accuracy test on the ambient sensor and chamber probe.

• Carry out a flow accuracy check on the chamber probe and humidifier.

• These tests are outlined in Section 16.2.

13.2 Safety Check

The humidifier should be tested to the current medical electrical standards for in-house testing for each specific country

(for example, refer to AS/NZS 3551 for Australia and New Zealand). If the humidifier is fitted with an Equipotential Stud on

the base, both the heater-plate and the Equipotential Stud should be tested for Earth Resistance.

NOTE: The correct ground test point location is on the heater-plate at the front underside edge, as shown in Figure 1,

where the insulating anodizing layer has been removed. Permanent damage to this humidifier will result if the serial port

is used as a ground point during electrical safety testing.

• If the heater base is fitted with an Equipotential Stud, this stud can be used as a ground test point as shown in Figure 2.

Figure 1 : Location of ground test point on the heater-plate

Figure 2: Location of ground test point on the earth stud

13.3 Cleaning Instructions

Refer to the Surgical Humidification System Instructions for Use (UI-185046315) for the humidifier’s cleaning

instructions or 900ST100 Adaptor Instructions for Use (UI-185046318) for the adaptor’s cleaning instructions.

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14. Troubleshooting & Front Panel Indicators

Symptom

Corrective Action

Reference

Hardware fault indicator on

Record the displayed error code.

Section 14.1

Hardware fault indicator on,

without an audible tone

1) There has been a microprocessor failure.

2) Replace the PCBs.

Section 15.2.2

Hardware fault indicator on

with an audible tone

1) Check that the mains supply is within specification. Provide adequate

mains supply if required. If the problem persists, refer to step 2.

2) Replace the PCBs.

Section 15.2.2

Heater-wire plug and

chamber probe indicator on

accompanied by an audible

tone

Section 15.2.2

1) Ensure that the humidifier is not in preheat mode.

2) Ensure that the adaptor is properly plugged into the humidified

insufflation tube. If the problem persists, refer to step 3.

3) Replace the humidified insufflation tube. Retest. If the problem persists,

refer to step 4.

4) Replace the adaptor, and check for intermittent connections. Retest. If the

problem persists, refer to step 5.

5) Replace the PCBs.

Adaptor plug indicator is on,

accompanied by an audible

tone occurring every 2 minutes

1) Ensure that that the adaptor is correctly plugged into the humidifier. If the

problem persists, refer to step 2.

Section 16.1.2

2) Perform a humidifier calibration check. If the problem persists, refer to

step 3.

3) Replace adaptor and re-test. If the alarm condition disappears, the

adaptor is faulty. Discard the faulty adaptor; otherwise refer to step 4.

Section 15.2.2

4) Replace the PCBs

Water indicator is on

1) Ensure that the humidification chamber has an appropriate level of water. Section 15.2.2

Fill the chamber with an adequate amount of water if required. If the

problem persists, refer to step 2.

2) Replace the PCBs.

Humidifier will not turn on with 1) Ensure that the humidifier is plugged into mains supply.

On/Standby button, and no

2) Check that the mains supply is within specification. Provide adequate

indicators are lit

mains supply if required. If the problem persists, refer to step 3.

3) Remove mains power and check the fuses. If the problem persists, refer

to step 4.

4) Check continuity of the mains power cord. Replace as necessary. If the

problem persists, refer to step 5.

5) Check the transformer windings are not open circuit.

• Primary Winding: Red wires

• Secondary 10 V winding: White wires

• Secondary 22 V winding: Yellow wires

• If any windings are open circuit, replace the transformer. If the problem

persists, refer to step 6.

6) Replace the PCBs.

Unit fails calibration check

Send the unit to a Fisher & Paykel Healthcare service representative for

calibration, or replace the PCBs.

Adaptor fails Accuracy Check

Replace the adaptor.

Unit fails to reach temperature

in heater control check

(Section 8.1.5)

1) If the chamber outlet temperature is low, the heater-plate element should

be checked. Replace the element as necessary. If the problem persists,

refer to step 2.

2) Replace the PCBs.

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Section 15.2.1

Section 15.2.6

Section 15.2.3

Section 15.2.2

Section 15.2.2

Section 15.2.4

Section 15.2.2

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Front Panel Indicators

Water indicator:

Indicates that no water

has been put in the

humidification chamber or

the water has run dry

Heater-wire Plug and

Chamber Probe Indicator:

Lights up when in preheat

mode, if the 900ST100

Adaptor is not inserted into

the humidified insufflation

tube, when the humidification

chamber temperature is being

displayed or if the 900ST100

Adaptor is faulty

ON indicator:

Solid light indicates that the

humidifier is on. Flashing light

indicates that the humidifier is

in preheat mode

Adaptor indicator:

Lights if the 900ST100 Adaptor

is not correctly plugged into the

humidifier or if the 900ST100

Adaptor is faulty

Hardware fault indicator:

The humidifier requires

servicing. Humidification will

not be delivered when this

indicator is illuminated.

For servicing refer to the MR860

Humidifier Technical Manual

(REF 1850436474)

Temperature display:

Indicates the humidification

chamber outlet temperature

when the temperature display

button is pressed

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14.1 “Hardware Fault” Error Codes

The following is an explanation of the error codes that are displayed in conjunction with the Hardware Fault indicator

flashing. A code is not displayed if the microprocessor has stopped functioning (see Troubleshooting - Section 14).

Instantly Latching

E01

No production test pass

E02

ROM checksum fault – corrupted software

E03

ROM version newer than that in EEPROM

E04

ROM version older than that in EEPROM

E05

Model number fault

E06

RAM stack overflow

E07

Display-temperature button stuck down

E08

On/Standby button stuck down

E09

EEPROM read/write fault

Transient Suppressed (must be present for > 7 seconds)

E10

Range-0 amplifier fault

E11

Range-1 amplifier fault

E12

Range-2 amplifier fault

E13

Range-3 amplifier fault

E14

Heater-wire triac open circuit

E15

Heater-wire triac short circuit

E16

Heater-wire relay short circuit

E17

Heater-plate thermistor short circuit

E18

Heater-plate thermistor open circuit

E19

Flow circuit fault

E20

Q17 open circuit

E21

Chamber to ambient thermistor short circuit

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15. Servicing Procedures

PRECAUTION: All servicing procedures should be followed by a humidifier performance test, and an electrical safety test to

ensure proper operation. The performance tests are outlined in Section 16.

15.1 Disassembly

15.1.1 Opening the case

1. Ensure mains power is disconnected from the unit.

2. Remove the four screws at the back of the humidifier.

3. Remove the front half of the case by sliding the two halves apart. Pull the front half of the case away from

the rear (Figure 3).

Figure 3: Removing the front half of the case

The control PCB is attached to the front half of the case. The PCB in the rear half of the case is the power PCB.

4. Slide the power PCB forward with the side panel (the side panel is attached to the power PCB). The side

panel will need to be pushed inwards during the sliding action in order to unlatch and clear the electrical

connector.

5. Unclip the three fasteners (Figure 4) which hold the front (control) PCB to the front of the case, and separate

the front PCB from the case.

Figure 4: PCB fasteners

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15.1.2 Closing the case

1. Make sure that all harnesses which were previously disconnected have been reconnected. If the mains

wiring was disconnected during servicing, check that the mains polarity is correct (see Section 15.2.6 for

mains cord polarity table).

2. Slide the power PCB back into position, ensuring that the side panel slides in the slots and latches into the

case rear.

3. Place the control PCB back into position in the front of the case, ensuring all clips are located properly.

4. Slide the case together, and replace the four screws.

5. In order to check that the humidifier is working properly, complete a full performance test as outlined in

Section 16.

15.2 Servicing

15.2.1 Replacing the fuses

1. Open the case (see Section 15.1.1).

2. The fuses can now be accessed (see Figure 5 for the location of the fuses on the power PCB).

Figure 5 : Location of the fuses on the power PCB

The four fuses have the following ratings:

Model Number

MR860AEU

Supply Voltage

Fuse Type

Part Number

F1: 1 A 250 V FastBlow

342042092

F2: 4 A 125 V FastBlow

342042093

F3: 2 A 250 V FastBlow

999 830 009

F4: 2 A 250 V FastBlow

999 830 009

230 V~

WARNING:

Be sure to replace the fuse with the correct rating and type. Do not under any

circumstances replace F2 with anything other than a fast blow fuse of the type and

rating specified, as serious injury could result.

3. Replace the fuse.

4. Close the case (Section 15.1.2).

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15.2.2 Replacement of Printed Circuit Boards

1. Open the case (Section 15.1.1).

2. Disconnect all harnesses attached to the power PCB. Disconnect the mains and protective earth wires by

unscrewing the terminal blocks, and cutting the cable ties (Figure 6).

3. Replace the PCBs. Note that the side panel (including the connector) is replaced, along with the power PCB.

4. Unpack the replacement PCBs, replace the mains fuses (F3, F4) with the correct type, and attach the mains

and protective earth wires, using the cable ties provided (Figure 6).

5. Connect the harnesses from the transformer and heater-plate to the power PCB.

6. Close the case (Section 15.1.2).

7. Update the EEPROM software version (Section 15.2.5).

8. Check that the humidifier powers up normally, and complete a full performance test (Section 16).

NOTE: Removal of the ribbon cables between the power PCB and control PCB will invalidate the calibration of

the unit. Do not separate the boards they must be replaced as a pair.

Figure 6: Humidifier power PCB wiring

15.2.3 Replacement of Transformer

1. Open the case (Section 15.1.1).

2. Disconnect the transformer’s primary and secondary harnesses attached to the power PCB.

3. Unscrew the four mounting screws fixing the transformer, and remove the transformer from the case.

4. Place the new transformer inside the case, and mount using the four screws.

5. Connect the transformer’s primary and secondary harnesses to the power PCB.

6. Close the case (Section 15.1.2).

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15.2.4 Servicing the heater-plate

Resetting the thermal cut-out

1. Open the case (Section 15.1.1).

2. Check the thermal cut-out on the heater-plate by pushing the red button with a pen or small screwdriver

(Figure 7).

Figure 7: Location of the thermal cut-out

3. If the thermal cut-out “clicks” when pushed, it has been previously activated, and is now reset.

NOTE: If the heater-plate is still hot, it must be allowed to cool sufficiently before the thermal cut-out will reset.

4. Close the case (Section 15.1.2).

Replacing the heater-plate thermistor

NOTE: A heater-plate thermistor service kit is required (Part Number: 043 041 254).

1. Open the case (Section 15.1.1).

2. Disconnect the heater-plate element, thermistor and thermal cut-out harnesses attached to the power PCB.

3. Remove the three screws holding the heater-plate (Figure 8).

Figure 8: Location of heater-plate screws

4. Cut the cable ties attached to the heater-plate harnesses.

5. Remove the screw holding heater-plate thermistor (Figure 9).

6. De-solder the wires attached to the thermal cut-out, and remove the old thermistor and harness.

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Figure 9: Location of heater-plate thermistor, thermal cut-out and element screws

7. Place the new thermistor into position, and attach using the screw.

8. Solder the wires from the new harness to the heater-plate thermal cut-out.

9. Attach the cable ties provided to the heater-plate harness.

10. Place the heater-plate back into position, ensuring the springs underneath the heater-plate are in place.

Attach to the humidifier’s case using the three long screws that were previously removed.

11. Connect the heater-plate element, thermistor and thermal cut-out harnesses to the power PCB.

12. Close the case (Section 15.1.2).

Checking the heater-plate element

1. Open the case (Section 15.1.1).

2. Disconnect the heater-plate element, thermistor and thermal cut-out harnesses from the power PCB.

3. Measure the resistance between the two contacts on the heater-plate element connector (this is the large

three-pin connector).

The resistance of the heater-plate element should measure the same, as outlined in the table below:

Model Number

MR860Axx

Supply Voltage

230 V~

Heater-plate Resistance

353 ± 12 Ohms

If the measured resistance is outside this range, replace the heater-plate element (steps 4 to 9). If the heaterplate element is within specification, go to step 10.

NOTE: If the heater-plate element requires replacing, a heater-plate element service kit is required - see

Section 18 : Heater-plate Assembly.

4. Remove the two visible screws holding the heater-plate element reflector. Remove the shield, making sure

the washers are not lost. Unscrew the last four screws on the element cover (Figure 9).

5. Remove the heater element, leaving the mica insulator in place.

6. Insert the new element into position, making sure the mica insulator is between the element and the heaterplate.

7. Replace the element cover, using the four screws that were previously removed.

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8. Replace the element reflector, ensuring the washers that separate the reflector from the cover are placed

back into position. Screw into place.

9. Place the heater-plate assembly back into position, making sure the springs underneath the heater-plate are

in place. Attach to the humidifier case using the three long screws that were previously removed.

10. Connect the heater-plate element, thermistor and thermal cut-out harnesses to the power PCB.

11. Close the case (Section 15.1.2).

Replacing the thermal cut-out

NOTE: A thermal cut-out service kit is required (Part Number: 349 040 052).

1. Open the case (Section 15.1.1).

2. Disconnect the heater-plate element, thermistor and thermal cut-out harnesses from the power PCB.

3. Remove the three screws holding the heater-plate (Figure 9).

4. De-solder the two black wires attached to the thermal cut-out.

5. Unscrew fasteners used to secure the thermal cut-out, and remove.

6. Place a new thermal cut-out in position and fasten using the screws provided.

7. Depress the thermal cut-out’s red button to ensure it is reset.

8. Solder the black wires that were previously disconnected to the contacts on the new thermal cut-out.

9. Place heater-plate back into position, ensuring the springs underneath the heater-plate are in place. Attach

to the humidifier’s case using the three long screws that were previously removed.

10. Connect the heater-plate element, thermistor and thermal cut-out harnesses to the power PCB.

11. Close the case (Section 15.1.2).

15.2.5 Installing new software

1. Open the case (Section 15.1.1).

2. Remove the ROM integrated circuit U3 (Figure 10) using the appropriate tools.

Figure 10: Location of U3 ROM

3. Place a new ROM into the empty socket, ensuring correct orientation.

4. Close the case (Section 15.1.2).

5. Apply mains power, press the On/Standby button to transfer the humidifier to On Mode, then press the

Temperature Display button when either “E03” or “E04” appears on the display. The humidifier will reset,

automatically updating the software version.

6. Check that the humidifier powers up normally, and complete a full performance test (Section 16).

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15.2.6 Replacing the mains cable

1. Open the case (Section 15.1.1).

2. Unscrew the three mains cable wires from the terminal blocks on the power PCB (Figure 6), and cut the cable

tie on the PCB.

3. Slide the mains cable retainer away from the rear of the case.

4. Replace the power cord, and affix to the case by forcefully pushing the retainer back into position (towards

the rear of the case).

5. Attach the three mains cable wires to the terminal blocks on the power PCB (see table below for correct

mains cable wiring), and attach the phase and neutral wires with a new cable tie.

CORD TYPE

PHASE

NEUTRAL

EARTH

NZ / AUSTRALIA(230 V)

Brown

Blue

Green / Yellow

U.K. (230 V)

Brown

Blue

Green / Yellow

European/IEC (230 V)

Brown

Blue

Green / Yellow

WARNING: When attaching the mains cable wires, ensure that the correct polarity

of the mains wiring is followed. The table above only applies to power cords

supplied by Fisher & Paykel Healthcare.

6. Close the case (Section 15.1.2).

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16 Performance Testing

This section discusses the performance testing of the Surgical Humidifier and also the adaptor. Performance testing is

required as part of ongoing maintenance or after servicing of the humidifier has been completed.

16.1

Surgical Humidifier Performance Testing

If the humidifier has been operating normally, but a performance check is required as part of the maintenance

schedule, it is recommended that the following tests be completed:

1. A humidifier calibration check (Section 16.1.2)

2. A humidifier display check (Section 16.1.4).

However, if there is a problem with the humidifier, or if the humidifier has recently been serviced, then the following

tests should be completed in addition to those outlined above.

3.

A humidifier performance and control check (Section 16.1.5).

16.1.1 Entering the service mode

The humidifier has a special mode which enables the operator to verify correct operation. To enter this mode, hold

down the On/Standby button on the front panel of the humidifier then apply mains power. The Hardware Fault

indicator will light up, and the humidifier will enter service mode. The service menu has four different tests:

Display

Description

Reference

-1-

Reference Probe Check

Section 16.1.2

-2-

Display Model and Software Version Number

Section 16.1.3

-3-

Adaptor Temperature Probe Check

Section 16.2.1

-4-

Display Test

Section 16.1.4

Pushing the Temperature Display button while a number is displayed enters the relevant service test. Service mode

exits automatically by resetting the heater-base after 30 minutes or can be exited manually or by cycling the power.

16.1.2 Humidifier Calibration Check

This section describes how to check the accuracy of the humidifier’s temperature and flow measurement electronics.

Equipment required

• Surgical Humidifier MR860AEU

• 900MR880 Reference Probe

1.

2.

3.

4.

Hold down the On/Standby button, then apply mains power to the humidifier. This action places the humidifier

into service mode.

Select service mode number 1 by pushing the Temperature Display button when ‘-1-’ is displayed.

Insert the grey plug of the Reference Probe into the adaptor port of the humidifier.

Allow the display to stabilize for a few seconds, and check the number shown on the humidifier display. The

table below shows the numbers displayed by the humidifier in this mode:

TEST

PASS

FAIL (LOW)

FAIL (HIGH)

Ambient Temperature

1.0

1.1

1.2

Chamber Temperature

1.0

1.3

1.4

Flow Temperature

1.0

1.5

1.6

If the humidifier displays any value other than ‘1.0’ or if the heater-wire plug and chamber probe indicator is on,

check that you have the correct calibration probe plugged in; otherwise the humidifier’s PCBs are faulty and need to

be replaced (see Section 15.2.2).

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5.

6.

7.

Press the Temperature Display button.

Insert the black plug of the Reference Probe into the adaptor port of the humidifier.

Allow the displayed value to stabilize for a few seconds. Check the humidifier display. The table below shows

the numbers displayed by the humidifier in this mode:

TEST

PASS

FAIL (LOW)

FAIL (HIGH)

Ambient Temperature

2.0

2.1

2.2

Chamber Temperature

2.0

2.3

2.4

Flow Temperature

2.0

2.5

2.6

TEST

Overheat

PASS

FAIL

2.0

Heater-wire plug and

chamber probe indicator

off

2.7

Heater-wire plug and chamber probe indicator on

If the humidifier displays any value other than ‘2.0’ or if the heater-wire plug and chamber probe indicator are on,

check that you have the correct end of the Reference Probe plugged in. Otherwise the humidifier’s PCBs are faulty

and will need to be replaced (see Section 15.2.2).

8. Remove the Reference Probe, and press the Temperature Display button to return to the service mode menu.

16.1.3 Humidifier Display Model and Software Version Number Check

1. Enter the service mode (Section 16.1.1).

2. Select service mode number 2 (Display Model and Software Version Number Check) by pushing the

Temperature Display button when ‘-2-’ is displayed.

3. Check that the humidifier displays its model number (860) on the seven-segment LED display.

4. Push the Temperature Display button and check that the humidifier displays the software version number

(3.0.2) on the seven-segment LED display.

16.1.4 Humidifier Display Test

This test is used to determine whether the humidifier’s display is working correctly.

1. Enter the service mode (Section 16.1.1).

2. Select service mode number 4 (display test) by pushing the Temperature Display button when ‘-4-’ is displayed.

3. Check that all of the display LEDs and indicators are turned on.

4. Check that the buzzer produced a single beep upon entering service mode number 4.

5. Push the Temperature Display button to exit back to return to the service mode menu.

If the humidifier does not pass the display test, then it is recommended that the humidifier’s PCBs be replaced

(Section 15.2.2).

16.1.5 Humidifier Performance and Control Check

This section describes how to check the humidifier’s heater control systems. This test should be performed if there is

a problem with the humidifier, or after servicing of the humidifier.

Equipment required

• Surgical Humidifier MR860AEU

• 900ST100 Adaptor

• Select one of the humidified kits (RT350, ST300, ST310) fill the chamber with water up to indicator line.

• Gas supply – CO2 insufflator (set to 2 ± 0.5 SLPM (Standard Litres per Minute)) or air supply at constant flow

of 2 ± 0.5 SLPM.

1. Make sure that the humidifier passes the calibration and display checks (refer Sections 16.1.2 and 16.1.4).

2. Set up the humidifier as shown in Instructions for Use. Make sure the chamber probe is correctly inserted.

3. Connect the humidifier chamber inlet to the 2 SLPM gas supply, and turn the humidifier on.

4. Wait approximately 15 minutes for the humidifier to stabilize.

Temperatures can be checked by using the temperature display mode.

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