Service Manual
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SERVICE MANUAL HEATER COOLING UNIT HCU 30
Copyright All rights reserved. No part of this publication may be duplicated, adapted or translated without prior written permission, except within the framework of the copyright laws. © Copyright MAQUET Cardiopulmonary AG Subject to technical changes Owing to our policy of continuous product development, the illustrations and technical data contained in this Service Manual may differ slightly from the current version of the device. Manufacturer MAQUET Cardiopulmonary AG Hechinger Strasse 38 72145 Hirrlingen, Germany Telephone:+49 (0) 7478 921-0 Fax: +49 (0) 7478 921-100 [email protected] www.maquet.com
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| HCU 30 | Table of Contents | 3 |
TABLE OF CONTENTS PART
PART
PART
PART
1
GENERAL
1.1 1.2 1.3 1.4 1.5 1.6 1.7
Special instructions Hazard notices Symbols Precautions Service requirement Service equipment Maintenance overview
2
SYSTEM COMPONENTS
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20
General Front view Rear view Internal overview - type 1 Internal overview - type 2 Description of functions Patient and cardioplegia circulation mode De-airing mode Emptying mode Cleaning mode Power supply section Power supply board Control board Operating panel Cooling circuit Heaters Pumps Valves Temperature sensors Pressure sensors
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6 6 7 8 8 9 10 11
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12 12 12 13 14 15 16 17 19 21 23 26 28 28 29 29 33 33 34 36 39
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41 41 41 42 42 42 43 46
3
INSPECTION
3.1 3.2 3.3 3.4 3.5 3.6 3.7
General Customer settings Performing servicing Visual inspection Electrical safety test Function check Replacement inspection sticker
4
SERVICING | 47 Changing tank water | 47 Cleaning components | 47 Cleaning valves | 48 Verification of water pressure sensor (only required for US)|49
4.1 4.2 4.3 4.4
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 4 | Table of Contents | HCU 30 |
PART
PART
PART
PART
PART
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
5
SERVICE MODE
5.1 5.2 5.3 5.4 5.5
Service menus System info / max. current menu Water pressure menu Connect to JOCAP PC Load
6
PC LOAD
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10
General Basic principles Window - Load... Window - PT 1000 Window - YSI Series 400 Window - Init. Value Window - Log Window - Error code... Control value Using PC Load
7
REPAIR
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12
General Hood Disassembling valves Replacing heaters Replacing pump Replacing ice sensor Replacing control board Replacing display board Replacing power supply board Accessing power supply section Checking pressure sensor check Ice sensor check
8
INSTALLATION
8.1 8.2 8.3
Unpacking Function check after installation Formal handover
9
TROUBLESHOOTING
9.1 9.2 9.3 9.4
Error messages Other errors Faulty components Startup test sequence flow charts
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51 51 52 52 52 52
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53 53 54 55 56 57 58 60 63 66 68
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75 75 77 79 81 89 90 93 94 94 95 95 97
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98 98 98 99
| 100 | 100 | 104 | 108 | 113
| HCU 30 | Table of Contents | 5 |
TABLE OF CONTENTS PART
10
DIAGRAMS
10.1 Functional main block diagram 10.2 Wiring diagram - boards and sensors - type 1 unit 10.3 Wiring diagram - power - type 1 unit 10.4 Wiring diagram - heater connection table - type unit 1 10.5 Wiring diagram - boards and sensors - type 2 unit 10.6 Wiring diagram - power type 2 unit 10.7 Control board, type 1 10.8 Control board, type 2 10.9 Power board, type 1 10.10 Power board, type 2 10.11 Service protocol
| 115 | 115 | 117 | 119 | 121 | 123 | 125 | 127 | 128 | 129 | 130 | 131
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 6 | 1 General | HCU 30 |
1 GENERAL The purpose of this service manual is to describe the HCU 30 and provide the information required for installation and maintenance. There are two different mechanical and hardware versions of the HCU 30:
Type 1 version: JOSTRA branded units independent of model no. (S/N 140xxxxx). MAQUET branded units with model no. 93 90 01 (S/N 100001-100400).
Type 2 version: MAQUET branded units with model No. (listed below) (S/N > 101000): 70 46 29 (100-120 V) 70 46 31 (200-240 V, RoW version) 70 55 01 (200-240 V, North America version).
The information in this manual is valid for both versions unless otherwise stated. Make sure that the user‘s manual version of the user‘s manual at hand corresponds to the HCU 30 version. Before use of the HCU 30, read the user’s manual thoroughly.
1.1
SPECIAL INSTRUCTIONS These special instructions are used in the service manual. Please bear them in mind. WARNING! Risk of serious injury! This is an instruction or procedure which must be observed to avoid injury to the user, patient or other persons. ATTENTION! Risk of damage to equipment! This is an instruction or procedure which must be observed to avoid the device being damaged. Note Important or explanatory information.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| HCU 30 | 1 General | 7 |
1.2
HAZARD NOTICES Responsibility for the safe functioning of the equipment reverts to the owner or user in all cases in which servicing or repair has been done by a non-professional or by persons who are not employed by or authorized by MAQUET, and if the equipment is used for other than its intended purpose. In addition to the important information given here and in related documents (e.g. user’s manual), always pay attention to applicable local and national regulations. WARNING! Energized electrical components! With power supply connected to the HCU 30, there are energized electrical components inside the device. All personnel must exercise extreme caution if troubleshooting or adjustments are performed with power supply connected. WARNING! Leakage currents! When the device is used together with other medical equipment the total leakage currents must be checked. WARNING! The system must not be used in the presence of leaking combustible or inflammable gases. WARNING! On type 2 units, current sensing may only be disabled (with PCLoad) during troubleshooting, never during clinical operation. WARNING! The heatsink on the power supply board is not earthed and may carry high voltage. Do not touch the heatsink when the hood is removed and mains power is connected to the unit. ATTENTION! Dry-running the HCU 30 will damage the circulation pumps and heaters. ATTENTION! Prevent damage of ESD sensitive components When handling ESD sensitive devices, established procedures must be observed to prevent damage. When working with ESD sensitive components, always use a grounded wristband and a grounded work surface. Adequate service tools must always be used.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 8 | 1 General | HCU 30 |
ATTENTION! Special waste This product contains cooling media, electronic and electrical components. Discard disposable, replaced and left-over parts in accordance with appropriate industrial and environmental standards. The refrigeration circuit in HCU 30 contains 250g cooling media. The cooling media used is HFC-134a (R134a) 1,1,1,2-Tetrafluoroethane. CAS No. 811-97-2, EC No. 212-377-0. For further information, refer to MSDS (Material Safety Data Sheet) supplied by manufacturers such as Honeywells, DuPont, BOC Gases, etc.
1.3
SYMBOLS Important, consults the documents supplied.
Consult the user‘s manual.
Only service engineers trained and authorized by MAQUET are permitted to install and maintain the HCU 30. Any maintenance must be noted in a service protocol. Warning of dangerous electrical voltage. There are energized electrical components inside the unit. Exercise extreme caution if power supply is connected and covers are removed. Service contract. Refers to the service contract supplied by MAQUET.
Recycling. Worn-out batteries must be recycled or disposed of properly in accordance with appropriate industrial and environmental standards. Separate collection of electric and electronic devices in accordance with Directive 2002/96/EC: Do not dispose of the device with normal domestic waste. Keep separate from domestic waste and dispose of in an environmentally safe way in compliance with local regulations.
1.4
PRECAUTIONS Disconnect the plug from power source before installation or maintenance of the HCU 30.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| HCU 30 | 1 General | 9 |
1.5 Personnel requirements
SERVICE REQUIREMENT WARNING! Servicing only by qualified service engineer! Only service engineers trained and authorized by MAQUET are permitted to install and maintain the HCU 30. Servicing by an unqualified service engineer may result in injury to the technician, the patient, or other personnel or may cause damage to the equipment.
To the responsible service personnel
If any significant difference is found between the product and this document, please contact MAQUET for further information. We reserve the right to modify products without amending this document or advising the user. Only MAQUET genuine spare parts must be used. Printed circuit boards (spare parts) must always be kept in a package for sensitive electronic devices. MAQUET will not otherwise assume responsibility for the materials used, the work performed or any possible consequences. Components on printed circuit boards must not be replaced. The printed circuit boards are only available as populated and tested units. The information in this manual regarding components on the printed circuit boards is intended for troubleshooting only. Many circuit boards have jumpers which require proper placement for correct operation. Verify that jumper settings on new boards are identical with the boards being replaced. If installing a newer revision board, contact MAQUET Technical Support for assistance. ATTENTION! Avoid any safety risks Always perform inspection after servicing/repair or after opening the device to avoid any safety risks. ATTENTION! Document all procedures All results of maintenance or installation must be recorded in the service protocol.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 10 | 1 General | HCU 30 |
1.6
SERVICE EQUIPMENT NOTE Use only calibrated measurement instruments for the service procedures. The following tools may be necessary to perform tests that have to be done during servicing:
Standard tools
Service tool kit HCU 30 H
I
J
K
M
L
N
O
HCU 30 basic equipment - Figure 1
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
A
Hand tools (basic equipment)
B
Laptop (running on Windows 2000 or Windows XP and equiped with serial port and network connection)
C
ESD workplace equipment (shielding cover, grounded wristband, adapter)
D
Universal test control unit, e. g. “Secutest S2/Gossen Metrawatt” (or equivalent) for electrical safety test.
E
Multimeter (for troubleshooting)
F
USB mouse (optional)
G
USB keyboard (optional)
H
Reference temperature unit
I
Test loop 1/2“ (main circuit)
J
Test loop 3/8“ (cardioplegia circuit)
K
PC Load service cable
L
Reference temperature box
M
Socket wrench for PT sensor
N
Vaseline
O
Citric acid
P
Service software “PCLoad“
| HCU 30 | 1 General | 11 |
Q
Water pressure/flow test loop Recalibrate water pressure/flow test loop every 12 months. Temperature measurement system (temperature meter and probe) must be calibrated by an accredited laboratory according to ISO 17025 or ANSI-Z540. Calibrate to system inaccuracy of ± 0.1°C at temperatures 0°C and 40°C. The pressure gauge must be calibrated at an accredited traceable laboratory. The calibration must be carried out at five or more pressure levels evenly divided over the instruments measuring range.
Water pressure/flow kit [Q] - Figure 2
Manuals
1.7
Service documentation for the HCU 30 consists of:
User’s manual
Service manual
Spare parts list
MAINTENANCE OVERVIEW Interval
INSPECTION Visual inspection
SERVICING
12 months
Electrical safety test
12 months
Functional test
12 months
Replacement inspection sticker
after each inspection
Changing tank water
if required
Cleaning components
12 months
Cleaning valves
12 months
Verification water pressure
12 months (only for US)
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 12 | 2 System components | HCU 30 |
2 SYSTEM COMPONENTS 2.1
GENERAL The HCU 30 is intended to circulate water through heat exchange circuits to warm or cool a patient during short-duration cardiopulmonary bypass procedures. For additional information, see HCU 30 user‘s manual.
2.2
FRONT VIEW [1] Handrail
1
2 3
4
HCU 30, front view - Figure 3
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
[2] Display panel [3] Lid over the funnel for the water tank [4] Wheels with foot-lever operated brake
| HCU 30 | 2 System components | 13 |
2.3 2
1
REAR VIEW [1] Globe valve for the 1st patient circulation (open in vertical position)
3
[2] Globe valve for the 2nd patient circulation (open in vertical position) [3] Globe valve for the cardioplegia circulation (open in vertical position) 4
5
6
7
8
9
Back valves - Figure 4
10
[4] Inlet (suction side) of the 1st patient circulation, 1/2" connection [5] Outlet (pressure side) of the 1st patient circulation, 1/2" connection [6] Inlet (suction side) of the 2nd patient circulation, 1/2" connection [7] Outlet (pressure side) of the 2nd patient circulation, 1/2" connection
11
[8] Inlet (suction side) of the cardioplegia circulation, 3/8" connection
12
[9] Outlet (pressure side) of the cardiplegia circulation, 3/8" connection
13
14
[10] Socket for remote controlling and service terminal [11] Cleaning door with magnet lock [12] Type label (behind the cleaning door)
15
[13] Condenser fan outlet (protected by a filter) [14] Tank drain valve lever (type 1 units only, behind the filter) [15] Drain valves for cardioplegia pump, tank and main pump (type 2 units only, on side of lower panel)
HCU 30, rear view - Figure 5
[16] Mains power switch incl. 20 A circuit-breaker 19
[17] Automatic fuse 12 A [18] Mains power inlet [19] Connection for potential equalization
16
17
18
HCU 30, mains connection - Figure 6
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 14 | 2 System components | HCU 30 |
2.4
INTERNAL OVERVIEW - TYPE 1 1 2 3
4 5
6
7 8 9
10
11 12 13
14
15 HCU 30 - type 1, internal overview - Figure 7
[1] Globe valves [2] Power supply board [3] Control board [4] Compressor [5] Tank return valve, cardioplegia circuit [6] Shunt valves [7] Stop valves [8] Outgoing temperature sensors [9] Pressure sensors [10] Heaters [11] Three-way valves including motor [12] Heater temperature sensors [13] Power supply section [14] Cardioplegia pump [15] Main pump The outlet for tank overflow and emptying is underneath the unit on the cardioplegia pump side, not visible in this illustration.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| HCU 30 | 2 System components | 15 |
2.5
INTERNAL OVERVIEW - TYPE 2 1
2
3
4 5
6
7 8 9 10 11 12 13
14
15
16
17
18
19
HCU 30 - type 2, internal overview - Figure 8
[1] Globe valves [2] Power supply board [3] Control board [4] Compressor [5] Tank return valve, cardioplegia circuit [6] Shunt valves [7] Stop valves [8] Pressure sensors [9] Outgoing temperature sensors [10] Heaters [11] Three-way valves including motor [12] Heater temperature sensors [13] Power supply section [14] Tank overflow outlet [15] Cardioplegia pump drain valve [16] Tank drain valve [17] Main pump drain valve [18] Cardioplegia pump [19] Main pump
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 16 | 2 System components | HCU 30 |
2.6
DESCRIPTION OF FUNCTIONS The following chapter‘s describe the functions of the components in the HCU 30 and illustrates the flows of water and air during the different operational modes. Each mode is illustrated with a flow chart and a corresponding text. The flow is also illustrated on images of the HCU 30. These general illustrations show the type 2 version of the HCU 30 but the flows in type 1 units are similar. For an overview of all components, including control board and power supply board functions, 10.1 Functional main block diagram, page 115. For further information about the electrical functions 10 Diagrams, page 115.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| HCU 30 | 2 System components | 17 |
2.7
PATIENT AND CARDIOPLEGIA CIRCULATION MODE
Cardioplegia circulation
Patient circulation
Globe valve
Globe valve Air supply valve
Air supply valve
Stop valve
T P
Shunt valve
P
Stop valve
Compressor
T
Shunt valve
P
Dryer
Condenser and fan
Freon valve Tank return valve
Flow restrictor Cooling coil
T Cardioplegia heater
Main heater Tank
T
Three-way valve Cardioplegia pump
T
Three-way valve Main pump
Tank overflow outlet Drain valves Note: Pump drain valves on type 2 units only.
Circulation diagram - Figure 9
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 18 | 2 System components | HCU 30 |
Cardioplegia circulation
Patient circulation
Patient and cardioplegia circulation flowchart - Figure 10
Water is circulated in the system by the main pump and the cardioplegia pump.
The water circulated is a mix of cold water from the tank and return water passing through the heaters. The mix is regulated by the three-way valves.
If no cold water is required to keep the set temperature, the threeway valves will be closed towards the tank and the water in the system will run in a closed circuit.
If cold water is required to keep the set temperature, an appropriate amount of water from the tank will be mixed with the return water, as shown in the schematic. To keep the same water volume in the circuit, an equal amount of return water will be returned from the top of the heaters into the tank.
During normal circulation mode, the valves are set as follows: Tank return valve (cardioplegia) open. Shunt valves closed. Stop valves open. Globe valves are manually set by the operator.
The system is monitored by a number of sensors: Heater temperature sensors to prevent overheating. Outgoing temperature sensors measure the temperature in the outgoing water. Main pressure sensor measures the pressure in the outgoing water.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
Ice sensor to control the ice level in the water tank.
| HCU 30 | 2 System components | 19 |
2.8
DE-AIRING MODE
Cardioplegia circulation
Patient circulation
Globe valve
Globe valve Air supply valve
Air supply valve
Stop valve
T P
P
Shunt valve
Stop valve
T P
Shunt valve
Compressor
Dryer
Condenser and fan
Freon valve Tank return valve
Flow restrictor Cooling coil
T Cardioplegia heater
Main heater
Tank
T
Three-way valve
T
Three-way valve
Cardioplegia pump
Main pump
Tank overflow outlet Drain valves Note: Pump drain valves on Type 2 units only.
De-airing diagram - Figure 11
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen
| 20 | 2 System components | HCU 30 |
Cardioplegia circulation
Patient circulation
De-airing flowchart - Figure 12
Water is circulated in the system by the main pump and the cardioplegia pump.
The water circulated is only cold water from the tank. Return water passes through the top of the heaters and back into the tank.
The three-way valves will be closed towards the heaters.
In the de-airing mode, the valves are set as follows: Tank return valve (cardioplegia) open. Shunt valves closed. Stop valves open. Globe valves are manually set by the operator.
The system is monitored by a number of sensors: Main pressure sensor measures the pressure in the outgoing water. Ice sensor to control the ice level in the water tank.
It may be difficult to de-air the blanket circuit. Tap the blanket systematically with the palm of your hand to release the air in the chambers of the blanket. If required, close the other patient circuit globe valve and de-air the blanket few minutes. WARNING! Check the pressure limit given by the manufacturer of the blanket and/ or heat exchanger before connection. Do not exceed these pressure limits.
HCU 30 | Service Manual | English | 05 Copyright MAQUET Cardiopulmonary AG, Hirrlingen