Warmflo Fluid Warming System

Model FW-538
SERVICE MANUAL
Nellcor Puritan Bennett Inc. is an affiliate of Tyco Healthcare. Warmflo is a registered trademark of
Nellcor Puritan Bennett. Tufram is a registered trademark of General Magnaplate Corporation.
Covered by the following patent: 5,381,510.
Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose .......................................................................................................... 1
Description ..................................................................................................... 1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Circuit Board: Start-Up .......................................................................... 3
Heater Control Circuitry .................................................................................. 4
Temperature Sensing Circuitry ....................................................................... 4
Over-Temperature Operation ......................................................................... 5
Secondary Over-Temperature Protection ...................................................... 5
Under-Temperature Operation ....................................................................... 5
Display Board ................................................................................................. 5
Keyboard ........................................................................................................ 6
Temperature Adjustment ................................................................................ 6
Alarm Control Buttons .................................................................................... 6
Warnings and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warnings: Blood/Fluid Warmer ...................................................................... 7
Precautions: Blood/Fluid Warmer ................................................................... 8
Precautions: Disposable Fluid Warming Sets ................................................ 8
Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Setting Up the Fluid Warmer System ........................................................... 11
Priming and Removing a Disposable Warming Set ............................ 13
Alarms .......................................................................................................... 13
Internal Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction ................................................................................................... 15
Tests ............................................................................................................. 15
Test #1: Zone Heating Monitoring ....................................................... 15
Test #2: Individual Thermistor Monitoring ........................................... 15
Test #3: Automatic Thermistor Zone Monitoring ................................. 15
System Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Testing ............................................................................................. 17
Equipment Required for Output Temperature Check ................................... 17
Test Procedure ............................................................................................. 18
Over-Temperature Alarm Check Procedure ................................................. 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Problems ...................................................................................................... 25
NVRAM Mode .............................................................................................. 29
Electromagnetic Interference ....................................................................... 29

i
Contents

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dimensions ................................................................................................... 33
Weight .......................................................................................................... 33
Technical Specifications ............................................................................... 33
Transportation and Storage .......................................................................... 34
Performance Requirements .......................................................................... 34
Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Disposable Fluid Warming Cassettes ........................................................... 35
Pressure Infusors ......................................................................................... 35
Spare Parts ................................................................................................... 35
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Main Control Board Schematic, Sheet 1of 2 ................................................ 39
Main Control Board Schematic, Sheet 2 of 2 ............................................... 41
Display PCB Schematic ................................................................................ 43

Figures
Figure 1: Increasing/Decreasing Temperature ......................................... 6
Figure 2: Tubing Channel and Filter Mount .............................................. 8
Figure 3: Fluid Warming Cassette and Red Clamp .................................. 9
Figure 4: Mounting Warmer on IV Pole .................................................. 11
Figure 5: Setup for Output Temperature Check ..................................... 18
Figure 6: Setup for Over-Temperature Alarm Function Check ............... 21
Figure 7: Accessing Heater Plates ......................................................... 31

Ta b l e s
Table 1: Alarm Conditions and Events .................................................. 14
Table 2: System Problems and Solutions ............................................. 25
Table 3: System Fault Codes ................................................................ 26
Table 4: System Preventative Maintenance .......................................... 32

ii Warmflo Model FW-538 Service Manual

Introduction

Purpose This manual is intended to be used by qualified biomedical technicians to conduct

preventative maintenance and verify performance of the FW-538 Warmflo® Fluid
Warming System.

Description

The FW-538 blood/fluid warmer is designed for use in medical environments, under
the direction of a physician, to warm blood, intravenous (IV), and irrigation fluids.
The FW-538 blood/fluid warmer uses a disposable fluid warming cassette that is
inserted between microprocessor-controlled heater plates located within the warmer
housing. The dry heat process is safe, reliable, and requires minimal warm up time.
There is a variety of disposable blood and fluid warming cassettes available for use in
routine surgery, and standard intravenous warming and irrigation applications.
The FW-538 blood/fluid warmer may be used as a gravity flow device, or in
conjunction with automatic and manual pressure infusors and irrigation pumps to
deliver fluids.

1
Theory of Operation

The FW-538 is used to warm fluids that are gravity fed or pressure infusor fed. The
blood/fluid warmer heats fluid as it flows through a deposals fluid warming cassette.
The cassette is inserted between two heater plates that are Tufram® coated for surface
protection. Maximum heat transfer is achieved when the cassette and heater plates are
clean, and the cassette expands due to a slight downstream resistance, creating
effective surface contact with the heater plates. Each heater plate contains three heater
elements and two thermistors (temperature sensors).
The blood/fluid warmer software monitors the temperature and duty cycle of the three
heater zones, and regulates the fluid temperature by turning the heaters on and off, as
needed, to maintain the fluid SET POINT temperature. The default SET POINT is
38°C. The temperature control range is from 28°C to 42°C. The preset temperature is
continuously displayed in the format ##.#, rounded to the nearest 0.5 degree.The
reading is updated at approximately once every second.
The major components of the FW-538 Blood/Fluid Warmer are:
• two heater plates with four embedded temperature sensors
• keyboard
• main circuit board
• display circuit board.
Schematics for the circuit boards are found in Appendices at the back of this manual.

Main Circuit When the unit is turned on, it enters a start-up test mode. The software executes a test
Board: Start- of the following microprocessor components:
Up • RAM (U5)
• ROM (U25)
• CPU registers
• watchdog (U30)
• NVRAM (Non-Volatile RAM, U19)
If one of these tests fails, an appropriate fault code, in the format “F_##”, indicates the
condition, and an alarm will sound. For fault code values, refer to Table 3, System
Fault Codes, on page 26. If a fault code is displayed, the unit must be turned off and
then restarted. If the fault has been resolved, the unit will then proceed through the
sequence of startup tests:

3
Theory of Operation

As start-up proceeds, the following events occur:

• Each thermistor is checked for “open”, “short”, and “within range” conditions.
• Each heater is tested to ensure that current flow is under software control, and that
the power triacs operate correctly.
• If all test results are normal, the unit conducts LED display test. All segments for
each digit are displayed and held for 2 – 3 seconds.
• The software version number is then displayed. The user should verify that all
segments are displayed during this time.
• The unit then enters the preheat mode, during which a running dash line is
displayed.
• When the default temperature setpoint is reached, 38°C is displayed.
At this point, the unit enters normal operational mode.

Heater The power for the heaters is supplied through power triacs whose drivers are isolated
Control from the microprocessor by zero-crossing type opto-couplers U1, U2, and U4. The
Circuitry microprocessor senses when current is being drawn through the heaters. Heater
Current Detect circuitry includes transformer T1, diodes D7 and D8, and comparator
U15B. The voltage induced in the secondary of the transformer T1 is clamped by D7
and D8. This circuit limits the output “swing” to one diode drop voltage. This voltage
is applied to the inputs of the comparator LM393, which in turn sends a
CURRENT_SENS signal to U21 (80C5552 microcontroller with an 11.0592 MHz
crystal).
The microcontroller initiates a HEATER_SET signal, which is applied to the
EXTERNAL_OT U10. Output from U10 is the HEATER_EN signal, which reflects the
status of the master triac. This signal may be set HIGH (triac disabled) by the EXT_OT
signal provided by hardware. The HEATER_EN (master enable) signal controls the U3
(optoisolator), which in turn powers the HEATER DRIVERS and HEATER CURRENT
SENSOR circuit. After heater current is detected, the microcontrollor initiates an
on/off test of each triac through signals DRV_ZN1 – DRV_ZN3 (Port 1 of U21), which
are applied to the octal buffer U13 in sequence. The HEATER_OC from U21 enables
or disables the buffer U13.

Temperature Four thermistors (SENS_ZN1, SENS_ZN2, SENS_ZN3, and Lower Plate) are
Sensing embedded in the heater plates using highly heat-conductive eutectic alloy which
Circuitry allows rapid sensing of zone temperature. Thermistors 1, 2, and 3 are connected to the
Main Circuit board through connector J6. The lower plate thermistor is connected to
the Main Circuit board through connector J9.
Each sensor is located in the voltage divider circuitry which comprises a precision
resistor (5760 ohms, 0.1%) and the corresponding temperature sensor. The output
signal from each voltage divider circuit is monitored by the microprocessor’s analog-
to-digital converter (P5.0-2, P5.6)

4 WarmFlo FW-538 Service Manual

 Theory of Operation

All four thermistors monitor the temperature of the heater plates. The output fluid
temperature is affected by both the rate of fluid flow through the cassette and the
length of the tubing between the blood/fluid warmer and the patient.

Over- If an output temperature of 44.5°C ± 1°C is detected for greater than two seconds, the
Temperature heater plates will be disabled, an intermittent, audible alarm will sound, and a display
Operation of temperature preceded by the letter “H” will indicate over-temperature condition. At
this point, all heaters are disabled, and the master triac is turned off.
All of the heater triacs are then tested. If any heaters is still producing current, the
program will enter the FAULT mode, an audible alarm will sound, and the appropriate
fault code will indicate the condition.

Secondary The blood/fluid warmer provides a secondary over-temperature shutdown, separate

Over- from the microcontroller, if the temperature exceeds 45°C ± 1°C. A continuous
Temperature audible alarm and display of temperature preceded by the letter “H” (HXX.X),
indicate this condition. If an fault code is reported, the display will alternate between
Protection
the temperature and the reported fault code.
The secondary over-temperature protection is hardware-implemented. The over-
temperature reference signal (OT_REF_HI) is formed by the voltage divider circuit,
which consists of R23 (5760 ohms, 1%), and R21 (4530 ohms, 0.1%) the output of
which is applied to the comparator U15 pin 13 which disables the heaters. If current to
the heaters is detected, this condition is not recoverable without turning off the unit. If
the condition is due to preheated fluid or overshoot due to an abrupt stoppage of flow,
the unit will resume operation when the fluid temperature falls below the temperature
setting.

Under- When the output temperature is 3°C or more below set point for ten seconds, a short
Temperature beep will sound every five seconds, and the display will flash with the first digit
Operation displaying “L” to indicate an under-temperature condition, but the warmers will
continue operation.

Display The display board is connected by a ribbon cable to J10 of the main circuit board.
Board The display consists of four-digit green LEDs. Each segment of the leading digit is
addressable by the microprocessor. In normal operating mode, the first LED segment
is blank, and the remaining three digit display only numbers 0 – 9. The display is
continuously on and updated at one second intervals. Blinking mode is reserved for
Edit Mode.
The display will flash will the heater setpoint is being increased or decreased. After no
change for three second, the display will stop blinking and display the setpoint.

5
Theory of Operation

Keyboard The keyboard is attached to the main circuit board through J12 connector. The user
interface buttons are monitored at a rate of 10 Hz or greater. Four buttons on the
keyboard are used to control temperature setpoint and to check or silence the audible
alarm.

Temperature
Adjustment

Figure 1: Increasing/Decreasing Temperature

The temperature set point can be adjusted by pressing the Increase or Decrease
button on the front panel, located below the temperature setpoint display. Pressing the
Increase button (up arrow) or Decrease button (down arrow) will alter the setpoint in
0.5 degree increments, to a maximum of 42°C or a minimum of 28°C. An error tone is
sounded if the setpoint is already at a limit value. While the user is increasing or
decreasing the temperature setpoint, the display flashes. After no change to the
setpoint is made for three seconds, the display stops flashing and displays the setpoint.

Alarm Control The Alarm Test buttons are located on either side of the setpoint display. Pressing the
Buttons Alarm Test causes a simulation of an over-temperature alarm, followed by a low
temperature alarm. Normal operation automatically resumes within ten seconds after
the test.
The Alarm Silence button causes any microprocessor-caused audible alarm to be
silenced for a two-minute timeout, while any visual alarms messages continue to be
displayed. If the condition persists after the timeout has elapsed, the audible alarm will
sound again.
Note: The secondary over-temperature alarm cannot be silenced with this button. The
unit must be turned off and allowed to cool.

6 WarmFlo FW-538 Service Manual

Wa r n i n g s a n d P r e c a u t i o n s

Warnings:
Blood/Fluid
Warmer
WARNING: Possible electrical shock hazard. Do NOT open or disassemble the
FW-538 blood/fluid warmer. If a malfunction occurs, please notify your sales/
service center.

WARNING: The blood/fluid warmer must be plugged into a properly grounded

115 Volt AC power source.

WARNING: Grounding reliability can only be achieved when the blood/fluid

warmer is connected to an equivalent receptacle marked HOSPITAL ONLY or
HOSPITAL GRADE.

WARNING: If a malfunction occurs in the blood/fluid warmer, immediately

discontinue use. Notify your sales/service center of the malfunction. The unit
must be service by an authorized service technician.

WARNING: Do not use a manual pressure pump in excess of 10 PSI. The high
pressure can cause the cassette to rupture.

7
Warnings and Precautions

Precautions:
Blood/Fluid
Warmer
Caution: Do not place hand between the heater plates. The heater plates may be hot.

Caution: Do not use preheated fluids with the blood/fluid warmer. Fluids preheated to
above 44°C may activate the heater safety mechanism, causing the Over-
Temperature Alarm mode to activate.
Caution: Do not store liquids on top of the blood/fluid warmer.

Caution: Use only Warmflo disposable fluid warming sets with the blood/fluid
warmer.

Caution: Do not use a manual pressure pump in excess of 10 psi. The high pressure
can cause the cassette to rupture.

Precautions:
Disposable
Fluid
Warming Sets

Caution: Refer to instructions for use provided with all disposable warming sets prior
to use.
Caution: To prevent kinks in the fluid line at point A (Figure 2 below), route the fluid
line through the channel in the filter mounting bracket as shown:

Figure 2: Tubing Channel and Filter Mount

Caution: Do not attempt to prime the disposable fluid set while the fluid warming
cassette is outside the blood/fluid warmer or while the door is not latched.

8 WarmFlo FW-538 Service Manual

 Warnings and Precautions

Caution: If the fluid set is primed before the fluid warming cassette is inserted into
the blood/fluid warmer, open all clamps distal to the fluid warming cassette
and allow the cassette to relax before attempting to insert the cassette.
Caution: After use, turn off the pressure infusor if used. Always close the red pinch
clamp prior to removal of the fluid warming cassette from the blood/fluid
warmer. Failure to do so could result in rupturing the fluid warming
cassette.

Fluid warming cassette

Red clamp

Figure 3: Fluid Warming Cassette and Red Clamp

9
Setup and Operation

Setting Up 1. Attach the blood/fluid warmer to a stable IV pole using the IV pole bracket
the Fluid located on the left side of the unit. Mount the unit no higher than at patient level.
Warmer Check that the pole and unit are stable and not easily tipped.
System 2. Attach the power cord to back of unit. Use the strain relief clamp to prevent the
cord from loosening. Plug into a 115 volt hospital grade AC outlet.

Figure 4: Mounting Warmer on IV Pole

3. Turn the FW-538 on using the power switch (I/O) located on the rear panel.
The control panel will display the start-up test mode, followed by the software
revision number. During the start-up routine a continuous beep will sound to test
the over-temperature safety system. When temperature set point is displayed
(38ºC) and three beeps are heard, unit is ready for operation.

Note: Listen for three beeps, indicating the unit is ready for operation, before
inserting cassette.
Note: If any fault code numbers are displayed during the start-up test mode (i.e. F_##),
turn the unit off and then on again to attempt to clear the fault. See the chapter,
Troubleshooting, beginning on page 25.

11
Setup and Operation

4. Adjust the temperature set point (28°C to 42°C) as required, using arrow keys.
The temperature display will flash for 5 seconds to indicate the new temperature
setting.

Caution: The use of preheated fluids above 44°C can activate the Over-Temperature
Alarm.
5. Push the door latch button to open the cassette door. The door will open
downward approximately 1/2 inch (12mm).

6. Slide the Warmflo disposable fluid warming cassette into the door opening until
fully inserted.

Caution: Do not prime the cassette with fluid prior to closing the door, as rupture of
the cassette and fluid leakage may occur.

12 WarmFlo FW-538 Service Manual

 Setup and Operation

7. Close the door by lifting firmly up until the door is latched into position as
indicated by the appearance of the green band on the top edge of the door latch
button.

Note: To be sure that the door is closed, pull out on the door latch button until the
green band is visible.

Caution: The door must be firmly latched prior to use to avoid potential rupture of the
fluid warming cassette.

Priming and 1. Prime the disposable fluid warming cassette according to the instructions for use
Removing a provided with each disposable warming set.
Disposable
2. After use, turn off the automatic pressure infusors or release pressure cuffs if used.
Warming Set Close the red clamp on the disposable warming set. Reduce the pressure on the
disposable fluid warming cassette by releasing fluid downstream.

3. Push the door release button to open the door and remove the cassette.
4. Discard the fluid warming set in appropriate manner.

Alarms
The Alarm Test button can be pressed at any time to check the audible and visual
alarms that occur when either an over-temperature or low temperature condition
exists. Normal system operation automatically resumes after the test, which takes less
than 15 seconds.
The Alarm Silence button causes any audible alarm to be silenced momentarily while
any visual alarm messages are maintained. The audible alarm is restored automatically
after 2 minutes if the alarm conditions persist.

13
Setup and Operation

The FW-538 has multiple independent temperature control and alarm systems to help
assure patient safety. The following alarms are intended to alert users to faulty
operation or out of range performance.

Table 1: Alarm Conditions and Events

Alarm Occurrence Audible Visual Note

Internal Component malfunction None Display of Fault Refer to troubleshooting

Malfunction detected. Code section for index of fault
codes and appropriate
responses.

Over-Temperature Temperature of the Repetitive tone at Flashing display Heater plates are
heater plates is detected one second disabled when over-
to be above 44.5°C for intervals temperature condition is
greater than two seconds. detected.

Low Temperature Temperature of the Short beep every Flashing display Warmer continues to
heater plates is detected five seconds operate.
to be 3°C below setpoint
for 10 seconds.

When performing the alarm test the FW-538 provides a visual temperature display.
The low alarm will display a reading that is three degrees below the set point
temperature. For example, with a set point of 38.0 degrees, L35.0 is displayed when
the unit is operating in an under-temperature condition.
The first over-temperature alarm display will display 44.5 with an “H” preceding the
temperature. The second over-temperature alarm will display 45.0 with an “H”
preceding the temperature.

14 WarmFlo FW-538 Service Manual

I n t e r n a l Te s t M o d e s

Introduction The Warmflo FW-538 software provides three internal test modes. After pressing the
Increase and Decrease temperature keys simultaneously for five seconds, the unit
enters the internal test mode. A series of test modes are accessible in a round-robin
fashion by pressing the Increase key. When a test is initially entered, its test number is
displayed in the first LED, while the other LEDs are blank. The test number is
displayed for one second.
Pressing the Alarm Silence key during any test will cause the program to return to
normal operating mode.

Tests All temperatures displayed in the internal test modes are actual temperatures without
rounding.

Test #1: Zone The first LED displays which zones are heating. The remaining three LEDs display
Heating the output temperature.
Monitoring

Test #2: The first LED displays the currently selected zone (1, 2, 3, lower plate). The selected
Individual zone is displayed as an illuminated segment in the first LED. These segments are
Thermistor mapped in the following way:
Monitoring

The remaining three LEDs display the temperature of currently monitored zone.
Pressing the Decrease key cycles the selected zone round-robin through Zone 1 to the
Lower Plate.

Test #3: The first LED displays the currently selected zone (1, 2, 3, or lower plate), using the
Automatic same method as in Test #2 above. The remaining three LEDs display the temperature
Thermistor of that zone. The zone number cycles automatically at a 1 Hz rate round-robin through
Zone zones 1 to the lower plate.
Monitoring

15
System Performance Checks

System There are two system performance checks for the FW-538 fluid warmer. The first
Testing check verifies the output temperature of fluid passing through a WF-8860 test
cassette. The second check confirms that the Over-Temperature Alarm is functioning
properly.

Equipment This procedure checks the output temperature of fluid passing through a test cassette
Required for installed in the FW-538. In addition to the FW-538 blood/fluid warmer, the following
Output equipment will be required.:
Temperature
Check • WF-8860 Test Kit (Part Number 8860), which contains:
– Cassette and Tubing
– Mycocardial Themocouple Temperature Probe (not required for this test)
– WI-48 High Flow Wound Irrigator
• Reusable TAB Instrument Cable (Part Number 502-0065)

• Mon-a-therm® Temperature Monitor, Model 6510 or equivalent (type T

thermocouple temperature monitor)
• Saline IV bag
• IV pole
The following equipment is optional:
• Warmflo Pressure Infusor or Warmflo Irrigation Pump
• Graduated cylinder

17
System Performance Checks

Test
Procedure

Figure 5: Setup for Output Temperature Check

Referring to Figure 5, check the output temperature of the FW-538 system:

1. Turn the Warmflo blood/fluid warmer power switch located at the rear of the unit
to the ON position. The control panel will display the start-up test mode, followed
by the software revision number. When the temperature set point is displayed
(38°C default), the unit is ready for operation.

2. Push the door latch button on the blood/fluid warmer to open the cassette door.
The door will open approximately 1/2 inch.

3. Slide a clean WF-8860 test cassette into the door opening until it is fully inserted.

18 WarmFlo FW-538 Service Manual

 System Performance Checks

4. Close the door by firmly lifting up on the door until it clicks into position. This is
indicated by the appearance of a green band on the top edge of the Door Latch
Button.

Note: To ensure that the door is closed, pull out on the door latch button until the
green band is visible.

5. Close the clamp indicated .

6. Mount the Air Elimination Chamber into the holder on the side of the FW-538.

7. Open the clamp indicated and use this line to spike the saline IV bag.

8. Hold both the saline bag and the Drip Chamber upside down. Squeeze the
saline bag to push air from the bag into the Drip Chamber. Continue to squeeze
until the Drip Chamber is half full of fluid.

9. Turn the saline bag right side up and hang the bag from the IV pole hook or install
it in the Warmflo Pressure Infusor or Irrigation Pump .

10. Close the roller clamp on the cassette outlet tube.

11. Open the clamp below the saline bag.

12. Pinch the ball in the Air Vent Tube on the Air Elimination Chamber . Saline
solution will begin to flow from the bag into the WF-8860 test cassette set. Allow
the chamber to fill 3/4 to the top with saline solution. Do not allow solution to rise
into the Air Vent Tube.

13. Tap the Air Elimination Chamber to release micro bubbles from the enclosed
filter screen.

14. Attach the female Luer end of the high flow wound irrigator WI-48 to the male
Luer end of the WF-8860 test cassette.

Caution: Use of the WF-8860 test cassette without the high flow wound irrigator
WI-48 attached may lead to lower-than-expected temperatures of the output
fluid while running the output temperature check.

15. Open the roller clamp and press the button on the WI-48 to open the line.
Allow solution to flow until air is purged from the high flow wound irrigator
tubing.

16. Release the WI-48 button and close the roller clamp.

17. Insert the Myocardial Thermocouple Temperature Probe into the distal
Y-injection port of the cassette set. The probe should be carefully positioned
inside the port so that fluid is flowing around the surface of the probe at its distal
end.

19
System Performance Checks

18. Connect the temperature probe to the reusable Instrument Cable , which in turn
should be connected to a type T Thermocouple Temperature Monitor , such as
a Mon-a-therm Model 6510.

19. Turn on the thermocouple temperature monitor.

20. Use the roller clamp on the cassette outlet tube to adjust the fluid flow to
100 ±25 ml per minute while the button on the WI-48 is depressed.

Note: This flow may be measured by timing fluid collection in a small graduated
cylinder.
21. Allow the fluid to flow for 1 minute before taking readings. The average fluid
output temperature should be 38° C ±2°C at 100 ±25 ml per minute, as measured
by the temperature probe.

22. If the above performance cannot be met, refer to the Troubleshooting section in
this manual.

Over- This procedure verifies the operation of the alarm system when an over-temperature
Temperature condition is detected during operation of the FW-538. In addition to the FW-538
Alarm Check blood/fluid warmer, the following equipment is required.:
Procedure
• WF-8860 Test Kit (Part Number 8860), which contains:
– Cassette and Tubing
– Mycocardial Themocouple Temperature Probe (not required for the test)
– WI-48 High Flow Wound Irrigator
• Saline IV bags (2): Cool one bag to 8-10°C; heat second bag to 55-65°C

WARNING: Liquid at 55-65°C is a burn hazard. Use care in handling the IV

bag and its heated contents.

• IV pole
The following equipment is optional:

• Warmflo Pressure Infusor(s) or Warmflo Irrigation Pump(s)

• Graduated cylinder

• Mon-a-therm® Temperature Monitor, Model 6510 or equivalent (type T

thermocouple temperature monitor) and reusable TAB Instrument Cable (Part
Number 502-0065)

20 WarmFlo FW-538 Service Manual

 System Performance Checks

Figure 6: Setup for Over-Temperature Alarm Function Check

Referring to Figure 6, set up the FW-588 to verify the operation of the
Over-Temperature Alarm:
1. Turn the Warmflo blood/fluid warmer power switch located at the rear of the unit
to the ON position. The control panel will display the start-up test mode, followed
by the software revision number. When the temperature set point is displayed
(38°C default), the unit is ready for operation.

2. Push the Door Latch Button on the blood/fluid warmer to open the cassette door.
The door will open approximately 1/2 inch.

3. Slide a clean WF-8860 test cassette into the door opening until it is fully inserted.

4. Close the door by firmly lifting up on the door until it clicks into position. This is
indicated by the appearance of a green band on the top edge of the door latch
button.

21
System Performance Checks

Note: To ensure that the door is closed, pull out on the door latch button until the
green band is visible.

5. Close the pinch clamp indicated .

6. Mount the air elimination chamber into the holder on the side of the FW-538.

7. Open the pinch clamp indicated and use this line to spike the 8-10° saline IV
bag. Install the 8-10°C saline IV bag as follows:

a. Hold both the saline bag and the drip chamber upside down. Squeeze the saline
bag to push air from the bag into the drip chamber. Continue to squeeze until
the drip chamber is half full of fluid .

b. Close the pinch clamp indicated .

c. Turn the saline bag right side up and hang the bag from the IV pole hook at
least one (1) meter from the warming unit or install it in a Warmflo Pressure
Infusor or Irrigation Pump .

8. Open the pinch clamp indicated and use this line to spike the 55-65°C saline
IV bag. Install the 55-65°C saline IV bag as follows:

Note: The Mon-a-therm monitor and temperature probe may be used to determine
the temperature of the pre-warmed IV solution.

a. Hold both the saline bag and the Drip Chamber upside down. Squeeze the
saline bag to push air from the bag into the Drip Chamber. Continue to squeeze
until the Drip Chamber is half full of fluid.

b. Close the indicated pinch clamp .

c. Turn the saline bag right side up and hang the bag from the IV pole hook at
least one (1) meter above the warming unit, or install it in a Warmflo Pressure
Infusor or Irrigation Pump .

9. Close the roller clamp on the cassette outlet tube.

10. Pinch the ball in the air vent tube on the air elimination chamber . Saline
solution will begin to flow from the bag into the 8860 test cassette set. Allow the
chamber to fill 3/4 to the top with saline solution. Do not allow solution to rise
into the Air Vent Tube.

11. Tap the air elimination chamber to release micro bubbles from the enclosed
filter screen.

12. Attach the female Luer end of the high flow wound irrigator WI-48 to the male
Luer end of a clean WF-8860 test cassette .

13. Open the roller clamp and depress the button on the WI-48 to purge the air
from the high flow wound irrigator tubing.

14. Close the roller clamp after air has been fully purged.

22 WarmFlo FW-538 Service Manual

 System Performance Checks

15. Activate the Internal Test Mode of the blood/fluid warmer by simultaneously
pressing the Increase and Decrease Temperature keys for five seconds.

16. Select Test Mode #2 (Individual Thermistor Monitoring) by pressing the Increase
Temperature key until the number “2” is briefly displayed in the first LED of the
fluid warmer display.

17. Press the Decrease Temperature key to select Zone 3 monitoring. When the
segment on the right side of the first LED is illuminated, Zone 3 monitoring is
active.

18. Open the pinch clamp below the 8-10°C bag.

19. Use the roller clamp on the cassette outlet tube to adjust the fluid flow to
100 ±25 ml per minute while the button on the WI-48 is depressed.

Note: This flow rate may be measured by timing fluid collection in a small
graduated cylinder.
20. Allow the 8-10°C fluid to flow for one minute.

21. Close the pinch clamp , stopping the flow of 8-10°C fluid through the system.

22. Open the pinch clamp below the 50-65°C saline bag and depress the button
on the WI-48 to allow the pre-warmed fluid to flow through the system.

23. Observe the temperature at the Zone 3 thermistor on the display of the blood/fluid
warmer.

As the 55-65°C fluid flows through the test cassette, the FW-538 heater plates
absorb the excess heat, driving their temperature above the set point of 38°C.

Two seconds after the temperature reaches 44.5°C ±1°C, the first
Over-Temperature Alarm activates. The heater plates are immediately disabled,
and an intermittent tone sounds at one second intervals.

If the temperature subsequently falls below 44.5°C, and there is no system fault
code reported, the unit will resume normal operation.

Note: If the unit is in the normal operating display mode when the first over-
temperature alarm sounds, the display will read H44.5 (±1.0°C).

23
System Performance Checks

24. Two seconds after the temperature exceeds 45°C ±1°C, the second over-
temperature alarm is activated. This condition is indicated by a continuous audible
alarm.

Note: If the unit is in the normal operating display mode when the second over-
temperature alarm sounds, the display will read H45.0 (±1.0°C), and will
alternate with the display of a fault code, if appropriate.
Note: If the temperature of the heater plates rises too quickly, the first temperature
alarm may not sound the intermittent beep. Rather, the first audible alarm
may be a continuous tone, signaling the second over-temperature alarm that
occurs above 45°C. The procedure may be repeated using a slower flow
rate or using pre-warmed saline solution of slightly lower temperature.
25. If the blood/fluid warmer fails to properly enter the Over-Temperature Alarm
condition, and/or fails to demonstrate both audible and visual over-temperature
alarms, immediately remove the unit from service. Notify your sales/service
center of the malfunction. The unit must be serviced by an authorized service
technician.

24 WarmFlo FW-538 Service Manual

Tro u b l e s h o o t i n g

If the solutions in this section fail to correct the problem, contact Nellcor’s Technical
Service Department (1-800-635-5267) or your local representative.

Problems
Table 2: System Problems and Solutions

Symptom Observe Solution

The LED display is AC power cord is not • Plug in the power cord.
dark plugged in.

Power switch is not turned • Turn the power switch on

on. rear panel to ON.

Fuse blown • Open enclosure and replace

with fuse value .63A 50V T
fuse.

LED connector is loose • Push down LED connector

into the J10 receptacle on
the main circuit board.

Cassette door will not The cassette is full of fluid • Close the red clamp at the
engage latch. and the tubing clamps are heat exchanger to release
closed. pressure on the cassette.
Release the fluid
downstream.
• If transferring a cassette
from one warmer to
another, be sure the red and
white clamps are open.

Cassette door will not The cassette is full of fluid • Close the red clamp at the
open and/or under pressure. heat exchanger to release
pressure on the cassette.
Release the fluid
downstream.

Spring mechanism inside • The Warmflo unit provides

door is broken. an emergency technique to
remove the cassette if
normal procedures do not
open the door. Locate the
hole in the middle part of
the bottom of the door. (It
can be felt with a finger.)
Insert a #2 Phillips
screwdriver. Push back
until door opens.
Note: Earlier units may not
have this hole.

25
Troubleshooting

Table 2: System Problems and Solutions (Continued)

Symptom Observe Solution

Fluid output The temperature set point • Adjust the temperature set
temperature is too low. is too low. point to the desired setting.

The fluid flow is being • Ensure all clamps above

restricted above the heat the heat exchanger for the
exchanger. spike in use are open.

Excessive high flow rate. • Reducing the flow rate will

increase warming
efficiency.

Heater plates are dirty. • Open the cassette door and

clean the heater plates
according to instructions in
Preventive Maintenance on
page 31.

Over-Temperature Pre-warmed fluids were • Do not use pre-warmed

Alarm used. fluids.

High flow rate stopped • Unit will cool and alarm

suddenly. will reset automatically.

Low Temperature Excessive high flow rate • Reduce the flow rate.
Alarm

Table 3: System Fault Codes

Fault Code Problem Solution

FAULT CODE 01 Defective or wrong • Replace main PCB assembly.

EPROM

FAULT CODE 02 Defective RAM • Replace main PCB assembly.

FAULT CODE 04 Defective NVRAM • Replace main PCB assembly.

FAULT CODE 05 Membrane panel switch is • Push the key again. Restart
stuck. the unit.
• Replace cover assembly if
problem persists.

FAULT CODE 08 Microprocessor failure • Replace main PCB assembly.

FAULT CODE 09 OT_REF offset out of • Replace main PCB assembly.

range Voltage Reference
error

FAULT CODE 10 EXT_OT failure • Replace main PCB assembly.

26 WarmFlo FW-538 Service Manual

 Troubleshooting

Table 3: System Fault Codes (Continued)

Fault Code Problem Solution

FAULT CODE 11 Heater Zone 1 thermistor • Thermistor in Zone 1 is open

failure or shorted, possibly caused
by a loose connector, J6, on
main board. Push J6
connector all the way down.
• Defective thermistor.
Replace chassis assembly.
• If the previous two steps
don’t resolve problem,
replace main PCB assembly.

FAULT CODE 12 Heat Zone 2 thermistor • Thermistor in Zone 2 is open

failure or shorted, possibly caused
by a loose connector, J6, on
main board. Push J6
connector all the way down.
• Defective thermistor.
Replace chassis assembly.
• If previous two steps don’t
resolve problem, replace
main PCB assembly.

FAULT CODE 13 Heater Zone 3 thermistor • Thermistor in Zone 3 is open

failure. or shorted, possibly caused
by a loose connector, J6, on
main board. Push J6
connector all the way down.
• Defective thermistor.
Replace chassis assembly.
• If previous two steps don’t
resolve problem, replace
main PCB assembly.

FAULT CODE 17 Heater lower plate • Thermistor in lower plate is

thermistor failure. open or shorted, possibly
caused by a loose connector,
J6, on main board. Push J6
connector all the way down.
• Defective thermistor.
Replace door assembly.
• If previous two steps don’t
resolve problem, replace
main PCB assembly.

FAULT CODE 20 Heater Enable failure. • Temperature higher than

44.5°C is sensed. Shut down
the unit. Wait for 5 minutes.
Restart the unit. If problem
persists, replace the main
PCB assembly.

27
Troubleshooting

Table 3: System Fault Codes (Continued)

Fault Code Problem Solution

FAULT CODE 21 Triac Zone 1 failure. • Shut down the unit. Wait for
Heater Zone 1 does not 5 minutes. Restart the unit.
turn on during • Defective Triac Q6 or
initialization. Optoisolator U4. Replace
main PCB assembly.

FAULT CODE 22 Triac Zone 2 failure. • Shut down the unit. Wait for
Heater Zone 2 does not 5 minutes. Restart the unit.
turn on during • Defective Triac Q4 or
initialization. Optoisolator U2. Replace
main PCB assembly.

FAULT CODE 23 Triac Zone 3 failure. • Shut down the unit. Wait for
Heater Zone 3 does not 5 minutes. Restart the unit.
turn on during • Defective Triac Q2 or
initialization. Optoisolator U1. Replace
main PCB assembly.

FAULT CODE 30 Heater Zone 1 failed • Cassette with preheated fluid

preheat test. A/D is used. Shut down the unit.
channel 1 failed preheat Wait for 5 minutes. Restart
warmer test. Temperature the unit.
higher than 42°C is sensed • Defective thermistor in
during preheat test. Zone 1. Replace main PCB
assembly.

FAULT CODE 31 Heater Zone 2 failed • Cassette with preheated fluid

preheat test. A/D is used. Shut down the unit.
channel 2 failed preheat Wait for 5 minutes. Restart
warmer test. Temperature the unit.
higher than 42°C is sensed • Defective thermistor in
during preheat test Zone 2. Replace main PCB
assembly.

FAULT CODE 32 Heater Zone 3 failed • Cassette with preheated fluid

preheat test. A/D is used. Shut down the unit.
channel 3 failed preheat Wait for 5 minutes. Restart
warmer test. Temperature the unit.
higher than 42°C is sensed • Defective thermistor in
during preheat test Zone 3. Replace main PCB
assembly.

FAULT CODE 41 Heater control failure. • Shut down the unit. Wait for
Heater is stuck on. 5 minutes. Restart the unit.
• Defective Triac. Replace
main PCB assembly.

FAULT CODE 42 Heater Zone 1 turn on • Shut down the unit. Wait for
failure. Heater Zone 1 5 minutes. Restart the unit.
does not turn on during run • Defective Triac Q6 or
time. Optoisolator U4. Replace
main PCB assembly.

28 WarmFlo FW-538 Service Manual

 Troubleshooting

Table 3: System Fault Codes (Continued)

Fault Code Problem Solution

FAULT CODE 43 Heater Zone 2 turn on • Shut down the unit. Wait for
failure 5 minutes. Restart the unit.
• Defective Triac Q4 or
Optoisolator U2. Replace
main PCB assembly.

FAULT CODE 44 Heater Zone 3 turn on • Shut down the unit. Wait for
failure 5 minutes. Restart the unit.
• Defective Triac Q2 or
Optoisolator U1. Replace
main PCB assembly.

FAULT CODE 45 External RAM test failure • Replace main PCB board.

FAULT CODE 46 Thermistor test failure • Shut down the unit. Wait for
5 minutes. Restart the unit.
• Replace main PCB board.

NVRAM Mode The systems uses an NVRAM (non-volatile random access memory) U19 chip for
permanent storage of fault codes. The microprocessor enters the NVRAM mode if the
test pin (J14 pin 1) is connected to ground (J14 pin 2). If the jumper is installed
between J14 pin 1 and pin 2 when the unit is powered on, the last fault code stored in
NVRAM is displayed. To clear the fault codes, remove the jumper from J14 while the
unit is displaying fault codes.
Note: Normal operation mode requires the jumper to be removed or to be installed on
one pin only.
The unit is supplied with a jumper only on one pin of the J14 connector. If the test pin
is not installed, the program will bypass the NVRAM mode and display a fault code
only when one is detected.
The NVRAM storage holds the most recent 16 fault codes. With the jumper in place,
the display shows the most recent fault memory cell in the format F_##. Press the
Increase key will cycle through all the stored fault codes in a round-robin fashion.
After reviewing the fault codes, remove the jumper while the unit is on, clearing all of
the fault codes. Install the jumper on only one pin. Turn off the unit. When the unit is
restarted, it will return to normal operation mode, and will display a fault code when
one is detected.

Electro- This device has been tested and found to comply with the limits for medical devices to
magnetic the IEC 60601-1-2:1993. These limits are designed to provide reasonable protection
Interference against harmful interference in a typical medical installation.
However, because of the proliferation of radio-frequency transmitting equipment and
other sources of electrical noise in the health-care environment, it is possible that high
levels of such interference, due to close proximity or strength of a source, may result
in disruption of performance of this device.

29
Troubleshooting

This equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with these instructions, may cause harmful
interference with other devices in the vicinity. Disruption or interference may be
evidenced by cessation of operation or incorrect functioning. If this occurs, the site of
use should be surveyed to determine the source of this disruption, and actions taken to
eliminate the source.
The user is encouraged to try to correct the interference by one or more of the
following measures:
• Turn equipment in the vicinity off and on to isolate the offending equipment.
• Reorient or relocate the other receiving device.
• Increase the separation between the interfering equipment and this equipment.
• If assistance is required, contact Nellcor’s Technical Service Department or your
local representative.

30 WarmFlo FW-538 Service Manual

Preventive Maintenance

WARNING: Electrical Shock Hazard. Disconnect the unit from AC power prior
to cleaning. Thoroughly dry before returning to service.

Caution: Do not scratch the heater plates. Do not use abrasive materials or polishing
cloth.
Caution: To prevent equipment damage, do not autoclave or immerse in liquids.

Note: For easy access to the heater plates, with cassette door in open position, push
the release button on the bottom of the unit. The door will swing open
approximately 3 inches. (See Figure 7 below.)

Figure 7: Accessing Heater Plates

31
Preventive Maintenance

The following Preventive Maintenance procedures are recommended.

Table 4: System Preventative Maintenance

Action Frequency Method

Clean exterior surfaces As required with use. Use warm, mild soap water
and soft cloth. Heater plates
must be smooth, clean and
free of surface imperfections
to assure proper warming
performance.
Clean heater plates As required if contaminated Use warm, mild soap water
with blood or other fluids or and soft cloth. Wipe dry with
debris. clean, soft cloth.

WARNING: Do not scratch heater plates. Do not use abrasive materials or a

polishing cloth.

Electrical safety check Prior to patient use and Refer to hospital standards.
annually thereafter.
Output temperature Annually Refer to System
performance check Performance Checks on
page 17.
Alarm test Annually. May be tested Press the Alarm Test button
prior to each use or at any on the front control panel.
time during use. Any time the unit is turned
on audible and visual high
and low temperature alarms
will cycle for approximately
10 seconds, then the unit will
automatically return to
normal operation.

32 WarmFlo FW-538 Service Manual

Specifications

Dimensions 4.75 inches x 5.75 inches x 11 inches (Height x Width x Depth)

Weight 8 pounds

Technical Complies with Standards: IEC 60601.1, UL 2601-1, CSA C22.2 No 601.1-M90
Specifi-
cations Supply Voltage 115 Volts AC
Operating Frequency 50 to 60 Hz
Maximum Operating Current 12 Amperes
Maximum Heating Power 1,440 Watts
Warmer Circuit Breaker Rating 12 Amperes
Electrical Equipment Class Class 1 equipment
Patient Applied Part Type BF equipment
Heat Transfer Method Dry Heat
Temperature Control Range 28.0 ° C to 42.0° C
Default Set Point Temperature 38.0° C
Low Temperature Alarm 3.0° C below set point
Over-Temperature Alarm 44.5° C
Secondary Heater Disable 45.0° C
Display Screen Four-digit green LED
Fluid Ingress Protection Drip Proof (IPX2)
Operating Temperature Range 10° C to 30° C
Operating Relative Humidity 10% to 95% non-condensing
Operating Elevation 0 to 10,000 feet
(0 to 3,048 meters)
Mode of Operation Continuous

33
Specifications

Transpor-
tation and
Storage Ambient Temperature -25°C to 55°C (-13º F to 131º F)

Relative Humidity 10% to 95% non-condensing

Elevation 0 to 10,000 feet

Performance 1. 10°C fluid at the input of the cassette must be warmed to a minimum of 34 °C at
Requirements four feet (1.2 meters) past the air trap with a 38°C temperature set point. This
applies to a flow rate range of 25-400 ml/minute.

2. 20°C fluid at the input of the cassette must be warmed to a minimum of 34°C at
four feet (1.2 meters) past the air trap with a 38°C temperature set point. This
applies to a flow rate range of 25 to 600 ml/minute.

34 WarmFlo FW-538 Service Manual

Accessories and Spare Parts

The following Warmflo disposable fluid warming cassettes, pressure infusors, and
spare parts are approved for use with the FW-538 blood/fluid warmer. Other fluid
cassettes may be available. Contact Nellcor’s Technical Service or your local
representative, or check the internet at:
http://www.mallinckrodt.com/respiratory/resp/Serv_Supp/Apartweb/main/
PartAcceMenu.html

Disposable WF-100 Cassette, Fluid Warming

Fluid WF-250 Cassette, Surgical Fluid Warming
Warming WF-8860 Test Cassette Kit
Cassettes

Pressure AD 500FW Infusor, 500 ml

Infusors AD 1000FW Infusor, 1000 ml
AD 1500FW Infusor, 500 & 1000 ml, Mounted
AD 2000FW Infusor, Dual 1000 ml, Mounted
If the FW-538 blood/fluid warmer is used with a Surgical Irrigation Pump or an
Automatic Pressure Infuser, carefully read the accessory directions for use, and all
warnings, precautions, and specifications before using the equipment with the
FW-538.

Spare Parts 128-5017SP Bracket, Air Filter Mount

520-0006SP Chassis Assembly
520-0008SP Cover Assembly
520-0010SP Door Assembly
128-5002SP Fuse, .063A 50 volt
520-0014SP PCB Assembly, Display
520-0007SP PCB Assembly, Main
128-5018SP Plug, Wire Cover
128-4020SP Power Cord, 14 ft.
128-0009SP Rear Panel Assembly
128-2039SP Screw, IV Pole
128-2036SP Screws, PCB Assembly
128-2031SP Screws, Rear Panel attachment
128-2020SP Strain Relief

35
Appendices

The following schematics for the FW-538 blood/fluid warmer are available for
reference:
Main Control Board Schematic, Sheet 1of 2
Main Control Board Schematic, Sheet 2 of 2
Display PCB Schematic

37
PART NUMBER 129-9001 VCC DATE SYM REVISION RECORD AUTH DR. CK.
ECO#
3/98 - INITIAL RELEASE 973 cde

R27
R23 R22 R24 R25 R26 R34 R36 R2

5760 .1%
5760 .1%
5760 .1% 5760.1% 4.7K 4.7K
OT_REF 5760 .1% 4.7K 5760 .1%
SENS_ZN_1
OT_REF_HI
R21 R20 SENS_ZN_2

4.530K 0.1% 4.870K 0.1% SENS_ZN_3

U28

8 9
GND IN9
7 10
IN7 IN10
6 11
IN6 IN11
5 12
IN5 IN12
4 13 Lower Plate
IN4 IN13 VCC
3 14
IN3 IN14 C11
2 15
IN2 IN15 C2 C3 C4 C7 C8 C10 .1
1 16 J6
IN1 VCC .1 .1 .1 .1 .1 .1
D[0..7] 1
U21
SP720AP 2
1 68
P5.0/ADC0 P5.1/ADC1 3
2 67 U23 U25
JMP4 VDD P5.2/ADC2 4
3 66 D0 3 2 10 11 D0
0 ohm STADC P5.3/ADC3 D0 Q0 A0 O0 5
Cut to 4 65 D1 4 5 9 12 D1
disable PWM0 P5.4/ADC4 VCC D1 Q1 A1 O1 6
5 64 C35 D2 7 6 8 13 D2
J12 U26 pin 11 watchdog PWM1 P5.5/ADC5 C34 D2 Q2 A2 O2
6 63 + D3 8 9 7 15 D3 ZONE SENSORS
EW P5.6/ADC6 D3 Q3 A3 O3
INCREASE 7 62 .1 D4 13 12 6 16 D4
1 P4.0/CMSR0 P5.7/ADC7 4.7 D4 Q4 A4 O4
DECREASE 8 61 D5 14 15 5 17 D5
2 P4.1/CMSR1 AVDD D5 Q5 A5 O5
ALARM_TEST 9 60 D6 17 16 4 18 D6
3 P4.2/CMSR2 AVSS D6 Q6 A6 O6
ALARM_SILENCE 10 59 100 ohm D7 18 19 3 19 D7
4 P4.3/CMSR3 AVREF+ RP1 D7 Q7 A7 O7
SPARE 11 58 A8 25
5 P4.4/CMSR4 AVREF- A8
TEST 12 57 D0 1 A9 24 J9
6 P4.5/CMSR5 P0.0/AD0 10 7 OC A10 A9
13 56 D1 11 21
7 P4.6/CMT0 P0.1/AD1 9 8 G A10 1
14 55 D2 A11 23
8 P4.7/CMT1 P0.2/AD2 12 5 A11 2
15 54 D3 74HC373N A12 2
9 J 14 RST P0.3/AD3 11 6 A12
16 53 D4 A13 26 Lower Plate Sensor
10 DRV_ZN1- P1.0/CT0I P0.4/AD4 14 3 A13
17 52 D5 A14 27
1 P1.1/CT1I P0.5/AD5 13 4 A14
KEYBD 18 51 D6
2 DRV_ZN2- P1.2/CT2I P0.6/AD6 16 1
19 50 D7 A15 20
P1.3/CT3I P0.7/AD7 15 2 CE
TEST 20 49 22
DRV_ZN3- P1.4/T2 EA OE
21 48 1 J10
P1.5/RT2 ALE VPP
22 47 D0
P1.6 PSEN 1
23 46 27C256-12/P D1
P1.7 P2.7/A15 VCC 2
24 45 [AT29C256-12PC] D2
P3.0/RXD P2.6/A14 3
25 44 D3
P3.1/TXD P2.5/A13 4
26 43 D4
P3.2/INT0 P2.4/A12 5
27 42 D5
P3.3/INT1 P2.3/A11 6
HEATER_SET+ 28 41 D6
P3.4/T0 P2.2/A10 7
29 40 D7
P3.5/T1 P2.1/A09 8
HEATER_OC- 30 39
P3.6/WR P2.0/A08 9
31 38
P3.7/RD NC 10
32 37
CURRENT_SENS- NC VSS VCC 11
33 36 U29
NC VSS 12
34 35 1 15
HEATER_EN- XTAL2 XTAL1 A Y0 13
2 14 U5
B Y1 14
3 13 8 9
C Y2 A0 D0 15

1
80C552-4A68 12 7 10
Y1 Y3 U10 A1 D1 16
11 6 11
Y4 74HC00 A2 D2
6 10 5 13 DISPLAY
G1 Y5 A3 D3
4 9 4 14
C38 C39 G2A Y6 A4 D4
11.0592 MHz 5 7 3 15
G2B Y7 A5 D5
22 pF 22 pF 2 16
A6 D6

8
7
6
5
4
3
2
1
74HC138N 1 17
A7 D7 U26
23
A8

R8
R7
R6
R5
R4
R3
R2
R1
22

3
4.7K_DIP
A9
19
A10
WR-
18
CE

R10
R11
R12
R13
R14
R15
COM
20

R9
WATCHDOG- OE
21
WE

LH5116-15

9
10
11
12
13
14
15
16
TONE
VCC

13
1
2
EXTERNAL OVER- CURRENT_SENS-
U12A

HEATER_SET+
U19
HEATER_OC-
4 3
DO DI
1 CSPUP
9 CE
1 61 2
SK
60

12
10 U21 Pin 6
U21 Pin
6
Configuration RECALL
7 RESET+
STORE VCC Vcc

X24C44P
U30 LS1
R45
7
26 44 ST
3
27 43 TOL C33

8
JMP 5 6 2 R47 4.7K
SRST TD U15A 270K
5 1 PBRST- OT_REF_HI 3 4.7 SPEAKER
RST RST + +
1
0 ohm DS1232 2
Lower Plate -
Cut to U27 LM393N
disable
3 2 R49

4
reset
1Y1 1A1
5 4 33K
1Y2 1A2 U12B
7 6
1Y3 1A3
9 10 3 R1
RESET+ 1Y4 1A4 Q5
4 6
11 12 5 2N3904
2Y1 2A1
13 14 4.7K
2Y2 2A2
74HC27
1
1G VCC
15
C18 2G

.1 74HC367N
U24

U12C
1 2
11
C12 3 4 C17 DISABLE
.1 10 8
5 6 EXT_OT-
9
J11 7 8
9 10 .1
5 11 12 74HC27
Ring
4 13 14 R48
3 15 16 VCC C15
4.7K
Tip 2
1 MAX202CPD
Shield VCC

RS 232 .1
C13
.1 VCC

+ C37 + C23 + C41 C32 C24 C43 C42 C36 C27 C26 C40 C29 C28 C22 C20 SHEET 1 of 2
.1 .1 .1 .1 .1 .1 .1 .1 .1 .1 .1 .1
4.7 4.7 4.7 ITEM DRAWING # DESCRIPTION REMARKS
GND TOLERANCES Nellcor Puritan Bennett, Inc
(except as noted)
Tyco Healthcare
Decimal
4280 Hacienda Drive.
.X ±
Pleasanton, CA 94585
.XX ±
.XXX ±
Fractional Title

Angular
±
Main Control Board Schematic
± Warmflo Model 538/588
Material Drawn By File Index No. Scale Date Drawing Number Rev.

C. EDWARD 129-9001-1 NTS 3/04/98 129-9001 -

This drawing is the property of Mallinckrodt Anesthesiology Division, Mallinckrodt Medical, Inc. and shall not be reproduced,
copied or used for any purpose except as specified by Mallinckrodt Anesthesiology Division, Mallinckrodt Medical, Inc.

39
PART NUMBER 129-9001 DATE SYM REVISION RECORD AUTH DR. CK.
ECO#
3/98 - INITIAL RELEASE 973 cde

DC POWER SUPPLY

U9 LM340T-5 Vcc

1 3 +5V
IN OUT
FOR 220-240 VAC INPUT CUT J2 AND J3

GND
F3
FOR 100-120 VAC INPUT CUT J1 + C5 C6 + C1 J4
470 10
D1 .1
F1 1
J3 RXE90

2
T2 2
LINE 1 5
1 - +
NEUTRAL FAN
2 J3
3 1/16 A_240_VAC Slo Blo
J1 0 Ohms

2
Power Input 2 6
MOV1 DF04
0 ohm
3 7
275 V BRIDGE
J2

1
0 Ohms

4 8

Prem SPW 1100

T1
TRANSFORMER
HEATER ENABLE

2
VCC
1 6 R8
VCC
100
+ Q1
C14 C25 C16 R33

2
Q6015L5
4.7 .1 .1 680
R10
2 4 3
510 U3 ZERO
1N4148

1
CROSS
CIRCUIT
D8
MOC3063-T
D7

1N4148

HEATER DRIVERS

1 6 R19
VCC
100
Q6

2
Q6015L5
HEATER CURRENT DETECT R32
2 4 3
510 U4 ZERO
UPPER HEATER

1
VCC CROSS
CSPUP CIRCUIT J1
MOC3063-T Zone 1
Zone 2 1
R14 Zone 3 2
1 6
VCC 100 3
R44
R40 4
10K U15B Q4 Heater Common

2
4.7K Q6015L5 Burndy HEADER
LM393N R41
8

R11
5 2 4 3
CURRENT_SENS- 7 - 100K 510 U2 ZERO
6

1
CROSS
+
C19 CIRCUIT
MOC3063-T
4

.1
R37
680 1 6 R13
VCC 100

Q2

2
Q6015L5
HEATER_SET+ R9
2 4 3
510 U1 ZERO

1
CROSS
CIRCUIT
MOC3063-T

EXTERNAL OVER- Power Connections

U10
TEMPERATURE 12
LOWER HEATER
11 PART ID +5V Ground
13 J2
EXT_OT-
U5 24 12
1
74HC00 U9 3 2 2
3
U10 14 7
4
HEATER_EN- U12 14 7
Burndy HEADER
U13 U13 20 10
DRV_ZN1- 2 18
1A1 1Y1 U15 8 4
4 16
1A2 1Y2
6 14
DRV_ZN2- 1A3 1Y3 U19 8 5
8 12
1A4 1Y4
DRV_ZN3- 11 9 U21 2 36&37
2A1 2Y1
13 7
2A2 2Y2 U23 20 10
15 5 HEATER_OC
2A3 2Y3
17 3 U24 16 15
2A4 2Y4
TEST U25 28 14
1
1G
HEATER_OC- 19 J13 U26 16 NA
2G Vcc +5V
1 2 U27 16 8
74HC244N OT_REF HI 3 4
U28 16 8
SHEET 2 of 2
5 6
7 8 U29 16 8
OT_REF 9 10
U30 8 4
11 12
CURRENT_SENS- 13 14 EXT_OT- ITEM DRAWING # DESCRIPTION REMARKS
15 16
HEATER_SET- TOLERANCES Nellcor Puritan Bennett Inc.
TEST (except as noted)
Tyco Healthcare
Decimal
4280 Hacienda Drive
U10 U10 .X ±
Pleasanton, CA 94588
PBRST- .XX ±
9 4
.XXX ±
8 6
Fractional Title
10 5

74HC00 74HC00 Angular

±
Main Control Board Schematic
± Warmflo Model 538/588
Material Drawn By File Index No. Scale Date Drawing Number Rev.

C. EDWARD 129-9001-2 NTS 3/04/98 129-9001 -

This drawing is the property of Mallinckrodt Anesthesiology Division, Mallinckrodt Medical, Inc. and shall not be reproduced,

41
copied or used for any purpose except as specified by Mallinckrodt Anesthesiology Division, Mallinckrodt Medical, Inc.
PART NUMBER 129-9002 DATE SYM REVISION RECORD AUTH DR. CK.
ECO#
3/98 - INITIAL RELEASE 973 cde

D3

16
A1
15
B1
3
C1
2 14
D1 DIG1
1
E1
18
F1
17
G1
4
DP1

11
A2
10
B2
8
C2
6
D2
5 13
E2 DIG2
12
F2
7
J1 G2
U1 9
DP2
D0 12 4
1 ID0 DP
D1 11 27 LN524GA
2 ID1 SEGA
D2 13 3
3 ID2 SEGB
D3 14 1
4 ID3 SEGC
D4 10 25
5 ID4(SHUT) SEGD
D5 6 2
6 ID5(DEC) SEGE
D6 5 24
7 ID6(HEXA) SEGF D3
D7 7 26
8 ID7(DATA) SEGG
A8 16
9 A1
9 18 15
10 MODE D8 B1
8 21 3
11 WRITE D7 C1
22 2 14
12 D6 D1 DIG1
17 1
13 D5 E1
20 18
14 D4 F1
23 17
15 D3 G1
16 4
16 D2 DP1
15
D1
CON16 11
A2
ICM7218AIPI 10
B2
8
VCC C2
6
D2
C1 5 13
C2 C3 C4 E2 DIG2
+ 12
F2
7
G2
47 uF .1 .1 .1 9
DP2

LN524GA

ITEM DRAWING # DESCRIPTION REMARKS

TOLERANCES Nellcor Puritan Bennett Inc.
(except as noted)
Tyco Healthcare
Decimal
4280 Hacienda Drive
.X ±
Pleasanton, CA 94588
.XX ±
.XXX ±
Fractional Title

Angular
±
Display PCB Schematic
± Warmflo Model 538/588
Material Drawn By File Index No. Scale Date Drawing Number Rev.

C. EDWARD 129-9002 NTS 3/04/98 129-9002 -

This drawing is the property of Nellcor Puritan Bennett Inc and shall not be reproduced,
copied or used for any purpose except as specified by Nellcor Puritan Bennett Inc.

43
Tyco Healthcare Group LP
Nellcor Puritan Bennett Division
Pleasanton, CA
1-800-635-5267

Rx ONLY

© 2001 Nellcor Puritan Bennett Inc. All rights reserved. 064664A-0102