Augustine Medical Bair Hugger 200 Series User manual

SERVICE MANUAL
Bair Hugger Series 200 and 500
Warming Units
*
* Bair Hugger, Total Temperature Management, 241, and Augustine Medical/light bulb logo/bright ideas...that work, are trademarks of Augustine Medical
Inc., registered or pending in the U.S. and other countries.

Worldwide Technical Service and Order Placement
United States, Puerto Rico, Canada, Worldwide
Technical Service TEL: [phone] Technical Service (USA) TEL: [phone]
1-800-733-7775 FAX: [phone]
Order Placement TEL: [phone] Technical Service (Germany) TEL: [phone]
1-800-733-7775 FAX: [phone]
FAX: [phone] Order Placement (USA) FAX: [phone]
1-800-775-0002
In-Warranty Repair and Exchange
Replacement parts to correct a problem are delivered at no charge. To return a device to
Augustine Medical, Inc. for service, first obtain a Return Authorization (RA) number from a
technical service representative. Please use this number on all correspondence when returning a
device for service. A shipping carton will be delivered to you at no charge, if needed. We will
service and ship your device within five (5) working days of our receipt. Call your local supplier
or sales representative to inquire about loaner devices while your device is being serviced.
When You Call for Technical Service
Remember, we will need to know the serial number of your Unit when you call us.

The Bair Hugger brand Total Temperature
Management System was developed by an
anesthesiologist to prevent and/or treat the
common but significant problem of hypothermia.
Examples of current applications for Bair Hugger systems
are post anesthesia care units (PACU), recovery rooms,
operating rooms, emergency departments, obstetrical
suites, and intensive care areas.
The warming unit draws ambient air through a filter and
warms the air to the specified temperature. It then
delivers the warmed air through a hose to the Bair Hugger
blanket over the patient.
When used properly, the Bair Hugger blanket distributes
the warm air around the patient’s body, creating a warm
environment.
This manual describes how to service Bair Hugger
warming units, and includes maintenance instructions
and specifications. Instructions for use can be found in
the Operation Manual, and instructions included with
Bair Hugger blankets and
2
4
1 fluid warming sets.
©2002 Augustine Medical, Inc. All rights reserved.
Total
Temperature
Management
System

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Augustine Medical, Inc.
Table Of Contents
Precautionary Information
Contraindications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Read Before Servicing Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Model 200 Series Warming Units
Cabinet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Board Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Over Heat Alarm Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Over Heat Alarm Thermostat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Normal Operating Temperature Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Normal Operating Temperature Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exploded Views of Model 200 and 250 Units. . . . . . . . . . . . . . . . . . . . . . . . 21
Model 500 Series Warming Units
Cabinet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Board Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Over Heat Alarm Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Over Heat Alarm Thermostat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Normal Operating Temperature Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Normal Operating Temperature Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 40
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exploded Views of Model 500 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
APPENDIX
Returning Units for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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Augustine Medical, Inc.
Precautionary Information
Contraindications
Temperature
Do not apply heat to lower extremities during aortic cross-
clamping. Thermal injury may occur if heat is applied to
ischemic limbs.
200 Series Units
Do not use 200 Series warming units in operating rooms.
Thermal injury and airborne contamination may result.
Warnings
200 Series Units
Do not use the HIGH temperature setting on 200 Series
warming units when treating patients with the following
conditions:
•Significant peripheral vascular disease (occlusive or
diabetic)
•Low cardiac output
•Total immobilization
•Marginal cutaneous perfusion
Monitor the patient’s temperature at least every 10 to 20
minutes. Risk of thermal injury is significant for this group of
patients.
Bair Hugger Therapy
Do not use Bair Hugger warming units with any forced-air
blanket or cover other than Bair Hugger blankets. Thermal
injury may result.
Do not use any fluid administration device other than the 241
fluid warming set with the Bair Hugger warming unit. Fluid
temperature outside the indicated range may result.
Do not warm patients with the warming unit hose alone.
Thermal injury may result. Always attach the hose to a Bair
Hugger blanket before providing skin surface warming therapy.
Do not use the 241 fluid warming set with any other forced air
warming system other than the 500 Series Bair Hugger system.
Fluid temperature outside the indicated range may result.

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Alarm
Do not continue therapy if the Over Heat Warning light
illuminates and the audible alarm sounds. Thermal injury may
result. Turn the warming unit off and contact qualified service
personnel. If using the 241 fluid warming set, immediately
stop fluid flow, and discard the fluid warming set.
Precautions
Monitor Temperature
Monitor the patient’s temperature at least every 10-20
minutes, and monitor patient vital signs regularly. Reduce air
temperature or discontinue therapy when the therapeutic goal
is reached or if vital sign instability occurs. Notify physician
immediately of vital sign instability.
Pediatric Use
To prevent suffocation from misuse, do not leave children or
infants unattended when administering Bair Hugger therapy.
Sterility
Except for specific blanket models, Bair Hugger blankets are
not sterile. All Bair Hugger blankets are intended for single
patient use only. Placing a sheet between the Bair Hugger
blanket and the patient does not prevent contamination of
this product.
Patient Safety
Series 500 and 600 blankets meet an international standard
for flammability, IEC 695-2-2, and the Consumer Product
Safety Commission’s flammable fabric regulation, 16 CFR
1610; however, follow standard safety protocols when using
high intensity heat sources.
Visual Distortion
The blanket’s clear plastic drape may cause visual distortion.
Lift the plastic drape to view the patient’s head clearly.
Read Instructions
See CONTRAINDICATIONS and WARNINGS before
administering therapy. Read the Operation Manual, blanket
instructions and fluid warming package instructions before
use.

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Important Information
Explosion Hazard
Do not use in the presence of flammable anesthetics.
Electrical Shock Hazard
Do not disassemble the warming unit; refer to an authorized
service technician. There are electrically live parts within the
warming unit when it is connected to the power source, even
when the switches are in the OFF or STANDBY position.
Electrical Interference
If radio frequency interference with monitoring equipment
should occur, connect the warming unit to a different power
source.
Read Before Servicing Equipment
The repair, calibration, and servicing of the warming unit
requires the skill of a qualified Medical Equipment Service
Technician who is familiar with good practice for medical
device repair. If service is designated as not requiring
manufacturer’s attention, the technical information is provided
in this Service Manual or will be provided, on request, by
Augustine Medical, Inc.
Refer to Service Manual
Perform all repairs and maintenance in accordance with the
instructions in this Service Manual.
Safety Inspection
Perform a safety inspection after making repairs to the
Bair Hugger warming unit, and before returning the warming
unit to service. A safety inspection should include a test of the
operating temperatures (described in this Service Manual), the
Over Heat Alarm system, as well as a leakage current test.
Proper Use and Maintenance
Augustine Medical, Inc. assumes no responsibility for the
reliability, performance, or safety of the equipment if:
•Modifications or repairs are performed by non-authorized
personnel.
•The equipment is used in a manner other than that
described in the Operation or Service Manuals.
•The equipment is installed in an environment that does
not meet the relevant grounding requirements.

Model 200 Series Warming Units
4Augustine Medical, Inc.

Cabinet Cleaning
Tools/Equipment
Soft cloth, lightly dampened with water and mild detergent.
Method
1. Disconnect the warming unit from the power source.
2. Wipe the exterior of the warming unit clean.
CAUTION: Do not use a dripping wet cloth when cleaning the
warming unit. Moisture may seep into the electrical contacts and
damage the components. Do not use alcohol or other solvents to
clean the cabinet. Solvents may damage the labels and other
plastic parts.
Hose Replacement
Tools/Equipment
Phillips-head screwdriver
Method
1. Remove the Phillips-head hose anchor screw at the blower
outlet (see Figure 2).
2. Pull the old hose off the blower outlet flange.
3. Insert the new hose into the blower outlet flange.
NOTE: There are a number of variations of hoses (Figure 1)
to provide for specific therapeutic needs. These various hose
options (e.g., non-swivel end, swivel end, extended length)
are not interchangeable. If the hose were to be mated
improperly, there would be an obvious fit problem. Do not
force a hose into a fitting, use adapters, or modify the hose
ends. Use of a wrong hose could result in temperatures
outside of the indicated range.
4. Secure the Phillips-head hose anchor screw. The screw is
self-tapping into the hose end.
5. Record the maintenance action taken.
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Augustine Medical, Inc.
Hose anchor screw
Blower outlet
Hour meter
Wiring shield
Figure 2. Location of Hose Anchor Screw.
Non-swivel
Swivel
Extended
length
Figure 1. Hose Options

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Power Fuse Replacement
Tools/Equipment
•Phillips-head screwdriver
•Small slotted screwdriver
Accessing the Power Fuses
1. Disconnect the warming unit from the power source.
2. Access the fuse. See Figures 3 and 4 for location of fuses
in 200 series units.
CAUTION: Replace only with the fuse capacity and type that is
indicated.
Figure 3. Locating the Power Fuses in Models with Power Entry Modules
Fuse carrier
Detail
Power entry
module
Detail
Fuse door (open
this door to remove
fuse carriers)
Fuse
Spare fuse
Fuse
carrier
Fuse carrier
3. To access the fuse, remove the two (2) Phillips-head screws that secure the cord
retainer. Remove the power cord.
4. Use the small screwdriver to remove the fuse carrier.
5. Remove the blown fuse(s) and replace with the new ones.
6. Replace the fuse carrier.
7. Reattach the power cord and the two (2) Phillips head screws that secure the
cord retainer.
Power entry
module
Delta Power Entry Module
Schurter Power Entry Module

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Storage
compartment
Blower outlet
flange Wiring shield 10A or 15A
Power fuse
Figure 4. Locating the Power Fuses in Models with No Power Entry Module
1. To replace the fuse, remove the wiring shield by
unscrewing the three Phillips screws.
2. Unscrew the fuse holder cap, remove the old fuse, and
insert the new fuse.
3. Reattach the wiring shield.
After replacing the fuses, reconnect the warming unit to the
power source and record the maintenance action taken.
Two (2)
10A 250V
fuses
Wiring shield

8Augustine Medical, Inc.
Control Board Fuse Replacement
Tools/Equipment
Phillips-head screwdriver
Method
1. Disconnect the warming unit from the power source.
2. Remove the four (4) Phillips-head screws on the rear
access panel.
3. Open the rear access panel and remove the filter.
4. Locate the fuse (see Figure 5) and replace as specified.
CAUTION: Replace only with the fuse capacity and type that is
indicated.
5. Put the filter back into place and close the rear access panel.
6. Replace the four (4) Phillips-head screws on the rear
access panel.
7. Reconnect the warming unit to the power source.
8. Record the maintenance action taken.
Control board fuse
Control board
(see Detail)
Detail of control board
Figure 5. Location of Control Board Fuses in 200 Series Units
1. To replace the fuse, remove the wiring shield by unscrewing the three
Phillips screws.
2. Unscrew the fuse holder cap, remove the old fuse, and insert the new fuse.
3. Reattach the wiring shield.
Blower
outlet
flange
Wiring
shield
.062A
Control
board fuse

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Augustine Medical, Inc.
Air filter
Airflow
direction
Air Filter Replacement
The air filter is mounted inside the rear access panel.
Service Frequency
Six-month intervals, or 500 hours of use
Tools/Equipment
Phillips-head screwdriver
Method
1. Disconnect the warming unit from the power source.
2. Remove the four (4) Phillips-head screws on the rear
access panel. Open the panel.
3. Lift out the old filter and read the hour meter, if
applicable.
4. Record the meter reading and date on the new air filter
label.
5. Insert the new filter in the filter frame (see Figure 6). The
airflow arrow should point into the warming unit.
6. Close the rear access panel and resecure the four (4)
Phillips-head screws.
7. Reconnect the warming unit to the power source.
8. Record the maintenance action taken.
Figure 6. Location of Air Filter

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Over Heat Alarm Testing
WARNING: Perform all testing and adjustments of warming unit
temperature with a calibrated Model 221 Temperature Test Kit or
a Model 22110 Temperature Test Unit. Augustine Medical, Inc.
assumes no responsibility for the reliability, safety, or performance
of the Bair Hugger system if warming unit temperature testing or
adjustments are made in any other manner than that described
here. Improper measurement or adjustment of the warming unit’s
over heat alarm setting could result in patient exposure to
temperatures outside of the indicated range, and may lead to
patient injury.
NOTE: The Model 221 Temperature Test Kit and the Model
22110 Temperature Test Unit are designed to simulate the
operating characteristics of Bair Hugger blankets when used with
Bair Hugger warming units; use of the temperature test device
with any other warming system may result in imprecise readings.
If using the Model 221 Test Kit, temperature readings are taken
from the test kit itself. If using the Model 22110 Test Unit,
temperature readings are taken from a calibrated temperature
meter.
NOTE: Some Model 200 warming units will not reset
automatically. If your unit has a manual reset, please call
Augustine Medical Customer Service for special instructions or
a replacement unit.
Service Frequency
Six-month intervals, or 500 hours of use
Tools/Equipment
•Model 221 Temperature Test Kit or Model 22110
Temperature Test Unit
•Phillips-head screwdriver
•Short jumper wire with alligator clips or needlenose
pliers.
If using the Model 22110 Temperature Test Unit:
•Use a calibrated temperature meter that can accept a
male subminiature connector for a K style thermocouple
(e.g., a Fluke Model 52 K/J Thermometer).
•If the connector does not fit your meter, you can remove
the provided connector and attach a connector that fits
your meter.
Accessing the Control Board
1. Disconnect the warming unit from the power source.
2. Remove the four (4) Phillips-head screws on the rear
access panel. Open the access panel.
3. Remove the filter to access the control board.

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Testing the Over Heat Alarm Thermostat
1. Prepare the control board as shown below.
Port
Port
TP3 & TP4
Figure 7. Control Boards for 200 Series Units
Units with the Series 80 control board:
Pull the blue lead from P3.
2. Reconnect the warming unit to the power source.
Electrical shock hazard. Dangerous voltages are now present on
the control board. Please use caution.
3. Insert the open hose end from the warming unit in the
port on the temperature test device (see Figure 8). Turn
the warming unit power ON.
NOTE:
•Do not block the rear air vents on the test device.
•The temperature setting will not affect the over heat test because
the control circuit has been bypassed.
P3
Figure 8. Temperature Test Devices
Model 22110
Units with the Watlow A007
control board: On the control
board, attach a jumper wire
from TP3 to TP4.

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4. The over heat condition activates both visual and
audible alarms. The warming unit will remain in an
alarm condition until the temperature drops sufficiently
to deactivate the thermostat. The alarm and reset
constitutes one cycle.
5. Allow the warming unit to cycle to alarm twice more.
6. When the alarm activates, note the alarm temperature
read-out on the temperature test device (see Table 1 for
specified limits).
NOTE: The first over heat cycle may be slightly higher
when started from a cold start.
7. If the results of the test did not meet the specified limit,
adjust the over heat thermostat. See the Over Heat Alarm
Thermostat Adjustment section.
8. If the results of the test did meet the specified limit, turn
the warming unit power OFF and disconnect the
warming unit from the power source.
9. Remove the hose from the port on the temperature test
device.
10. Remove the jumper wire from TP3 and TP4, (or
reattach the blue lead to P3, if applicable). See Figure 7.
11. Put the filter back into place, close the rear access panel,
and resecure the Phillips-head screws.
12. Reconnect the warming unit to the power source.
13. Record the maintenance action taken.
Table 1. Over Heat Specification
Model 200 Series (Except Model 275) High Temperature
Thermostat
The thermostat interrupts power to the heater and activates the alarm at a
preset high temperature of 56°±3°C (132.8°± 5.4°F), or less, at the end of
the hose, as determined by the Augustine Medical temperature test device.
Model 275 High Temperature Thermostat
The thermostat interrupts power to the heater and activates the alarm at a
preset high temperature of 53°±3°C (127.4°± 5.4°F), or less, at the end of a
hose, as determined by the Augustine Medical temperature test device.
Over Heat Alarm Testing

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Augustine Medical, Inc.
Over Heat Alarm Thermostat Adjustment
WARNING: Improper adjustment of the warming unit’s over heat
alarm setpoint could result in patient exposure to temperatures
outside of the indicated range, and may lead to patient injury.
•Dangerous voltages are present at the terminals of the thermostat.
•Always use a Model 221 Temperature Test Kit or the 22110
Temperature Test Unit to verify output temperatures.
•Recalibrate the Temperature Test Kit at least once a year. The
Model 22110 Temperature Test Unit does not need to be
calibrated. The meter it is connected to must be calibrated.
Follow the calibration instructions in the meter service manual or
follow standard facility calibration schedules.
•When in doubt, contact Augustine Medical Customer Service for
assistance in temperature adjustment.
Tools/Equipment
•Small slotted screwdriver
•Phillips-head screwdriver
•Short jumper wire with alligator clips or needlenose pliers
•Model 221 Temperature Test Kit or Model 22110
Temperature Test Unit
Accessing and Preparing the Control Board
1. Disconnect the warming unit from the power source.
2. Remove the four (4) Phillips-head screws on the rear
access panel. Open the access panel.
3. Remove the filter to access the control board.
4. Prepare the control board before adjusting the thermostat.
See Figure 9.
Figure 9. Control Boards
for 200 Series Units Units with the Series 80 control board:
Pull the blue lead from P3. This will override
the temperature control and send the unit into
an overtemperature condition.
TP3 & TP4
Units with the Watlow A007
control board: On the control
board, attach a jumper wire
from TP3 to TP4.
P3

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Over heat alarm
thermostat
Thermostat
connections
Thermostat
connections Set screw
Set
screw
5. Find the over heat alarm thermostat (see Figure 10).
Figure 10. Locating the Thermostat
Set screw

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Adjusting the Over Heat Alarm Thermostat
1. Reconnect the warming unit to the power source and
turn the warming unit power ON.
Electrical shock hazard. Dangerous voltages are present on the
control board. Please use caution.
NOTE:
•The temperature setting will not affect the over heat
adjustment and subsequent testing because the control
circuit has been bypassed.
•Adjustment of the over heat alarm thermostat is most
easily done while the temperature read-out on the
temperature test device is climbing.
2. Insert the open hose end from the warming unit into the
port on the temperature test device.
NOTE: Do not block the rear air vents on the test device.
3. Use a small slotted screwdriver to adjust the thermostat.
•If the tested alarm temperature was below specified
limits, turn the screwdriver CLOCKWISE to increase
the alarm temperature.
•If the tested alarm temperature was above specified
limits, turn the screwdriver COUNTERCLOCKWISE
to lower the alarm temperature.
4. Fine-tune the adjustment until the warming unit alarms
at the specified temperature.
5. Retest the over heat alarm at least twice to verify correct
adjustment.
6. When the warming unit alarm setting is within the
specified limit, turn the warming unit OFF, and
disconnect the warming unit from the power source.
7. Remove the hose end from the temperature test device.
8. Remove the jumper from test points TP3 and TP4, (or
reattach the blue lead to P3, if applicable).
9. Put the filter back into place and close the rear access
panel.
10. Replace the four (4) Phillips-head screws on the rear
access panel.
11. Record the maintenance action taken.

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Ambient Room Temperature (°C)
At HIGH, Nominal Temperature on Test Kit (°C)
Figure 11. Room Temperature v.s. High Temperature Output
Warming Unit Temperature Setting Should Be on HIGH When Conducting This Test
Ambient Room Temperature (°F)
At HIGH, Nominal Temperature on Test Kit (°F)
Normal Operating Temperature Testing
WARNING: Perform all testing and adjustments of warming unit
temperature with a calibrated Model 221 Temperature Test Kit or
a Model 22110 Temperature Test Unit. Augustine Medical, Inc.
assumes no responsibility for the reliability, safety, or performance
of the Bair Hugger system if warming unit temperature testing or
adjustments are made in any other manner than that described
here. Improper measurement or adjustment of the warming unit’s
normal operating temperature could result in patient exposure to
temperatures outside of the indicated range, and may lead to
patient injury.
Service Frequency
Six-month intervals, or 500 hours of use
Tools/Equipment
Model 221 Temperature Test Kit or Model 22110
Temperature Test Unit.
Method
1. Insert the open hose end from the warming unit in the
port on the temperature test device (see Figure 8).
NOTE: Do not block the rear air vents on the test kit.
2. Turn the warming unit power ON and select the HIGH
temperature setting. Always begin testing with the
HIGH setting.
3. Note the ambient room temperature.
4. After approximately five (5) minutes of operation, note
the temperature read-out. Use Figure 11 to correlate
ambient temperature to the warming unit’s operating
temperature.