Storz THERMOFLATOR User manual

THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Service Manual
Technical
Description and
Service Instructions
for
THERMOFLATOR®
MODEL 26 4320 20
MODEL 26 4320 20-1
Order No. SV3339
March 2014-0.05 SM-26-01-V1.7

03.14
©All pictures, photos and product descriptions are the intellectual
property of KARL STORZ GmbH & Co. KG
Utilization and copies by third parties have to be authorized by
KARL STORZ GmbH & Co. KG
All rights reserved.

03.14 / V1.7 0-1
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Contents
Section Title Page
0. General .................................................................................................................. 0-
1. Instruction Manual ............................................................................................... 1-
2. Physical Design .................................................................................................... 2-
2.1 Exploded views of the THERMOFLATOR® ........................................................... 2-2
2.1.1 Exploded view of the THERMOFLATOR® with standard housing ......................... 2-2
2.1.2 Exploded view of the THERMOFLATOR® with new system housing .................... 2-3
2.2 Spare parts of the THERMOFLATOR®................................................................... 2-4
3. Descriptions of Operation and Circuit Diagrams ............................................. 3-
3.1 Description of operation of the THERMOFLATOR®.............................................. 3-2
3.2 Block diagram of the THERMOFLATOR®.............................................................. 3-3
3.3 Wiring diagram of the THERMOFLATOR®............................................................. 3-4
3.4 Electronics of the THERMOFLATOR®.................................................................... 3-5
3.4.1 Control board ......................................................................................................... 3-5
3.4.1.1 Brief description of the control board operation ................................................... 3-5
3.4.1.2 Block diagram of the control board ....................................................................... 3-5
3.4.1.3 Circuit diagram of the control board ..................................................................... 3-6
3.4.1.4 Component diagram of the control board ............................................................. 3-7
3.4.2 Display board ......................................................................................................... 3-8
3.4.2.1 Brief description of the display board operation ................................................... 3-8
3.4.2.2 Block diagram of the display board ...................................................................... 3-8
3.4.2.3 Circuit diagram of the display board ..................................................................... 3-9
3.4.2.4 Component diagram of the display board ............................................................ 3-12
3.4.3 Controller board ..................................................................................................... 3-13
3.4.3.1 Brief description of the controller board operation ............................................... 3-13
3.4.3.2 Block diagram of the controller board ................................................................... 3-13
3.4.3.3 Circuit diagram of the controller board ................................................................. 3-14
3.4.3.4 Component diagram of the controller board ......................................................... 3-14
3.4.4 Power supply unit .................................................................................................. 3-15
3.4.4.1 Brief description of the power supply unit operation ............................................ 3-15
3.4.5 Gas preheater ........................................................................................................ 3-16
3.4.5.1 Brief description of the gas preheater operation ................................................... 3-16
3.4.5.2 Block diagram of the gas preheater ...................................................................... 3-16
3.4.6 KARL STORZ-SCB®flash module ......................................................................... 3-17
3.4.6.1 Description of KARL STORZ-SCB®flash module operation ................................. 3-17
3.4.6.2 Block diagram of the KARL STORZ-SCB®flash module ...................................... 3-17
3.5 Troubleshooting ..................................................................................................... 3-18
3.6 Technical data ....................................................................................................... 3-19
4. Replacement of Individual Assemblies .............................................................. 4-
4.1 Information about replacements ............................................................................ 4-2
4.2 Tools required for replacing the individual assemblies ......................................... 4-2
4.3 Opening the various types of housing ................................................................... 4-3
4.4 Replacement of the control board, controller board, display board and
front panel .............................................................................................................. 4-5
4.5 Replacement of the pressure manifold, power supply unit and gas preheater .... 4-8
4.6 Replacement of the EPROM and the microcontroller ........................................... 4-11

0-2 03.14 / V1.7
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Section Title Page
5. Testing and Adjustments .................................................................................... 5-
5.1 Notes to testing and adjustments ......................................................................... 5-2
5.2 Test instruments required for the individual adjustment procedures ................... 5-2
5.3 Testing and adjusting the control board ............................................................... 5-3
5.3.1 Adjusting the operating voltage ............................................................................. 5-3
5.3.2 Offset calibration .................................................................................................... 5-3
5.3.3 Amplification calibration for patient pressure ........................................................ 5-3
5.3.4 Amplification calibration for flow rate .................................................................... 5-3
5.3.5 Adjusting the volume of the acoustic alarm signal ................................................ 5-4
5.3.6 Temperature adjustment of the OPTITHERM®heating element ........................... 5-5
5.3.6.1 Adjustment for devices with software versions up to S012001Q ......................... 5-5
5.3.6.2 Adjustment for devices with software versions as from C012001R ..................... 5-5
5.4 Functional test of the low-pressure safety valve ................................................... 5-6
5.5 Further tests and functional tests .......................................................................... 5-7
5.5.1 Pressure and control behavior test ....................................................................... 5-7
5.5.2 Pressure drop test ................................................................................................. 5-7
5.5.3 Functional test of excess pressure alarm messages ............................................ 5-7
5.5.4 Negative alarm ....................................................................................................... 5-8
5.5.5 Dangerous increase of pressure ............................................................................ 5-8
5.5.6 Interrupted flow of gas during semi-continuous operating mode ......................... 5-8
5.5.7 Blow-off valve ........................................................................................................ 5-8
6. Maintenance and Safety Checks ........................................................................ 6-
6.1 Safety functions of the THERMOFLATOR®........................................................... 6-2
6.2 Safety checks ........................................................................................................ 6-5
6.3 Safety devices ........................................................................................................ 6-7
6.4 Maintenance operations ........................................................................................ 6-7
6.5 Servicing and repair ............................................................................................... 6-7
6.6 Fuse replacement .................................................................................................. 6-7
7. Modifications and Supplements ......................................................................... 7-
7.1 KARL STORZ-SCB®flash module ......................................................................... 7-2
7.1.1 Description of KARL STORZ-SCB®flash module operation ................................. 7-2
7.1.2 Block diagram of the KARL STORZ-SCB®flash module ...................................... 7-2
7.1.3 Notes on the KARL STORZ-SCB®upgrade kit ..................................................... 7-3
7.1.4 Installing the KARL STORZ-SCB®upgrade kit in the standard housing ............... 7-3
7.1.4.1 Tools required for installing the KARL STORZ-SCB®upgrade kit in the standard
housing .................................................................................................................. 7-3
7.1.4.2 Fitting the KARL STORZ-SCB®boards in the standard housing .......................... 7-4
7.1.4.3 Replacing the EPROM and the microcontroller .................................................... 7-8
7.1.5 Installing the KARL STORZ-SCB®upgrade kit in the new system housing .......... 7-10
7.1.5.1 Tools required for installing the KARL STORZ-SCB®upgrade kit in the new
system housing ...................................................................................................... 7-10
7.1.5.2 Installing the KARL STORZ-SCB®boards in the new system housing ................. 7-11
7.1.5.3 Replacing the EPROM ........................................................................................... 7-15
7.2 Functionality of two or more identical devices in the KARL STORZ-SCB®.......... 7-17
7.2.1 Tools required to adjust the serial number ............................................................ 7-17
7.2.2 System design for adjustment of the serial number ............................................. 7-17

03.14 / V1.7 0-3
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Section Title Page
7.2.3 Installation of the SCB Service Tool ...................................................................... 7-18
7.2.4 Adjustment of the serial number ........................................................................... 7-19
7.2.5 Sticking on the ID number sticker ......................................................................... 7-20
7.3 Software versions .................................................................................................. 7-21
7.3.1 Software version S012001M ................................................................................. 7-21
7.3.1.1 Note to software version S012001M ..................................................................... 7-21
7.3.2 Software version S012001O .................................................................................. 7-22
7.3.2.1 Note to software version S012001O ..................................................................... 7-22
7.3.3 Software version S012001P .................................................................................. 7-24
7.3.3.1 Note to software version S012001P ...................................................................... 7-24
7.3.4 Software version S012001Q .................................................................................. 7-25
7.3.4.1 Note to software version S012001Q ..................................................................... 7-25
7.3.5 Software version C012001R .................................................................................. 7-25
7.3.5.1 Note to software version C012001R ..................................................................... 7-25
7.3.6 Software version C012001S .................................................................................. 7-26
7.3.6.1 Note to software version C012001S ..................................................................... 7-26
8. Appendix ............................................................................................................... 8-
Test report - Safety check ...................................................................................... 8-1

0-4 03.14 / V1.7
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1

03.14 / V1.7 0-5
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
0. General
Thank you for your expression of confidence in the KARL STORZ brand name. Like all of our other prod-
ucts, this product is the result of years of experience and great care in manufacture. You and your orga-
nization have decided in favor of a modern, high-quality piece of equipment from KARL STORZ.
KARL STORZ instruments and equipment are for use only by qualified medical personnel who are
trained in their use. All electrical installations at the location of use should meet applicable national and
local electrical codes.
Refer servicing to duly authorized KARL STORZ service personnel. Always use genuine replace-
ment parts from KARL STORZ. To determine which replacement parts are required please refer to the
enclosed replacement parts list. Repair and calibration of this device requires special tools and gauges;
certain internal adjustments must not be altered.
For further information, please consult this service manual or contact:
KARL STORZ GmbH & Co. KG KARL STORZ Endoscopy-America, Inc.
Mittelstrasse 8, 78532 Tuttlingen 2151 East Grand Avenue
PO Box 230, 78503 Tuttlingen El Segundo, CA 90245-5017
Germany USA
Phone: [phone] Phone: [phone]
Fax: [phone] [phone]
E-Mail: [email protected] Fax: [phone]
Web: www.karlstorz.com
Warranty
All KARL STORZ instruments and equipment are warranted to be free from defects in workmanship and
materials for two (2) years from date of sale, unless otherwise specified; any instruments or equipment
with such defects during the applicable warranty period will be promptly repaired or replaced at no
charge to the customer.
KARL STORZ shall not be liable, expressly or implicitly, for:
• Any damages which might arise or be caused, whether by the customer or by any of the users of the
instrument or equipment, as a result of:
– misuse, mishandling, and/or improper operation,
– repairs, modifications and/or alterations performed other than by KARL STORZ or a KARL STORZ
authorized repair facility, or
– use in combination with adaptors and/or equipment, or use in any manner or medical procedure,
other than those for which it is designed; and
• Any special, indirect and/or consequential damages of any kind and however caused arising from the
sale or use of the instrument and/or equipment.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED, AND/OR
STATUTORY, INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY, FITNESS,
AND/OR OF SUITABILITY FOR A PARTICULAR PURPOSE, AND OF ALL OTHER OBLIGATIONS OR
LIABILITIES ON KARL STORZ’S PART.
KARL STORZ neither assumes nor authorizes any person to assume for it any other liabilities in connec-
tion with the sale of said instrument and equipment. To ensure proper use, handling, and care of instru-
ments and equipment, consult the applicable product literature, catalog, brochure, instruction manual,
teaching film and other materials which are included with the product and/or otherwise available from
KARL STORZ, at no charge, upon request.

0-6 03.14 / V1.7
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Maintenance and Repair
KARL STORZ recommends that all equipment be checked and inspected once a year by KARLSTORZ,
or by an authorized agent. All services such as modifications, repairs, calibrations, and/or readjustments
may only be performed by KARL STORZ or by an authorized agent.
2CAUTION: Repairs may only be performed by qualified technicians trained in electrical or
electronic engineering, in compliance with the relevant occupational, safety and accident prevention
regulations.
Always unplug the equipment before performing any repairs.
Safety Testing based on IEC EN62353, IEC / UL 60601-1, whichever may apply, must be performed
after servicing has been completed.
By making the enclosed technical information available, KARL STORZ does not authorize any service or
repair by unauthorized service personnel. Tampering with the instruments or equipment, or unauthorized
service or repair of the device nullifies and voids the warranty.
Reservation of Rights
This documentation is the sole and exclusive property of KARL STORZ and may neither be copied nor
passed on to third parties without the express written authorization and approval of KARL STORZ.
KARL STORZ reserves the right to make engineering modifications in the interest of promoting tech-
nological progress and generating performance improvements without obligation on the part of
KARLSTORZ to submit prior notice thereof.

03.14 / V1.7
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Direction Sign:
Physical Design 2
Descriptions of Operation and Circuit Diagrams 3
Replacement of Individual Assemblies 4
Testing and Adjustments 5
Maintenance and Safety Checks 6
Modifications and Supplements 7
Appendix 8
Section 1.
Instruction Manual
1. Instruction Manual

03.14 / V1.7

THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Direction Sign:
1 Instruction Manual
Descriptions of Operation and Circuit Diagrams 3
Replacement of Individual Assemblies 4
Testing and Adjustments 5
Maintenance and Safety Checks 6
Modifications and Supplements 7
Appendix 8
Section 2.
Physical Design
2. Physical Design

03.14 / V1.7 2-1
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Contents 2. Physical Design
Section Title Page
2. Physical Design .................................................................................................... 2-
2.1 Exploded views of the THERMOFLATOR® ........................................................... 2-2
2.1.1 Exploded view of the THERMOFLATOR® with standard housing ......................... 2-2
2.1.2 Exploded view of the THERMOFLATOR® with new system housing .................... 2-3
2.2 Spare parts of the THERMOFLATOR®................................................................... 2-4
1. Instruction Manual
2. Physical Design

2-2 2-2 03.14 / V1.7
KARL STORZ - ENDOSKOPE
M
+
-+
-
!
thermoflator 264320 20
mmHg l/min
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
19
18
24
25
20
14a 14b
14c
14d
21 21
22
23
A
15
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
2.1 Exploded views of the THERMOFLATOR®
2.1.1. Exploded view of the THERMOFLATOR® with standard housing

03.14 / V1.7 2-3
1
6
7
8
9
10
11
21
12
5
2
4
3
17
23
16
15
19
18
24
25
20
14b
14
14a
14c
14d
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
2.1.2. Exploded view of the THERMOFLATOR® with new system housing

2-4 03.14 / V1.7
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Position Item description Order no.
1
2
3
4
5
5a
6
7
8
9
10
11
12
13
14
14a
14b
14c
14d
15
16
17
18
19
19a
19b
20
21
21a
22
23
24
25
–
–
Front panel
OPTITHERM®heating element socket
Insufflation line fitting, line to patient
Power switch
Display board
Module display board “new system housing” consisting of:
Display board and 7-segment-displays
Temperature controller board
Controller board with supply line
Gas flow splitter with hose set connected
Pressure relief valve
Low pressure blow off valve, blue
High pressure transducer with supply line
High pressure blow off valve, black
Pressure manifold with high pressure sensor and solenoid valve con-
nected
Gas preheater, complete
Heat cartridge including swirl body
Sealing fluid, thermal resistance up to 200 °C (392 °F)
Temperature limiter
Temperature regulator
Power supply unit, 110 W
Line plug with line filter
Line fuses 2 x T 2.0 AL / 250 V
Silicone tubing set
OPTITHERM®heating element with connecting cord, sterilizable
Valve with lever to the heating element
Spring cover to lever
Power cord (with ground lead)
Power cord “hospital grade” (USA)
Pressure sensor (patient pressure, …)
Pc board pressure sensor, equipped
Flow sensor (control board)
Bottle holder
LUER-LOCK connector to the device, male
Connector, plastic, male, cone 15 mm
High pressure inline gas filter
Gasket to CO2 bottle with German connector
26 4320 85
26 4320 89
26 4320 88
20 0112 80
26 4320 83
26 4320 93
26 4320 86
26 4320 84
26 4320 81
20 0120 80
20 4001 81
20 0121 80
20 4005 81
26 4320 80
20 0122 80
5903550
49600000001
49600000002
20 0119 80
20 0115 80
20 2759 0
20 4000 43
20 4320 30
6567591
VO4210
400A
400B
20 0109 80
45413004L00
20 0108 80
20 4000 31
20 3001 84
20 4000 81
20 4000 32
2903490
2.2 Spare parts of the THERMOFLATOR®
Important note:
When ordering replacement parts always provide the following data
Item description Order no.

03.14 / V1.7 2-5
THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
Position Item description Order no.
–
–
–
–
Gasket to CO2bottle with Pin-Index connector
Software Update Set (includes the latest software version)
KARL STORZ-SCB®upgrade kit
Utility lines
2903390
26 4320 75-V02
26 4320 77
A012-507
A012-605
Important note:
When ordering replacement parts always provide the following data
Item description Order no.

03.14 / V1.7


THERMOFLATOR®
MODEL 264320 20
MODEL 264320 20-1
3. Descriptions of
operating and
Circuit Diagrams
Direction Sign:
1 Instruction Manual
2 Physical Design
Replacement of Individual Assemblies 4
Testing and Adjustments 5
Maintenance and Safety Checks 6
Modifications and Supplements 7
Appendix 8
Section 3.
Descriptions of Operation and
Circuit Diagrams