Heater-Cooler Unit HCU 20

Service Manual
Heater-Cooler Unit HCU 20
Service Manual
The information in this document may change without notice. Names and
data used in examples are fictitious unless otherwise noted. No part of
this document may be reproduced, transmitted or transcribed, in any form
or by any means, without the prior written permission of Jostra AB.
© Copyright 1998 Jostra AB. All rights reserved.
Jostra AB
Annedalsvägen 2 B
227 64 Lund, SWEDEN
Phone: +46 46-33 31 00
Fax: +46 46-33 31 05
Article number: 923651
Change order: J681
Heater-Cooler Unit HCU 20 Contents

Contents
1. General ................................................................................................. 5
1.1 Description of function ................................................................... 5
1.1.1 Patient mode............................................................................ 5
1.2 Front view of the HCU 20 .............................................................. 6
1.3 Rear view of the HCU 20 ............................................................... 7
1.4 Front panel of the HCU 20 ............................................................. 8
1.5 Remote control unit RCU 20-610................................................... 9
2. Functional description ...................................................................... 10
2.1 Flowchart ...................................................................................... 10
2.2 Flow outline .................................................................................. 11
2.3 Inside of the HCU 20.................................................................... 12
2.4 Board placement ........................................................................... 13
3. Maintenance....................................................................................... 14
3.1 Daily ............................................................................................. 14
3.2 Weekly .......................................................................................... 14
3.3 Monthly......................................................................................... 14
3.3.1 Checking the remote control function................................... 15
3.4 Annually ....................................................................................... 15
4. Service................................................................................................. 16
4.1 Competence of the service engineer ............................................. 16
4.2 Disassembly and replacements ..................................................... 17
4.3 Changing the UV-lamp................................................................. 18
4.4 Calibrations and adjustments........................................................ 19
4.5 Filling an empty unit..................................................................... 19
4.6 De-airing the internal circulation.................................................. 19
4.7 Checking the minimum temperature............................................. 20
4.8 Checking the maximum temperature............................................ 20
4.9 Calibrating the minimum water level ........................................... 20
4.10 Calibrating the maximum water level......................................... 20
5. Service terminal ................................................................................. 21
5.1 Calibrating the minimum water level ........................................... 23
5.2 Calibrating the maximum water level........................................... 23
5.3 Storing the temperature sensor calibration values........................ 24
5.4 Checking the temperature sensor calibration values .................... 25
5.5 Choice of language ....................................................................... 25
5.6 Storing the UV-lamp intensity...................................................... 26
5.7 Storing the UV-lamp limit ............................................................ 26
6. Display and error messages .............................................................. 27
6.1 Display messages when switching on........................................... 27
6.2 Display messages.......................................................................... 27
6.3 Error messages.............................................................................. 28
7. Technical data.................................................................................... 29

Service Manual Art.no. 923651 C.o. J681 3

Contents Heater-Cooler Unit HCU 20

Appendix A...........................................................................................A-1
Electrical diagrams and drawings .....................................................A-1
Appendix B ...........................................................................................B-1
Spare parts list...................................................................................B-1

4 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 General

1. General

1.1 Description of function

The Jostra Heater-Cooler Unit HCU 20 supplies temperature-controlled
water for blood heat exchangers in extracorporeal circulation and for
blankets with which patients can be warmed or cooled.
The water temperature is adjustable from 3° C to 41° C. A 33 litre tank
of ca. 3° C cold water assures quick cooling of the patient.
Two external water circuits can be attached, each with their own water-
flow adjustment system (but with a common temperature control).
A safety system monitors the regulation in order to prevent the
temperature from rising above 42° C.
The HCU 20-602 and the HCU 20-603 have a UV-lamp in the water tank
to prevent the growth of algae, fungus, mould, bacteria and other
microbes. The HCU 20-600 and the HCU 20-601 are prepared for a
UV-lamp.
The differences between the HCU 20-600 and the HCU 20-602 versus
the HCU 20-601 and the HCU 20-603 are the circulation method, the
flow capacity and the maximum pressure (see “7. Technical data”).
The HCU 20 is supplied with the remote control cable RCC 20-611 and
the water supply tubing WST 20-700. The remote control unit
RCU 20-610 is optional.

NOTE Use an independent power supply, protected by a 20 A automatic

thermic fuse.

WARNING The radiation from the UV-lamp in the water tank is instantly
injurious to the eye. Never look down the funnel of the water tank.
Keep the lid on whenever possible. Never risk exposure during
disassembly.

1.1.1 Patient mode

To prevent a too abrubt heating or cooling, the water temperature is only
allowed to deviate from the temperature of the patient by certain values,
gradients, in “patient mode”. This provides a more physiologically
optimised heating and/or cooling than the direct setting of the water
temperature.

Service Manual Art.no. 923651 C.o. J681 5

General Heater-Cooler Unit HCU 20

1.2 Front view of the HCU 20

Fuses
1 Press the screws and turn them ¼
turn counter-clockwise to open the
2 lid over the automatic fuses.
3

8 Normal fuse positions

9 Compressor: pressed in
10 Pump: pressed in

11 Heater: to the right

12

13

1. Funnel for the water tank

2. Front panel
3. Mains switch
4. Fuses
5. Stopcock for the right circulation (open in vertical position)
6. Stopcock for the left circulation (open in vertical position)
7. Inlet (suction side) of the left circulation
8. Outlet (pressure side) of the left circulation
9. Outlet (pressure side) of the right circulation
10. Inlet (suction side) of the right circulation
11. Cover for service
12. Opening for tank overflow
13. Wheels with foot-lever operated brake

NOTE Keep the lid of the fuse box closed during normal operation.

6 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 General

1.3 Rear view of the HCU 20

1. Funnel for the water tank

2. Mains cable holder
3. Socket for remote control and service terminal
4. Automatic fuse for the mains circuit
5. Connection for potential equalization
6. Type label
7. Mains cable
8. Drain cock for the water tank

Service Manual Art.no. 923651 C.o. J681 7

General Heater-Cooler Unit HCU 20

1.4 Front panel of the HCU 20

1. Set temperature (alphanumeric display)

2. Water temperature, temperature of the cold water or water level
(alphanumeric display)
3. Patient temperature or error codes (alphanumeric display)
4. Circulation on/off button
Lit when circulating.
5. Local/remote button
Lit when remote control is on.
6. Adjustment knob
Hold down the “Set Temp.” button and turn the adjustment knob to set a
temperature.
7. Audio off button
Flashes when the present acoustic alarm is switched off. The acoustic alarm returns
with every new alarm condition.
8. Cooling LED
Lit when cooling the water.
9. Heating LED
Lit when warming the water.
10. Tank temperature button
Press to see the temperature in the cold water tank in the middle display. Press
together with the “Set temp.” button for three seconds to see the water level in the
middle display.
11. Set temperature button (2.9° C to 41° C)
Hold down this button and turn the adjustment knob to set a temperature. Press
together with the “Audio off” button to alter the brightness of the displays in three
grades

8 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 General

1.5 Remote control unit RCU 20-610

Connect the remote control cable RCC 20-611 to the remote control
socket at the rear side of the HCU 20. Connect the other end to the socket
at the underside of the remote control unit.

1 2

1. Temperature sensor socket (for the YSI 400 series manufactured by

Yellow Springs or other compatible sensor)
2. Remote control cable socket (9-pin DSUB)

Service Manual Art.no. 923651 C.o. J681 9

Functional description Heater-Cooler Unit HCU 20

2. Functional description

2.1 Flowchart
The outlet water is taken from the water tank or the heater (or both)
depending on the position of the motor valve.
T: Temperature sensor for measuring and control (and to prevent over-
heating if the system is accidentally operated without water)
P: Pressure sensor to measure the water level

33 litres

Manual
control
valves

Heat
exchanger

Flowchart: HCU 20-600 with pressure and suction pump

10 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Functional description

2.2 Flow outline

Flow outline: HCU 20-600 with pressure and suction pump

Service Manual Art.no. 923651 C.o. J681 11

Functional description Heater-Cooler Unit HCU 20

2.3 Inside of the HCU 20

1. Water tank
2. Overflow tube
3. Regulator for the mixing valve
4. Tank temperature sensor
5. Outlet temperature sensor
6. Heater temperature sensor
7. Mixing valve
8. Heater
9. Water level (pressure) sensor with tube
10. Drain tube
11. Pump

12 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Functional description

2.4 Board placement

Open the front panel to reach the control board and the power supply
board. Remove the stainless cover to reach the control board.

Control board

Power supply board

Service Manual Art.no. 923651 C.o. J681 13

Maintenance Heater-Cooler Unit HCU 20

3. Maintenance
WARNING The radiation from the UV-lamp in the water tank is instantly
injurious to the eye. Never look down the funnel of the water tank.
Keep the lid on whenever possible.

CAUTION Do not use any fully desalinated or distilled water as this would etch
the copper cooling spirals and the heater core.

1, 4

2, 5

3.1 Daily
1. Check that the water level is 33 litres.
2. Check that air can circulate unobstructed to the condenser (rear side)
to ensure good cooling capacity. The unit must be at least 30 cm from
walls or cupboards.

3.2 Weekly
3. Empty the cold water tank through the drain cock underneath.
4. Refill with new softened water (through the funnel on top).

3.3 Monthly
(or after every 100 hours of operation)
5. Clean the condenser at the back with a brush.

14 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Maintenance

3.3.1 Checking the remote control function

Press the “local/remote” button on the HCU 20 for three seconds, when it
is connected to the HL 20 or the RCU 20-610, to enter the remote control
mode. The “local/remote” button should light up and an acoustic signal
sound.

3.4 Annually
A complete service by a service engineer is recommended, including
calibration of the minimum and the maximum water levels and the
components, check of the minimum and the maximum temperatures and
change of the UV-lamp.

Service Manual Art.no. 923651 C.o. J681 15

Service Heater-Cooler Unit HCU 20

4. Service
WARNING Refrigeration circuit repairs (except the condenser fan) must be
performed by Jostra service personnel. Recharging and replacements
may be subcontracted to a competent refrigeration organisation.
The HCU 20 must never be laid on its side. If accidentally put in
another position, it must stand upright for at least 24 hours before
operation.

4.1 Competence of the service engineer

The service should be performed by a qualified service engineer to assure
that the unit is maintained satisfactory. Qualification requires:
• Practical experience of the product, the HCU 20.
• Access to the recommended spare parts, supplied by Jostra.
• Access to and understanding of the User Manual and the Service
Manual regarding the HCU 20 model which is to be serviced.

16 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Service

4.2 Disassembly and replacements

WARNING The radiation from the UV-lamp in the water tank is instantly
injurious to the eye. Disconnect the power supply before
disassembly.
The temperature sensors may only be changed by Jostra authorized
personnel.

The top panel is held by four screws. In the rear

end of the top panel there is a rubber tube which
Top
panel
goes down to the water tank. When the top panel is
removed the tube is pulled out of the tank.
Front
panel The front panel can be opened after the removal of
the top panel and the two screws above the
Valve stopcocks. It is mounted on hinges in the top end.
panel
The lower panel is held by three screws in the
Stopcocks upper end and three nuts in the lower end.
Lower The valve panel can be lifted up and pulled out
panel after the removal of the front panel and the lower
panel.

NOTE Empty the water tank and connect tubes to the outlets and open the
stopcocks to release the pressure before removing any components in
the water circuit.

To remove the motor valve

Mounting
plate first unscrew the mounting
plate to get access to the valve
Tank fastening screws.
temperature
sensor

Mixing valve

Service Manual Art.no. 923651 C.o. J681 17

Service Heater-Cooler Unit HCU 20

4.3 Changing the UV-lamp

NOTE Replace the UV-lamp annually.

WARNING The radiation from the UV-lamp in the water tank is instantly
injurious to the eye. Disconnect the power supply before
disassembly.

B
D

A C

1. Disconnect the power supply and remove the top panel.

2. Loosen the cord squeezing screws and unscrew the lamp cord end of
the connection box (A). Pull out the contents and loosen the
connection screws.
3. Unscrew the lamp holder (B).
4. Remove the lamp with the cord (C).
5. Connect the service terminal, see “5. Service terminal”. Light into the
tank with a flashlight and check that the “UV-INT” value changes (on
the “JNS HYPO II” page), to see that the lamp sensor is working.
Disconnect the service terminal.
6. Disconnect the power supply again.
7. Lower the new lamp carefully into the holder at the bottom of the
tank (D). Mount the upper lamp holder and the cord connection.
8. Mount the top panel.
9. Store the UV-lamp intensity, see “5.6 Storing the UV-lamp
intensity”.
10. Store the UV-lamp limit (if the old value should be changed), see
“5.7 Storing the UV-lamp limit”.

18 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Service

4.4 Calibrations and adjustments

To calibrate components and to adjust the temperature controller (e.g.
after a replacement), contact Jostra service.

4.5 Filling an empty unit

Fill a completely empty unit as follows, to avoid an airlock in the pump.
1. Prepare a length of tubing with a Walther type male ½" quick
connector at one end and a connector suitable for your soft water
supply at the other.
2. Connect the tubing between one outlet of the unit and the soft water
supply.
3. Switch the unit on and press the “Set Temp.” and the “Tank Temp.”
buttons simultaneously for three seconds to see the water level in the
middle display.
4. Open the outlet stopcock of the unit and turn on the water supply. Fill
to a level of 33 litres.
5. Turn off the water supply and close the outlet stopcock. Remove the
tubing from the water supply.
6. Press the “Tank Temp.” button to leave the “level mode”.

NOTE If the water tank is over-filled or if a maximum filled unit is moved

the superfluous water is released through the overflow opening
(above the left front wheel).

4.6 De-airing the internal circulation

1. Prepare a short transparent tubing with a Walther type male ½" quick
connector at both ends.
2. Connect the tubing between one outlet and the corresponding inlet.
Open the outlet stopcock.
3. Switch the unit on and hold down the “Set temp.” button and turn the
adjustment knob to set the temperature to 2.9° C (“tank mode”). Wait
till the display message “TANK” stops flashing.
4. Press the circulation button. Circulate until no bubbles can be seen in
the tubing and the water pump runs with an even, gentle sound. The
internal circulation is now free of air.

Service Manual Art.no. 923651 C.o. J681 19

Service Heater-Cooler Unit HCU 20

4.7 Checking the minimum temperature

1. Switch on the unit and let it cool down the water in the tank (this may
take up to 60 minutes depending on the initial temperature of the
water).
2. Connect the heat exchanger and the blanket.
3. Place the probe of an accurate temperature recorder in the tubing near
the outlet.
4. Set the temperature to 2.9° C (“tank mode”) and wait until the display
message “TANK” stops flashing. Start the circulation.
5. When the middle display shows that the outlet water has reached the
set temperature, wait one minute and check that the temperature
recorder shows a stable temperature that corresponds to the set
temperature.

4.8 Checking the maximum temperature

Follow the steps in “4.4 Check the minimum temperature”, but set the
temperature to the maximum 41° C instead. It is not necessary to wait
until the water in the tank is cooled down.

4.9 Calibrating the minimum water level

1. Empty the tank.
2. Set the temperature to 5.9° C.
3. Switch off the unit and back on again.
4. During the initial self-test at switch on, press the “Set Temp.”,
“local/remote” and “Audio off” buttons simultaneously until the three
displays show “SET OFF SET”.
5. Press the “Set Temp.” and the “local/remote” buttons simultaneously
to store the current water level as zero.

4.10 Calibrating the maximum water level

1. Fill up the tank to the maximum.
2. Set the temperature to 5.9° C.
3. Switch off the unit and back on again.
4. During the initial self-test at switch on, press the “Tank Temp.”,
“local/remote” and “Audio off” buttons simultaneously until the three
displays show “SET NIV 25.0”.
5. Turn the adjustment knob until the patient temperature display shows
“33.4”.
6. Press the “Set Temp.” and the “local/remote” buttons simultaneously
to store the water level.

20 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Service terminal

5. Service terminal
In this section, text on the service terminal is written in the type-face
Courier like this and entries are indicated by underlining like this.
Entered values are echoed and the user is asked to confirm them.

WARNING A service terminal must be connected and used by a service engineer

with the competence described in “4.1 Competence of the service
engineer”.

Interface
• Serial RS232
• 9600 Baud
• 8 data Bits
• 1 stop Bit
• No parity

Usage
1. Connect a terminal to the service terminal socket of the HCU 20
according to the interface characteristics.
2. “Cold-start” the HCU 20 and wait until the terminal has completed
the “JNS HYPO II” page.
3. Press <Shift><S> to enter the “HYPO SERVICE-MENU”.

Service Manual Art.no. 923651 C.o. J681 21

Service terminal Heater-Cooler Unit HCU 20

HYPO SERVICE-MENU
HYPO SERVICE-MENU:
--------------------------

1 Initialise EEPROM on controller board

2 Reset hour meter on controller board
3 ZERO water level
4 Calibrate water level
5 Init. Temp. SENSOR calibration values
6 SET Temp. SENSOR calibration values
7 Check Temp. SENSOR calibration values
8 Select speech
T Activate test output
U Store UV-LAMP value
S Set UV-LAMP limit

Q QUIT

YOUR SELECTION :

WARNING Never select option “1”. The EEPROM may only be initialised by
Jostra service in some exceptional cases.
Never select option “2”. The hour meter may only be reset by Jostra
service.
It should not be necessary to use option “5”. If the temperature
sensor calibration values are initialised, there will be temperature
deviations until all accurate values have been restored.
Wrongly set values on the service terminal could be hazardous to the
patient.

NOTE Option “T” displays a record of test values. These are normally useful
just for Jostra service.

After use
1. Choose “Q QUIT” in the “HYPO SERVICE-MENU”.
2. Switch off the HCU 20 and disconnect it from the terminal.

22 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Service terminal

5.1 Calibrating the minimum water level

This can also be done without a service terminal, see “4.9 Calibrating the
minimum water level”.
1. Empty the tank.
2. Choose “3 ZERO water level” on the “HYPO SERVICE-MENU”:

YOUR SELECTION : 3

Set water level offset Y / N ?:Y

5.2 Calibrating the maximum water level

This can also be done without a service terminal, see “4.10 Calibrating
the maximum water level”.
1. Fill up the tank to the maximum.
2. Choose “4 Calibrating water level” on the “HYPO SERVICE-
MENU”:

YOUR SELECTION : 4

Calibrate water level Y / N ? Y

CALIBRATE WATER-LEVEL
-----------------------

LITER (25.0 ... 35.0): 33.4

PASSED

Service Manual Art.no. 923651 C.o. J681 23

Service terminal Heater-Cooler Unit HCU 20

5.3 Storing the temperature sensor

calibration values
WARNING The temperature sensor calibration values may only be stored by
Jostra authorized personnel.

A label with the serial number and the calibration values is attached to
the cable of the sensor. For an accurate temperature control, these values
must be entered like in the example below. (Just press “Enter” to keep an
old value.)
1. Choose “6 SET Temp. SENSOR calibration values” on the “HYPO
SERVICE-MENU”:

YOUR SELECTION : 6
STORE NEW CAL-values into serial EEPROM!
serial number R-0øC R-50øC
HEATER CONTROL SENSOR: INIT C-HEA 100.000 119.400
HC: 61831 100.232 119.640
HC: 61831 100.232 119.640 values OK (Y/N)?:Y
HEATER SAFETY SENSOR: INIT S-HEA 100.000 119.400
HS: 61831 100.124 119.518
HS: 61831 100.124 119.518 values OK (Y/N)?:Y
MIXER CONTROL SENSOR: INIT C-MIX 100.000 119.400
MC: 61832 100.181 119.576
MC: 61832 100.181 119.576 values OK (Y/N)?:Y
MIXER SAFETY SENSOR: INIT S-MIX 100.000 119.400
MS: 61832 100.121 119.509
MS: 61832 100.121 119.509 values OK (Y/N)?:Y
COLD-W CONTROL SENSOR: INIT C-COL 100.000 119.400
WC: 61834 100.094 119.491
WC: 61834 100.094 119.491 values OK (Y/N)?:Y
COLD-W SAFETY SENSOR: INIT S-COL 100.000 119.400
WS: 61834 100.157 119.557
WS: 61834 100.157 119.557 values OK (Y/N)?:Y
HEATER CONTROL SENSOR: HC: 61831 100.232 119.640
HEATER SAFETY SENSOR: HS: 61831 100.124 119.518
MIXER CONTROL SENSOR: MC: 61832 100.181 119.576
MIXER SAFETY SENSOR: MS: 61832 100.121 119.509
COLD-W CONTROL SENSOR: WC: 61834 100.094 119.491
COLD-W SAFETY SENSOR: WS: 61834 100.157 119.557
values OK (Y/N)?:Y
New CAL-values stored!

24 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Service terminal

5.4 Checking the temperature sensor

calibration values
1. Choose “7 Check Temp. SENSOR calibration values” on the
“HYPO SERVICE-MENU”:

YOUR SELECTION : 7

serial number R-0øC R-50øC

HEATER CONTROL SENSOR: HC: 61831 100.232 119.640

HEATER SAFETY SENSOR: HS: 61831 100.124 119.518

MIXER CONTROL SENSOR: MC: 61832 100.181 119.576

MIXER SAFETY SENSOR: MS: 61832 100.121 119.509

COLD-W CONTROL SENSOR: WC: 61834 100.094 119.491

COLD-W SAFETY SENSOR: WS: 61834 100.157 119.557

CAL-FAC CRC OK!

5.5 Choice of language

1. Choose “8 Select speech” on the “HYPO SERVICE-MENU”:

YOUR SELECTION : 8

HYPO speech selection:

1 English version
2 French version
3 German version

Your selection: 3

German version selected!

Service Manual Art.no. 923651 C.o. J681 25

Service terminal Heater-Cooler Unit HCU 20

5.6 Storing the UV-lamp intensity

1. Wait for 10 minutes (after switching on the HCU 20) until the UV-
lamp intensity has stabilised.
2. Choose “U Store UV-LAMP value” on the “HYPO SERVICE-
MENU”:

YOUR SELECTION : U

Store uv-lamp intensity into the EEPROM (Y/N)?:Y

Store UV-lamp intensity

-----------------------

UV-INTENSITY
467

Are You sure to overwrite UV-intensity (Y/N)?: Y

New UV-Intensity stored!

5.7 Storing the UV-lamp limit

The error message “UV!” is displayed when the UV-lamp intensity is
below the set limit. The limit can be set between 10 % and 100 % of the
stored UV-lamp intensity.
1. Choose “S Set UV-LAMP limit” on the “HYPO SERVICE-
MENU”:

YOUR SELECTION : S

Store uv-lamp limit into the EEPROM (Y/N)?:Y

Store UV-lamp limit

-----------------------

UV-INTENSITY UV-LIMIT UV-SET

467 745 50

Set new UV-SET (in %): 60 60 UV-LIMIT OK? (Y/N):Y

New UV-LIMIT stored!

26 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Display and error messages

6. Display and error messages

6.1 Display messages when switching on

Display 1 Display 2 Display 3 Meaning
1. „„„„ „„„„ „„„„ Lamp test: all display points and all LEDs are lit and
the acoustic alarm beeps.
2. E1.5 HOUR / XXX E1.5: Present software version (E = English).
HEUR / XXX: Operating hours since the last service.
STD.
3. –OK– HYPO –OK– Self-test concluded without errors.

6.2 Display messages

English French German Meaning
ERR ERR. FEHL Error (continued by a further message), see
“6.3 Error messages”
NO NON KEIN Lost connection between HCU 20 and remote
COM COMM KOM. control.
H2O! H2O! H2O! Water level too low.
KEY! CLAV TAST Invalid button depressed, button depressed for
longer than 15 seconds or “Set” button depressed for
longer than 3 minutes.
–::– –::– –::– “Water mode”.
–––– –––– –––– Sensor not connected.
TANK TANK TANK Flashing display: The internal mixing-valve is
turning to open the cold water circuit. The pump
stops.
Steady display: The internal mixing-valve has
opened the cold water circuit. The pump can be
started again.
UV! UV! UV! UV-lamp out of order.
COMP COMP KOMP Compressor out of order.
SET SET SET See “4.9 Calibrating the minimum water level”
OFF OFF OFF
SET SET SET
SET SET SET See “4.10 Calibrating the maximum water level”
NIV. NIV. NIV.
25.0 25.0 25.0

Service Manual Art.no. 923651 C.o. J681 27

Display and error messages Heater-Cooler Unit HCU 20

6.3 Error messages

ER English French German Error source
01 ROM ROM ROM Program memory defect; an incorrect LRC has been found.
EPROM defect; access control of the EPROM defect.
02 RAM RAM RAM Data memory test failed. SRAM defect, access control of the
SRAM defect, Micro controller defect (internal RAM).
03 EEPROM EEPROM EEPROM EEPROM test failed. EEPROM defect; access control of
EEPROM defect; max. writing cycles of the EEPROM reached.
04 AD-CONV. AD-CONV. AD-CONV. Time out of the processor internal AD-converter. Micro
controller defect.
05 OFFSET OFFSET OFFSET OFFSET test failed. Reference voltage not adjusted; AD-
converter defect; AD- input not connected.
06 REFERENC REFERENC REFERENZ Reference voltage test failed. Reference voltage out of
tolerance; AD-converter defect, reference voltage not adjusted.
07 + 5VTEST + 5VTEST + 5VTEST +5V supply voltage test failed. +5V supply voltage out of
tolerance; AD-converter defect; Reference voltage not
adjusted; AD-input not connected; wrong voltage divider.
08 +12VTEST +12VTEST +12VTEST +12V-supply voltage test failed. +12V-supply voltage out of
tolerance; reference voltage not adjusted; AD-converter defect;
AD-input not connected; wrong voltage divider.
09 –12VTEST –12VTEST –12VTEST -12V-supply voltage test failed. -12V-supply voltage out of
tolerance; reference voltage not adjusted; AD-converter defect;
AD-input not connected; wrong voltage divider.
0A LAMPTEST LAMPTEST LAMPTEST Lamp test failed. Displays defect; the access control of the
display is defect.
0C COMP-REL REL-COMP KOMP-REL The compressor relay is defect.
10 S-STOP S-STOP S-STOP Stop input of the safety system. The stop function of the
heater relays and pump relays of the safety system are defect.
11 SAFETY-S SECU.SYS SCHUTZ-S Safety system not OK. The lines SS_OK1 and SS_OK2 show
an error of the safety system.
13 ILL. ERR ERR ILL. ILL. ERR Illegal error. Illegal software status.
14 KEY !! CLAVIER! TASTE !! Key is jammed. Key is jammed; key pressed during key port
test.
17 FATAL IMPREVU! FATAL Illegal software status. Fatal error!
18 ARITHMET ARITHMET ARITHMET Arithmetic error. Division by 0; fatal error.
19 ILL. ERR ILL. ERR ILL. ERR Illegal error code in error byte. Fatal error!
1A PUMP-REL REL-POMP PUMP-REL Pump relays show faulty state. Pump relays defect
1B HEAT-REL REL-CHAU HEIZ-REL Heater relays show faulty state. Heater relays defect
1C TEMP.-H! TEMP-CH! TEMPHEIZ Heater temperature too high.
1D TEMP.-M! TEMP-MI! TEMPMIX. Mixer temperature too high.
22 CALIBRA. CALIBRA. KALIBRA. During the calibration a value out of the limits is detected.
2F CRC CRC CRC The CRC over the calibration values is not correct.

28 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Technical data

7. Technical data
Type designation HCU 20-600 and HCU 20-601 and
HCU 20-602 HCU 20-603 (if different)

Temperature control
Control range 3° C to 41° C
Setting resolution 0.1° C
Temperature accuracy ±0.3° C
Display range of temperatures 0° C to 50° C
Cooling system
Method Compressor refrigeration
Cooling media R 134 a
Capacity of water tank 33 litres
Temperature of cold water 2° C to 3° C
Initial cooling capacity 3800 kJ/h
Continuous cooling capacity 3000 kJ/h (830 W)
Cooling time from 20° C to 10° C ca. 26 minutes
Cooling time from 20° C to 2° C ca. 50 minutes
Heating system
Method Electrical heater
Capacity 2250 W (230 V); 1150 W (115 V); 1100 W (100 V)
Safety Monitoring against dry-run
Circulation
Method Pressure/suction pump Pressure pump
Flow capacity ca. 10 litres/minute ca. 20 litres/minute
Maximum pressure ca. 0.8 bar ca. 1.5 bar
Flow regulation Stopcocks
Inlet/outlet connections Coupling MD-012
Power supply
Mains 220–240 V / 50 Hz; 100–115 V / 60 Hz; 100 V / 50 Hz
Mains fuse 20 A thermic
Power consumption 3200 W (230 V); 2070 W (115 V); 1800 W (100 V)
Other
Measurements, LxWxH 410 x 575 x 905 mm
Weight (empty) ca. 90 kg
Water quality Softened tap water
Accessories
Remote control cable, 6 metres RCC 20-611
Water supply tubing, 6 metres WST 20-700
Remote control unit RCU 20-610 (optional)
Blanket connection kit BCK 20-710 (optional)
Cooling blanket adult CBA 20-730 (optional)
Cooling blanket paediatric CBP 20-731 (optional)
UV-lamp kit UVL 20-620 (upgrade)

Service Manual Art.no. 923651 C.o. J681 29

Technical data Heater-Cooler Unit HCU 20

30 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Appendix A

Appendix A

Wiring Diagram

Service Manual Art.no. 923651 C.o. J681 A-1

Appendix A Heater-Cooler Unit HCU 20

A-2 Art.no. 923651 C.o. J681 Service Manual

Heater-Cooler Unit HCU 20 Appendix B

Appendix B

Spare parts list

Denomination Article number
220–240 V 100–115 V, 100 V
Shut-off valve 530015 530015
Connectors 530004 530004
3-way valve 460011 460011
Splint 681013 681013
Stirrer 914851 914852
UV-lamp 930291 930291
Heater core complete 923621 923622
Pressure/suction pump, 50 Hz 460030 460006
Pressure/suction pump, 60 Hz 460014 460013
Pressure pump, 50 Hz 460017 460018
Pressure pump, 60 Hz 460020 460019
Temperature sensor – 930371 930371
Heater/Tank/Mixer
Pressure sensor complete 907321 907321
Fan motor 460004 460008
Circuit-breaker – Main 434015 (20 A) 434015 (20A)
Circuit-breaker – Heater 434016 (12 A) 434007 (16 A)
Circuit-breaker – Compressor 434017 (5 A) 434006 (10 A)
Circuit-breaker – 434002 (1 A) 434008 (2 A)
Pressure/suction pump
Circuit breaker – Pressure pump 434003 (4 A)
Fuse – Power supply board 431010 (800 mA)
Relay contactor 440001 440002
Mini puls pot. 150002 150002
Varistor 150001 150001
Solid state relay 440004 440004
Choke complete 913831 913831
Bellows 922321 922321
Plug 922311 922311
Main switch lamp 420002 420002
Remote control cable 903251 903251

Service Manual Art.no. 923651 C.o. J681 B-1

Appendix B Heater-Cooler Unit HCU 20

B-2 Art.no. 923651 C.o. J681 Service Manual

Jostra AG
Hechinger Straße 38
72145 Hirrlingen
Germany
Phone: +49 7478 921-0
Fax: +49 7478 921-100
E-mail: info@jostra.net
Jostra Italia S.p.A.
Via Aldo Moro 1/A
43035 Felino (Parma)
Italy
Phone: +39 0521 337267 / 68
Phone & Fax: +39 0521 338626
Jostra Bentley S.L.
Parque Empresarial San Fernando
Edificio Dublin
28830 Madrid
Spain
Phone: +34 916 781 652
Fax: +34 916 781 652

Jostra AB Jostra France S.A.R.L. Jostra Bentley Inc.

Annedalsvägen 2 B
227 64 Lund
Sweden
Phone: +46 46 33 31 00
Fax: +46 46 33 31 05
E-mail: info@jostra.se
28 – 30 Avenue Gallieni
94100 Saint Maur des Fosses
France
Phone: +33 1 55 12 35 50
Fax: +33 1 55 12 35 51
P.O. Box 1553
Añasco, 00610-1553
Puerto Rico
Phone: +1 787 826 3131
Fax: +1 787 826 4093

Jostra (Hong Kong) Ltd. Jostra Jostra Bentley Corp.

Beijing Representative Office
Rm. 204, Hui Jing Ge Building
No. 8 Ban Bi Dian Nan Lu Road
Haidian District
Beijing 100089
P.R. of China
Phone: +86 10 6873 0880
Fax: +86 10 6873 1849
Sales Office UK & Ireland
Caledonian House
Phoenix Crescent
Strathclyde Business Park
Bellshill ML4 3NJ
Scotland
Phone: +44 1698 849800
Fax: +44 1698 844646
17511 Armstrong Avenue
Irvine, CA 92614
USA
Phone: +1 800 854 0567
Fax: +1 888 570 4009

Jostra (Hong Kong) Ltd. Jostra

Shanghai Representative Office
17 F-B, Bldg. B ,Victoria Plaza
1068 Xi Kang Rd.
Shanghai 200060
P.R. of China
Phone: +86 21 6276 3952
Fax: +86 21 6227 7851
Sales Office The Netherlands
Postbus 445
1440 AK Purmerend
The Netherlands
Phone: +31 299 47 39 39
Fax: +31 299 47 41 37

Jostra Japan k.k. Jostra

Sasazuka North Odakyu Bldg. 12 F
2-26-2 Sasazuka Shibuya-ku
Tokyo 151-0073
Japan
Phone: +81 3 5333 3601
Fax: +81 3 5333 3609
Sales Office Norway
Krohnåsveien 85 A
5239 Rådal
Norway
Phone: +47 55 13 43 70
Fax: +47 55 13 05 85

www.jostra.net