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Manual Reference
Covidien WarmTouch Convective Warming Unit Service Manual, Part No. 10079261, including publicly available Revisions C (September 2012) and E (May 2013). Medtronic now supports the Covidien WarmTouch product family. Service-test access differs by manual/software revision, so verify the unit label, installed software, and current regional documentation before testing.
Manufacturer Recommendation / AEM Status
Covidien requires the Temperature Accuracy Test and Thermostat Test once a year. The manufacturer also calls for visual inspection of the warming unit, power cord, and safety labels before each use. The HEPA filter must be replaced at 2,000 operating hours or 365 days, whichever occurs first; software counters track both limits.
The service documentation provides power-on, keypad, display, airflow, temperature, thermostat, and electrical-safety procedures. Depending on revision/software, controlled tests are accessed through the on-unit service screen or the WarmTouch Service Utility. Electrical-safety tests are explicitly required after specified repairs; facilities may also include them in scheduled PM under their adopted standard. Do not change the manufacturer-listed annual temperature/alarm or filter schedule without an approved AEM assessment.
What This PM Procedure Covers
- Identity, software/error history, cleaning, enclosure, labels, power cord, hose, nozzle, mounting hardware, and filter status
- Power-on self-test, operator controls, display colors, audible indications, normal warming modes, and Heat Off operation
- Annual temperature accuracy at 34 °C and 47 °C and the over-temperature thermostat/alarm test
- Manual-specified fan test at 50% duty cycle, HEPA replacement and counter reset when due, and applicable Class I Type BF electrical safety
Required Tools and Equipment
- Current WarmTouch WT 6000 service and operator documentation for the installed software
- Calibrated temperature probe accurate to ±0.25 °C or better from 10–60 °C, with a cable long enough to reach the hose-duct screen
- Manual-specified service-screen access; or, when the applicable revision requires it, the WarmTouch Service Utility, compatible computer, and USB 2.0 A-to-Micro-B data cable
- Torque driver with No. 2 Phillips bit when service-port access is required
- Calibrated electrical-safety analyzer and ground-bond capability suitable for Class I Type BF equipment
- Manufacturer-approved replacement HEPA filter kit when the hour/day limit is reached
- Known-good WarmTouch blanket for no-patient operational verification; never free-hose heated air
- 70% isopropyl alcohol solution, soft cloths, PPE, and facility-approved cleaning materials compatible with the manual
Step-by-Step PM Procedure
1. Remove the Unit From Clinical Use
Action: Confirm no patient is connected or relying on the warmer. Remove disposable blankets and accessories, place the WT 6000 in a controlled service area, and disconnect mains power before inspection or cleaning.
Expected outcome: The unit is safely controlled for PM and cannot be used on a patient during testing.
2. Verify Identity, Ratings, and Documentation
Action: Record asset tag, serial number, exact WarmTouch configuration, line-voltage rating, department, software version, service-manual revision, and PM due date. Confirm the label identifies Class I, Type BF equipment and the No Free Hosing warning.
Expected outcome: The device matches CMMS, the correct documentation applies, and all safety/rating labels are legible.
3. Review History and Error Information
Action: Review prior PM, repairs, filter changes, overheating complaints, weak airflow, alarms, drops, liquid exposure, and electrical-safety results. Use System Information to record the software version and recent errors; retrieve the complete error log through the manual-specified service interface when qualified and required.
Expected outcome: Known problems, overdue work, recurrent errors, and repair-related retest requirements are identified before functional testing.
4. Clean and Dry the Warming Unit
Action: Follow the service manual cleaning procedure using compatible materials. Keep liquid out of the enclosure, inlet, hose, nozzle, connectors, and USB opening. Do not immerse, spray directly, or use the unit until completely dry.
Expected outcome: External surfaces are clean, dry, and free of residue or liquid intrusion.
5. Inspect the Enclosure, Labels, and Mounting Hardware
Action: Inspect the front/rear/filter enclosures, handle, feet, seams, fasteners, display lens, keypad, USB cover, bed hook, three pole clamps/feet/knobs, cart interface, and all safety/identification labels for damage, looseness, contamination, or modification.
Expected outcome: The housing, controls, mounting features, and labels are complete, secure, legible, and mechanically safe.
6. Inspect the Power Cord and Grounding Features
Action: Inspect the full cord, hospital-grade plug, inlet connection, routing bracket, strain relief, equipotential stud, and accessible grounding hardware for cuts, exposed conductors, bent pins, looseness, discoloration, overheating, or contamination.
Expected outcome: The cord and protective-earth path are intact, secure, and free of damage.
7. Inspect the Air Path, Hose, and Nozzle
Action: Inspect the air inlet, filter enclosure, hose, duct adapter, internal screen visible at the hose base, nozzle, nozzle guides, retaining clip, nozzle strap, and No Free Hosing labels. Check for cracks, tears, kinks, obstruction, lint, contamination, looseness, or heat damage.
Expected outcome: The air path is unobstructed; hose/nozzle components and the blanket-retention features are intact and secure.
8. Check HEPA Filter Status and Replace When Due
Action: View Filter Information and record hours and days remaining. Replace the HEPA filter at 2,000 operating hours or 365 days, whichever occurs first, using the current manual and approved kit. After correct replacement, reset the counters through the manufacturer procedure and verify they show zero elapsed hours/days.
Expected outcome: The filter is within both limits, or is replaced correctly with its counters reset and the filter enclosure securely restored.
9. Perform the Power-On Test
Action: Connect to a suitable grounded mains outlet and power on using the normal sequence. Confirm the power-on self-test completes, the audible tone sounds, the display and status indicators initialize, and the unit reaches the expected Ready state without an unresolved alarm.
Expected outcome: Startup completes normally with stable power, normal indications, and no persistent error.
10. Test the Keypad, Display, and Audible Indications
Action: Exercise On/Standby, Menu, Exit, Fan Off, Heat Off, and each temperature key. Perform the documented keypad and display tests; confirm the display can show uniform white, black, blue, green, and red without bad pixels. Verify key clicks and test tones are clear.
Expected outcome: Every control responds once per press, display colors are uniform and readable, and audible indications are distinct.
11. Verify Normal Operating Modes
Action: Attach a compatible WarmTouch blanket before delivering heated air. Briefly verify Heat Off and available temperature modes, stable fan operation, displayed temperature response, Ready/Standby transitions, and normal shutdown. Do not operate heated airflow without a blanket.
Expected outcome: The unit changes modes correctly, delivers unobstructed airflow, and produces no abnormal odor, noise, vibration, or alarm.
12. Perform the Annual 34 °C Temperature Accuracy Test
Action: Fully compress the hose and position it vertically with the nozzle up. Center the calibrated probe on the metal screen at the hose-duct base. Select 34 °C and allow at least three minutes for stabilization before recording the reference temperature.
Expected outcome: Measured temperature is within ±1 °C of 34 °C.
13. Perform the Annual 47 °C Temperature Accuracy Test
Action: With the probe in the same documented position, select 47 °C, allow at least three minutes for stabilization, and record the reference temperature.
Expected outcome: Measured temperature is within ±1 °C of 47 °C.
14. Perform the Manual-Specified Flow Test
Action: Qualified personnel shall access the flow test through the on-unit service screen or WarmTouch Service Utility specified for the installed software/manual. Compress and position the hose as directed, set the fan to 50% duty cycle at ambient temperature, wait at least 30 seconds, record the reported speed, and stop the fan/test using the applicable procedure.
Expected outcome: Fan speed at 50% duty cycle is 4,200 ±1,000 rpm (3,200–5,200 rpm).
15. Perform the Annual Thermostat and Alarm Test
Action: Start the thermostat test through the service screen or utility specified by the applicable manual. Verify the heater and fan start, then shut down with an audible and visual alarm, normally within one to two minutes. Stop the test as directed, confirm the reported temperature decreases on readings 10–20 seconds apart, and verify error code 006 in the error log. Allow the unit to cool 5–10 minutes.
Expected outcome: The thermostat opens, heater/fan shut down, audible/visual alarm occurs, temperature falls, and error 006 is logged. A thermostat that does not open within 20 minutes produces test failure and requires removal from service.
16. Perform Applicable Electrical Safety Tests
Action: Using the current manual, analyzer instructions, and facility standard, perform the Class I ground-bond, earth-leakage, and enclosure-leakage tests required by the PM scope or preceding repair. Test all specified normal, reversed, and single-fault conditions.
Expected outcome: Every applicable measurement meets the manufacturer limits listed below.
17. Restore, Recheck, and Document
Action: Exit the applicable service interface, disconnect any service cable, close and secure the USB cover, restore approved accessories, route and secure the power cord, perform a final power-on/no-patient functional check with a compatible blanket, clean/dry the unit, and document filter readings, test results, parts, repairs, and disposition.
Expected outcome: The WT 6000 is complete, clean, electrically safe, fully functional, and either returned to service with traceable results or clearly removed from service.
Electrical Safety Testing
The WarmTouch WT 6000 is Class I, Type BF equipment. The service manual requires technicians to follow applicable institutional/country standards and supplies the following device-specific maximums:
- Ground bond: ≤100 mΩ without the power cord; ≤200 mΩ with the power cord
- Earth leakage: 300 µA normal/reversed polarity with line and neutral closed; 1,000 µA with line open or neutral open
- Enclosure leakage: 100 µA normal/reversed with line, neutral, and ground closed; 500 µA for each specified open-neutral or open-ground single-fault condition
Record the analyzer, calibration status, standard/mode, test configuration, highest result for each condition, applicable limit, and pass/fail status. Electrical-safety testing is specifically required after designated repairs; follow facility policy for its inclusion in routine annual PM.
Pass / Fail Criteria
PM Pass Criteria
- Identification, ratings, software/history, labels, enclosure, mounting hardware, cord, grounding features, air path, hose, and nozzle pass
- HEPA filter is within 2,000 hours and 365 days or has been correctly replaced and reset
- Power-on, keypad, display, audible indicators, controls, modes, and no-patient operation pass
- 34 °C and 47 °C readings are each within ±1 °C
- Flow is 4,200 ±1,000 rpm at 50% duty cycle
- Thermostat opens, heater/fan stop, audible/visual alarm occurs, temperature decreases, and error 006 is logged
- All applicable ground-bond and leakage-current measurements pass
Remove From Service Criteria
- Damaged enclosure, mounting hardware, labels, cord, protective-earth path, hose, nozzle, clip, air path, or other safety-critical component
- Expired filter not replaced/reset, persistent error, failed POST, unreliable control/display/alarm, abnormal heat/odor/noise, or liquid intrusion
- Temperature outside ±1 °C at either annual test point or flow outside 3,200–5,200 rpm
- Thermostat/alarm failure, missing error 006 after the controlled test, or temperature that does not decrease after shutdown
- Any electrical-safety result above the applicable manufacturer limit or incomplete required post-repair testing
Copy/Paste CMMS Work Order Procedure
Use the current WarmTouch WT 6000 service manual and qualified service personnel for controlled temperature, thermostat, airflow, filter-counter, and electrical-safety procedures. Follow the test-access method for the installed software/manual revision. Never perform testing with a patient connected, and never direct heated air from the hose without a compatible WarmTouch blanket.