Thermacare REF TC3003 - Stryker€¦ · (such as those found in rail cars or automobile trunks on...

Thermacare® REF TC3003

Convective Warming System

Service ManualP/N: 11898000 Rev. A 3/10

Before you begin . . .

Important• Refer to the TC3003 Convective Warming

System Operating Manual for detailedoperating instructions. Read and understandthe Operating Manual and all precautions priorto using the Convective Warming System.

• Review the SAFETY PRECAUTIONS (see page2) prior to servicing the Convective WarmingUnit (Power Unit).

• For technical assistance, contact your localdealer.

NOTE: Extremely high storage temperatures(such as those found in rail cars or automobiletrunks on hot summer days) can cause thethermostats within this device to actuate. Shouldthis occur, the REMOVE FROM USE indicator willlight when the Power Unit is turned on. If thishappens, the thermostats must be manuallyreset. Refer to section 7, Functional Check andSafety Inspection.

Attention: consult accompanyingdocuments

Dangerous voltage

Protective earth (ground)

Type BF applied equipment

Fan only (no heat)

32°C

38°C

43°C

46°C

Do not use in operating room(OR) or Intensive Care Unit (ICU)

Off-on switch

REMOVE FROM USE(indicator light, amber color)

Symbols used within this manual:

16°C - 29°C Ambient operating temperature

Contents

Section Introduction Page1.0 Safety Precautions .............................................................. 22.0 Repair Policy / Return Authorization ..................................... 33.0 Specifications ...................................................................... 44.0 Theory of Operation ............................................................. 55.0 Controls and Indicators ........................................................ 76.0 Preventive Maintenance ....................................................... 77.0 Functional Check and Safety Inspection ............................... 88.0 Inspection Form ................................................................ 169.0 Troubleshooting ................................................................. 19

10.0 Repair Procedures ............................................................. 2111.0 Drawings/Parts List ........................................................... 2412.0 TC20 Test Tool Schematic ................................................. 2713.0 Wiring Diagram ................................................................. 28

IllustrationsFigure Description Page

1 Convective Warming System ...............................................52A/B Power Unit Mounting ...........................................................5

3 Pole Mounting Height Limit .................................................54 Operator Control Panel ........................................................65 TC20 Test Tool ....................................................................96 Temperature Sensor Location .............................................107 Troubleshooting Chart - NO HEAT .......................................198 Troubleshooting Chart - NO AIR FLOW................................209 Drawing/Parts List .............................................................24

10 Drawing/Parts List .............................................................2511 Drawing/Parts List .............................................................26

11a Power Cord Plugs ..............................................................2712 TC20 Test Tool Schematic ..................................................2713 Wiring Diagram ..................................................................28

TablesTable Description Page

1 Air Temperatures .................................................................42 Functional Check/Inspection Form.......................................16

Table of Contents

1

2

1.0 Safety PrecautionsReview the following SAFETY PRECAUTIONS priorto testing the Power Unit. • After performing the thermostat test

procedure, verify that the TC20 Test Toolor any installed test jumpers have beenremoved before returning the Power Unitto patient use.

Failure to remove the TC20 Test Tool ortest jumpers may result in death, seriousinjury or equipment malfunction.

• Always unplug the Power Unit beforeattaching or removing the TC20 Test Toolor test jumpers and when resettingthermostats. Failure to unplug the PowerUnit could result in electrical shock andcause death or serious injury.

• Use only Gaymar replacement parts asidentified in the parts lists (pp. 24-27). Useof substitute parts could lead to powerunit malfunction or patient injury.

• The Temperature Control PC Board ispre-set at the factory. Do not attempt tocalibrate it. Adjustment of the Control PCBoard in the field could result in patientinjury.

• Use care when resetting the thermostats.Excessive force (force greater than 5pounds) can damage the overtempprotection device and/or inadvertentlyalter the trip temperature of the device.

DANGER

• Explosive hazard. Do not use in thepresence of flammable anesthetics.

• Risk of electric shock. Disconnect powerbefore servicing the TC3003 Power Unit.

WARNING

WARNING

This device generates heated air flow.Excessive heat could cause thermalstress or skin lesions. Failure to followthese precautions could result in death orserious injury:

• Use this system only under direction of aphysician. Read and understand theOperating Manual, Quilt Instructions forUse, and all precautions before using.

• Repairs should be performed only byqualified personnel such as certifiedbiomedical electronics technicians orcertified clinical engineers familiar withrepair practices for servicing medicaldevices, and in accordance with theService Manual. Damage to the PowerUnit or malfunction could otherwiseresult.

• Always perform the FUNCTIONALCHECK AND SAFETY INSPECTION aftermaking repairs and before returning thePower Unit to patient use. Documentyour findings on the INSPECTIONFORM. Improper repair may result indeath or serious injury, equipmentdamage, or malfunction.

(continued next column)

Section 1 - Safety Precautions

• U. S. Federal law restricts this device tosale by or on the order of a physician.

• For grounding reliability, plug only into aproperly grounded outlet.

• The HEPA filter must be installed correctly.Failure to install the filter correctly willprevent it from functioning properly andcould allow unfiltered air to reach thepatient.

• When using an I. V. pole, do not mount thePower Unit higher than 1 meter. Otherwise,the Power Unit could tip over.

CAUTION

2.0 Repair PolicyFor customers who repair Gaymar Power Units attheir location, this manual contains information toallow a qualified biomedical technician to makenecessary repairs.

2.1 Limited WarrantyThe Thermacare TC3003 Power Unit is warrantedfree of defects in material and workmanship undernormal use and operation for a period of twoyears, under the terms and conditions of theGaymar warranty in place at time of purchase.During the warranty period, Gaymar will repair orreplace at its sole option, free of charge, anydefective parts or products returned with priorauthorization prepaid to Gaymar Industries.Consumable items such as filters are excluded.The full warranty is available from Gaymar uponrequest.

Warranty does not cover products abused,misused, or altered outside the factory. There areno obligations on the part of Gaymar forconsequential damages arising out of or inconnection with the use or performance of theproduct. Gaymar disclaims all implied warrantiesincluding, but not limited to, the implied warrantiesof merchantability and of fitness for a particularpurpose.

2.2 In-Warranty RepairsAll in-warranty field repairs must be authorized byGaymar's Export Department before proceeding.

2.3 Out-of-Warranty RepairsIf the Power Unit becomes inoperative and thecause cannot be determined, the complete PowerUnit may be returned to the factory for servicing atthe purchaser's expense. Please contactGaymar's Export Department to obtain a returnedgoods (“RG”) number prior to returningequipment.

Section 2 - Repair Policy

3

2.4 Return AuthorizationPlease contact your local dealer.

3.3 Temperature SettingsThe air temperatures are identified on theoperator control panel and indicate the averageair temperature at the hose end using a Quilt.

NOTE: The air temperature around the patientis affected both by the ambient roomtemperature and the use of an insulatingblanket on top of the Quilt.

3.4 Safety SystemDual Patient Safety Temperature LimitThermostats

Either of two independently operatingthermostats will shut off the TC3003 at apreset high limit temperature. The heaterelement and blower will remain off until thethermostat is manually reset.

HeaterOvertempHeater overtemp thermostat will shut off theTC3003 in the event of a blower failure orlack of air movement. The heater elementand blower will remain off until thethermostat is manually reset.

High Temp IndicatorThe REMOVE FROM USE indicator will lighton the front panel when a patient safetythermostat or heater overtemp thermostathas tripped. Also, the heating element andblower will turn off.

HEPA Filter Interlock SwitchThe REMOVE FROM USE indicator will lighton the front panel when the HEPA filter hasbeen installed incorrectly or is missing. Also,the heating element and blower will turn off.

3.5 QuiltsAll Quilts are made of a nonwoven layer bondedto a plastic film.

Quilt material meets U. S. flammability standards:

• NFPA 702 “Normal Flammability”• CPSC Part 1632• California Title 19, Subchapter 7

Clear drape material meets NFPA 702 “NormalFlammability.”

Section 3 - Specifications

3.0 Specifications

3.1 PhysicalDimensions 42 cm x 28 cm x 27 cmWeight 6.8 kgEnclosure ThermoplasticFilter HEPA filtration down to

0.2 micron particle size

3.2 ElectricalClassification Type BF, Class 1, grounded

equipment suitable forcontinuous operation. Notclassified for protection againstharmful ingress of liquid.

Input 220-240 V (± 10%), 50 Hz,7 amps max

Motor 1/25 HP, single phaseHeater 1200W heating elementDetachable Use only an InternationalCord (Harmonized) three wire

cordset using cordageapproved to HD-21. Conductorsize is 1.0 mm2

(H05VVF3G1.00)Circuit Breaker 10 ampCurrent Leakage (Earth) 100 microamps max.

(90 microamps typical)Ground Resistance 0.15 ohms nominal;

0.5 ohms maximumAmbient Operating Temperature

16°C to 29°C

4Table 1 - Air Temperatures

TemperatureSetting

Temperature

Fan only

32°C

38°C

43°C

46°C

Section 4 - Theory of Operation

4.0 Theory of Operation

4.1 Convective Warming SystemThe Convective Warming System (fig. 1)provides a continuous means of warming patientsto help prevent and/or treat hypothermia. Thesystem consists of a Convective Warming Unit(Power Unit) and a disposable Quilt. A connectinghose conducts heated air from the Power Unit tothe Quilt.

Figure 2B - Bed rail mounted

Figure 3 - Pole mounting height limit

1 metermaximum

Figure 1 - Convective Warming System

4.2 TC3003 Power UnitThe TC3003 Power Unit provides a continuoussource of air to the Quilt. The Power Unit consistsof a HEPA filter, blower, heater, and temperaturecontroller. The Power Unit is a hand-carriedportable device which has dual mountingprovisions. It can hang on a bedrail or footboardusing the bedrail hooks on the back of the unit(see fig. 2B). It can also mount to an I. V. pole oroptional accessory stand using the I. V. poleclamp (see fig. 2A). Output air temperatures maybe set to one of five temperature settings:fan only, 32°C, 38°C, 43°C, or 46°C.

When using an I. V. pole, do not mount thePower Unit higher than 1 meter (see fig. 3).Otherwise, the Power Unit could tip over.

CAUTION

5

Figure 2A - I. V. Pole or Stand mounted

IV PoleClamp

BedrailHook

Section 4 - Theory of Operation (cont’d)

6

Figure 4 - Operator Control Panel

Ambient air is drawn in through air vents in thebottom of the enclosure. Air passes through aHEPA filter and across a 1200 watt, open coilheater located in the inlet of a blower. Output airtemperature is monitored by a thermistor locateddirectly in the output air stream (plenum) andprovides feedback to the solid-state controller.The controller compares the output airtemperature to the selected temperature and,using an on-off control scheme, turns the heateron or off accordingly. The maximum output airtemperature is limited not only by the controlsystem but by two redundant bimetallic latchingthermostats. These thermostats are located in theoutput air stream and will interrupt power to boththe heater and the blower, and light the REMOVEFROM USE indicator on the front panel should theoutput air temperature exceed predeterminedlimits. A similar thermostat located directly abovethe heater is used to protect the internalcomponents in the event of a motor failure. It toowill interrupt power to the heater and blower andlight the REMOVE FROM USE indicator.

Air is delivered to the Quilt using a permanentlyattached, flexible hose. The hose has a sleevewhich is stain resistant and easy to clean.

4.3 QuiltsThe Quilts distribute air evenly over the coveredareas of the patient through openings in thepatient side of the Quilt. Quilts consist of layersof plastic and nonwoven material bondedtogether. Refer to the instructions enclosed witheach Quilt.

32°C 38°C 43°C 46°C

Section 5 - Controls and IndicatorsSection 6 - Preventive Maintenance

6.0 Preventive Maintenance

6.1 HEPA FilterDirt that has accumulated on the internal HEPA airfilter will reduce the efficiency of the blower andheater. Under normal use, replace the HEPA filterevery 1000 operating hours or 12 months,whichever occurs first. Replace the filter only withthe Gaymar P/N listed (see parts list, fig. 9, p.24).

Use only Gaymar replacement parts asidentified in the parts lists (pp. 24-27).Use of substitute parts could result inpower unit malfunction or patient injury.

Refer to Functional Check, 7.6 Filter Switch Test& Filter Replacement (p. 14) for instructions.

6.2 BlowerThe blower motor and fan do not requirelubrication.

6.3 Enclosure ExteriorClean the control panel and Power Unit exteriorwith a soft cloth lightly dampened with anonstaining hospital disinfectant.

6.4 QuiltsQuilts are not sterile.Quilts are intended for single patient use only.Quilts should be discarded after use.

Small rips or tears in quilt material may betemporarily fixed with adhesive tape.

6.5 HoseClean the hose with a soft cloth lightly dampenedwith a nonstaining hospital disinfectant. Place theconnector hose under the bed rail hooks when notin use.

6.6 Air VentsClean accumulated dir t from the air vents with avacuum cleaner.

5.0 Controls and Indicators

5.1 PowerAn on/off circuit breaker is located on the frontof the unit in the bottom left corner. It controlspower to the entire unit. When switched to theON position, a power indicator in the switch willlight.

5.2 Control PanelAn operator control panel (fig. 4, p. 6) ismounted at the top of the Power Unit:

• [Power Up] When the power unit is turned on,the system defaults to the 32°C temperaturesetting. A green light directly above theselector switch will glow indicating theselected temperature range.

• [Temperature Settings] Temperature settingsare selected by pressing the appropriate push-button -- fan only, 32°C, 38°C, 43°C, or 46°C.

• [Power Interruption] If electrical power isinterrupted momentarily, the existingtemperature setting will remain. If electricalpower remains off, the TC3003 will default tothe 32°C setting when power is restored.

A REMOVE FROM USE indicator will light:

• if a patient safety thermostat or heaterthermostat has tripped.

• if the HEPA filter has been installed incorrectlyor is missing.

The heating element and blower will automaticallyturn off when these conditions occur.

7

WARNING

• Adhesive Tape

• TC20 Test Tool*, or two 16 gauge insulatedTest Jumpers

* The TC20 Test Tool is available fromGaymar. This tool was designed to allowfor more convenient testing of thethermostats and eliminate the need toinstall jumpers. Contact Gaymar'sTechnical Service Department for moreinformation.

• INSPECTION FORM (table 2, pp. 16-18)

ProceduresPerform the following procedures carefully,paying particular attention to test setups. Anydeviation from the setups, procedures, or testequipment may result in incorrect ormisleading results.

7.1 EnclosureExamine the overall condition of the Power Unitexterior:

1. Unplug the power unit.

2. Examine the enclosure, checking for cracks.

3. Check that exterior screws are tight.

4. Check that labelling and markings arelegible.

5. Clean accumulated dir t from the air ventswith a vacuum cleaner.

6. Check hose assembly for holes and brokenfittings. Replace if necessary.

7.2 Plug, Line CordExamine the plug and line cord:

1. Examine the attachment plug on the line cordto be sure it is in good condition.

2. Examine the line cord along its entire lengthfor physical damage, such as cuts orcracked insulation. Replace, rather thanrepair, damaged line cords.

7.0 Functional Check and SafetyInspection

To assure optimum performance, dependabilityand safety, perform FUNCTIONAL CHECK ANDSAFETY INSPECTION as follows:

• After repair, and every 12 months thereafter— the FUNCTIONAL CHECK AND SAFETYINSPECTION consists of all procedures(sections 7.1 through 7.9).

If your facility's procedures call for morefrequent functional test and safety inspections,note this fact on the INSPECTION FORM.

Inspection FormAn INSPECTION FORM (table 2, pp. 16-18) isprovided at the end of this section to facilitateand document the inspection process.

Test EquipmentThe following test equipment (or equivalent) isrequired in order to perform the preventivemaintenance procedures:

• Digital air thermistor thermometer(YSI 400 series)

Range: 10°C to 71°CSystem accuracy: ± 0.6°C

• Temperature sensor(P/N 77948-000)

NOTE:

1. Include the accuracy of the measuringequipment when making judgmentsabout observed temperature readings.

2. Test Conditions: 230 VAC ± 2 ,21°C-24°C ambient (with heater on); thismay require the use of a variabletransformer.

• #2 Phillips screwdriver

• Current Leakage / Ground Resistance Tester

• Model TC1050CE, TC2050CE, TC2052CE, orTC2054CE Quilt

• Stopwatch

Section 7 - Functional Check and Safety Inspection

8

Section 7 - Functional Check and Safety Inspection (cont’d)

7.3 Power SwitchCheck the power switch light:

1. Plug in the Power Unit. Turn the power switchon.

2. Verify that the power switch is lit.

3. Verify the Power Unit starts in the 32°C heatsetting.

7.4 Temperature Settings SwitchesExamine the overall condition of thecontrol panel:1. Select each of the five temperature settings.

Verify that the appropriate indicator for eachlights.

7.5 Thermostat and REMOVE FROMUSE AlertTest the Patient Limit Thermostats and REMOVEFROM USE Alert.

The following procedure describes two differentapproaches for measuring the trip points(actuation temperatures) of the Power Unit'spatient limit thermostats. There are two patientlimit thermostats (item 18, fig. 11, p. 26) withinthe Power Unit and each must be tested. TheTC20 Test Tool helps simplify these tests. Steps1 to 20 (pp. 9-11) should be followed when aTC20 Test Tool is available. For those facilities nothaving access to a TC20, follow steps 21 to 50(pp. 12-13).

NOTE: A third thermostat, the heater overtempthermostat (item 33, fig. 11, p. 26), is providedto protect internal components in the event of amotor blockage or failure. It does not need tobe function tested.

7.5.1 TC20 Test Tool Procedure(steps 1 to 20) [see fig. 10, p. 25, forTC20 Test Tool part number]

1. Unplug the Power Unit.

Always unplug the Power Unitbefore attaching or removing theTC20 Test Tool and when resettingthermostats. Failure to unplug thePower Unit could result inelectrical shock and cause deathor serious injury.

2. Remove the six screws on the back of theunit. Carefully separate the two halves of theenclosure.

3. Connect the TC20 Test Tool (fig. 5) to the5-pin field test connector on back of the PCboard and route the TC20 Test Tool cable outthrough the opening in the bottom of the unit(see fig. 10, p. 25). Close the two halves ofthe enclosure and temporarily secure itclosed with adhesive (duct) tape. Plug in thepower unit.

9

Figure 5 - TC20 Test Tool(for schematic, see figure 12, p. 27)

HEAT

S3S2

OVERTEMP

THERMOSTATBYPASS

WARNING

10


Figure 6 - Temperature sensor location

4. Set the two TC20 Test Tool toggle switches asfollows:

• THERMOSTAT BYPASS -- place in centerposition;

• HEAT/OVERTEMP -- place in HEATposition.

5. Locate the air temperature sensor at the centerof the end of the hose (fig. 6A). Secure thesensor with adhesive tape. Verify that thesensor is located at the center of the hose.

6. Connect the hose to a Model TC1050CE,TC2050CE, TC2052CE, or TC2054CE Quilt(fig. 6B).

7. Turn the Power Unit on. Select the 46°Csetting.

8. Run the Power Unit for 5 to 10 minutes at the46°C setting. The temperature will oscillate.During this time interval, familiarize yourselfwith the following steps 9 through 14. Have astopwatch ready.

9. Place the HEAT/OVERTEMP switch toOVERTEMP. The temperature should start toincrease. When the air temperature reaches48°C, start the stopwatch.

10. Allow the Power Unit to heat until either the S2or S3 Test Tool thermostat indicator is lit. Stopthe stopwatch and note the highesttemperature displayed. This is the upper limittemperature for one of the thermostats.Record the time and temperature on theINSPECTION FORM.

Verify that the REMOVE FROM USE light is lit.

NOTE: It is acceptable if both thermostatstrip simultaneously, in which case the S2and S3 indicators will both be off. If thisoccurs, record the elapsed time andtemperature. Verify that the REMOVE FROMUSE indicator is lit. Verify that both the S2and S3 indicators light by toggling theTHERMOSTAT BYPASS switch from the S2 toS3 position. (If both thermostats havetripped, skip steps 11-14 and proceed tostep 15.)

11. Switch the TC20 THERMOSTAT BYPASS towhichever thermostat (S2 or S3) is lit. Thiswill short out the thermostat which openedfirst so that the second thermostat can betested.

Switch the TC20 from OVERTEMP to HEAT toallow the Power Unit to return to normaloperating temperature before testing thesecond thermostat.

12. Run the Power Unit again for 5 to 10 minutesin the 46°C setting. The temperature willoscillate. Have a stopwatch ready.

13. Place the OVERTEMP/HEAT switch toOVERTEMP. The temperature should start toincrease. When the air temperature reaches48°C, start the stopwatch.

14. Continue to monitor the TC20 Test Tool untilthe second thermostat indicator is lit. Stop thestopwatch and note the highest temperaturedisplayed. This is the upper limit temperature

Figure 6A - Hose detail, showing sensor location Figure 6B - Test setup

for the other thermostat. Record the time andtemperature on the INSPECTION FORM (table2, pp. 16-17). Plot these values on table 2, p.18.

Verify that the REMOVE FROM USE light is lit.

15. Thermostat trip acceptance

Both thermostats must trip within theacceptance window (see table 2, p. 18).If this condition is not met, do not put thePower Unit in service. Call Gaymar's TechnicalService Department for assistance (see insidefront cover for telephone numbers).

16. Unplug the power unit. Open the enclosure toallow the Power Unit to cool for 5-10 minutes.

17. Locate the two patient limit thermostats (item18, fig. 11, p. 26). Reset S2 by gently pressingthe center reset button.

Use care when resetting thethermostats. Excessive force (forcegreater than 5 pounds) can damagethe overtemp protection device and/or inadvertently alter the triptemperature of the device.

NOTE: Use care when resetting thethermostats since the power terminals aredelicate. Avoid flexing the terminals.Thermostats with loose terminals should bereplaced and retested.

18. Press the center reset button of S3. Verify ithas reset (indicated by an audible "click" andtactile feedback). If it "clicks", proceed to step19.

If you don't hear a "click", then what wasassumed to be the patient limit thermostat S3tripping was actually the heater overtempthermostat S4 in the same circuit. This willrarely occur. If it has occurred, proceed asfollows:

a. Remove the filter retainer and nut.Remove the filter. Jumper out the S4thermostat. Replace the filter, filterretainer and nut.

b. Run the Power Unit for 5 to 10 minutesin the 46°C setting.

c. Bypass S2 by placing theTHERMOSTAT BYPASS switch in theS2 position. Place the HEAT/OVERTEMP Switch to OVERTEMP.Allow the Power Unit to operate. Whenthe air temperature reaches 48°C,start the stopwatch.

d. Allow the Power Unit to heat until theS3 thermostat indicator is lit. Stop thestopwatch and note the highesttemperature displayed. This is theupper limit temperature for the S3thermostat. Record the elapsed timeand temperature.

e. Verify that the REMOVE FROM USElight is lit.

f. The S3 thermostat must trip within theacceptance window (see table 2, p.18). If this condition is not met, do notput the Power Unit in service. CallGaymar's Technical ServiceDepartment for assistance (see insidefront cover for telephone numbers).

g. Unplug the Power Unit.

h. Open the enclosure and allow thePower Unit to cool for 5-10 minutes.

i. Remove the filter retainer and nut.Remove the filter. Remove the jumperfrom the S4 thermostat. Press the S4reset button and insure it is reset.Replace the filter, filter retainer, andnut.

j. Reset both the S3 and S2 thermostatsby pressing their center reset buttons.(The S2 thermostat may haveretripped.)

19. Remove the TC20 Test Tool.

After performing the preceding testprocedure, verify that the TC20 TestTool and all jumpers have beenremoved before returning the PowerUnit to patient use. Failure to do somay result in death, serious injury,or equipment malfunction.

20. Proceed to the FILTER SWITCH TEST(section 7.6, p. 14).


11

WARNING

WARNINGARNING

7.5.2 ALTERNATE Test JumperProcedure (steps 21 to 50)21. Unplug the Power Unit.

Always unplug the Power Unitbefore attaching or removingjumpers and when resettingthermostats. Failure to unplug thePower Unit could result inelectrical shock and cause death orserious injury.

22. There are two patient limit thermostats withinthe Power Unit and each must be tested. One16 gauge insulated stranded wire jumper withalligator clips will be required. To helpremember to remove the test jumper, label aLARGE, distinctive tag “REMOVE AFTERTEST” and tie the tag to the jumper.

Remove the six screws on the back of theunit. Install a jumper across thermostat S3(item 18, fig. 11, p. 26). Temporarily securethe two halves of the enclosure together withadhesive (duct) tape.

23. Locate the air temperature sensor at thecenter of the end of the hose (fig. 6A, p. 10).Secure the sensor with adhesive tape. Verifythat the sensor is located at the center ofthe hose.

24. Connect the hose to a Model TC1050CE,TC2050CE, TC2052CE, or TC2054CE Quilt(fig. 6B, p. 10).

25. Plug in the Power Unit and turn it on. Selectthe 46°C setting. Run the Power Unit for 5 to10 minutes. The temperature will oscillate.During this time interval, familiarize yourselfwith the following steps 26 through 31, sothat the procedure can be accomplishedquickly, without letting the Power Unit cool.

NOTE: Perform the following steps 26through 31 as quickly as possible, toprevent the Power Unit from cooling down:

26. Unplug the Power Unit. Carefully separate theenclosure slightly.

27. Unplug the thermistor (item 13, fig. 10,p. 25) from the back of the control board.NOTE: The power resistor on the back sideof the PC board may be hot to touch.

28. Put the enclosure back together and secure itwith adhesive (duct) tape.

29. Plug in the Power Unit and turn it on. Leaveunit in 32°C temperature setting. Have astopwatch ready.

NOTE: Do not set the TEMPERATURESETTINGS switch to fan only since thissetting disables the heater.

30. The temperature should increase. When theair temperature reaches 48°C, start thestopwatch. The Power Unit will heat until theS2 thermostat trips. When this happens, theblower and heater will shut off. Stop thestopwatch and note the highest temperaturedisplayed. This is the upper limit temperaturefor thermostat S2. Record the time andtemperature on the INSPECTION FORM(table 2, pp. 16-17).

31. Verify that the REMOVE FROM USE light is lit.


33. Open the enclosure and allow the Power Unitto cool for 5-10 minutes.

34. Locate the two patient limit thermostats (item14, fig. 11, p. 26). Gently press the resetbutton in the center of each thermostat. Movethe jumper across thermostat S2.

Use care when resetting thethermostats. Excessive force (forcegreater than 5 pounds) candamage the overtemp protectiondevice and/or inadvertently alterthe trip temperature of the device.

NOTE: If both thermostats reset, boththermostats have tripped. This isacceptable.


12

WARNING

WARNING

NOTE: Use care when resetting thethermostats since the power terminals aredelicate. Avoid flexing the terminals.Thermostats with loose terminals shouldbe replaced and retested. Be certain thethermostats have cooled for 5-10 minutesbefore resetting.

NOTE: If thermostat S2 does not reset, theheater overtemp thermostat has tripped. Inthe unlikely event that this has occurred,perform the following:a) remove the filter retainer and nut;b) remove the filter;c) jumper the S4 heater overtemp thermostat; andd) replace the filter, filter retainer, and nut. Return to step 25.

35. Reconnect the thermistor to the controlboard.

36. Put the enclosure back together and secure itwith tape.

37. Plug in the Power Unit. Turn it on.

38. Run the Power Unit for 5-10 minutes in the46°C setting to stabilize the systemtemperature.

NOTE: Perform the following steps 39 through44 as quickly as possible, to prevent the PowerUnit from cooling down:

39. Unplug the Power Unit. Carefully separatethe enclosure slightly.

40. Unplug the thermistor (item 13, fig. 10, p.25) from the back of the control board.


42. Plug in the Power Unit and turn it on. Leaveunit in 32°C temperature setting. Have astopwatch ready.

NOTE: Do not set the TEMPERATURESETTINGS switch to fan only since thissetting disables the heater.

43. The temperature should start to increase.When the air temperature reaches 48°C, startthe stopwatch. Allow the Power Unit to heatuntil thermostat S3 trips. Stop the stopwatch


13

and note the highest temperature displayed.This is the upper limit temperature for thatthermostat. Record the time and temperatureon the INSPECTION FORM (table 2, p. 17).Plot these values on table 2, page 18.

44. Verify that the REMOVE FROM USE light is lit.


46. Open the enclosure and allow the Power Unitto cool for 5-10 minutes.

47. Thermostat trip acceptance

Both thermostats must trip within theacceptance window (see table 2, p. 18).If this condition is not met, do not put thePower Unit in service. Call Gaymar'sTechnical Service Department for assistance(see inside front cover).

48. Remove the jumper from the patient limitthermostat.

If a jumper was used on the S4 heaterovertemp thermostat, remove the filterretainer, nut, and filter. Remove the jumperfrom S4. Reset S4 (indicated by an audible"click" and tactile feedback). Replace thefilter, filter retainer, and nut.

After performing the preceding testprocedure, verify that all test jumpershave been removed before returningthe Power Unit to patient use.Failure to remove test jumper(s)may result in death, serious injury,or equipment malfunction.

49. Reconnect the thermistor connector to theback of the control board.

(continued)

WARNING

6. Unplug the Power Unit. Install filter. (Installnew filter every 1000 operating hours or 12months, whichever occurs first.) Replace thefilter only with the Gaymar P/N listed (seeparts list, fig. 9, p.24). Record the hour timerreading onto the new filter label. Reattachfilter and nut.

The HEPA filter must be seatedproperly. Failure to install the filtercorrectly will prevent it fromfunctioning properly, and couldallow unfiltered air to reach thepatient and cause injury.

7. Replace the six screws holding theenclosure together.

7.7 Quilt TemperatureVerify temperature output at each heat setting:

1. Prepare the Power Unit test setup, if it hasnot been previously prepared:

a. Locate the air temperature sensor atthe center of the end of the hose (fig.6A, p. 10). Secure the sensor withadhesive tape. Verify that the sensoris located at the center of the hose.

b. Connect the hose to a ModelTC1050CE, TC2050CE, TC2052CE,or TC2054CE Quilt (fig. 6B, p. 10).

c. Plug in the Power Unit and turn it on.

2. Set the TEMPERATURE SETTINGS switch to32°C. Run the Power Unit for 5 minutes.After 5 minutes, note the two highest andtwo lowest temperature readings. Record theaverage of these four temperatures on theINSPECTION FORM (table 2, p. 17).

Allowable 32°C temperature:30.6°C to 33.9°C average

50. Reset the thermostats by gently pressing thecenter reset buttons.

Use care when resetting thethermostats. Excessive force(force greater than 5 pounds) candamage the overtemp protectiondevice and/or inadvertently alterthe trip temperature of the device.

NOTE: Use care when resetting thethermostats since the power terminals aredelicate. Avoid flexing the terminals.Thermostats with loose terminals shouldbe replaced and retested.

7.6 Filter Replacement and FilterSwitch Test (every 12 months or 1000operating hours, whichever occurs first)1. Unplug the Power Unit. Separate the two

halves of the enclosure. Lay the Power Uniton its back.

2. Remove the filter retainer and nut. Removethe filter.


4. Plug in the Power Unit. Turn it on. Verify thatthe blower does not start and that theREMOVE FROM USE light is lit.

5. A timer which counts total running hours islocated inside the Power Unit for use byservice personnel. Timer readings may beused to track HEPA filter usage intervals. Toread the hour timer:

a. Unplug the Power Unit. Separate thetwo halves of the enclosure again.Locate the hour timer (see figure 10, p.25). Plug in the Power Unit and turn iton. Read the hour timer and record thetotal running hours on the INSPECTIONFORM.

b. Turn the Power Unit off.


14

CAUTION

WARNING

3. Repeat step 2 for 38°C setting. Averagetemperatures and record.


4. Repeat step 2 for 43°C setting. Averagetemperatures and record.


5. Repeat step 2 for 46°C setting.


6. If the temperatures in steps 2 through 5 arenot correct, do not put the Power Unit intoservice. Call your local dealer for assistance.


7.8 Ground ResistanceCheck grounding resistance:

1. Use a current leakage/ground resistancetester to measure the resistance between thegrounding pin on the power entry moduleand the I. V. pole clamp. An unplated area onthe underside of the I. V. pole clamp hasbeen provided for this test. Record the value.

2. The value should be less than 0.5 ohms.

7.9 Current LeakageMeasure current leakage:

1. Measure and record the maximum earthcurrent leakage (ground open). An unplatedarea on the underside of the I. V. pole clamphas been provided if needed for this test.Measure at all combinations of:

• line polarity

• neutral open/closed

2. The current leakage should not exceed 100microamperes in any condition.


15

7.10 Completing the Functional Checkand Safety InspectionIf the Power Unit has passed the FUNCTIONALCHECK AND SAFETY INSPECTION for allrequirements of procedures 7.1 through 7.9 , thePower Unit should be considered operational andsuitable for return to service.

This completes the recommended FUNCTIONALCHECK AND SAFETY INSPECTION for the TC3003series Power Unit.

Section 8 - Inspection Form

16Table 2 - Functional Check / Inspection Form (p. 1)

mroFnoitcepsnIytefaSdnakcehClanoitcnuFtinUrewoP3003CT

_____________________etaD_______________slaitinI_________________________________________________noitacoL

______________________rebmuNlaireS_______oN_______seY:retliFAPEHdecalpeR_____________)sruohlatot(remitruoH

)s(erudecorP ?enoD)kcehc(

noitcA **stluseR)noitceleselcric(

1.7 erusolcnE

1 .tinUrewoPgulpnU

2 .skcarcroferusolcnekcehC ssaP liaF

3 .swercskcehC ssaP liaF

4 .sgnikramdnagnillebalkcehC ssaP liaF

5 .stnevrianaelc/kcehC ssaP liaF

6 .ylbmessaesohkcehC ssaP liaF

2.7,drocenil,gulP

feilerniarts

1 .gulpenimaxE ssaP liaF

2 .feilerniartskcehC.drocenimaxE ssaP liaF

3.7 hctiwsrewoP1 .sthgilrekaerbtiucricehttahtkcehC.tinUrewoPnigulP ssaP liaF

3 .gnittestaehC°23nistratstinUrewoPtahtyfireV ssaP liaF

4.7ERUTAREPMET

sehctiwsSGNITTES1 .thgilsrotacidnietairporppayfireV.gnitteserutarepmethcaekcehC ssaP liaF

1.5.7

dna*tatsomrehTMORFEVOMER

trelaESULOOTTSET02CT(

)ERUDECORP

1 .swercsevomeR.tinUrewoPgulpnU

3 .tinUrewoPnigulP.desolcerusolcneepaT.looTtseT02CTtcennoC

4 .noitisopretnecniecalp--SSAPYBTATSOMREHT:sgnitteslooTtseT02CT.noitisoptaeHniecalp--PMETREVO/TAEH

5 fodneehtforetnecehttarosneserutarepmetriatnuoM.putestseteraperP.tliuqottcennoC.esoheht

7 .gnittesC°64tceleS.notinUrewoPnruT

8 .ezilibatsotgnittesC°64tasetunim01-5roftinUrewoPnuR

9 .C°84tahctawpotstratS.PMETREVOot02CTecalP

01 .erutarepmet/emitetoN.sthgil02CTnorotacidni3S/2SnehwhctawpotspotSC°_________sdnoces___________.stluserdroceR

.sthgilrotacidniESUMORFEVOMERtahtyfireV ssaP liaF

11 .TAEHotPMETREVOmorf02CThctiwS.tatsomrehtssapyB

21 .ezilibatsotgnittesC°64tasetunim01-5roftinUrewoPnuR

31 .C°84tahctawpotstratS.PMETREVOot02CTecalP

41 .erutarepmet/emitetoN.sthgil02CTnorotacidni3S/2SnehwhctawpotspotSC°__________sdnoces___________.stluserdroceR

.sthgilrotacidniESUMORFEVOMERtahtyfireV ssaP liaF

51 llafstatsomrehthtobrof41dna01spetsniseulaverutarepmet/emitehttahtyfireV.MROFNOITCEPSNIehtfo3egapnowodniwecnatpeccaehtnihtiw

ssaP liaF

61 .setunim01-5roflooctinUrewoPteL.erusolcnenepO.tinUrewoPffonruT

71 .tatsomrehttimiltneitap2SteseR

81 .91petsotdeecorp,draehsikcilcafI.tatsomrehttimiltneitap3SteseR.j81hguorht.a81spetsmrofrep,draehtonsikcilcfI

91 .looTtseT02CTevomeR

02 .TSETHCTIWSRETLIF,6.7otdeecorP

2.5.7


trelaESUTSETETANRETLA(

REPMUJ)ERUDECORP

rehtonodeunitnoc[]edis

12 .desolcerusolcneepaT.3StatsomrehtssorcarepmujllatsnI.swercsevomeR.tinUrewoPgulpnU

32 fodneehtforetnecehttarosneserutarepmetriatnuoM.putestseteraperP.tliuqottcennoC.esoheht

52 setunim01-5roftinUrewoPnuR.gnittesC°64tceleS.notinUrewoPnruT".TSETRETFAEVOMER"repmujlebaL.ezilibatsotgnittesC°64ta

62 .ylthgilserusolcneehtetarapeS.tinUrewoPgulpnU

72 .draoblortnocehtmorfrotsimrehtehtgulpnU

82 .desolcerusolcneepaT

92 .gnittesC°23nievaeL.tinUrewoPnonrutdnanigulP

03 .ffostuhsretaeh/rewolbnehwhctawpotspotS.C°84tahctawpotstratSC°__________sdnoces___________.stluserdroceR.erutarepmet/emitetoN

13 .sthgilrotacidniESUMORFEVOMERyfireV ssaP liaF

23 .tinUrewoPehtgulpnU

33 .setunim01-5rofloocottinUrewoPwollA.erusolcnenepO

43 .2StatsomrehtotrepmujevoM.)s(tatsomrehtteseR

53 .draoblortnocehtotrotsimrehtehttcennoceR


.03nisa34nidna,01nisa41nistluseremasehtdrocer,)erutarepmetdnaemitemasehtta,.e.i(ylsuoenatlumispirtstatsomrehthtobfI*.ecnatsissarofrelaedlacolruoytcatnoC.deriuqersiriaperroecivressetacidni"liaF"gnilcriC**

Section 8 - Inspection Form (cont’d)

Table 2 - Functional Check / Inspection Form (p. 2)17

mroFnoitcepsnIytefaSdnakcehClanoitcnuFtinUrewoP3003CT

)s(erudecorP ?enoD)kcehc(

noitcA **stluseR)noitceleselcric(

2.5.7


trelaESUETANRETLA(REPMUJTSET)ERUDECORPmorfdeunitnoc[

]edisrehto

73 .notinunruT.tinUrewoPnigulP

83 .ezilibatsotgnittesC°64ehtnisetunim01-5roftinUrewoPehtnuR

93 .ylthgilserusolcneehtetarapeS.tinUrewoPgulpnU

04 .draoblortnocehtmorfrotsimrehtehtgulpnU


24 .gnittesC°23nievaeL.tinUrewoPnonrutdnanigulP

34 .ffostuhsretaeh/rewolbnehwhctawpotspotS.C°84tahctawpotstratSC°__________sdnoces_________.stluserdroceR.erutarepmet/emitetoN

44 .sthgilrotacidniESUMORFEVOMERyfireV ssaP liaF

54 .tinUrewoPgulpnU

64 .setunim01-5rofloocottinUrewoPwollA.erusolcnenepO

74 ehtnihtiwllafstatsomrehthtobrof34dna03spetsniseulaverutarepmet/emitehttahtyfireV.MROFNOITCEPSNIehtfo3egapnowodniwecnatpecca

ssaP liaF

84 .tatsomrehtpmetrevoretaehdnatatsomrehttimiltneitapehtmorf)s(repmujehtevomeR

94 .draoblortnocehtotrotsimrehtehttcennoceR

05 .snottubteserretnecgnisserpybstatsomrehtehtteseR

6.7tnemecalperretliF

hctiwsretlifdnatset

1 .sevlaherusolcneetarapeS.tinUrewoPgulpnU

2 .retlifevomeR.tundnareniaterretlifevomeR

3 .desolcerusolcneehtepaT

4 .nonruttonseodrewolbehtyfireV.tinUrewoPnigulP ssaP liaF

.sthgilrotacidniESUMORFEVOMERehtyfireV ssaP liaF

5 .remitruohdaerdna,notinrut,tinUrewoPnigulP.erusolcneetarapeS.tinUrewoPgulpnU.tinUrewoPffonruT.MROFNOITCEPSNIdnalebalretlifwennosruohgninnurlatotdroceR

6 .lebalretlifwenotnognidaerremitruohdroceR.yrassecenfiretlifwenllatsnI.tinUrewoPgulpnU.tundnareniaterretlifecalpeR

7 .swercshcattaeR.erusolcneesolC

7.7 erutarepmettliuQ

1 .tinUrewoPnigulP.esohehtfodneehtforetnecehttarosneserutarepmetriatnuoM.putestseteraperP

2 tsehgih2etoN.setunim5roftinUrewoPnuR.C°23otSGNITTESTAEHteS.tinUrewoPnonruTC°___________:eulavdroceR.sgnidaer4ehtegarevA.serutarepmettsewol2dna

]C°9.33dnaC°6.03neewtebebtsumseulavC°23foegarevA[

ssaP liaF

3 C°__________:eulavdroceR.gnittesC°83rof2petstaepeR].C°4.93dnaC°1.63neewtebebtsumseulavC°83foegarevA[

ssaP liaF


ssaP liaF


ssaP liaF

7 .tinUrewoPehtgulpnU

8.7 ecnatsiserdnuorG1 smho_________:ecnatsiserdnuorgdrocerdnaerusaeM.tinUrewoPehtgulpnU

].smho5.0nahtsselebtsumecnatsiserdnuorG[ssaP liaF

9.7 egakaeltnerruC

1 :sgnittesgniwollofehttaegakaeltnerrucerusaeM

ENILLARTUEN YTIRALOPENIL EULAV

nepO lamroN

nepO esreveR

desolC lamroN

desolC esreveR

2 .snoitidnocevoballarofAµ001deecxetonseodegakaeltnerrucyfireV ssaP liaF

.03nisa34nistluseremasehtdrocer,)erutarepmetdnaemitemasehtta,.e.i(ylsuoenatlumispirtstatsomrehthtobfI*.ecnatsissaroftnemtrapeDecivreSlacinhceTs'ramyaGtcatnoC.deriuqersiriaperroecivressetacidni""liaF""gnilcriC**

Table 2 - Functional Check / Inspection Form (p. 3)

Section 8 - Inspection Form (cont’d)

18

485052545658606264666870

010

2030

4050

6070

8090

100

110

120

130

140

150

160

170

180

190

Tim

e (S

econ

ds)

Hose output air temperature (°C)

Fail

(The

rmos

tat t

rip p

oint

too

high

)

Fail

(The

rmos

tat t

rip p

oint

too

low

)

PASS

(Saf

e ra

nge)

19

Section 9 - Troubleshooting

Always perform the FUNCTIONAL CHECKAND SAFETY INSPECTION after makingrepairs and before returning the Power Unitto patient use. Failure to perform theFUNCTIONAL CHECK AND SAFETYINSPECTION could result in patient injury.

WARNING

Figure 7 - Troubleshooting Chart - NO HEAT

In addition to the following troubleshootingcharts, refer to PREVENTIVE MAINTENANCE(section 6, p. 7) and REPAIR PROCEDURES(section 10, pp. 21-23).

NO HEAT

DOESQUILT

INFLATE?

GO TO NO AIR FLOWSYMPTOM

PRESSEACH SETTINGBUTTON. DOES

CORRESPONDINGLED LIGHT?

CALL TECHNICALSERVICE

UNPLUG UNIT;MEASURE HEATER

RESISTANCE

ISHEATER

RESISTANCEBETWEEN 36.4

AND 40.2OHMS?

REPLACE HEATER

UNPLUG RT1THERMISTORASSY. TURNPOWER ON.

DOESUNIT HEAT?

SUSPECT PCBOARD; CONTACT

TECHNICAL SERVICE

REPLACE RT1THERMISTOR ASSY

SYMPTOM:

NO

YES

NO

YES

NO

YES

NO

YES

Section 9 - Troubleshooting (cont'd)

Figure 8 - Troubleshooting Chart - NO AIR FLOW20

NO AIR FLOW

ENSURE UNIT ISPLUGGED IN

UNPLUG UNIT; CHECKCIRCUIT BREAKERREPAIR/REPLACE

ISRFU LIT?

CALL TECH SERVICE

UNPLUGUNIT ANDOPEN IT

REINSTALLFILTER

IS S2OR S3

TRIPPED?

RESETS2, S3

IS RT1THERMISTOR ASSY

CONNECTED?

PERFORM FUNCTION CHECK--POSSIBLE CAUSES:1. TOO HIGH STORAGE TEMP2. UNIT OUT OF CAL.3. LOW SPEC ON S2, S3

PERFORMFUNCTIONAL

CHECK

DOES RFUREOCCUR?

POSSIBLE CONTROLLERFAILURE; CALL TECH

SERVICE

RUN UNIT IN32°C SETTING

FOR 10 MINUTES

S4 HASTRIPPED

RESET S4

IS THERE ABLOCKED,BENT,OR MISALIGNED

BLOWER WHEEL?

POWER UPUNIT.

AIRFLOW?

REPAIR/REPLACEMOTOR

NO

YES

NO

YES

IS CIRCUITBREAKER LIT?

IS FILTERINSTALLED

CORRECTLY?

REMOVE BLOCKAGE;REPLACE/ALIGNBLOWER WHEEL

RECONNECT RT1THERMISTOR

ASSEMBLY

YES

YES

NO

YES

NO

YES

NO

YES

NO

NO

PERFORMFUNCTIONAL

CHECK

NO

YES

SYMPTOM:

4. Remove the ten screws securing the filterinlet plate.

5. Remove the screw and lock washer securingthe ground wire to the backing plate.Remove the two screws securing theterminal block.

6. Carefully lift the filter inlet plate, exposing theblower wheel.

7. Remove the blower wheel using 1/8" hexwrench through hole in one blade of blowerwheel.

8. Remove the two #6 screws holding theheater to the motor bracket.

9. Disconnect the short wire from the heater tothe motor.

10. Remove the red heater wire from terminalblock location TB1-3 (refer to figure 11).Remove cable ties.

11. Remove the heater.

12. Install the replacement heater.

13. Reroute the red wire through the 4-holegrommet.

14. Reconnect both wires. Refer to TB1designators in the schematic (figure 13) andterminal block wiring designators in figure11. Install cable ties.

15. Reinstall the blower wheel, making surethere is 2.5 mm clearance between thewheel and the blower inlet ring (see fig. 9).(NOTE: the hex screw must be aligned withthe flat on the motor shaft.)

16. Place the filter inlet plate back on top of thescroll. Secure the ten screws.

17. Replace the terminal block. Reconnect theground wire to the backing plate; make surethe lock washer is reinstalled.

18. Replace the HEPA filter. Secure it with thefilter retainer and nut.

19. Perform the FUNCTIONAL CHECK ANDSAFETY INSPECTION (section 7, pp. 8-15).

10.0 Repair Procedures

Use only Gaymar replacement parts asidentified in the parts lists (pp. 24-27).Use of substitute parts could result inpower unit malfunction or patient injury.

To identify replacement parts, refer to figures9-11 (pp. 24-27). To order replacement parts,contact Gaymar's Export Department:

Telephone: (716) 662-8636

Fax: (716) 662-0730

10.1 Replacing the Patient LimitThermostat(s) (S2 & S3)To replace either thermostat (item 18, fig. 11):


2. Remove the six screws securing theenclosure. Open the enclosure.

3. Carefully unplug the terminals from thethermostat.

4. Remove the two #4 nuts from thethermostat.

5. Replace the thermostat. Reinstall the nuts.

6. Carefully replace the terminals.


10.2 Replacing the HeaterTo replace the heater (item 3, fig. 9):



3. Remove the filter retainer and nut. Removethe HEPA filter.

Section 10 - Repair Procedures

WARNING

21

10.3 Replacing the ThermistorAssembly (RT1)To replace the thermistor assembly (item 4, figs.9-10):



3. Unplug the thermistor assembly from the PCboard.

4. Cut the cable ties holding the thermistor wiresto the wire harness and enclosure standoff.Be careful not to cut the insulation on thestandoff.



7. Remove the two screws securing the terminalblock. Remove the screw and lock washersecuring the ground wire to the backing plate.

8. Depending on the method of mounting, eitheruse wire cutters to remove the spring clip, orloosen the speed nut securing the thermistorassembly to the filter inlet plate.

9. Replace the thermistor assembly. Secure itwith the new speed nut supplied with thethermistor assembly.

10. Place filter inlet plate back on top of thescroll. Secure the ten screws.

11. Replace the terminal block. Reconnect theground wire to the backing plate. Make surethe lock washer is reinstalled.

12. Plug the thermistor assembly into the controlboard. Use the cable ties supplied with thethermistor assembly to hold the thermistorwires to the PC board wire harness andenclosure standoff.



10.4 Replacing the motorTo replace the motor:





5. Remove the screw securing the ground wireto the backing plate. Remove the two screwssecuring the terminal block.

6. Carefully lift the filter inlet plate, exposing theblower wheel.

7. Remove the blower wheel using a 1/8" hexwrench through hole in one blade of blowerwheel.

8. Cut wire tie holding wiring harness (fig. 11).

9. Unplug terminals from the motor.

10. Remove the two #8 screws and two #8 nutsfrom the bottom of motor.

11. Loosen the two #8 screws on top of motor.Slide filter support bracket off. Loosencorresponding screws on new motor andreplace filter support bracket. Tightenscrews.

12. Remove and replace the motor.

13. Secure with mounting hardware.

14. Reconnect the terminals.

15. Secure wire harness to motor with a wire tie.

16. Reinstall the blower wheel, making sure thereis 2.5 mm clearance between the wheel andthe blower inlet ring (see fig. 9).NOTE: the hex screw must be aligned withthe flat on the motor shaft.

17. Place the filter inlet plate back on top of thescroll. Secure the ten screws.

18. Replace the terminal block. Reconnect theground wire to the backing plate; make surethe lock washer is installed.

Section 10 - Repair Procedures (cont’d)

22



10.5 Replacing the I. V. Pole MountBracketTo replace the I. V. pole mount bracket:



3. Remove the two screws securing theterminal block from the backing plate.

4. Remove the two screws and the lock washerholding the I. V. pole mount bracket to thebacking plate.

5. Remove the I. V. pole mount bracket from therear half of the enclosure.

6. Insert new I. V. pole mounting bracket intorear half of the enclosure.

7. Replace the two screws and the lock washerinto the backing plate and I. V. pole mountingbracket.

8. Replace the terminal block.


10.6 Temperature Control PC Board

To replace the P.C. board assembly(item 11, fig. 10):


Section 10 - Repair Procedures (cont’d)

23


3. Cut the four cable ties which secure the PCboard wires together.

4. Unplug the following wires from the PCboard assembly at the terminal block (item30, fig. 11):

• Yellow wire from TB1-1C

• Gray wire from TB1-2C

• Red wire from TB1-3C

• White wire from TB1-4C

• Black wire from TB1-5C

5. Unplug the main harness (5-pin connector)from PC board.

6. Unplug the 2-pin harness from the PC board.

7. Remove the six screws securing the PCboard assembly.

8. Remove the old PC board assembly andinstall the new PC board assembly.

9. Reassemble in reverse order.


WARNING

The Temperature Control PC Board ispre-set at the factory. Do not attempt tocalibrate it. Adjustment of the ControlPC Board in the field could result inpatient injury.

Section 11 - Drawings/Parts Lists

Figure 9 - TC3003 Detail Drawing

24

2.5 mm

1

5

4

8

7

3

2

6a

6b

Item Description Part Number

1 HEPA filter 78018-000

2 Filter retainer nut 91396-005

3 Heater 78019-000

4 RT1 Thermistor assembly 77942-000

5 Blower wheel 91369-000

6 a. Clip 90228-004

b. Rachet 91428-002

7 Label, Caution 08985-000

8 Bed rail hook 77943-000

Section 11 - Drawings/Parts Lists (cont’d)

Figure 10 -TC3003 Detail Drawing

25

TEST PLUG

HOUR TIMER

HEAT

S3S2

OVERTEMP

THERMOSTATBYPASS

14

4

12

11

10

9

13

Figure 11 - TC3003 Detail Drawing

Section 11 - Drawings/Parts Lists (cont’d)

26

S3S2

S4

16

17

18

19

22 23

24

20

21

25

26

27

28

29

31

30

32

33

34

35

ROTATION

To release wires fromterminal block, insert asmall screwdriver inslot nearest wire andpull towards center.

wire tie

Section 12 - TC20 Test Tool Schematic

Figure 12 - TC20 Test Tool Schematic

(see Figures 11/11A)

ATTENTION

Static-SensitiveDevices

Figure 11A - Power cord plugs

27

PC001 PC004 PC006PC002 PC005 PC007PC003

metI noitpircseD rebmuNtraP metI noitpircseD rebmuNtraP

61 eludomyrtnerewoP 000-39980 03 noituaC,lebaL 000-06990

71 tikrotoM 000-22087 13 kcolblanimreT 000-64319

81 )3S,2S(statsomrehttimiltneitaP 500-32319 23 ylbmessapartsdroC 000-19730

91 ylbmessaesoH 000-05977 33 )4S(tatsomrehtretaeH 000-52087

02 tnemecalperlebal,drac,tiK 000-01187 43 hctiwskcolretnI 000-57319

12 )gnilebalsedulcni(tikgnisuohraeR 200-81187 53 GL"2/14,gniveelS 000-45018

22 ylbmessapmalcelop.V.I 000-41680 -- )eporuElatnenitnoC(drocrewoP 100CP

32 eohselggoT 000-93419 -- )modgnIKdetinU(drocrewoP 200CP

42 knalB/keerG,noitacidniartnoC,draC 000-77890 -- )ailartsuA(drocrewoP 300CP

52 hsinniF/hsidewS,noitacidniartnoC,draC 000-67890 -- )dnalreztiwS(drocrewoP 400CP

62 hsinaD/hctuD,noitacidniartnoC,draC 000-57890 -- )ylatI(drocrewoP 500CP

72 namreG/nailatI,noitacidniartnoC,draC 000-47890 -- )kramneD(drocrewoP 600CP

82 eseugutroP/hsinapS,noitacidniartnoC,draC 000-37890 -- )learsI(drocrewoP 700CP

92 hcnerF/hsilgnE,noitacidniartnoC,draC 000-27890

28

Section 13 - Wiring Diagram

ATTENTION

Static-SensitiveDevices

Figure 13 - Wiring Diagram

29

Section 13 - Wiring Diagram (cont’d)

Gaymar Industries, Inc.10 Centre Drive

Orchard Park, NY 14127-2295 USA

Telephone: +1 716 662-8636 +1 716 662-2551

Fax: +1 716 662-0730 +1 716 662-6120

www.gaymar.com

Gaymar and Thermacare trademarks are registered in the US Patent and Trademark Office.

©2010. Gaymar Industries, Inc. All rights reserved.

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