Gaymar TP500 Service Manual

®

P/N 11950-000 9/03

T/PUMP®

TP500 / TP500CHeat Therapy System

SERVICE MANUAL

LISTED 304L

STANDARD (NORME)C22.2 NO. 125 RISKCLASS (CATEGORIEDE RISQUES) NO. 2G

SERVICE MANUALTP500/TP500C T/PUMP

CONTENTS

T/PUMP, T/PAD, Mul•T•Pad, Clik-Tite, and Gaymar are registered trademarks of Gaymar Industries, Inc. U. S. PATENT 4,068,870

© 2001. Gaymar Industries, Inc. All rights reserved. www.gaymar.com

CONTENTSSafety Precautions ..................... 1

Introduction ......................... 2

Features............................ 3

Specifications ........................ 4

Operating Instructions .................. 5

Storage/Cleaning ...................... 7

Theory of Operation ................... 8

Functional Check and Safety Inspeciton ....... 10

Inspection Form ...................... 15

Disassembly/Reassembly ................. 16

Calibration .......................... 19

Troubleshooting ...................... 21

Replacement Parts ..................... 27

Warranties .......................... 30

ILLUSTRATIONS1 T/Pump® Heat Therapy System ........ 2

2 Features/Specifications.............. 3

3 Clik-Tite® Connectors.............. 5

4 Colder-style Connectors ............ 5

5 T/Pump Components .............. 9

6 Motor ........................ 11

7 TPC1 Test Covers ................ 22

8 Functional Check Test Diagram ....... 23

9 Circuit Diagram for T/Pump .......... 24

10 Circuit Diagram for TPC1 Test Cover ... 25

11 Exploded View of T/Pump ........... 26

BEFORE YOU BEGIN . . .

Read and understand thisT/PUMP SERVICE MANUAL and allPRECAUTIONS (see page 1) prior toservicing the T/Pump.The purpose of this manual is to provide operation,service, and repair information for GAYMAR heattherapy pumps.

RECEIVING INSPECTIONCheck the shipping carton for damage immediatelyupon receipt. If package damage is discovered, thedevice should be unpacked with the carrier's agentpresent. Any claims for shortage or damage must befiled with the delivering carrier by the purchaser. Donot return pumps damaged in shipment to GAYMARwithout contacting our Technical ServiceDepartment for advice (see phone numbers below).If damaged goods are returned to GAYMAR withoutnotifying the carrier, GAYMAR will assume therepairs will be made at the customer's expense.

TO RETURN PUMPS TO FACTORYFOR REPAIR OR EXCHANGEMerchandise returned to GAYMAR must beaccompanied by a Return Goods Number (RG#),issued by GAYMAR, authorizing goods to bereturned. Call Customer Service or TechnicalService at

(716) 662-25511 800 828-7341

Advise model, serial number, and nature of problem.You will be given a Return Goods Number (RG#).

The serial number is on the back of the T/Pump(see figure 2, p. 3).


1

• Risk of explosion. Do not use in the presence of flammableanesthetics.

• Risk of electric shock. Disconnect power before servicingthe T/Pump.

DANGER

SAFETY PRECAUTIONS

• Do not perform any powered tests with the reservoir empty.Damage to the T/Pump may result.

CAUTION

WARNING

Group/Condition at risk Potential injury

Pediatric patients Hyperthermia/hypothermia

Patients with impaired circulation Ischemia

Areas of application are under pressure Ischemia

In combination with topical solutions whose toxicitymay be affected by the application of heat

Chemicalinjury

In combination with other heat sources Thermal injury

• This device pumps warmed water through a pad. Set padtemperature only as prescribed by and under the guidance of aphysician. Monitor the patient's temperature and skin conditionevery 20 minutes or as directed by a physician. Failure toadhere to these warnings could result in patient injury.

The following Groups/Conditions require additional surveillance:

• Only qualified medical service personnel should repair theT/Pump. Improper repair may result in death orserious injury, equipment damage, or malfunction.

• Always perform the FUNCTIONAL CHECK AND SAFETYINSPECTION (pp. 10-14) after making repairs and beforereturning the T/Pump to patient use. Document yourfindings on the INSPECTION FORM (p. 15). Improperrepair may result in death or serious injury,equipment damage, or malfunction.


INTRODUCTION

2

Figure 1—T/Pump Heat Therapy System

Heat therapy is effective in the dilation of blood vessels, thereby increasingthe blood flow to the heated area. Heat therapy has a variety of uses, themost common being treatment of aches and pains in joints and muscles.

The GAYMAR T/Pump® Heat Therapy System provides a means ofapplying heat therapy by supplying temperature-controlled water through aconnector hose to a Gaymar T/Pad®. The hose is terminated in easy-to-useClik-Tite® or Colder-style connectors.

The T/Pad provides the interface for delivering the heat therapy. Theunique button design allows water to flow and provides trouble-freeoperation when the pad is folded. This reduces the number of pads yourfacility must keep in inventory. The pads are applied to the part of thebody requiring heat therapy, and the circulating water maintains the pad atthe set point temperature. The temperature setpoint is key-operated toprevent tampering.

The T/Pads can be interconnected (on model TP500 only) to providetherapy to more than one body site at a time.

Single Pad Multiple Pads


3

Attached Hose 10 ft (305 cm) dual hose. Connectors allow pads to beconnected to the pump (see figs. 3 and 4, p. 5).

Tip-over Turns heater off if pump is tipped.Switch NOTE: This does not activate the OVER TEMP light.

Hospital ID A label is provided on the back of the T/Pump for yourLabel convenience. Use a felt tip or ball point pen to add any

required hospital identification.

OVER TEMP Indicates the pump and heater have been turned off.Light This light is activated by the two OVER TEMP safety

thermostats. Refer to the TROUBLESHOOTING section.

Circuit Breaker When the circuit breaker trips, the small button inthe center will extend 1/4", exposing a white band.Refer to the TROUBLESHOOTING section.

OVER TEMP Either of two limit thermostats will shut off pump and heaterSafety if the high temperature limit is exceeded. The OVER TEMPThermostats light will glow. Refer to the TROUBLESHOOTING section.

FEATURES

FEATURES

Figure 2—T/Pump Features

SERVICE MANUALTP500/TP500C T/PUMPSPECIFICATIONS

Size (approx.) 8-1/8" x 5-5/8" x 6-1/4"(20.6 cm x 14.3 cm x 15.9 cm)

Weight (empty) 5 lbs, 2 oz (2.3 kg)

Reservoir capacity 51 oz (1500 ml) maximum

Flow rate 9 gph (34 lph) minimum with pad attached

Ambient operating 60°F to 90°F (15.6°C to 32.2°C)temperatures

Storage temperatures -30°F to 160°F (-34.4°C to 71.1°C)(empty)

Temperature set point 85°F to 107°F (29.4°C to 41.7°C)range

Average operating ±2°F at 107°F settingtemperature accuracy

Power cord 18 AWG, 3 conductor, 9 ft (274 cm), Type SJTwith molded, hospital grade plug

Circuit breaker 3 amperes

1st backup limit Bimetallic (trip point fixed)thermostat 110°F to 117°F (43.3°C to 47.2°C)(manifold mounted)

2nd backup limit Bimetallic (trip point fixed)thermostat 110°F to 122°F (43.3°C to 50°C)(well mounted)

Current leakage 100 microamperes maximum

Ground resistance 0.5 ohm maximum

Electrical requirements

Voltage (VAC) 120Frequency (Hz) 60Current (amps) 1.8Power req'd (watts) 200

Safety approvals Tested to UL 544 and CSA C22.2, No. 125

SPECIFICATIONS

4


5

OPERATING INSTRUCTIONS

Figure 3A–3D—Clik-Tite® Connectors

COLDER-STYLE CONNECTORS(on TP500C):1. To attach Colder-style connectors to a pad,

push the male coupling onto the female cou-pling. When you hear an audible “click”, theconnectors are joined (fig. 4A).

2. To disconnect Colder-style connectors, pressdown on the thumb tab of the female coupling.The couplings will partially disconnect. Pull themale coupling out fully to disconnect (fig. 4B).

T/Pumps are supplied with one of two types of hose connectors:TP500 T/Pumps have Clik-Tite® connectors;TP500C T/Pumps have Colder-style connectors.

CLIK-TITE® CONNECTORS(on TP500):

To attach Clik-Tite connectors from hose to pad:

1. Insert male fittings into female fittings witha twisting motion (figs. 3A and 3B).

2. When fittings are fully inserted, snap lockingring into place (figs. 3C and 3D).

3. To disconnect, simply reverse the procedure.

4. To open or close the hose pinch clamps:

• Open the clamp by pushing the serratedend (fig. 3E).

• Close the clamp by pressing the clamptogether (fig. 3F).

Figure 4—Colder-style Connectors

4A

NOTE: Refer to figure 1 (p. 2) anditem 9 (p. 6) when connectingmultiple pads.

4B

Figure 3E–3F—Hose Pinch Clamps

3E 3F


6

OPERATING INSTRUCTIONS

1. Before filling, always attach a T/Pad to the T/Pump connector hose (seefigs. 3 and 4, p. 5). Unkink pad and hose. Open hose clamps.

2. Open the fill cap on top of the pump. Fill the pump with roomtemperature (i.e., not hot) distilled water to the operating levelindicated on the side of the pump.NOTE: Using tap water will decrease the life of the pump.

3. Insert temperature setting key. Set temperature as prescribed by thephysician. Remove key to prevent tampering.

4. Plug the pump into a properly grounded outlet.

5. Turn on the power switch. The selected water temperature will bereached in approximately 20 minutes.

6. If the water level drops below the operating level, add water. Do notoverfill. Overfilling can result in reduced pump motor life.

7. Apply T/Pad to the patient. Follow T/Pad instructions.

8. For specified performance, keep the pump at or above the level of thepad.

9. If the pump is placed below the pad(s), water will drain into the pumpwhen it is shut off. If the pump has been overfilled or if multiple padsare connected, excess water can leak out onto the floor or causereduced motor life.

1. Turn off pump before disconnecting pad. Close all hose clamps.To prevent water spillage, always disconnect pad from pump withconnectors raised above the level of the pad and pump.

2. Connect the T/Pad Clik-Tite connectors together, where applicable.

3. Connect the ends of the T/Pump connector hose together(TP500 only).

SHUTDOWN PROCEDURE

START-UP PROCEDURE


7

Disconnect pad. Connect ends of the connector hoses together,where applicable. Open hose clamps. Leave water in the reservoir.To prevent hose kinks, coil the hose rather than folding it. Fasten the hoseand cord with strap.

Connect pad. Open hose clamps. Add 1/4 ounce GAYMAR MTA33germicidal or equivalent to water already in reservoir. Run for two (2)minutes. Drain pump. Close hose clamps. Disconnect pad. To prevent hosekinks, coil the hose rather than folding it. Fasten the hose and cord withstrap and store pump.

Unplug the power cord. Disconnect the pad or hoses from one another,keeping hoses at or above the level of the T/Pump. Remove the fill cap andinvert the T/Pump over a sink. When all fluid has drained from the hosesand reservoir, replace the fill cap and connect the hoses together, whereapplicable.

Unplug the power cord.

To clean the external surfaces, use a non-abrasive cleaning solution (suchas warm, soapy water) and a damp cloth.

To clean the fluid system, drain the pump. Fill the reservoir to the operat-ing level indicated on the side of the pump. Add 1/4 ounce GAYMARcatalog MTA33 germicidal or equivalent. Set the temperature indicator toits lowest setting (fully counterclockwise). Start the T/Pump and circulatethe solution for one hour. Drain the solution and refill the pump withdistilled water. Using distilled water retards algae growth and mineralbuildup.

Change the distilled water monthly or more often depending upon use.

For best results use only GAYMAR T/Pads® or Mul•T•Pads®. The uniquebutton design allows water to flow and provides trouble free operationwhen the pad is folded. This reduces the number of different sizes of padsyour facility must keep in inventory. The T/Pads can be interconnected (onmodel TP500 only) to provide therapy to more than one body site at atime (see fig. 1, p. 2). For a brochure listing the various pads, contact theGAYMAR Customer Service Department (see inside cover for telephonenumbers).

An optional bed bracket (model TP20A) is available to mount the T/Pumpon the footboard of a bed.

Storage (Short term)

Storage (Long term)

Draining

Cleaning

Pads / Accessories

STORAGE / CLEANING


8

There are four devices that control the operation of the heater in theGAYMAR T/Pump:

• The temperature controller is thermistor actuated (fig. 5, item 1, p. 9).This controller is adjustable over a temperature range of 85°F to 107°F(29.4°C to 41.7°C). The desired water temperature is set with a specialremovable key (fig. 5, item 7). To prevent unauthorized temperaturesetting changes, remove the key after the temperature has been set.

• The manifold backup limit thermostat (fig. 5, item 9) is mounted on thebrass manifold block (fig. 5, item 8). This thermostat senses watertemperature flowing to the pad and will shut off the pump and heaterand activate the OVER TEMP light if the water temperature exceedsspecific limits. The purpose of the manifold backup limit thermostat is toprevent the pump from providing water at too high a temperature tothe pad.

• The well backup limit thermostat (fig. 5, item 5) is mounted on the brassplate (fig. 5, item 11) that extends along and under the heater (fig. 5,item 4) near the bottom of the reservoir. This thermostat senses watertemperature in the reservoir and will shut off the pump and heater andactivate the OVER TEMP light if the reservoir temperature exceedsspecific limits. The purpose of the well backup limit thermostat is toboth prevent the pump from providing water at too high a temperatureto the pad and to protect the pump from high temperature damage dueto a low water level.

• The tip-over switch (fig. 5, item 2; see also fig. 12, item 64, p. 27) ismounted on the PC board. This mercury-type switch will shut off theheater if the pump is tipped more than 45° from the vertical position.

NOTE: The tip-over switch does not shut off the pumpmotor or activate the OVER TEMP light.

The pump (fig. 5, item 12) is a sump configuration driven by an impedanceprotected, shaded pole AC motor (fig. 5, item 6).

The return hose fitting (fig. 5, item 10) is machined internally to act as anorifice. This maintains a back pressure in the pad to make it resistant toflow restrictions.

WATER TEMPERATURECONTROL

THEORY OF OPERATION

FLUID SYSTEM


9

T/PUMP COMPONENTS

FIGURE 5—T/PUMP COMPONENTS

TOP(wire harness removed for clarity)

BOTTOM


FUNCTIONAL CHECK &SAFETY INSPECTION

10

FUNCTIONAL CHECK

This section is designed to provide a complete check of all pump param-eters. The order of tests should be followed so that the functional testingcan be completed in the least possible time.

Follow the FUNCTIONAL CHECK AND SAFETY INSPECTION carefully, payingparticular attention to test setups. Any deviation from the setups,procedures, or test equipment may result in incorrect or misleading results.

Before making any repairs, be sure to recheck your test setup, procedure,and test equipment.

Risk of electric shock. Disconnect power before servicing theT/Pump.

• Only qualified medical service personnel should repair theT/Pump. Improper repair may result in death or seriousinjury, equipment damage, or malfunction.

• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTIONafter making repairs and before returning the T/Pump to patient use.Document your findings on the INSPECTION FORM (p. 15).Improper repair may result in death or serious injury,equipment damage, or malfunction.

Do not perform any powered tests with the reservoir empty.Damage to the T/Pump may result.

To assure the optimum performance, dependability and safety, the followingshould be performed once per year (or as specified in the facility'spreventive maintenance program) and after making repairs.

TPT9 ---------- GAYMAR Flow and Temperature Tester[When testing TP500C, use also anAdaptor Hose Assembly, P/N 77926-000)

TFC1---------- Thermometer, 30°F to 125°F (-2°C to 52°C), 1°Caccuracy, 12" long, 3" immersion (e.g., BrooklynThermometer #73544 or equivalent, BrooklynThermometer Co., Farmingdale, NY 11735)

T/Pad --------- Any GAYMAR “12” or “22” series T/Pad;or, TP612 or TP622 pad as applicable

TPC1 --------- GAYMAR T/Pump Test Cover

Ground Resistance Tester

Current Leakage Meter

Distilled Water --- 2 liters (approximate)

Synthetic Oil----- Anderol #465 (GAYMAR P/N 77137-000)

INSPECTION FORM- (p. 15)

DANGER

WARNING

CAUTION

INTERVAL

REQUIRED TOOLS


11

FUNCTIONAL CHECK

PHYSICAL CONDITIONCHECK

MOTOR LUBRICATION

1. Examine the line cord along its entire length for physical damage, suchas cuts or cracked insulation. A damaged line cord should be replacedrather than repaired. Check the quality of the strain reliefs at both endsof the line cord.

2. Examine the plug on the line cord to be sure it is in good condition. Ifunit has non-molded type plug, open plug and check for wire breakageand loose terminal screw(s). If defective, replace with a hospital gradeplug. Torque terminal screw(s) and outside housing screws to 12 in.-lbs.

3. Operate switches and control settings at all positions. If defective,replace.

4. Visually inspect pump. Check for cracked or damaged plastic parts.Be sure unit is unplugged. Remove retainer cap. Remove four (4)screws holding cover and remove cover. (Be sure not to lose fill neckgasket.) Perform visual inspection of all internal parts. Remove anyaccumulated dirt with a vacuum cleaner or compressed air hose. Leavecover off for balance of inspection.

5. Check connectors for cracks, missing O rings, or other damage.Replace connectors if necessary.

1. Locate the motor manufacturer's ID on the top bearing housing.If the pump motor is by Jakel, no oiling is required. If the pump motoris by Uppco, proceed with the following oiling instructions.

2. Oil the pump motor every 6 months with Anderol #465 (GAYMARP/N 77137-000) or equivalent to extend the life of the T/Pump motor.Anderol #465 is a synthetic oil. Do not use a petroleum-based oil sinceit will leave a residue as it breaks down, causing the motor to seize.Add four (4) drops of oil to the vent hole in the bearing housing of themotor located below the fan. Using a micro oiler, apply a similaramount to the lower bearing at the location indicated in figure 6.

Figure 6—PUMP MOTOR

NOTE: Early versions ofthe pump motor have anoiler tube which doesnot effectively distributeoil to the lower bearing.Do not use the oilertube to apply oil to thelower bearing. Use amicro oiler to apply oildirectly to the locationsshown in figure 6.

SERVICE MANUALTP500/TP500C T/PUMPFUNCTIONAL CHECK

12

1. When connecting the test cover, do not remove any wiring connec-tions in the T/Pump. Simply clip the test cover alligator clips ontoterminals with the same color wire.

2. Connect TPC1 test cover (see fig. 7A/7B, p. 22 and 10A/10B, p. 25).Always match the color of TPC1 wiring connections to the color ofT/Pump wiring. Be sure to keep wires away from fan. Install test cover.Be sure to push cover on tightly. It is not necessary to install screws.

3. Connect pump with test cover, pad, TPT9 flow/temp tester, andadaptor hose assembly if required (see fig. 8, p. 23). Be sure the TPT9 isconnected to the supply side of the T/Pump, before the pad.

4. Fill unit with room temperature distilled water and replace fill cap.Connect pad. Place pad on an insulating material (e.g., cloth or towel).

5. Set both test cover switches to the OPEN position.

Risk of electric shock. Be sure unit is unplugged when performingthe ground resistance test.

1. Use a ground resistance meter to measure the resistance between theground pin on the plug and the brass manifold block (fig. 11, item 47).Contact is available through the hole where the hoses connect to thepump. This value should not be more than 0.5 ohm.

It will be convenient to check current leakage at this point since the unit isfull and connected to a pad.

1. Measure the maximum current leakage in all combinations of heater“ON” or “OFF” and power switch “ON” or “OFF.” Access to chassisground for current leakage testing is available through the hole wherethe hose connects to the pump. The highest reading is typically lessthan 30 microamperes. The maximum allowable reading is 100microamperes. Record the highest reading.

2. Disconnect leakage meter setup.

1. Check the tip-over switch at this point, since the test cover is onand the unit is full. Set temperature to maximum (107°F) on dial.The heater indicator (fig. 7, p. 22) will be on. Tip the unit approxi-mately 45°. If the heater indicator goes out, the tip-over switch isoperating. If not, repair or replace the PC board (p. 17). Recordresults.

TPC1 TEST COVERINSTALLATION

DANGERGROUND RESISTANCECHECK

CURRENT LEAKAGECHECK

TIP-OVER SWITCH CHECK

SERVICE MANUALTP500/TP500C T/PUMP FUNCTIONAL CHECK

13

1. Be sure the pad is flat and warm (approximately 107°F) and at the samelevel as the pump. Top of TPT9 float (see fig. 8, p. 23) should read atleast 9 gph. Record reading.

NOTE: If flow is below 9 gph, refer to TROUBLESHOOTING section(p. 21).

1. Make sure temperature is set to maximum (107°F) on dial. Allow unitto come to a steady temperature, approximately thirty (30) minutes.

2. To ensure accurate temperature readings, add a small amount of waterto TPT9 well. Insert thermometer in TPT9 well.

3. Take readings every thirty (30) seconds for five (5) minutes for a totalof ten (10) readings. The average of these readings should be 107°F±2°F. Record the average value. If the unit is out of calibration, refer toCALIBRATION section (p. 19).

4. Do not let the pump cool down. Proceed directly to Backup LimitThermostat Test.

1. With the pump operating properly at 107°F ±2°F, move the primaryshorting switch to the SHORT position (see fig. 7A/7B, p. 22). This willshort out the temperature controller and allow the pump to continueheating to the trip point of the backup limit thermostat(s).

2. Carefully observe the rising temperature and record the highestreading. When a thermostat opens, the pump will turn off, the OVERTEMP light will be lit, and the HEATER INDICATOR light on the testcover will turn off. (If the OVER TEMP light does not light and a thermo-stat has tripped, replace the light.) Either the MANIFOLD or WELL lighton the test cover will be lit or both lights will be off, depending onwhich thermostats have tripped.

• If the manifold thermostat light is on, then the manifold thermostathas opened. The temperature recorded must be between 110°F to117°F (43.3°C to 47.2°C). If the thermostat operates outsideits intended range, it must be replaced (see page 18).Proceed to step 3.

• If the well thermostat light is on, then the well thermostat hasopened. The temperature recorded must be between 110°F to 122°F(43.3°C to 50°C). If the thermostat operates outside itsintended range, it must be replaced (see page 18). Proceed tostep 3.

• If neither light is on, then both thermostats have opened at the sametemperature. To confirm this, toggle the thermostat shorting switchto the MANIFOLD position. (The MANIFOLD light should be on.)Next, toggle switch to the WELL position. (The WELL light should beon.) If either thermostat opens outside its intended range asdefined above, it must be replaced (see page 18). Proceed tostep 4.

FLOW RATE TEST

OPERATINGTEMPERATURE TEST

BACKUP LIMITTHERMOSTAT TEST


3. To test the remaining thermostat, toggle the limit thermostat shortingswitch to the position corresponding to the non-tripped thermostat.(This will short out the previously opened thermostat and allow theunit to continue heating.) Both thermostat indicator lights should be offand the HEATER INDICATOR light should be on. Carefully observe therising temperature and record the highest reading. When the watertemperature rises to the trip point of the remaining thermostat, theOVER TEMP light will be on, the pump will turn off, the heater indicatorlight will turn off, and the appropriate thermostat light will be on.

• If the manifold thermostat light is on, then the manifold thermostathas opened. The temperature recorded must be between 110°F to117°F (43.3°C to 47.2°C). If the thermostat operates outsideits intended range, it must be replaced (see page 18).

• If the well thermostat light is on, then the well thermostat hasopened. The temperature recorded must be between 110°F to122°F (43.3°C to 50°C). If the thermostat operates outsideits intended range, it must be replaced (see page 18).

4. Unplug the unit, remove the test cover and proceed to LEAK TEST.

1. Immediately upon completion of Backup Limit Thermostat Test,reinstall fill cap tightly. Put your finger over the hole in the cap and tiltunit toward you so the front is down. Hold for three (3) minutes.

2. Return the unit to upright position and carefully check inside of trayand reservoir tray joint for leaks. Repeat process turning pump on backface. If leakage is found, refer to the DISASSEMBLY/REASSEMBLY section(pp. 16-18), and correct problem.

When reinstalling cover, be sure the fill neck gasket (fig. 11, item 6, p. 26)is in place. Push cover down as tightly as possible. Hold in place whentightening cover screws.

This completes the FUNCTIONAL CHECK procedure. Returnpump to service if it is operating properly, or proceed to theDISASSEMBLY/REASSEMBLY section pertaining to the problem(s).

14

FUNCTIONAL CHECK

LEAK TEST

COVER AND FILL NECKGASKET REINSTALLATION

SERVICE MANUALTP500/TP500C T/PUMP INSPECTION FORM

15

Inspection forms vary from hospital to hospital.The following sample form is intended as a guideso that the important parameters are recorded.

mroFnoitcepsnIytefaSdnakcehClanoitcnuFpmuP/T

______________etaD

_____________________rebmuNledoM __________________rebmuNlaireS

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srotcennocdnasnoitcennocesohtcepsnI

.2 rotometacirbuL

.3 ;revoctset1CPTtcennoCsnoitcennocfosroloceriwhctam

.4 ...mho5.0<;ecnatsiserdnuorgerusaeMeulavetacidni

.5 ...Aµ001<;egakaeltnerrucerusaeMeulavetacidni

.6 hctiwsrevo-pitkcehC

.7 eulavetacidni...)hpl43(hpg9>;wolferusaeM

.8 ...F°2±F°701@erutarepmetgnitarepoerusaeMegarevaetacidni

.9 ;tnioppirttatsomrehttimilpukcabdlofinamdroceReulavetacidni...)C°2.74otC°3.34(F°711otF°011

;tnioppirttatsomrehttimilpukcabllewdroceReulavetacidni...)C°05otC°3.34(F°221otF°011

setarepothgilPMETREVO

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.11 teksagkcenllifehtdnarevocllatsnieR

________________________________________________________________________________erutangiS


16

DISASSEMBLY/REASSEMBLY


• Only qualified medical service personnel should repair the T/Pump.Improper repair may result in death or serious injury,equipment damage, or malfunction.

• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION(pp. 10-14) after making repairs and before returning the T/Pump topatient use. Document your findings on the INSPECTION FORM(p. 15). Improper repair may result in death or seriousinjury, equipment damage, or malfunction.


NOTE: All wires are terminated with slip-on connectors.When text says “remove wire,” the slip-on connector isto be removed from the mating lug on the specific item.

1. Unscrew fill cap/valve assembly (fig. 11, item 1, p. 26) and remove.Unscrew plastic retainer.

2. Remove the four screws which retain the cover, two on each end ofthe pump.

NOTE: When reinstalling the cover, do not forget to replace the fillneck gasket (fig. 11, item 6).

1. Place a screwdriver under fan hub (fig. 11, item 7, p. 26) and twist toremove fan.

NOTE: When replacing the fan, make sure the hub is flush with top ofmotor shaft.

2. Remove green ground wire and orange and blue power wires.

NOTE: To prevent breaking the motor lugs, support them whenremoving the slip-on lugs.

3. Remove the four retaining screws and washers on the top face of themotor.

DANGER

WARNING

CAUTION

COVER

M O T O R


17

DISASSEMBLY/REASSEMBLY

4. It is necessary to remove the reservoir to remove the motor. Removethe eight (8) screws located around the inside wall of the tray.NOTE: It is not necessary to remove the front label (fig. 11, item 37,p. 26). The front label is attached only to the tray and will slip off thereservoir.

5. Gently separate the reservoir from the tray. Do not damage the large Oring that seals the tray and reservoir.

6. Turn the tray on its backside (front label up). Place a screwdriver againstthe white impeller in the bottom of the pump housing to prevent theimpeller from turning and remove the screw retaining the impeller. It isnot necessary to remove the bottom housing (fig. 11, item 24, p. 26) ofthe pump.

7. The impeller may now be slipped off the shaft. Return the tray assemblyto an upright position. The motor may be removed by lifting straight up.

8. Center the new motor seal gasket over opening and insert new motorthrough seal. Replace impeller onto shaft and secure motor.

9. Do not overtorque the four (4) motor mounting screws. Torque value is6 to 8 in.-lbs.

10. If tray inserts are loose or motor mounts are worn, a new tray withsensor bracket should be installed.

1. Remove the ground wire (green) and the two heater wires (red and blue).

NOTE: On reassembly, the red wire goes on the front post of the heater.

2. Remove the three (3) nuts retaining the heater. The screws are retainedin the tray. The heater can then be removed by raising and tilting the topof the heater toward the left side of the T/Pump.

3. Reassembly is the reverse of the above.

4. Do not forget to install heater gasket (fig. 11, item 11, p. 26).

1. Using the plastic key (fig. 5, item 7, p. 9), turn the temperature indicatorto the eleven o'clock position. The slotted coupling should then bepositioned with the slot opening up.

2. Cut the plastic tie holding the wire bundle to the PC board. Remove thered, orange, and blue wires from the PC board.

3. Remove the two screws (fig. 11, items 56 & 57, p. 26) retaining the PCboard. The board can then be raised from the tray, exposing the ther-mistor probe assembly in the brass manifold block (fig. 11, item 47,p. 26). Use caution to be sure no strain is put on thermistor leads (finewhite wires).

4. Carefully remove the thermistor capsule from the manifold. To avoiddamaging the thermistor, do not pull on the wires. A dental pick orscribe can be used to pry the capsule out of the hole.

HEATER

PC BOARD

SERVICE MANUALTP500/TP500C T/PUMPDISASSEMBLY/REASSEMBLY

5. On reassembly, put a small quantity of silicone heat sink compound(Dow Corning #340 or equivalent) around the thermistor capsule.Carefully insert the thermistor capsule into the hole on the brassmanifold block. To avoid damaging the thermistor, do not push on thewires. The capsule may be seated by placing needle nose pliers ortweezers on the edge of the capsule.

6. The remainder of the reassembly is the reverse of the above. Uponinserting the P. C. Board, the potentiometer shaft (fig. 11, item 52,p. 26) must be in the vertical position to mate with the slot in thetemperature indicator (fig. 11, item 40, p. 26). Refer to CALIBRATIONprocedures (pp. 19-20).

1. Remove the two (2) wire lugs. Note the position of the color codedwires. Facing the front of the T/Pump, the purple wire goes on the lefthand lug, and the orange wire goes on the right hand lug.

2. Remove the two (2) screws retaining the thermostat to the brassmanifold block.

3. Reassembly is the reverse of the above.

4. Always be sure to check the backup limit thermostats according to theFUNCTIONAL CHECK (pp. 13-14).

NOTE: Do not attempt to replace the well thermostat. Toinsure proper operation of this thermostat, it is riveted and sealedto the tray assembly. Experience has proven that it cannot besuccessfully replaced. If this item is defective, replace theentire tray assembly (fig. 11, item 17, p. 26).

1. Remove the eight (8) screws (fig. 11, item 15, p. 26) around the insidewall of the tray. Gently pry the reservoir from the tray.

2. Remove all components including seal, bushing, and clips from the oldtray and reinstall into the new tray assembly.

3. Attach the reservoir to the tray. Check that the reservoir ring seal(fig. 11, item 19, p. 26) is properly located in the groove in the tray.Install the eight (8) screws torqued to approximately 6 in.-lbs.

4. Always be sure to check the backup limit thermostats according to theFUNCTIONAL CHECK (pp. 13-14).

18

MANIFOLD BACKUPLIMIT THERMOSTAT

WELL BACKUPLIMIT THERMOSTAT

TRAY

SERVICE MANUALTP500/TP500C T/PUMP CALIBRATION

19


• Only qualified medical service personnel should repair theT/Pump. Improper repair may result in death or seriousinjury, equipment damage, or malfunction.

• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION(pp. 10-14) after making repairs and before returning the T/Pump topatient use. Document your findings on the INSPECTION FORM(p. 15). Improper repair may result in death or seriousinjury, equipment damage, or malfunction.


TPT9 ---------- GAYMAR Flow and Temperature Tester[When testing TP500C, use also anAdaptor Hose Assembly, P/N 77926-000)

TPC1 --------- GAYMAR T/Pump Test Cover

TFC1---------- Thermometer, 30°F to 125°F (-2°C to 52°C), 1°Caccuracy, 12" long, 3" immersion (e.g., BrooklynThermometer #73544 or equivalent)

Insulated alignment tool

T/Pad --------- Any GAYMAR “12” or “22” series T/Pad;or, TP612 or TP622 pad as applicable

The calibration should be performed in a temperature controlled room,between 70°F and 75°F.

1. Remove the pump cover by removing the two (2) screws at each endof the pump. The fill cap/valve assembly can be removed by unscrewingthe cap and plastic retainer. The cover is now free to be removed.

2. Carefully remove the blue torque seal from the R3 trim pot (fig. 12,item 63, p. 27), located at the top right corner of the printed circuitboard.

3. Install test cover. See FUNCTIONAL CHECK (p. 12) and figures 7A/7B.

DANGER

WARNING

CAUTION

CALIBRATION

CALIBRATIONEQUIPMENT

SERVICE MANUALTP500/TP500C T/PUMPCALIBRATION

20

4. Connect pump, pad, TPT9 flow/temp tester, and adaptor hose assem-bly if required (see fig. 8, p. 23).

5. Fill pump with room temperature distilled water.

6. Set Temp Dial to 107°F (maximum).

NOTE: Be sure the temperature dial is always set to themaximum clockwise position when makingcalibration measurements and adjustments.

7. The primary shorting switch (fig. 7A/7B, p. 22) on the test cover mustbe in the OPEN position. The backup limit thermostat shorting switch(fig. 7A/7B) must be in the OPEN position.

8. Turn unit on and allow to come to a steady temperature, approxi-mately thirty (30) minutes.

The HEATER INDICATOR on the cover should be on whenever theheater is on.

NOTE: Flow must be 9 gph, minimum.If not, refer to TROUBLESHOOTING (p. 21).

9. Start recording the temperature readings every thirty (30) seconds forfive (5) minutes for a total of ten (10) readings. The average of thesereadings should be 107°F ±2°F. If not, it will be necessary to adjust theR3 trim pot (fig. 7A/7B, p. 22). This is accomplished by inserting aninsulated alignment tool through the small hole in the left side of theTPC1 test cover. Turn the potentiometer screw clockwise to increasethe water temperature. Turn the screw counterclockwise to decreasethe water temperature.

Do not force the adjusting screw past its stops.

10. After the final adjustment is made, let the unit run for one-half hourand recheck the calibration as described in step 9. The bandwidthshould not exceed 2°F. Bandwidth is the difference between themaximum and minimum temperature excursions. If the OVER TEMPlight is activated during the calibration adjustment, the water must bereplaced with water 75°F or less and the calibration procedurerepeated.

11. Without letting the pump cool, proceed directly to the Backup LimitThermostat Test as outlined in the FUNCTIONAL CHECK (p. 13).Record all results when recalibrating.

Apply blue torque seal after the trim pot has been adjusted properly.


21

TROUBLESHOOTING

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Figure 7A—‘NEW’ STYLE TPC1 TEST COVER

22

TPC1 TEST COVERS

CAUTIONNOTE:

Always match color of TPC1 wiringconnections to color of T/Pump wiring.

Route TPC1 wires as shown to avoidinterference with T/Pump fan motor.


23

TEST SETUP

Figure 8A—FUNCTIONAL CHECK TEST DIAGRAM (TP500)

Figure 8B—FUNCTIONAL CHECK TEST DIAGRAM (TP500C)


Figure 9—CIRCUIT DIAGRAM

24

CIRCUIT DIAGRAM, T/PUMP

FRONT VIEW

FRONT VIEW

REAR VIEW

REAR VIEW

Switch wiring:

Larger

switch

Smaller

switch

AT

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R6

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Figure 10A—CIRCUIT DIAGRAM FOR TPC1 TEST COVER (To connect, refer to figure 7A)

25

CIRCUIT DIAGRAMS, TEST COVERS

SERVICE MANUALTP500/TP500C T/PUMPEXPLODED VIEW

26

Figure 11—EXPLODED VIEW


27

REPLACEMENT PARTS

* The well backup limit thermostat is part of the tray assembly.Do not attempt to drill out the old thermostat. A leakproof installation is not possible.Install tray assembly (see p. 18).

metI N/P ytQ noitpircseD

1 100-35540 1 ylbmessAevlaV/paC

2 000-57877 1 ]4metihtiwdedulcnI[)tiKtnemecalpeR(eldnaH

3 000-23680 1 ]4metihtiwdedulcnI[lebaLnoitcurtsnI

4 000-78080 1 ]95dna,85,3,2smetisedulcni[ylbmessArevoC

5 330-58009 4 ]4metihtiwdedulcnI[pilCrenetsaF

6 000-05630 1 teksaGlliF

7 000-25140 1 naF

8 000-12177 1 ]31metisedulcni[tiKrotoM

9 200-09119 3 TSS23-6,tuN

01 000-31040 1 )V021(retaeH

11 000-96050 2 teksaGretaeH

21 300-58009 1 pilCthgiLPMETREVO

31 000-77840 1 ]8metihtiwdedulcni[teksaGlaeSrotoM

41 140-58009 1 pilCrekaerBtiucriC

51 110-27219 8 TSS,Bepyt,"8/5x02-6,wercS

61000-91090 1 ]71metihtiwdedulcni[005PT,lebaLLU

000-80401 1 ]71metihtiwdedulcni[C005PT,lebaLLU

71000-90087 1 ]73,81,61smetisedulcni[005PT*tatsomrhT,tkrBrosneS/wyarT

100-90087 1 ]73,81,61smetisedulcni[C005PT*tatsomrhT,tkrBrosneS/wyarT

81 000-24280 1 ]71metihtiwdedulcni[lebaLnoituaC/gninraW

91 000-86970 1 laeSriovreseR

02 160-81009 4 TSS,"2/1x23-6,wercS

12 000-76530 1 gnisuoHpmuP

22 000-11630 1 rellepmI

A32 750-81009 2 TSS,"4/1x23-6,daehnap,wercS

B32 250-45419 2 TSS,"4/1x23-6,daehretsillif,wercS

SERVICE MANUALTP500/TP500C T/PUMPREPLACEMENT PARTS

28


42 000-86530 1 gnisuoHmottoB

52 110-41509 6 TSS,TBepyt,"8/5x02-6,wercS

62 1;82metihtiwdedulcni[lebaLrebmuNlaireS

]YLETARAPESELBALIAVATON

72 000-09080 1 ]82metihtiwdedulcni[lebaLnoitacifitnedIlatipsoH

82 000-76877 1 ]92,72,62smetisedulcni[)tiKtnemecalpeR(riovreseR

92 100-75240 1 ]82metihtiwdedulcni[lebaLleveLretaW

03 000-58309 4 puCnoitcuS

13 000-20018 1 gnol"2/1-3xDI"4/1,gnibuT

23 000-00509 1 pilC/wrekaerBtiucriC

33 000-49330 2 gnittiFdlofinaM

43 000-18830 1 rehsaWgniraeBssarB

53 000-10387 1 )V021(tiKhctiwS

63 700-28219 1 pilchtiwpmaLPMETREVO

73 000-48111 1 ]71metihtiwdedulcni[lebaLtnorF

A83 000-68080 1 ]B14dnaA14smetisedulcni[005PT,ylbmessAesoH

B83 000-84680 1 ]24metisedulcni[C005PTylbmessAesoH

93 720-57219 2 TSS,"8/3x04-4,wercS

04 000-57930 1 rotacidnI

A14 000-78830 1 ]A83metihtiwdedulcni[etiT-kilCelaM

B14 000-48830 1 ]A83metihtiwdedulcni[etiT-kilCelameF

24 000-82087 2C005PT,rotcennoCelyts-redloCelameF

]B83metihtiwdedulcni[

34 810-67009 1 gnihsuBfeileRniartS

44 000-51387 1 gulpdedlomhtiwtiKdroCrewoP

54 000-98930 1 )decifiro(gnittiFesoH

64 000-88930 1 )ecifiroon(gnittiFesoH

74 000-38930 1 kcolBdlofinaMssarB

84 000-18330 1 teksaGdlofinaM

94 000-55209 1 )tnemecalper(gulP


29

REPLACEMENT PARTS


05 000-63409 1 rehsaWerbiF

15 510-58009 1 pilCrenetsaF

25 000-96930 1 tfahSretemoitnetoP

35 000-35087 1 )dlofinam(tatsomrehTtimiLpukcaB

45 000-26409 2 recapS

55 000-96877 1 rotsimrehtsedulcni,ylbmessAdraoBCP

65 400-93109 2 lanretnI,rehsawkcoL

75 520-81009 2 TSS,"4/1x04-4,wercS

85 000-99970 1 ]4metihtiwdedulcnI[lebaLOGOL

95 ]YLETARAPESELBALIAVATON.4metihtiwdedulcnI[partSesoH

06 000-16630 2 ]NWOHSTON[yeKgnitsujdAerutarepmeT

16 1CFT 1 ]NWOHSTON[retemomrehT

26 1CPT 1 ]NWOHSTON[revoCtseT

36 9TPT 1 ]NWOHSTON[looTtseTerutarepmeTdnawolF

46 000-62977 1 ]B8erugifees[ylbmessArotpadAesoH


30

GAYMAR equipment and products are warranted against defects inmaterial and workmanship under normal use and operation from the dateof purchase for the time periods listed below for the respective equipmentand products. Except for such warranty, GAYMAR disclaims allother express and/or implied warranties including, but notlimited to, the implied warranties of merchantability and offitness for a particular purpose.

All labor performed and parts provided free of charge for a period of one(1) full year from the date of purchase, provided the equipment is returnedwith prior authorization* prepaid to an authorized GAYMAR servicecenter or the factory.

Free replacement of product where defects in materials and/orworkmanship are evident at time of delivery provided the product isreturned with prior authorization* prepaid to GAYMAR Industries.

Free replacement of product where defects in materials and/orworkmanship occur within 90 days from date of delivery provided theproduct is returned with prior authorization* prepaid to GAYMARIndustries.

Defective parts will be exchanged free of charge where defects in materialsand/or workmanship occur within 90 days from date of delivery providedthe parts are returned with prior authorization* prepaid to GAYMARIndustries.

* For prior authorization on all items being returned to the factory andfor a Return Goods Number (RG#), call Customer Service at

(716) 662-25511 800 828-7341

WARRANTIES

PAD, REUSABLE

PAD, SINGLEPATIENT USE

PUMP

PARTS

WARRANTIES


31


32

T/PUMPS® AND T/PADS®

ARE MADE IN THE USA

®

GAYMAR INDUSTRIES, INC.

10 Centre DriveOrchard Park, NY

14127-2295

Phone:1 800

(716) 662-2551

FAX:1 800

(716) 662-0748

828-7341

993-7890

Gaymar TP500 Service Manual

Documents

Transcript of Gaymar TP500 Service Manual