Gaymar SPR Plus III User manual

SPR•Plus®IIISPR•Plus®III
P/N 100695000 Rev A 10/10
Service Manual
SPR•Plus®III
Control Unit
• CL360
LISTED
UL 2601-1
LISTED CAN/CSA
C22.2 NO. 601.1
®
®
SPR•PLUS® III PRODUCTS
ARE MADE IN THE USA
GAYMAR ®
GAYMAR INDUSTRIES, INC.
10 Centre Drive
Orchard Park, NY
14127-2295
Phone:
1.800.828.7341
716.662.2551
FAX:
1.800.993.7890
716.662.0730

SPR•Plus®IIISPR•Plus®III
24
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SPR•Plus®IIISPR•Plus®III
Important
Use the SPR•Plus® III Control Unit only under the direction
of a physician.
Before using the SPR•Plus III Control Unit, read and
understand the SPR•Plus III Operator's Manual and the
SAFETY PRECAUTIONS.
Only qualied medical service personnel should repair the
SPR•Plus III Control Unit.
In the event of any questions, contact Gaymar's Technical
Service Department for assistance.
USA:
Phone [phone]
[phone]
Fax [phone]
International:
Phone [phone]
Fax [phone]
SPR•Plus is a registered trademark of Gaymar Industries, Inc.
© 2000. Gaymar Industries, Inc. All rights reserved. www.gaymar.com
Table of Contents
Section Description Page
1.0 Indications/Contraindications/Precautions .1
2.0 Receiving Inspection ............................................2
3.0 Repair Policy ............................................................2
4.0 Specications ..........................................................3
5.0 Care and Maintenance .........................................3
6.0 Theory ........................................................................4
7.0 Control Panel ...........................................................6
8.0 Functional Check and Safety Inspection .......7
9.0 Troubleshooting .................................................. 10
10.0 Repair Procedures ............................................... 12
Illustrations
Figure Description Page
1 SPR•Plus III System .................................................4
2 SPR•Plus III Control Unit ......................................5
3 Control Panel ...........................................................6
4 Cushion Simulator .................................................8
5 Calibration Check ................................................ 11
6 Compressor Pump ............................................. 13
7 PC Board ................................................................. 14
8a Pump Assembly ...................................................15
8b Pump Assembly ...................................................17
9 Compressor and Support Assembly ............ 19
10 Wiring Diagram ................................................... 21
Tables
Table Description Page
1 Functional Check /
Safety Inspection Form ........................................9
2 Troubleshooting Chart...................................... 10
23
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SPR•Plus®IIISPR•Plus®III
1
Contraindications/Safety Precautions
• If a large bulge in the top surface of the mattress
is noticed, call your Dealer or Gaymar Industries'
Customer Service Department. A large bulge may
cause the patient to roll over when not desired,
resulting in potential injury or discomfort.
• U. S. Federal law restricts this device to
sale by or on the order of a physician.
• For grounding reliability, plug only into a
grounded outlet labeled “Hospital Grade.”
• Use minimal layers of sheeting and incontinence
pads. Too many layers between the patient's skin
and the SPR•Plus III Cushion will reduce the
pressure-redistibution capabilities of the therapy
system.
• Do not pull linens tightly over cushion, but leave
loose. Tight sheets may cause “hammocking” and
reduce eectiveness of therapy.
• Some medical conditions may not respond to
therapy of this type. Patient's skin should be
inspected regularly for redness or breaks. If
redness or breaks in the skin occurs, consult the
attending physician.
• Disconnect power before servicing the SPR•Plus
III Control Unit.
• Repairs should be performed only by qualied
personnel familiar with repair practices for
servicing medical devices.
1.0 Indications for Use
This device is intended to assist in prevention and
treatment of decubitus ulcers (bed sores).
1.1 Contraindications
Air support therapy is not recommended when spinal
stability is a concern.
1.2 Safety Precautions
Review the following SAFETY PRECAUTIONS prior to using
the SPR•Plus III System.
• Explosion hazard. Do not use in the presence of
ammable anesthetics.
• Risk of electric shock. Refer servicing to qualied
service personnel.
• Be sure the cushion is securely installed on
mattress. Be sure straps are securely positioned
over corners of mattress. Failure to secure
cushion may permit cushion shifting and may
cause improper therapy or patient injury.
• Do not operate system with bed side rails down.
Patients should never be left unattended with
lowered side rails, since patient injury could
occur.
• Do not reuse the SPR•Plus III Cushion. Reuse
of cushion may risk cross-contamination and
infection.
• Disinfect the control unit and hose between
patient installations, utilizing standard hospital
protocol and disinfectants. Failure to disinfect
may risk cross-contamination and infection.
• Deate mattress before performing CPR or CPR
will be ineective.
• Keep bedding dry. Use incontinence pads if
necessary. Failure to keep the patient's skin clean
and dry may lead to maceration.
(continued next column)
Wiring Diagram
22
8

SPR•Plus®IIISPR•Plus®III
2
Receiving Inspection/Repair Policy
2.0 Receiving Inspection
Upon receipt, unpack the SPR•Plus III Control Unit and
inspect for concealed damage. Save all packing material. If
any damage is found, notify the carrier at once and ask for
a written inspection. Prepare a written description of any
damage. Photograph any damage.
Failure to take the above action within 15 days of receipt
may result in loss of claim.
Do not return the SPR•Plus III Control Unit to
GAYMAR. Contact Gaymar's Technical Service
Department for instructions.
USA only: 1 800 828-7341
[phone]
Outside USA: [phone]
3.0 Repair Policy
The SPR•Plus III Control Unit (CL360) is warranted free
of defects in material and workmanship for a period of
one (1) year.
The SPR•Plus III Low Air Loss Cushion (CL212/CL272) is
warranted free of defects in material and workmanship for
a period of thirty (30) days.
The Control Unit and Low Air Loss Cushion are
warranted under the terms and conditions of the Gaymar
warranty in place at the time of purchase. A copy of the
warranty is available upon request. Gaymar disclaims all
implied warranties including, but not limited to, the implied
warranties of merchantability and of tness for a particular
purpose.
Control Units may be returned to the factory for servicing
(see 3.3, Return Authorization).
For customers who choose to repair Gaymar SPR•Plus
III Control Units at their location, this manual contains
information to allow a qualied biomedical technician to
make necessary repairs. For technical support, contact
Gaymar's Technical Service Department.
3.1 In-Warranty Repairs
All in-warranty eld repairs must be authorized by
Gaymar's Technical Service Department before proceeding.
3.2 Out-of-Warranty Repairs
The following repair options are available when servicing
SPR•Plus III Control Units:
1. Defective Components - replacement parts
may be ordered by specifying the Gaymar
part number as shown in the parts lists (pp.
13 – 23).
2. SPR•Plus III Control Unit Repairs - If
the SPR•Plus III Control Unit becomes
inoperative and the cause cannot be
determined, the complete control unit may
be returned to the factory for servicing at
the purchaser's expense (see 3.3, Return
Authorization).
3.3 Return Authorization
Please be sure to obtain a return goods (RG)
authorization number from GAYMAR's Customer Service
Department before returning the SPR•Plus III Control
Unit or any component parts to GAYMAR.
USA only: 1 800 828-7341
[phone]
Outside USA: [phone]
21
Wiring Diagram
Figure 9—Wiring Diagram
ATTENTION
Static-Sensitiv e
Dev ices
NOTES:
1. ALL RESISTANCES ARE IN OHMS.
2. ALL RESISTORS ARE 5% CARBON UNLESS NOTED.
3. ALL CAPACITORS ARE IN MICROFARADS UNLESS NOTED.
4. CAUTION: THE ACTUAL ASSEMBLIES ARE SUSCEPTIBLE TO DAMAGE FROM
ELECTROSTATIC DISCHARGE. HANDLING OF THE ASSEMBLIES SHALL BE
ACCOMPLISHED WITH ADEQUATE GROUNDING PROVISIONS TO PREVENT
ELECTROSTATIC DISCHARGE DAMAGE.
5. THIS DRAWING CORRELATES TO DRAWING (D) 09055 REVISION: D.
6 FOR CLP250 & CL360 P/N 09055-000 F3 AND F4 ARE 3/10A.
FOR CL750 P/N 09055-001 F3 AND F4 ARE .25A.
7 FOR CLP250 & CL360 P/N 09055-000 JUMPERS ARE IN 120V LOCATIONS.
FOR CL750 P/N 09055-001 JUMPERS ARE IN 240V LOCATIONS.
8 FOR CL750 P/N 09055-001 C12 IS 0.01-800V.

SPR•Plus®IIISPR•Plus®III
3
4.0 Specications
Physical
Dimensions 13 1/8" H x 121/8" W x 4 1/2" L
(33 cm x 31 cm x 11 cm)
Weight 13 pounds (5.9 kg)
Chassis ABS plastic
Operating Ambient 60°F to 90°F (16°C to 32°C)
Temperature Range
Note: If the SPR•Plus III Control Unit is stored at
temperatures below 60°F (16°C) or above
90°F (32°C), the control unit must be allowed
to stabilize for one hour within the operating
ambient temperature range before use.
Output
Pressure 18 to 30 mm Hg
Flow Rate 0.4 SCFM (12.5 lpm) minimum
@ 30 mm Hg
Cushion
Dimensions (inated) 33½" wide x 75¼" long
Weight 5 pounds, 10 ounces
Material vinyl
Electrical
Input 120 VAC (+5, –10%), 60 Hz,
20 W (nominal)
Power Cord 15 ft, 16 AWG cord with hospital
grade plug
Fuses (2) 0.3 A
Current Leakage 100 µA maximum (chassis)
Ground Resistance 0.15 ohms or less nominal
0.5 ohms maximum
Specications
5.0 Care and Maintenance
Although the SPR•Plus III System is very easy to maintain,
perform the following care and maintenance to assure
proper performance and reliability. Unplug the power cord
before performing preventive maintenance.
5.1 After each use:
1. Dispose of cushion in accordance with hospital waste
management policy.
2. Clean and disinfect the hose, control unit, and
power cord according to hospital protocol and
manufacturer's instructions. Do not autoclave.
3. Coil the power cord and secure it with a tie-wrap.
5.2 Cleaning
5.2.1 Chassis exterior
To clean, use soap and water and a clean cloth to wipe
down the pump, power cord, and hoses. Wipe dry with a
clean dry cloth. Do not autoclave.
NOTE: Blood and other uids must be thoroughly cleaned
from all surfaces before applying the disinfectant. Apply a
hospital grade disinfectant according to the manufacturer's
instructions and hospital protocol. Allow to completely
dry. The contact time is what makes the solution eective.
5.2.2 Cushions
Outside surfaces of cushions may be cleaned with a damp
cloth and mild detergent. Do not disinfect with alcohol,
which may accelerate cushion deterioration.
Cushions are made of vinyl. If it is necessary to sterilize
cushions, use ETO sterilization and handle like any other
vinyl product. Sterilization temperatures must not exceed
57°C (135°F).
20
Repair Procedures/Replacement Parts
Figure 9—Compressor and Support Assembly Parts List
VA LVE, RELIEF90498-000
91444-000
08898-000
08939-000
08969-000
08987-000
09968-000
09985-000
08896-000
90950-032
50015-000
90569-000
80705-000
91399-000
91456-000
90795-002
91450-000
90140-006
90018-059
JUMPER, BAR CODE TYPE
RESONATOR, VACUUM FORMED
PLATE ASSY, PUMP SUPPORT
COMPRESSOR ASSY,110V
GASKET, PUMP SUPPORT PLATE
SPACER, BRASS
GASKET
PLATE SUPPORT
WASHER, SPECIAL .188 IDx.658 ODx3/64 THK
LOCKWASHER, EXT, NO. 6
SEALER, THREAD 1/4
FITTING, ELBOW MALE 90°,BRASS
TAPE, DOUBLE SIDED, 2" LG
BLOCK, TERMINAL, TB1
SCREW,MACH, PA N HD, CROSS RECESSED, M3x12MM LG, SST
SCREW,PAN HD, LONG-LOK, CROSS RECESSED, 10-32UNFx5/8 LG, SST
GROMMET
SCREW, MACH, PA N HD, CROSS RECESSED, 6-32UNCx3/8 LG, SST
91398-000
90947-003
90228-024
09295-004
10168-000
10222-000
80987-000
80987-000
80987-000
80987-000
10252-000
50522-001
90666-003
FITTING, 30° ELBOW HOSE
TUBING, 1/4 IDx3/8 ODx18LG
TUBING, 1/4 IDx3/8 ODx11/2 LG
TUBING, 1/4 IDx3/8 ODx10 1/2 LG
TUBING, 1/4 IDx3/8 ODx33/4 LG
WASHER, FLATM3
INSULATION, FOAM CUSHION
ADAPTER, MALE/FEMALE THREADED, 5/8 HEX
CLIP, 3/8 IDRIBBED
FOAM, SOUND
TY-WRAP,37/8 LG
FITTING, 90° ELBOW HOSE
ORIFICE
PA RT NO.
30
12
DESCRIPTION
3
ITEM
2
1
5
4
6
7
8
9
11
10
21
14
13
15
16
17
18
20
19
23
22
24
25
26
27
29
28
32
31
Source Locally

SPR•Plus®IIISPR•Plus®III Theory
Figure 1—SPR•Plus III System
4
6.0 Theory, SPR•Plus III System
This manual describes the operation of the SPR•Plus
III System as an aid in pressure ulcer prevention and
treatment.
The SPR•Plus III System is a pressure redistribution
support system intended to assist in reducing the potential
for development of pressure ulcers on at-risk patients or
to assist in the treatment of existing pressure ulcers.
The SPR•Plus III System consists of an electromechanical
ination pump control unit (CL360) connected
to an overlay (CL212/CL272) through a hose assembly
permanently connected to the ination pump. See
gures 1 and 2.
The overlay consists of a vinyl cushion with holes in the
top surface to provide air loss. The overlay also provides
continuous pressure redistribution to the patient below
the tissue interface pressure experienced on a standard
hospital mattress. Air is vented through micro-vents in the
top surface of the overlay to provide low air loss.
The pump has an on/o switch and is microprocessor
controlled. It has pressure selection options of 18, 21, 24,
27, and 30 mm Hg. The pressure selection options adjust
the rmness of the overlay to the rmness desired by the
operator.
The hose assembly for the SPR•Plus III System connects
the ination pump to the overlay through a threaded
tting in the overlay.
6.1 Electrical System
For electrical system information, refer to the System
Wiring Diagram (pp. 21–22) and the PC Board Diagram (p.
14).
The SPR•Plus III Control Unit uses:
• 1 control board
• 1 on/o mains switch
• 3 rocker arm air pumps
6.2 Power Supply
Power enters the SPR•Plus III Control Unit through a
power switch. It then enters the control board at J3 to
feed the pumps and transformer.
Power to drive the low voltage circuits on the control
board is derived from the stepdown transformer. The
transformer output is rectied and ltered to generate
+5VDC.
The transformer's secondary is fused with two
19
Repair Procedures/Replacement Parts
Figure 9—Compressor and Support Assembly
B
B
A
A
12
REF
17
17
16 TYP
WHITE WIRE FROM PUMP2TO TB1-2C
BLACK WIRE FROM PUMP2TO TB1-3C
30
TYP
18
20
19
31
REF
30
32
16
34
6
16 31
32
WHITE WIRE FROM PUMP1TO TB1-3D
BLACK WIRE FROM PUMP1TO TB1-2D
17
10
14
15
SECTION
A-A
SECTION
TYP 2PLACES
B-B
1
2
13
WHITE WIRE FROM PUMP 3TO TB1-2B
BLACK WIRE FROM PUMP 3TO TB1-3A
TYP
16
21
TYP
23
22
24
25
1
2
6
TYP 6
PLACES
11
10
5
7
1
9
2
8
12
28
16
27
29
30
26
31
29
8
7
End View End View
Clamp Open
3
4
Terminal Block-TB1
BA B
D C
ABABA
DCDCDC
12 3 4
WHITE WIRE
FROM PUMP 1
TO TB1-3D
WHITE WIRE
FROM PUMP 2
TO TB1-2C
BLACK WIRE
FROM PUMP 1
TO TB1-2D
BLACK WIRE
FROM PUMP 2
TO TB1-3C
WHITE WIRE
FROM PUMP 3
TO TB1-2B
BLACK WIRE
FROM PUMP 3
TO TB1-3A
Note:
Pump wire connections must be as shown
to achieve proper performance.

SPR•Plus®IIISPR•Plus®III
5
Figure 2—SPR•Plus III Control Unit
board-mounted 1/8 A fuses for circuit protection.
6.3 Miscellaneous
The mechanical overpressure relief valve bleeds air when
the system pressure exceeds approximately 50 mm Hg.
18
Repair Procedures/Replacement Parts
Figure 8b—Pump Assembly Parts List
90566-003
09237-000
11649-000
11648-000
91552-000
11566-000
91303-009
05305-000
91519-024
78396-000
11531-000
09008-001
90426-000
91551-000
90018-133
90806-001
11673-000
11542-000
90018-080
91450-000
90031-043
90139-020
11538-000
90018-075
90566-004
PART NO.
1
3
4
5
6
7
8
9
10
11
12
14
15
16
17
18
19
20
21
22
23
24
25
13
2
ITEM
BUMPER, VINYL 3/4, DIA BLACK
CAP, AIR VALVE ASSEMBLY
LABEL, DANGER/WARNING/CAUTION
LABEL, UL/ULC
RING, SPLIT 1.07 ODx.930 ID, SST
PIN, DETENT
SPRING, COMPRESSION
STRAP,ALTERED
SCREW,PH PLASTITE, No8x3/8 LG
HANGER
BUSHING, HANGER
CORD, POWER ASSEMBLY
BUSHING, STRAIN RELIEF
SPRING, COMPRESSION, FLAT WIRE
SCREW,PH 1/4-20UNCx1/2 LG, SST
WASHER, FENDER, 1/4 IDx11/4 OD
ENCLOSURE, REAR
COMPRESSOR&SUPPORT ASSY
SCREW,PH MACH, No8x3/4 LG SST
WASHER, SPECIAL .685 ODx.188 ID ZINC
NUT, HEX, JAM 3/8-24UNF SST
LOCKWASHER, 3/8 INTERNAL, SST
FITTING, BULKHEAD, BARBED
SCREW, PH, 8-32UNCx3/8 LG, SST
BUMPER, POLYURETHANE 5/16 DIA,CLEAR
DESCRIPTION

SPR•Plus®IIISPR•Plus®III
6
Figure 3—CL360 Control Panel
Control Panel
7.0 Control Panel
CL360—see gure 3
7.1 Monitors and Indicators
1Set point indicator
illuminated LED indicates the set point and cushion
pressure in millimeters mercury (mm Hg).
Alert indicator
• Alert LED will light when internal cushion pressure
varies from the desired set point by ± 2 mm Hg for
more than 15 minutes.
• Alert LED will light and an audible alarm will
sound if the internal cushion pressure is outside
the operating range (minimum and maximum set
points) by ± 2 mm Hg for more than 30 minutes:
• Check hose and connections.
• Check for slashes and tears in cushion.
• Remove from service.
7.2 Controls and Labeling
3Firmness/Set point Button
Adjusts the set point pressure to one of ve settings.
4 Hand Check
Slide at hand, palm up, under cushion beneath
patient's boney prominence. Keep ngers at.
Optimum therapy occurs when patient's boney
prominence is lifted just above hand.
2
Figure 8b—Pump Assembly
DANGER
!
P/N11649-00010/02 P/N11648-00010/02
CL360
25
22 21
24
23
14
20
15
16
17
18
19 11
3
5
4
13
6
12
7
8
910
2TYP 4PLACES
ADHERE BUMPER TO
CENTER OF HANGER BUSHING, ITEM 12, AS
SHOWN. TYP 2 PLACES
1
17

SPR•Plus®IIISPR•Plus®IIIFunctional Check and Safety Inspection
8.1 Enclosure
Examine the exterior of the SPR•Plus III Control Unit for
overall condition:
1. Examine the chassis. It should be clean and free of
cracks.
2. Check that exterior screws are tight.
3. Check that legends and markings are legible.
8.2 Hose
Examine hose for cracks and restrictions. Replace if
necessary.
8.3 Plug, Line Cord, and
Strain Relief
Examine the plug, line cord, and strain relief for wear or
damage:
1. Examine the line cord plug to be sure it is in good
condition.
2. Examine the line cord along its entire length for physi-
cal damage, such as cut or cracked insulation. Replace
(rather than repair) damaged line cord. A nominal cord
length of 15 feet is recommended in order to reach an
electrical outlet at the head of the bed.
3. Check the tightness of the strain relief.
8.4 On/O Switch
Verify the on/o switch function:
1. Examine the physical condition of the on/o switch.
2. Cycle the switch on and o several times. The switch
should have a positive engagement (“click”) for the
“ON” and “OFF” positions.
8.5 Automatic Test
Verify the automatic test sequence:
1. Connect the Cushion Simulator to the SPR•Plus III
Control Unit and a manometer. See gure 4.
2. Turn the control unit on. The control unit will initiate
an automatic test sequence to verify that it is working
properly. The alert light should ash and the alert tone
should sound momentarily.
8.0 Functional Check and Safety
Inspection
To assure optimum performance, dependability and safety,
perform the following functional check procedures every
12 months or as specied in your facility's preventive
maintenance program.
Inspection Form
A Functional Check and Safety Inspection Form (p. 9) is
provided at the end of this section to facilitate and
document the inspection process. Each of the following
procedure numbers correspond to a Functional Check and
Safety Inspection Form item number.
Always perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION after making repairs and
before returning the SPR•Plus III Control Unit to
patient use.
Failure to perform the FUNCTIONAL
CHECK AND SAFETY INSPECTION could
result in damage to or malfunction of the
control unit.
Test Equipment
The following equipment (or equivalent) is required in
order to perform the preventive maintenance procedures:
• Cushion Simulator (P/N 78059-000)
• Current Leakage/Ground Resistance Tester
• Grounding Wrist Strap (electrostatic control
device)
• Manometer (0-100 mm Hg)
• Inspection Form
NOTE: Test equipment should be calibrated to NIST
(National Institute of Standards and Technology) guidelines
to insure accurate test readings.
Before performing the Functional Check and Safety
Inspection, be sure to recheck your test setup, procedure,
and test equipment for correctness.
Follow all procedures carefully, paying particular
attention to test setups. Any deviation from the
setups, procedures, or test equipment may lead to
improper results.
7
I
O
Hand Check
SPR PLUS III
Low Air Loss System
19
3
20
Figure 8a—Pump Assembly
Figure 8 & 8a—Pump Assembly Parts List 16
SCREW, PH, THD CUTTING 6-32x3/8 SST90154-008
91519-013
91519-024
90228-024
90018-057
80071-000
11642-000
11642-001
09273-003
10342-006
11673-001
90342-003
09273-004
SCREW,PH PLASTITE, No6x3/8 LG
SCREW,PH PLASTITE, No8x3/8 LG
CLIP, WIRE HARNESS 3/8 ID, WHITE
SCREW,PH MACH, No6x1/4 LG SST
TUBING, 5/32 IDx9/32 ODx.25 LG
LABEL, CONTROL LABEL
LABEL, INSTRUCTION
WIRE HARNESS ASSEMBLY
PC BOARD ASSEMBLY
ENCLOSURE, FRONT
SWITCH, ROCKER
WIRE HARNESS ASSEMBLY
11304-000
11730-000
91519-017
91390-002
50522-001
90228-025
11673-000
TOROID, FERRITE RING
LABEL, POWER CORD
SCREW,PH PLASTITE, No6x3/4 LG
FOAM, ALTERED
TY-WRAP,37/8 LG
CLIP, WIRE HARNESS 1/2 ID, BLACK
ENCLOSURE, REAR, ALTERED
PA RT NO.
12
DESCRIPTION
3
ITEM
2
1
5
4
6
7
8
9
11
10
14
13
15
16
17
19
20
18

SPR•Plus®IIISPR•Plus®III
8
8.8 Current Leakage
Verify current leakage is within safe limits:
1. Measure the current leakage at the ground access hole
on the rear of control unit.
The current leakage should not exceed
100 microamps in either the grounded or
ungrounded condition.
Note: If additional information is required,
refer to AAMI American National Standard,
Safe Current Limits for Electromedical
Apparatus or contact GAYMAR's Technical
Service Department.
8.9 Ground Resistance
Verify grounding resistance is within allowable limits:
1. Unplug the power cord.
2. Use a ground resistance meter to measure the
resistance between the grounding pin on the line cord
attachment plug and the ground access hole.
3. Maximum value is 0.5 ohms.
8.10 Completing the Functional
Check and Safety Inspection
This completes the recommended FUNCTIONAL CHECK
AND SAFETY INSPECTION for the SPR•Plus III Control
Unit.
If the SPR•Plus III Control Unit passes all requirements of
items 8.1 through 8.9, it should be considered operational
and suitable for return to service.
Figure 4—Cushion Simulator
8.6 Pressure Display Range and
Accuracy
Verify that the pressure indicator and rmness button
function:
1. Press the FIRMNESS button until the light reaches
18 mm Hg. After a moment, verify that the reading on
the manometer connected to the Cushion Simulator is
within 2 mm Hg of the display. See gure 4.
2. Verify that the pressure indicators for 21, 24, 27 and 30
mm Hg are also within ±2 mm Hg.
8.7 Maximum Cushion Pressure
Verify that the maximum cushion pressure is within
allowable limits:
1. Press the FIRMNESS button until the light reaches
30 mm Hg.
2. After a moment, block the cushion simulator orice
with your thumb.
3. The maximum manometer reading should be less than
60 mm Hg.
Functional Check and Safety InspectionRepair Procedures/Replacement Parts
15
White
P/N11304-000 3/01
12
3
4
18
17
TYP 6
PLACES
10
6
6
11
11
12
13
14
14 NOT
SHOWN
NOT
SHOWN
16
15
14
5
7
8
9
TYP 5
PLACES
56
LOCATE FOAM INSIDE
OF FRONT ENCLOSURE,
CENTERED AS SHOWN
Figure 8—Pump Assembly

SPR•Plus®IIISPR•Plus®III
9
Functional Check/Safety Inspection Form
Table 1—Inspection Form
PC Board
Figure 7—PC Board
14
SPR•Plus III Control Unit (CL360)
Functional Check / Safety Inspection Form
Initials ______________ Date
__________________
Location
_______________________________________________
Serial Number
__________________________________
Item(s) Action Observation Results (1) Trouble-
sho oting
Codes
(2)
8.1 Enclosure Unplug power cord.
Examine chassis.
Physical condition OK? Ye s No 1
8.2 Hose Examine hose. Physical condition OK? Ye s No 2
8.3 Plug, cord, and
strain relief
Examine plug, cord, and strain
relief.
Physical condition OK? Ye s No 2
8.4 ON/OFF switch Examine ON/OFF switch. Physical condition OK? Ye s No 3
8.5 Automatic test Connect Cushion Si mulator (fig.
4). Turn SPR• P lus Control Uni t
ON. Verify automatic test
sequence.
Alert light flashes and Alert
tone sounds at power up?
Ye s No 4
8.6 Pressure display
range and accuracy
Wi th Cushion Si mulator
connected, select each firmness
set point.
Is manometer reading
within
2 mm Hg of display?
Ye s No 5, 6
8.7 Maximum cushion
pressure
Wi th Cushion Si mulator
connected, block orifice on
cushi on simulato r.
Does manometer read less
than 60 mm Hg?
Ye s No 7
8.8 Current Leakage Measure current leakage. Is current leakage less than
100 µA
Ye s No 8
8.9 Ground Resistance Unplug power cord.
Measure ground resistance.
Is ground resistance less
than 0.5 ohms?
Ye s No 9
NOTES:
(1) If any "No"s are checked, repair the SPR•Plus III Control Unit before returning it to service.
(2) See table 2, "Troubleshooting Chart," for explanation of troubleshooting codes.
ID Description P/N ID Description P/N
T1 Transformer 91459-000 R1 Potentiometer, 100K-15T 90728-010
S1 Switch, P ushb utton 91247-040 R2 Potentiometer, 5K-15T 90728-008
PS1 Transducer, Pressure 91116-002 U2 Regulator, Voltage LM340T-590712-017
LS1 Alarm, Audible 90919-001 Q5 Tr i a c 90709-015
U5, U6 IC, MOC3021 90886-000 F1, F2 Fuse 0.125A 90695-040
Q1 thru Q4 Transistor, 2N3904 90868-015 F3, F4 Fuse, 0.3A 90695-026
DS21, DS22 Led, Lamp Yellow 90761-014 U4 Prom, Programmed (v2.3) 09053-004
DS1 thru DS5 Led, Lamp Green 90761-013

SPR•Plus®IIISPR•Plus®III
Always perform the FUNCTIONAL CHECK
AND SAFETY INSPECTION after making repairs
and before returning the SPR•Plus III Control
Unit to patient use. Failure to perform the
Functional Check and Safety Inspection
could result in damage to or malfunction of
the control unit.
9.0 Troubleshooting
In addition to the following chart, refer to 10.0 REPAIR
PROCEDURES (p. 12) and 5.2 CLEANING (p. 3).
Table 2—Troubleshooting Chart
Troubleshooting
10
13
10.5 Replacement of Coils
Before replacing coils, remove the compressors (see 10.3).
1. Remove old coil from compressor housing by
removing screw (g. 6, item 6).
2. Install new coil.
3. Adjust diaphragm/valve body assembly so that there
is a 0.020" – 0.035" gap between the rocker arm
magnets and coil. Do not force the shim gauges (brass
or aluminum shims should be used), as they may push
the rocker arms away from the coil and give a false
reading.
4. Energize each pump assembly and let it run for
approximately one minute. Recheck the gap between
the rocker arm magnets and coil. If the gap is below
0.020", loosen the coil and screw slightly and pull the
coil away from the magnets. Retighten the coil screw.
If additional gap is required, loosen valve body screws
and slightly move away from coil. Energize the pump
again and check for 0.020" – 0.035" gap.
5. Attach the pump assemblies to the pump cover plate
leaving the screws loose.
6. Tighten grommet screws into compressor housing.
7. Tighten pump cover plate screws.
8. Install coil wires into the terminal block TB1.
9. Attach tubing and ribbed clip removed in section10.3,
steps 3 and 4.
10. Install cover assembly.
10.6 Replacement Parts
To identify replacements parts, refer to pp. 13–22.
CL360:
To order replacement parts, contact GAY-
MAR's Customer Service Department:
Direct 716. 662.2551
Toll Free 1.800. 828.7341
Repair Procedures
Compressor Assembly
Figure 6—Compressor Assembly
Troubleshooting
Code
Action
1 Repair Chassis.
2 Replace hose, power cord, and/or strain relief.
3 Replace ON/OFF switch.
4Automatic Test Sequence Failure:
Check main fuses F3, F4. Replace fuses.•
Check Transformer fuses F1, F2. Replace PC board.•
PC board disconnected at J3. Check connections.•
PC board faulty. Replace PC board.•
Power Unit Doesn’t Produce Air:
Check power switch. Turn on or replace.•
Check main fuses F3, F4. Replace fuses.•
Check transformer fuses F1, F2. Replace PC board.•
PC board disconnected at J3. Check connections.•
PC board faulty. Replace PC board.•
Pump disconnected at TB1. Check connections.•
Triac faulty. Replace PC board.•
Pumps faulty. Repair/replace pumps.•
5 Calibrate/replace PC board, see pp. 11-12.
6Power Unit Output Pressure Wrong:
Transducer faulty. Replace PC board.•
Transducer hose disconnected. Check connection.•
Pump faulty. Repair/replace pump.•
Alert Light and Audible Stuck On at Power-Up:
Automatic test sequence failed. Replace PC board.•
7 Replace relief valve (item 15, page 20).
8 Inspect the internal wire harness for cuts and abrasions. Inspect the power cord, plug, and
insulation. Replace if necessary. If the wire and power cord are not damaged, investigate
pump components to determine current leakage source.
9 Verify that the green lead from the power cord is securely attached to the chassis. If ground
resistance is greater than 0.5 ohms (see p. 9), replace the power cord.
NOTE: If the preceding steps fail to correct the problem, replace the PC board.
ID Description P/N
1Knurled Threaded Insert, 10-32 UNF 91401-000
2Nut w/Lockwasher, M3 91195-001
3Brass Eyelet 90461-001
4 Compressor Housing 08942-000
5Black Tubing 3/16" ID x 3/4" LG 80636-000
6Screw, sems, pan head, CR,
M3 x 25 mm, SST 91208-148
7Coil, 110V, 60 Hz 09411-000
8Plain Washer No. 4, Type B, SST 90234-002
9Diaphragm / Valve Body Assembly 08937-000
10 Screw, pan head, CR, M3 x 14 mm, SST 90950-033

SPR•Plus®IIISPR•Plus®III
11
9.1 Calibration Check
1. Assemble set up:
• Open unit, prepare test set up as shown
below. See Figure 5.
• Connect digital voltmeter to test points on
J1, Vout = PIN 6, GND = PIN 1.
• Connect a load (CL212 cushion; or
P/N 78059-000 cushion simulator) to end of
outlet hose.
2. Apply power and the unit should start controlling
pressure. Verify that the manometer reading equals the
digital voltmeter reading (Note: Vout scaling =
0.1 V/mm Hg). If the readings dier by 1/2 (0.5) mm Hg,
calibration is required. If the readings agree, calibration
is not the problem. Check for holes in hoses, kinked
tubing, or foreign obstructions.
9.2 Calibration
1. Set setpoint on control panel to the lowest setting.
When controller is stabilized, adjust oset until the
manometer and voltmeter readings agree.
2. Set setpoint on the control panel to the highest setting.
When the controller is stabilized, adjust the gain setting
until the two meters agree.
3. Repeat steps 1 and 2 as necessary until ± 0.5 mm Hg
accuracy is attained.
Troubleshooting
Figure 5—Calibration Check
12
10.0 Repair Procedures
10.1 Removing the Cover Assembly
1. Unplug the power cord.
2. Remove the four screws holding the cover on (see
gure 8a, item 31).
3. Carefully separate the two halves. Use care not to
strain the internal tubing or wiring connections.
4. Reverse steps 1-3 to replace cover assembly. Be careful
not to pinch wires or tubing when replacing cover
assembly.
10.2 Removing the PC Board
Wear a grounding wrist strap to ensure that
any accumulated electrostatic charge will
be discharged from your body to ground.
Electrostatic discharge can damage PC
board components.
1. Unplug the power cord.
2. Remove cover assembly (see 10.1 above).
3. Remove six screws holding control board to top cover.
4. Lift upward carefully, taking care not to strain the
pressure tubing and electrical wire connections.
5. Remove pressure tubing from tting on pressure trans-
ducer.
6. Unplug the 9-pin connector at J3 on the control board.
7. Reverse steps 2-6 to reinstall control board and cover.
8. Perform the FUNCTIONAL CHECK AND SAFETY
INSPECTION.
10.3 Removing the Compressors
We recommend replacing all three diaphragm/valve body
assemblies at the same time (see g. 7, item 2).
1. Unplug the power cord.
2. Remove the cover assembly (see 10.1).
3. Disconnect the resonator tubing at the 30° barbed
“Y” tting (see g. 9, item 20).
4. Remove the three screws that hold the three washers
(item 26) and clips (items 25) to the pump support
plate assembly (item 3).
5. Disconnect all wires from the terminal block, TB1
(item 10). Push down with thin blade screwdriver thru
access hole in top of terminal block to release wire.
6. Remove the six screws and lockwashers (items 15
and 16) that hold the resonator (item 6) to the
pump support plate assembly (item 3) . Remove the
resonator.
7. Remove the three compressors and the pump
support plate assembly.
8. Remove the remaining mounting screws (item 19)
that hold each compressor to the pump support plate
assembly.
Repair Procedures
10.4 Replacement of Diaphragm/
Valve Body Assembly
1. Remove Diaphragm/Valve Body Assembly (g. 7A, item
9) from all three compressors.
2. Install new Diaphragm/Valve Body Assembly in each
housing so that there is a 0.020" – 0.035" gap between
the rocker arm magnets and coil. Do not force the
shim gauges (brass or aluminum shims should be
used), as they may push the rocker arms away from
the coil and give a false reading.
3. Energize each pump assembly and let it run for
approximately one minute. Recheck the gap between
the rocker arm magnets and coil. If the gap is below
0.020", loosen the coil and screw slightly and pull the
coil away from the magnets. Retighten the coil screw.
If additional gap is required, loosen valve body screws
and slightly move away from coil. Energize the pump
again and check for 0.020" – 0.035" gap.
4. Attach the pump assemblies to the pump cover plate.
Leave the screws loose.
5. Tighten grommet screws into compressor housing.
6. Tighten pump cover plate screws.
7. Reinstall the resonator and gasket with six screws and
lockwashers.
8. Reinstall wires into the terminal block TB1.
See gure 9.
9. Attach tubing and ribbed clip removed in section 10.3,
steps 3 and 4.
10. Install cover assembly.