Gaymar Thermacare REF TC3249 User manual

Gaymar Industries, Inc.
10 Centre Drive
Orchard Park, NY 14127-2295 USA
Telephone: [phone]
[phone]
Fax: [phone]
[phone]
www.gaymar.com
Gaymar and Thermacare trademarks are registered
in the US Patent and Trademark Office.
©2010. Gaymar Industries, Inc.
All rights reserved.
Thermacare®REF TC3249
Convective Warming System
Service Manual
P/N: 100077000 Rev. C 11/10
Thermacare

Before you begin . . .
Important
•Refer to the TC3249 Convective Warming
System Operating Manual for detailed
operating instructions. Read and understand
the Operating Manual and all precautions prior
to using the Convective Warming System.
•Review the SAFETY PRECAUTIONS (see page
2) prior to servicing the Convective Warming
Power Unit.
•Fortechnicalassistance,contactyourlocal
dealer.
NOTE: Extremely high storage temperatures
(such as those found in rail cars or automobile
trunks on hot summer days) can cause the
thermostats within this device to actuate. Should
this occur, the REMOVE FROM USE indicator
will light when the Power Unit is turned on. If
this happens, the thermostats must be manually
reset. Refer to section 7, Functional Check and
Safety Inspection.
Attention: consult accompanying
documents
Dangerous voltage
Protective earth (ground)
Type BF applied equipment
MIN (Fan only)
LOW (90°F, 32°C)
MED (100°F, 38°C)
HIGH (110°F, 43°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:
60°F -85°F
(16°C-2 9°C)
Ambient operating temperature
29
Section 13 - Wiring Diagram (cont’d)

Contents
Section Introduction Page
1.0 Safety Precautions................................................................2
2.0 Repair Policy / Return Authorization.......................................3
3.0 Specifications .......................................................................4
4.0 Theory of Operation ..............................................................5
5.0 Controls and Indicators .........................................................7
6.0 Preventive Maintenance ........................................................7
7.0 Functional Check and Safety Inspection.................................8
8.0 Inspection Form..................................................................16
9.0 Troubleshooting ..................................................................19
10.0 Repair Procedures ..............................................................21
11.0 Drawings/Parts List ............................................................24
12.0 Test Tool Schematic............................................................27
13.0 Wiring Diagram...................................................................28
Illustrations
Figure Description Page
1 Convective Warming System ...............................................5
2A/B Power Unit Mounting ........................................................... 5
3 Pole Mounting Height Limit..................................................5
4 Operator Control Panel.........................................................6
5 Test Tool..............................................................................9
6 Temperature Sensor Location .............................................10
7 Troubleshooting Chart - NO HEAT ...................................... 19
8 Troubleshooting Chart - NO AIR FLOW................................20
9 Drawing/Parts List..............................................................24
10 Drawing/Parts List..............................................................25
11 Drawing/Parts List..............................................................26
12 Test Tool Schematic ...........................................................27
13 Wiring Diagram .................................................................. 28
Tables
Table Description Page
1 Air Temperatures.................................................................. 4
2 Functional Check/Inspection Form.......................................16
Table of Contents
128
Section 13 - Wiring Diagram
Figure 13 - Wiring Diagram
ATTENTION
Sta tic-Sensitive
Dev ic es

2
1.0 Safety Precautions
Review the following SAFETY PRECAUTIONS prior
to testing the Power Unit. •After performing the thermostat test
procedure, verify that the Test Tool or any
installed test jumpers have been removed
before returning the Power Unit to patient
use.
Failure to remove the Test Tool or test
jumpers may result in death, serious
injury or equipment malfunction.
•AlwaysunplugthePowerUnitbefore
attaching or removing the Test Tool
or test jumpers and when resetting
thermostats. Failure to unplug the Power
Unitcouldresultinelectricalshockand
cause death or serious injury.
•Use only Gaymar replacement parts as
identified in the parts lists (pp. 24-27).
Useofsubstitutepartscouldleadto
power unit malfunction or patient injury.
•TheTemperatureControlPCBoardis
pre-set at the factory. Do not attempt to
calibrateit.AdjustmentoftheControl
PC Board in the field could result in
patient injury.
•Use care when resetting the thermostats.
Excessive force (force greater than
5 pounds) can damage the overtemp
protection device and/or inadvertently
alter the trip temperature of the device.
DANGER
•Explosivehazard.Donotuseinthe
presence of flammable anesthetics.
•Riskofelectricshock.Disconnectpower
before servicing the TC3249 Power Unit.
WARNING
WARNING
This device generates heated air flow.
Excessive heat could cause thermal
stressorskinlesions.Failuretofollow
these precautions could result in death or
serious injury:
•Use this system only under direction of
a physician. Read and understand the
Operating Manual, Quilt Instructions for
Use, and all precautions before using.
•Repairs should be performed only by
qualified personnel such as certified
biomedical electronics technicians or
certified clinical engineers familiar with
repair practices for servicing medical
devices, and in accordance with the
Service Manual. Damage to the Power
Unitormalfunctioncouldotherwise
result.
•AlwaysperformtheFUNCTIONAL
CHECK AND SAFETY INSPECTION after
makingrepairsandbefore returning the
PowerUnittopatientuse.Document
your findings on the INSPECTION
FORM. Improper repair may result
in death or serious injury, equipment
damage, or malfunction.
(continued next column)
Section 1 - Safety Precautions
•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.”
•The HEPA filter must be installed correctly.
Failure to install the filter correctly will
prevent it from functioning properly and
could allow unfiltered air to reach the
patient.
•When using an I. V. pole, do not mount
the Power Unit higher than 3 feet
(0.9 meter). Otherwise, the Power Unit
could tip over.
Section 12 - Test Tool Schematic
ATTENTION
Static-Sensitive
Dev ic es
27
Figure 12 - Test Tool Schematic
(see Figure 11/11A)
Section 11 - Drawings/Parts Lists (cont’d)
Item Description Part
Number
30 Label, Caution 12762000
32 Cord strap assembly 03791000
33 Heater thermostat (S4) 78025000
34 Interlock switch 91375000
35 Sleeving 4 1/2" LG 81054000
- Power cord (Continental Europe) PC001
- Power cord (United Kingdom) PC002
- Power cord (Australia) PC003
- Power cord (Switzerland) PC004
- Power cord (Italy) PC005
- Power cord (Denmark) PC006
- Power cord (Israel) PC007
PC001PC004 PC006PC002 PC005PC007PC003
Item Description Part
Number
16 Power entry module 08993000
17 Motor kit 78022000
18 Patient limit thermostats (S2,S3) 91323005
19 Hose assembly 78423000
20 Kit, card, label replacement 78110000
21 Rear housing kit (includes labeling) 78118002
22 I.V. pole clamp 08614000
23 Toggle shoe 91439000
24 Card, Contraindication, Greek/Blank 09877000
25 Card, Contraindication, Swedish/Finnish 09876000
26 Card, Contraindication, Dutch/Danish 09875000
27 Card, Contraindication, Italian/German 09874000
28 Card, Contraindication, Spanish/ Portuguese 09873000
29 Card, Contraindication, English/French 09872000
Figure 11A - Plugs
CAUTION

2.0 Repair Policy
For customers who repair Gaymar Power Units at
their location, this manual contains information to
allow a qualified biomedical technician to make
necessary repairs.
2.1 Limited Warranty
The Thermacare TC3249 Power Unit is warranted
free of defects in material and workmanship
under normal use and operation for a period of
two years, under the terms and conditions of the
Gaymar warranty in place at time of purchase.
During the warranty period, Gaymar will repair
or replace at its sole option, free of charge, any
defective parts or products returned with prior
authorization prepaid to Gaymar Industries.
Consumable items such as filters are excluded.
The full warranty is available from Gaymar upon
request.
Warranty does not cover products abused,
misused, or altered outside the factory. There
are no obligations on the part of Gaymar for
consequential damages arising out of or in
connection with the use or performance of the
product. Gaymar disclaims all implied warranties
including, but not limited to, the implied
warranties of merchantability and of fitness for a
particular purpose.
2.2 In-Warranty Repairs
All in-warranty field repairs must be authorized by
Gaymar's Export Department before proceeding.
2.3 Out-of-Warranty Repairs
If the Power Unit becomes inoperative and the
cause cannot be determined, the complete
Power Unit may be returned to the factory for
servicing at the purchaser's expense. Please
contact Gaymar's Export Department to obtain a
returned goods (“RG”) number prior to returning
equipment.
2.4 ReturnAuthorization
Please contact your local dealer.
Section 2 - Repair Policy
3
Figure 11 - TC3146 Detail Drawing
Section 11 - Drawings/Parts Lists (cont’d)
26
To release wires from
terminal block, insert
a small screwdriver in
slot nearest wire and
pull towards center.
S3
S2
S4
16
17
18
19
22 23
24
20
21
25
26
27
28
29
30
32
33
34
35
ROTATION

HEAT
S3S2
OVERTEMP
THERMOSTAT
BYPASS
14
4
12
11
10
9
13
3.3 Temperature Settings
The air temperatures are identified on the operator
control panel and indicate the average air
temperature at the hose end using a Quilt.
NOTE: The air temperature around the
patient is affected both by the ambient room
temperature and the use of an insulating
blanket on top of the Quilt.
3.4 Safety System
Dual Patient Safety Temperature Limit
Thermostats
Either of two independently operating
thermostats will shut off the TC3249 at a
preset high limit temperature. The heater
element and blower will remain off until the
thermostat is manually reset.
Heater Overtemp
Heater overtemp thermostat will shut
off the TC3249 in the event of a blower
failure or lack of air movement. The heater
element and blower will remain off until the
thermostat is manually reset.
High Temp Indicator
The REMOVE FROM USE indicator will light
on the front panel when a patient safety
thermostat or heater overtemp thermostat
has tripped. Also, the heating element and
blower will turn off.
HEPAFilterInterlockSwitch
The REMOVE FROM USE indicator will light
on the front panel when the HEPA filter has
been installed incorrectly or is missing. Also,
the heating element and blower will turn off.
3.5 Quilts
All Quilts are made of either a nonwoven layer
bonded to a plastic film, or two nonwoven layers.
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 “Normal
Flammability.”
Section 3 - Specifications
3.0 Specifications
3.1 Physical
Dimensions 16 1/4"H x 10 3/4"W x 10 1/2"D (42 cm
x 28 cm x 27 cm)
Weight 15 lbs (6.8 kg)
Enclosure Thermoplastic
Filter HEPA filtration down to
0.3 micron size
3.2 Electrical
Classification Type BF, Class 1, grounded equipment
suitable for continuous operation.
Not classified for protection against
harmful ingress of liquid.
Input 220-240 V (+10%, -10%), 50 Hz,
7 amps max
Motor 1/25 HP, single phase
Heater 1200W heating element
Power Cord (Harmonized) three wire cordset
using cordage approved to HD-21.
Conductor size is 1.0 mm2
(H05VVF3G1.00)
CircuitBreaker 10 amp
CurrentLeakage(Earth) 100 microamps max,
90 microamps typical
Ground Resistance 0.15 ohms nominal;
0.5 ohms maximum
AmbientOperating 60°F to 85°F
Temperature (16°C to 29°C)
4
Table 1 - Air Temperatures
Temperature
Setting
Temperature
MIN Fan only
LOW 90ºF (32ºC)
MED 100ºF (38ºC)
HIGH 110ºF (43ºC)
Section 11 - Drawings/Parts Lists (cont’d)
Figure 10 - TC3249 Detail Drawing
25
TEST PLUG
HOUR TIMER
Item Description Part
Number
9 Rubber foot 77944000
10 Standoff 77945000
11 P.C. Board assembly kit 78436001
12 Mounting screws 77946000
13 Front housing kit (includes
labeling)
100086000
14 Circuit breaker 90961008
-- Label, Control Panel 08964001
-- Label, Rear 100003000
-- Label, On/Off 09023000
-- Test Tool 08606000

Section 4 - Theory of Operation
4.0 Theory of Operation
4.1 Convective Warming System
The Convective Warming System (fig. 1)
provides a continuous means of warming patients
to help prevent and/or treat hypothermia. The
system consists of a Convective Warming Power
Unit and a disposable Quilt. A connecting hose
conducts heated air from the Power Unit to the
Quilt.
Figure 2A - I. V. Pole or Stand mounted
Figure 2B - Bed rail mounted
IV Pole
Clam p
Figure 1 - Convective Warming System
4.2 TC3249PowerUnit
The TC3249PowerUnit provides a continuous
source of air to the Quilt. The Power Unit consists
of a HEPA filter, blower, heater, and temperature
controller. The Power Unit is a hand-carried
portable device which has dual mounting
provisions. It can hang on a bedrail or footboard
using the bedrail hooks on the back of the unit
(see fig. 2B). It can also mount to an I. V. pole
or optional accessory stand using the I. V. pole
clamp (see fig. 2A). Output air temperatures may
be set to one of four temperature settings:
MIN (fan only), LOW (90°F, 32°C), MED (100°F,
38°C), or HIGH (110°F, 43°C).
When using an I. V. pole, do not mount the
Power Unit higher than 3 feet (0.9 meter)
(see fig. 3).
Otherwise,thePowerUnitcouldtipover.
5
CAUTION
Figure 3 - Pole mounting height limit
Donotm ount
higherthan 3 ft.
CAUTION
Bedrail
Hook
Section 11 - Drawings/Parts Lists
Figure 9 - TC3249 Detail Drawing
24
2.5mm
1
5
4
8
7
3
2
6a
6b
0.10"
Item Description Part
Number
1HEPA lter 78018000
2 Filter retainer nut 91396005
3 Heater 78019000
4 RT1 Thermistor assembly 77942000
5 Blowerwheel 91369000
6 a. Clip 90228004
b. Rachet 91428002
7 Label, Caution 08985000
8 Bed rail hook 77943000
(0.9 M)
IV Pole
Clamp
Bedrail
Hook
CAUTION
Do not mount
higher than 3 ft. (0.9 M)

Section 4 - Theory of Operation (cont’d)
6
Figure 4 - Operator Control Panel
Ambient air is drawn in through air vents in the
bottom of the enclosure. Air passes through a
HEPA filter and across a 1200 watt, open coil
heater located in the inlet of a blower. Output
air temperature is monitored by a thermistor
located directly in the output air stream (plenum)
and provides feedback to the solid-state
controller. The controller compares the output
air temperature to the selected temperature and,
using an on-off control scheme, turns the heater
on or off accordingly. The maximum output air
temperature is limited not only by the control
system but by two redundant bimetallic latching
thermostats. These thermostats are located in the
output air stream and will interrupt power to both
the heater and the blower, and light the REMOVE
FROM USE indicator on the front panel should
the output air temperature exceed predetermined
limits. A similar thermostat located directly
above the heater is used to protect the internal
components in the event of a motor failure. It too
will interrupt power to the heater and blower and
light the REMOVE FROM USE indicator.
Air is delivered to the Quilt using a permanently
attached, flexible hose. The hose has a sleeve
which is stain resistant and easy to clean.
4.3 Quilts
The Quilts distribute air evenly over the covered
areas of the patient through openings in the
patient side of the Quilt. Quilts consist of layers
of plastic and nonwoven material bonded
together. Refer to the instructions enclosed with
each Quilt.
20. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).
10.5 Replacing the I. V. Pole Mount
Bracket
To replace the I. V. pole mount bracket:
1. UnplugthePowerUnit.
2. Remove the six screws securing the
enclosure. Open the enclosure.
3. Remove the two screws securing the
terminal block from the backing plate.
4. Remove the two screws and the lock washer
holding the I. V. pole mount bracket to the
backing plate.
5. Remove the I. V. pole mount bracket from
the rear half of the enclosure.
6. Insert new I. V. pole mounting bracket into
rear half of the enclosure.
7. Replace the two screws and the lock washer
into the backing plate and I. V. pole mounting
bracket.
8. Replace the terminal block.
9. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).
7. Connect brown and blue wires to the circuit
breaker (refer to label on inside of case).
8. Reconnect ground wire to filter inlet plate.
9. Secure wires with wire tie provided.
10. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).
Section 10 - Repair Procedures (cont’d)
23
10.6 Temperature Control PC Board
To replace the P.C. board assembly
(item 11, fig. 10):
1. UnplugthePowerUnit.
2. Remove the six screws securing the
enclosure. Open the enclosure.
3. Cut the four cable ties which secure the PC
board wires together.
4. Unplug the following wires from the PC
board assembly at the terminal block:
 •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 PC
board assembly.
8. Remove the old PC board assembly and
install the new PC board assembly.
9. Reassemble in reverse order.
10. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).
WARNING
The Temperature Control PC Board is
pre-set at the factory. Do not attempt to
calibrateit.AdjustmentoftheControl
PC Board in the field could result in
patient injury.
P/N 08964-001 3/06
®
Patient Warming System
43°C38°C
32°C
Label, Control Panel
TC3249
P/N 08964-001
AW-5720

Section 5 - Controls and Indicators
Section 6 - Preventive Maintenance
6.0 Preventive Maintenance
6.1 HEPAFilter
Dirt that has accumulated on the internal HEPA
air filter will reduce the efficiency of the blower
and heater. Under normal use, replace the HEPA
filter every 1000 operating hours or 12 months,
whichever occurs first. Replace the filter only with
the Gaymar P/N listed (see parts list, fig. 9, p.24).
Use only Gaymar replacement parts as
identified in the parts lists (pp. 24-27).
Useofsubstitutepartscouldresultin
power unit malfunction or patient injury.
Refer to Functional Check, 7.6 Filter Switch Test &
Filter Replacement (p. 14) for instructions.
6.2 Blower
The blower motor and fan do not require
lubrication.
6.3 Enclosure Exterior
Clean the control panel and Power Unit exterior
with a soft cloth lightly dampened with a
nonstaining hospital disinfectant.
6.4 Quilts
Quilts 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 be
temporarily fixed with adhesive tape.
6.5 Hose
Clean the hose with a soft cloth lightly dampened
with a nonstaining hospital disinfectant. Place the
connector hose under the bed rail hooks when not
in use.
6.6 AirVents
Clean accumulated dirt from the air vents with a
vacuum cleaner.
5.0 Controls and Indicators
5.1 Power
An on/offcircuitbreaker is located on the front
of the unit in the bottom left corner. It controls
power to the entire unit. When switched to the ON
position, a power indicator in the switch will light.
5.2 Control Panel
An operator control panel (fig. 4, p. 6) is
mounted at the top of the Power Unit:
•[Power Up] When the power unit is turned on,
the system defaults to the MED (100°F, 38°C)
temperature setting. A green light directly
above the selector switch will glow indicating
the selected temperature range.
•[Temperature Settings] Temperature settings
are selected by pressing the appropriate push-
button -- MIN (fan only), LOW (90°F, 32°C),
MED (100°F, 38°C), or HIGH (110°F, 43°C).
•[Power Interruption] If electrical power
is interrupted momentarily, the existing
temperature setting will remain. If electrical
power remains off, the TC3249 will default to
the MED (100°F, 38°C) setting when power is
restored.
A REMOVE FROM USE indicator will light:
•if a patient safety thermostat or heater
thermostat has tripped.
•if the HEPA filter has been installed incorrectly
or is missing.
The heating element and blower will automatically
turn off when these conditions occur.
7
WARNING
10.3 ReplacingtheThermistorAssembly
(RT1)
To replace the thermistor assembly (item 4, figs.
9-10):
1. UnplugthePowerUnit.
2. Remove the six screws securing the
enclosure. Open the enclosure.
3. Unplug the thermistor assembly from the PC
board.
4. Cut the cable ties holding the thermistor wires
to the wire harness and enclosure standoff.
Be careful not to cut the insulation on the
standoff.
5. Remove the filter retainer and nut. Remove the
filter.
6. Remove the ten screws securing the filter inlet
plate.
7. Remove the two screws securing the terminal
block. Remove the screw and lock washer
securing the ground wire to the backing plate.
8. Depending on the method of mounting, either
use wire cutters to remove the spring clip, or
loosen the speed nut securing the thermistor
assembly to the filter inlet plate.
9. Replacement thermistor assemblies may be
slightly larger than the original. If necessary,
open hole slightly, to 1/4".
10. Replace the thermistor assembly. Secure
it with the new speed nut supplied with the
thermistor assembly.
11. Place filter inlet plate back on top of the scroll.
Secure the ten screws.
12. Replace the terminal block. Reconnect the
ground wire to the backing plate. Make sure
the lock washer is reinstalled.
13. Plug the thermistor assembly into the control
board. Use the cable ties supplied with the
thermistor assembly to hold the thermistor
wires to the PC board wire harness and
enclosure standoff.
14. Replace the HEPA filter. Secure it with the filter
retainer and nut.
15. Perform the FUNCTIONAL CHECK AND SAFETY
INSPECTION (section 7, pp. 8-15).
10.4 Replacing the motor
To replace the motor:
1. UnplugthePowerUnit.
2. Remove the six screws securing the
enclosure. Open the enclosure.
3. Remove the filter retainer and nut. Remove
the filter.
4. Remove the ten screws securing the filter
inlet plate.
5. Remove the screw securing the ground wire
to the backing plate. Remove the two screws
securing the terminal block.
6. Carefully lift the filter inlet plate, exposing the
blower wheel.
7. Remove the blower wheel using a 1/8" hex
wrench through hole in one blade of blower
wheel.
8. Cut wire tie holding wiring harness (fig. 11).
9. Unplug terminals from the motor.
10. Remove the two #8 screws and two #8
nuts from the bottom of motor.
11. Loosen the two #8 screws on top of motor.
Slide filter support bracket off. Loosen
corresponding screws on new motor and
replace filter support bracket. Tighten
screws.
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
there is 0.10" (2.5 mm) clearance between
the wheel and the blower inlet ring (see fig.
9). NOTE: the hex screw must be aligned
with the flat on the motor shaft.
17. Place the filter inlet plate back on top of the
scroll. Secure the ten screws.
18. Replace the terminal block. Reconnect the
ground wire to the backing plate; make sure
the lock washer is installed.
19. Replace the HEPA filter. Secure it with the
filter retainer and nut.
Section 10 - Repair Procedures (cont’d)
22

•Stopwatch
•Adhesive Tape
•TestTool*(P/N08606000),or two 16 gauge
insulated Test Jumpers
* TheTestToolisavailablefromGaymar.
This tool was designed to allow for more
convenient testing of the thermostats
and eliminate the need to install jumpers.
Contact Gaymar's Technical Service
Department for more information.
•INSPECTION FORM (table 2, pp. 16-18)
Procedures
Perform the following procedures carefully,
paying particular attention to test setups.
Anydeviationfromthesetups,procedures,
or test equipment may result in incorrect or
misleading results.
7.1 Enclosure
Examine the overall condition of the Power Unit
exterior:
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 are legible.
5. Clean accumulated dirt from the air vents
with a vacuum cleaner.
6. Check hose assembly for holes and broken
fittings. Replace if necessary.
7.2 Plug, Line Cord
Examine the plug, line cord:
1. Examine the attachment plug on the line cord
to be sure it is in good condition.
2. Examine the line cord along its entire
length for physical damage, such as cuts
or cracked insulation. Check the quality of
the strain relief. Replace, rather than repair,
damaged line cords.
7.0 FunctionalCheckandSafety
Inspection
To assure optimum performance, dependability
and safety, perform FUNCTIONAL CHECK AND
SAFETY INSPECTION as follows:
•Afterrepair,andevery12monthsthereafter
— the FUNCTIONAL CHECK AND SAFETY
INSPECTION consists of all procedures
(sections 7.1 through 7.9).
If your facility's procedures call for more
frequent functional test and safety inspections,
note this fact on the INSPECTION FORM.
Inspection Form
An INSPECTION FORM (table 2, pp. 16-18) is
provided at the end of this section to facilitate and
document the inspection process.
Test Equipment
The following test equipment (or equivalent)
is required in order to perform the preventive
maintenance procedures:
•Digital air thermistor thermometer
(YSI 400 series)
Range: 50°F to 160°F (10°C to 71°C)
System accuracy: ±1°F (±0.6°C)
•Temperaturesensor
(P/N 77948-000)
NOTE:
1. Include the accuracy of the measuring
equipment when making judgments
about observed temperature readings.
2. Test Conditions: 230 VAC ± 2 ,
70°F-75°F (21°C-24°C) ambient.
(With heater on, may require the use of a
variable transformer.)
•#2 Phillips screwdriver
•Current Leakage / Ground Resistance Tester
•Quilt (See page 10, Figure 6B)
Section7-FunctionalCheckandSafetyInspection
8
the HEPA filter.
4. Remove the ten screws securing the filter
inlet plate.
5. Remove the screw and lock washer
securing the ground wire to the backing
plate. Remove the two screws securing the
terminal block.
6. Carefully lift the filter inlet plate, exposing the
blower wheel.
7. Remove the blower wheel using 1/8" hex
wrench through hole in one blade of blower
wheel.
8. Remove the two #6 screws holding the
heater to the motor bracket.
9. Disconnect the short wire from the heater to
the motor.
10. Remove the red heater wire from terminal
block location TB1-3 (see figure 11).
Remove cable ties.
11. Remove the heater.
12. Install the replacement heater.
13. Reroute the red wire through the 4-hole
grommet.
14. Reconnect both wires. Refer to TB1
designators in the schematic (figure 13) and
terminal block wiring designators in figure
11. Install cable ties.
15. Reinstall the blower wheel, making sure
there is 0.10" (2.5 mm) clearance between
the wheel and the blower inlet ring (see
fig. 9). NOTE: the hex screw must be
aligned with the flat on the motor shaft.
16. Place the filter inlet plate back on top of the
scroll. Secure the ten screws.
17. Replace the terminal block. Reconnect the
ground wire to the backing plate; make sure
the lock washer is reinstalled.
18. Replace the HEPA filter. Secure it with the
filter retainer and nut.
19. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).
10.0 Repair Procedures
Use only Gaymar replacement parts as
identified in the parts lists (pp. 24-27).
Useofsubstitutepartscouldresultin
power unit malfunction or patient injury.
To identify replacement parts, refer to figures
9-11 (pp. 24-27). To order replacement parts,
contact Gaymar's Export Department:
Export Telephone: [phone]
Fax: [phone]
10.1 Replacing the Patient Limit
Thermostat(s) (S2 & S3)
To replace either thermostat (item 18, fig. 11):
1. UnplugthePowerUnit.
2. Remove the six screws securing the
enclosure. Open the enclosure.
3. Carefully unplug the terminals from the
thermostat.
4. Remove the two #4 nuts from the
thermostat.
5. Replace the thermostat. Reinstall the nuts.
6. Carefully replace the terminals.
7. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).
10.2 Replacing the Heater
To replace the heater (item 3, fig. 9):
1. UnplugthePowerUnit.
2. Remove the six screws securing the
enclosure. Open the enclosure.
3. Remove the filter retainer and nut. Remove
Section 10 - Repair Procedures
WARNING
21