Gaymar Thermacare TC3001 User manual

Service Manual
®
Thermacare®TC3001
Convective Warming Unit
P/N 11897-000 02/06

Before you begin . . .
Important
•Refer to the TC3001 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
Unit (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
Fan only (no heat)
32°C
38°C
43°C
46°C
Do not use in operating room
(OR) or Intensive Care Unit (ICU)
Off-on switch
REMOVE FROM USE
(indicator light, amber color)
Symbols used within this manual:
16°C - 29°C
Ambient operating temperature
© 2000. Gaymar Industries, Inc. All rights reserved.
Gaymar and Thermacare trademarks are registered in
U. S. Patent and Trademark Office. www.gaymar.com

1
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 TC20 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 TC20 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 TC20 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

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 TC20 Test Tool
or any installed test jumpers have been
removed before returning the Power Unit
to patient use.
Failure to remove the TC20 Test Tool or
test jumpers may result in death,
serious injury or equipment malfunction.
• Always unplug the Power Unit before
attaching or removing the TC20 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 TC3001 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
properly grounded outlet.
•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 1 meter.
Otherwise, the Power Unit could tip over.
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 TC3001 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.
Section 2 - Repair Policy
3
2.4 Return Authorization
Please contact your local dealer.

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 TC3001 at a
preset high limit temperature. The heater
element and blower will remain off until the
thermostat is manually reset.
HeaterOvertemp
Heater overtemp thermostat will shut off the
TC3001 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 a nonwoven layer bonded
to a plastic film.
Quilt material meets U. S. flammability standards:
•NFPA 702 “Normal Flammability”
•CPSC Part 1632
•California Title 19, Subchapter 7
Clear drape material meets NFPA 702 “Normal
Flammability.”
Section 3 - Specifications
3.0 Specifications
3.1 Physical
Dimensions 42 cm x 28 cm x 27 cm
Weight 6.8 kg
Enclosure Thermoplastic
Filter HEPA filtration to 0.2 micron
particle size
3.2 Electrical
Input 100 V (+10%, –5%),
50/60 Hz, 14 amps max
Motor 1/25 HP, single phase
Heater 1200W heating element
Power Cord 4.6 meters, 14 AWG cord with
hospital grade plug.
Circuit Breaker 15 amp
Current Leakage (Earth)
100 microamps max.
Ground Resistance
0.15 ohms nominal;
0.5 ohms maximum
Ambient Operating Temperature
16°C to 29°C
4
Table 1 - Air Temperatures
Temperature Setting Temperature
Fan only
32°C
38°C
43°C
46°C

Section 4 - Theory of Operation
4.0 Theory of Operation
4.1 Convective Warming 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 Unit
(Power Unit) and a disposable Quilt. A connecting
hose conducts heated air from the Power Unit to
the Quilt.
5
IV Pole
Clamp
Figure 3 - Pole mounting height limit
1 meter
maximum
Figure 1 - Convective Warming System
4.2 TC3001 Power Unit
The TC3001 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. It
can also mount to an I. V. pole or optional
accessory stand using the I. V. pole clamp (see
figs. 2A/2B). Output air temperatures may be set
to one of five temperature settings: fan only,
32°C, 38°C, 43°C, or 46°C.
When using an I. V. pole, do not mount the
Power Unit higher than 1 meter (see fig. 3).
Otherwise, the Power Unit could tip over.
CAUTION
Figure 2A - I. V. Pole or Stand mounted
Figure 2B - Bed rail mounted
Bedrail
Hook

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.
32°C 38°C 43°C 46°C

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).
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 32°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 -- fan only, 32°C, 38°C, 43°C, or 46°C.
•[Power Interruption] If electrical power is
interrupted momentarily, the existing
temperature setting will remain. If electrical
power remains off, the TC3001 will default to
the 32°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

•Stopwatch
•Adhesive Tape
• TC20 Test Tool*, or two 16 gauge insulated
Test Jumpers
* The TC20 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 your dealer 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, and Strain Relief
Examine the plug, line cord, and strain relief:
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: 10°C to 71°C
System accuracy: ± 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: 100 VAC ± 2 ,
21°C-24°C ambient (with heater on); this
may require the use of a variable
transformer.
•#2 Phillips screwdriver
•Current Leakage / Ground Resistance Tester
•Model TC1050, TC2050, TC2052, or TC2054
Quilt
Section 7 - Functional Check and Safety Inspection
8