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

Section 7 - Functional Check and Safety Inspection (cont’d)
7.3 Power Switch
Check the power switch light:
1. Plug in the Power Unit. Turn the power switch
on.
2. Verify that the power switch is lit.
3. Verify the Power Unit starts in the 32°C heat
setting.
7.4 Temperature Settings Switches
Examine the overall condition of the control panel:
1. Select each of the five temperature settings.
Verify that the appropriate indicator for each
lights.
7.5 Thermostat and REMOVE FROM
USE Alert
Test the Patient Limit Thermostats and REMOVE
FROM USE Alert.
The following procedure describes two different
approaches for measuring the trip points
(actuation temperatures) of the Power Unit's
patient limit thermostats. There are two patient
limit thermostats (item 17, fig. 11, p. 26) within
the Power Unit and each must be tested. The
TC20 Test Tool helps simplify these tests. Steps
1 to 20 (pp. 9-11) should be followed when a
TC20 Test Tool is available. For those facilities not
having access to a TC20, follow steps 21 to 50
(pp. 12-13).
NOTE: A third thermostat, the heater overtemp
thermostat (item 25, fig. 11, p. 26), is provided
to protect internal components in the event of a
motor blockage or failure. It does not need to
be function tested.
7.5.1 TC20 Test Tool Procedure
(steps 1 to 20) [see fig. 10, p. 25, for
TC20 Test Tool part number]
1. Unplug the Power Unit.
Always unplug the Power Unit
before attaching or removing the
TC20 Test Tool and when resetting
thermostats. Failure to unplug the
Power Unit could result in
electrical shock and cause death
or serious injury.
2. Remove the six screws on the back of the
unit. Carefully separate the two halves of the
enclosure.
3. Connect the TC20 Test Tool (fig. 5) to the
5-pin field test connector on back of the PC
board and route the TC20 Test Tool cable out
through the opening in the bottom of the unit
(see fig. 10, p. 25). Close the two halves of the
enclosure and temporarily secure it closed
with adhesive (duct) tape. Plug in the power
unit.
9
Figure 5 - TC20 Test Tool
(for schematic, see figure 12, p. 27)
HEAT
S3S2
OVERTEMP
THERMOSTAT
BYPASS
WARNING

10
Section 7 - Functional Check and Safety Inspection (cont’d)
Figure 6 - Temperature sensor location
4. Set the two TC20 Test Tool toggle switches as
follows:
•THERMOSTAT BYPASS -- place in center
position;
•HEAT/OVERTEMP -- place in HEAT
position.
5. Locate the air temperature sensor at the center
of the end of the hose (fig. 6A). Secure the
sensor with adhesive tape. Verify that the
sensor is located at the center of the hose.
6. Connect the hose to a Model TC1050, TC2050,
TC2052, or TC2054 Quilt (fig. 6B).
7. Turn the Power Unit on. Select the 46°C
setting.
8. Run the Power Unit for 5 to 10 minutes at the
46°C setting. The temperature will oscillate.
During this time interval, familiarize yourself
with the following steps 9 through 14. Have a
stopwatch ready.
9. Place the HEAT/OVERTEMP switch to
OVERTEMP. The temperature should start to
increase. When the air temperature reaches
48°C, start the stopwatch.
10. Allow the Power Unit to heat until either the S2
or S3 Test Tool thermostat indicator is lit. Stop
the stopwatch and note the highest temperature
displayed. This is the upper limit temperature for
one of the thermostats. Record the time and
temperature on the INSPECTION FORM.
Verify that the REMOVE FROM USE light is lit.
NOTE: It is acceptable if both thermostats trip
simultaneously, in which case the S2 and S3
indicators will both be off. If this occurs,
record the elapsed time and temperature.
Verify that the REMOVE FROM USE indicator is
lit. Verify that both the S2 and S3 indicators
light by toggling the THERMOSTAT BYPASS
switch from the S2 to S3 position. (If both
thermostats have tripped, skip steps 11-14
and proceed to step 15.)
11. Switch the TC20 THERMOSTAT BYPASS to
whichever thermostat (S2 or S3) is lit. This will
short out the thermostat which opened first so
that the second thermostat can be tested.
Switch the TC20 from OVERTEMP to HEAT to
allow the Power Unit to return to normal
operating temperature before testing the
second thermostat.
12. Run the Power Unit again for 5 to 10 minutes
in the 46°C setting. The temperature will
oscillate. Have a stopwatch ready.
13. Place the OVERTEMP/HEAT switch to
OVERTEMP. The temperature should start to
increase. When the air temperature reaches
48°C, start the stopwatch.
14. Continue to monitor the TC20 Test Tool until the
second thermostat indicator is lit. Stop the
stopwatch and note the highest temperature
displayed. This is the upper limit temperature for
the other thermostat. Record the time and
temperature on the INSPECTION FORM
Figure 6A - Hose detail, showing sensor location Figure 6B - Test setup

(table 2, pp. 16-17). Plot these values on table
2, page 18.
Verify that the REMOVE FROM USE light is lit.
15. Thermostat trip acceptance
Both thermostats must trip within the
acceptance window (see table 2, p. 18).
If this condition is not met, do not put the
Power Unit in service. Contact your dealer for
assistance.
16. Unplug the power unit. Open the enclosure
to allow the Power Unit to cool for 5-10
minutes.
17. Locate the two patient limit thermostats (item
17, fig. 11, pp. 26). Reset S2 by gently
pressing the center reset button.
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.
NOTE: Use care when resetting the
thermostats since the power terminals are
delicate. Avoid flexing the terminals.
Thermostats with loose terminals should
be replaced and retested.
18. Press the center reset button of S3. Verify it
has reset (indicated by an audible "click" and
tactile feedback). If it "clicks", proceed to
step 19.
If you don't hear a "click", then what was
assumed to be the patient limit thermostat S3
tripping was actually the heater overtemp
thermostat S4 in the same circuit. This will
rarely occur. If it has occurred, proceed as
follows:
a. Remove the filter retainer and nut.
Remove the filter. Jumper out the S4
thermostat. Replace the filter, filter
retainer and nut.
b. Run the Power Unit for 5 to 10 minutes
in the 46°C setting.
c. Bypass S2 by placing the
THERMOSTAT BYPASS switch in the S2
position. Place the HEAT/OVERTEMP
Switch to OVERTEMP. Allow the Power
Unit to operate. When the air
temperature reaches 48°C, start the
stopwatch.
d. Allow the Power Unit to heat until the
S3 thermostat indicator is lit. Stop the
stopwatch and note the highest
temperature displayed. This is the
upper limit temperature for the S3
thermostat. Record the elapsed time
and temperature.
e. Verify that the REMOVE FROM USE
light is lit.
f. The S3 thermostat must trip within the
acceptance window (see table 2, p.
18). If this condition is not met, do not
put the Power Unit in service. Call
Gaymar's Technical Service
Department for assistance (see back
cover for telephone numbers).
g. Unplug the Power Unit.
h. Open the enclosure and allow the
Power Unit to cool for 5-10 minutes.
i. Remove the filter retainer and nut.
Remove the filter. Remove the jumper
from the S4 thermostat. Press the S4
reset button and insure it is reset.
Replace the filter, filter retainer, and
nut.
j. Reset both the S3 and S2 thermostats
by pressing their center reset buttons.
(The S2 thermostat may have
retripped.)
19. Remove the TC20 Test Tool.
After performing the preceding test
procedure, verify that the TC20 Test
Tool and all jumpers have been
removed before returning the Power
Unit to patient use. Failure to do so
may result in death, serious injury, or
equipment malfunction.
20. Proceed to the FILTER SWITCH TEST
(section 7.6, p. 14).
Section 7 - Functional Check and Safety Inspection (cont’d)
11
WARNING
WARNING

7.5.2 ALTERNATE Test Jumper
Procedure (steps 21 to 50)
21. Unplug the Power Unit.
Always unplug the Power Unit
before attaching or removing
jumpers and when resetting
thermostats. Failure to unplug the
Power Unit could result in
electrical shock and cause death
or serious injury.
22. There are two patient limit thermostats
within the Power Unit and each must be
tested. One 16 gauge insulated stranded
wire jumper with alligator clips will be
required. To help remember to remove the
test jumper, label a LARGE, distinctive tag
“REMOVE AFTER TEST” and tie the tag to
the jumper.
Remove the six screws on the back of the
unit. Install a jumper across thermostat S3
(item 17, fig. 11, p.26). Temporarily secure
the two halves of the enclosure together with
adhesive (duct) tape.
23. Locate the air temperature sensor at the
center of the end of the hose (fig. 6A, p. 10).
Secure the sensor with adhesive tape. Verify
that the sensor is located at the center of
the hose.
24. Connect the hose to a Model TC1050,
TC2050, TC2052, or TC2054 Quilt (fig. 6B,
p. 10).
25. Plug in the Power Unit and turn it on. Select
the 46°C setting. Run the Power Unit for
5 to 10 minutes. The temperature will
oscillate. During this time interval, familiarize
yourself with the following steps 26 through
31, so that the procedure can be
accomplished quickly, without letting the
Power Unit cool.
NOTE: Perform the following steps 26
through 31 as quickly as possible, to
prevent the Power Unit from cooling
down:
26. Unplug the Power Unit. Carefully separate the
enclosure slightly.
27. Unplug the thermistor (item 12, fig. 10, p. 25)
from the back of the control board.
NOTE: The power resistor on the back side
of the PC board may be hot to touch.
28. Put the enclosure back together and secure
it with adhesive (duct) tape.
29. Plug in the Power Unit and turn it on. Leave
unit in 32°C temperature setting. Have a
stopwatch ready.
NOTE: Do not set the TEMPERATURE
SETTINGS switch to fan only since this
setting disables the heater.
30. The temperature should increase. When the
air temperature reaches 48°C, start the
stopwatch. The Power Unit will heat until the
S2 thermostat trips. When this happens, the
blower and heater will shut off. Stop the
stopwatch and note the highest temperature
displayed. This is the upper limit temperature
for one of the thermostats. Record the time
and temperature on the INSPECTION FORM
(table 2, pp. 16-17).
31. Verify that the REMOVE FROM USE light is
lit.
32. Unplug the Power Unit.
33. Open the enclosure and allow the Power Unit
to cool for 5-10 minutes.
34. Locate the two patient limit thermostats
(item 17, fig. 11, p. 26). Gently press the
reset button in the center of each
thermostat. Move the a jumper across
thermostat S2.
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.
Section 7 - Functional Check and Safety Inspection (cont’d)
12
WARNING
WARNING

NOTE: If both thermostats reset, both
thermostats have tripped. This is
acceptable.
NOTE: Use care when resetting the
thermostats since the power terminals are
delicate. Avoid flexing the terminals.
Thermostats with loose terminals should
be replaced and retested. Be certain the
thermostats have cooled for 5-10 minutes
before resetting.
NOTE: If thermostat S2 does not reset, the
heater overtemp thermostat has tripped.
In the unlikely event that this has
occurred, perform the following:
a) remove the filter retainer and nut;
b) remove the filter;
c) jumper the S4 heater overtemp
thermostat; and
d) replace the filter, filter retainer, and nut.
Return to step 25.
35. Reconnect the thermistor to the control
board.
36. Put the enclosure back together and secure
it with tape.
37. Plug in the Power Unit. Turn it on.
38. Run the Power Unit for 5-10 minutes in the
46°C setting to stabilize the system
temperature.
NOTE: Perform the following steps 39 through
44 as quickly as possible, to prevent the Power
Unit from cooling down:
39. Unplug the Power Unit. Carefully separate
the enclosure slightly.
40. Unplug the thermistor (item 12, fig. 10, p.
25) from the back of the control board.
41. Put the enclosure back together and secure
it with tape.
42. Plug in the Power Unit and turn it on. Leave
unit in 32°C temperature setting. Have a
stopwatch ready.
NOTE: Do not set the TEMPERATURE
SETTINGS switch to fan only since this
setting disables the heater.
43. The temperature should start to increase.
When the air temperature reaches 48°C, start
the stopwatch. Allow the Power Unit to heat
until thermostat S3 trips. Stop the stopwatch
and note the highest temperature displayed.
This is the upper limit temperature for
thermostat S3. Record the time and
temperature on the INSPECTION FORM
(table 2, p. 17). Plot these values on table 2,
page 18.
44. Verify that the REMOVE FROM USE light is lit.
45. Unplug the Power Unit.
46. Open the enclosure and allow the Power Unit
to cool for 5-10 minutes.
47. Thermostat trip acceptance
Both thermostats must trip within the
acceptance window (see table 2, p. 18).
If this condition is not met, do not put the
Power Unit in service. Contact your dealer for
assistance.
48. Remove the jumper from the patient limit
thermostat.
If a jumper was used on the S4 heater
overtemp thermostat, remove the filter
retainer, nut, and filter. Remove the jumper
from S4. Reset S4 (indicated by an audible
"click" and tactile feedback). Replace the filter,
filter retainer, and nut.
After performing the preceding test
procedure, verify that all test jumpers
have been removed before returning
the Power Unit to patient use.
Failure to remove the test jumper
may result in death, serious injury, or
equipment malfunction.
49. Reconnect the thermistor connector.
(continued)
Section 7 - Functional Check and Safety Inspection (cont’d)
13
WARNING

6. Unplug the Power Unit. Install filter. (Install
new 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). Record the hour timer
reading onto the new filter label. Reattach
filter retainer and nut.
The HEPA filter must be seated
properly. Failure to install the filter
correctly will prevent it from
functioning properly, and could
allow unfiltered air to reach the
patient and cause injury.
7. Replace the six screws holding the
enclosure together.
7.7 Quilt Temperature
Verify temperature output at each heat setting:
1. Prepare the Power Unit test setup, if it has
not been previously prepared:
a. Locate the air temperature sensor at
the center of the end of the hose (fig.
6A, p. 10). Secure the sensor with
adhesive tape. Verify that the sensor
is located at the center of the hose.
b. Connect the hose to a Model TC1050,
TC2050, TC2052, or TC2054 Quilt
(fig. 6B, p. 10).
c. Plug in the Power Unit and turn it on.
2. Set the TEMPERATURE SETTINGS switch to
32°C. Run the Power Unit for 5 minutes.
After 5 minutes, note the two highest and two
lowest temperature readings. Record the
average of these four temperatures on the
INSPECTION FORM (table 2, p. 17).
Allowable 32°C temperature:
30.6°C to 33.9°C average
3. Repeat step 2 for 38°C setting. Average
temperatures and record.
Allowable 38°C temperature:
36.1°C to 39.4°C average
50. Reset the thermostats by gently pressing the
center reset buttons.
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.
NOTE: Use care when resetting the
thermostats since the power terminals are
delicate. Avoid flexing the terminals.
Thermostats with loose terminals should
be replaced and retested.
7.6 Filter Replacement and Filter
Switch Test (every 12 months or 1000
operating hours, whichever occurs first)
1. Unplug the Power Unit. Separate the two
halves of the enclosure. Lay the Power Unit
on its back.
2. Remove the filter retainer and nut. Remove
the filter.
3. Put the enclosure back together and secure it
with tape.
4. Plug in the Power Unit. Turn it on. Verify that
the blower does not start and that the
REMOVE FROM USE light is lit.
5. A timer which counts total running hours is
located inside the Power Unit for use by
service personnel. Timer readings may be
used to track HEPA filter usage intervals. To
read the hour timer:
a. Unplug the Power Unit. Separate the two
halves of the enclosure again. Locate the
hour timer (see figure 10, p. 25). Plug in
the Power Unit and turn it on. Read the
hour timer and record the total running
hours on the INSPECTION FORM.
b. Turn the Power Unit off.
Section 7 - Functional Check and Safety Inspection (cont’d)
14
CAUTION
WARNING

4. Repeat step 2 for 43°C setting. Average
temperatures and record.
Allowable 43°C temperature:
41.7°C to 45.0°C average
5. Repeat step 2 for 46°C setting.
Allowable 46°C temperature:
44.7°C to 47.5°C average
6. If the temperatures in steps 2 through 5 are
not correct, do not put the Power Unit into
service. Contact your dealer for assistance.
7. Unplug the Power Unit.
7.8 Ground Resistance
Check grounding resistance:
1. Use a current leakage/ground resistance
tester to measure the resistance between the
grounding pin on the power entry module
and the I. V. pole clamp. An unplated area on
the underside of the I. V. pole clamp has
been provided for this test. Record the value.
2. The value should be less than 0.5 ohms.
7.9 Current Leakage
Measure current leakage:
1. Measure and record the maximum earth
current leakage (ground open). An unplated
area on the underside of the I. V. pole clamp
has been provided if needed for this test.
Measure at all combinations of:
•line polarity
•neutral open/closed
2. The current leakage should not exceed 100
microamperes in any condition.
Section 7 - Functional Check and Safety Inspection (cont’d)
15
7.10 Completing the Functional Check
and Safety Inspection
If the Power Unit has passed the FUNCTIONAL
CHECK AND SAFETY INSPECTION for all
requirements of procedures 7.1 through 7.9, the
Power Unit should be considered operational and
suitable for return to service.
This completes the recommended FUNCTIONAL
CHECK AND SAFETY INSPECTION for the TC3001
series Power Unit.

Section 8 - Inspection Form
16 Table 2 - Functional Check / Inspection Form (p. 1)
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Section 8 - Inspection Form (cont’d)
Table 2 - Functional Check / Inspection Form (p. 2) 17
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Table 2 - Functional Check / Inspection Form (p. 3)
Section 8 - Inspection Form (cont’d)
18
48 50 52 54 56 58 60 62 64 66 68 70
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
Time (Seconds)
Hose output air temperature (°C)
Fail (Thermostat trip point too high)
Fail (Thermostat trip point too low)
PASS (Safe range)