Gaymar T/PUMP TP400 Series User manual

®
P/N 11203-000 5/01
T/PUMP®
TP400 Series
Heat Therapy System
SERVICE MANUAL
LISTED 304L
STANDARD (NORME)
C22.2 NO. 125 RISK
CLASS (CATEGORIE
DE RISQUES) NO. 2G

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
BEFORE YOU BEGIN . . .
T/PUMP, T/PAD, Mul••T••Pad, Clik-Tite, and Gaymar are registered trademarks of Gaymar Industries, Inc.
U. S. PATENT 4,068,870 © 2001. Gaymar Industries, Inc. All rights reserved. www.gaymar.com
READ AND UNDERSTAND THIS T/PUMP SERVICE
MANUAL AND ALL PRECAUTIONS (SEE PAGE 2) PRIOR
TO SERVICING THE T/PUMP.
The purpose of this manual is to provide operation, service, and repair
information for GAYMAR heat therapy pumps.
Check the shipping carton for damage immediately upon receipt. If package
damage is discovered, the device should be unpacked with the carrier's
agent present. Any claims for shortage or damage must be filed with the
delivering carrier by the purchaser. Do not return pumps damaged in
shipment to GAYMAR without contacting our Technical Service
Department for advice (see phone numbers below). If damaged goods are
returned to GAYMAR without notifying the carrier, GAYMAR will assume
the repairs will be made at the customer's expense.
RECEIVING INSPECTION
Merchandise returned to GAYMAR must be accompanied by a Return
Goods Number (RG#), issued by GAYMAR, authorizing goods to be
returned. Call Customer Service or Technical Service at
[phone]
1 800 828-7341
Advise model, serial number, and nature of problem. You will be given a
Return Goods Number (RG#).
The serial number can be found on the back of the T/Pump (see figure 2,
page 4).
TO RETURN PUMPS
TO FACTORY FOR
REPAIR OR EXCHANGE

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
1
CONTENTS
ILLUSTRATIONS
SAFETY PRECAUTIONS .......................................................... 2
INTRODUCTION....................................................................... 3
FEATURES .................................................................................. 4
SPECIFICATIONS ...................................................................... 5
OPERATING INSTRUCTIONS ................................................ 6
STORAGE AND CLEANING .................................................... 7
THEORY OF OPERATION ....................................................... 8
FUNCTIONAL CHECK AND SAFETY INSPECTION ....... 10
INSPECTION FORM ................................................................ 15
DISASSEMBLY / REASSEMBLY ............................................. 16
CALIBRATION ......................................................................... 19
TROUBLESHOOTING ............................................................ 21
REPLACEMENT PARTS LISTS .............................................. 28
WARRANTIES .......................................................................... 31
1 T/PUMP®HEAT THERAPY SYSTEM ...................................... 3
2 T/PUMP FEATURES/SPECIFICATIONS ................................ 4
3 CLIK-TITE®CONNECTORS..................................................... 6
4 T/PUMP COMPONENTS .......................................................... 9
5 MOTOR...................................................................................... 11
6 TPC1 TEST COVERS ............................................................... 22
7 FUNCTIONAL CHECK TEST DIAGRAM ............................ 23
8 CIRCUIT DIAGRAM FOR T/PUMP ....................................... 24
9 CIRCUIT DIAGRAM FOR TPC1 TEST COVERS ................ 25
10 EXPLODED VIEW OF T/PUMP ............................................. 26
11 PC BOARD ASSEMBLY........................................................... 27
CONTENTS

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
• Risk of explosion. Do not use in the presence of flammable
anesthetics.
• Risk of electric shock. Disconnect power before servicing
the T/Pump.
DANGER
SAFETY PRECAUTIONS
2
•Do not perform any powered tests with the reservoir empty.
Damage to the T/Pump may result.
CAUTION
•This device pumps warmed water through a pad. Set pad
temperature only as prescribed by and under the guidance of a
physician, and monitor the patient's temperature and skin
condition every 20 minutes or as directed by a physician. Fail-
ure to adhere to these warnings could result in patient
injury.
The following Groups/Conditions require additional surveillance:
WARNING
•Only qualified medical service personnel should repair the
T/Pump. Improper repair may result in death or serious
injury, equipment damage, or malfunction.
•Always perform the FUNCTIONAL CHECK AND SAFETY
INSPECTION (pp. 10-14) after making repairs and before returning
the T/Pump to patient use. Document your findings on the
INSPECTION FORM (p. 15). Improper repair may result in
death or serious injury, equipment damage, or
malfunction.
Group/Condition at risk Potential injury
Pediatric patients Hyperthermia/
hypothermia
Patients with impaired circulation Ischemia
Areas of application are under pressure Ischemia
In combination with topical solutions whose toxicity
may be affected by the application of heat Chemical injury
In combination with other heat sources Thermal injury

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series) INTRODUCTION
3
Figure 1 - T/Pump Heat Therapy System
Heat therapy is effective in the dilation of blood vessels, thereby increas-
ing the blood flow to the heated area. Heat therapy has a variety of uses,
the most common being treatment of aches and pains in joints and
muscles.
The GAYMAR T/Pump®Heat Therapy System provides a means of
applying heat therapy by supplying temperature controlled water through
a connector hose to a Gaymar T/Pad®. The hose is terminated in
easy-to-use Clik-Tite®connectors.
The T/Pad provides the interface for delivering the heat therapy. The
unique button design allows water to flow and provides trouble-free
operation when the pad is folded. This reduces the number of pads your
facility must keep in inventory. The pads are applied to the part
of the body requiring heat therapy, and the circulating water maintains
the pad at the set point temperature. The temperature setpoint is
key-operated to prevent tampering.
The T/Pads can be interconnected to provide therapy to more than one
body site at a time.
Single Pad Multiple Pads

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
Attached Hose 10 ft (305 cm) dual channel. Connectors have male/female
with Clik-Tite fittings (see fig. 3, p. 6) allowing pads to be interconnected,
Connectors providing therapy to more than one body site at a time
(fig. 1, p. 3).
Tip-over Turns heater off if pump is tipped.
Switch NOTE: This does not activate the OVER TEMP light.
Hospital ID A label is provided on the back of the T/Pump for your
Label convenience. Use a felt tip or ball point pen to add any
required hospital identification.
OVER TEMP Indicates the pump and heater have been turned off.
Light This light is activated by the two OVER TEMP safety
thermostats. Refer to the TROUBLESHOOTING section.
Circuit Breaker When the circuit breaker trips, the small button in
the center will extend 1/4", exposing a white band.
Refer to the TROUBLESHOOTING section.
OVER TEMP Either of two limit thermostats will shut off pump and heater
Safety if the high temperature limit is exceeded. The OVER TEMP
Thermostats light will glow. Refer to the TROUBLESHOOTING section.
FEATURES
FEATURES
Figure 2 - T/Pump Features/Specifications
4

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series) SPECIFICATIONS
Size (approx.) 8-1/8" x 5-5/8" x 6-1/4" (20.6 cm x 14.3 cm x 15.9 cm)
Weight (empty) 5 lbs, 2 oz (2.3 kg)
Reservoir capacity 51 oz (1500 ml) maximum
Flow rate 9 gph (34 lph) minimum with pad attached
Ambient operating 60°F to 90°F (15.6°C to 32.2°C)
temperatures
Storage temperatures –30°F to 160°F (–34.4°C to 71.1°C)
(empty)
Temperature setpoint 85°F to 105°F (29.4°C to 40.6°C)
range
Average operating ±2°F at 105°F setting
temperature accuracy
Power cord 18 AWG, 3 conductor, 9 ft (274 cm), Type SJT
with molded, hospital grade plug
Circuit breaker 3 amperes
1st backup limit Bimetallic (trip point fixed)
thermostat 108°F to 115°F (42.2°C to 46.1°C)
(manifold mounted)
2nd backup limit Bimetallic (trip point fixed)
thermostat 108°F to 122°F (42.2°C to 50°C)
(well mounted)
Current leakage 100 microamperes* maximum
* applies to all models except TP420,
which is 200 microamperes maximum
Ground resistance 0.5 ohm maximum
Electrical requirements TP400* TP401 TP420
Voltage (VAC) 120 100 220
Frequency (Hz) 60 50/60 50/60
Current (amps) 1.8 2.0 1.0
Power req'd (watts) 200 200 200
* Tested to UL 544 and
CSA C22.2, No. 125
SPECIFICATIONS
5

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
6
OPERATING INSTRUCTIONS
START-UP PROCEDURE
CLIK-TITE®CONNECTORS:
To attach Clik-Tite connectors from hose to
pad:
1. Insert male fittings into female fittings
with a twisting motion (figs. 3A and 3B).
2. When fittings are fully inserted, snap
locking ring into place (figs. 3C and 3D).
3. To disconnect, simply reverse the
procedure.
4. To open or close the hose pinch clamps:
•Open the clamp by pushing the
serrated end (fig. 3E).
•Close the clamp by pressing the clamp
together (fig. 3F).
NOTE: Refer to figure 1 (p. 3) and
item 9 (p. 7) when connecting
multiple pads.
1. Before filling, always attach a T/Pad to the T/Pump connector hose.
Unkink pad and hose. Open hose clamps.
2. Open the fill cap on top of the pump. Fill the pump with room
temperature (i.e., not hot) distilled water to the operating level
indicated on the side of the pump. NOTE: Using tap water will
decrease the life of the pump.
3. Insert temperature setting key. Set temperature as prescribed by the
physician. Remove key to prevent tampering.
4. Plug T/Pump into a properly grounded outlet.
5. Turn on the power switch. The selected water temperature will be
reached in approximately 20 minutes.
6. If the water level drops below the operating level, add water.
Do not overfill. Overfilling can result in reduced pump motor
life.
7. Apply T/Pad to the patient. Follow T/Pad instructions.
8. For specified performance, keep the pump at or above the level of the
pad.
9. If the pump is placed below the pad(s), water will drain into the pump
when it is shut off. If the pump has been overfilled or if multiple pads
are connected, excess water can leak out onto the floor or cause
reduced motor life.
Figure 3E–3F—Hose Pinch Clamps
3E 3F
Figure 3A–3D—Clik-Tite®Connectors

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
7
Disconnect pad. Connect ends of the connector hoses together. Open
hose clamps. Leave water in the reservoir. To prevent hose kinks, coil the
hose rather than folding it. Fasten the hose and cord with strap.
Disconnect pad. Connect ends of the connector hose together. Open hose
clamps. Add 1/4 ounce AirKem A-33, GAYMAR MTA33 germicidal or
equivalent to water already in reservoir. Run for two (2) minutes. Drain
pump. To prevent hose kinks, coil the hose rather than folding it. Fasten
the hose and cord with strap and store pump.
Unplug the power cord. Disconnect the pad or hoses from one another,
keeping hoses at or above the level of the T/Pump. Remove the fill cap and
invert the T/Pump over a sink. When all fluid has drained from the hoses
and reservoir, replace the fill cap and connect the hoses together.
Unplug the power cord.
To clean the external surfaces, use a non-abrasive cleaning solution (such
as warm, soapy water) and a damp cloth.
To clean the fluid system, drain the pump. Fill the reservoir to the operat-
ing level indicated on the side of the pump. Add 1/4 ounce GAYMAR
catalog MTA33 germicidal or equivalent. Set the temperature indicator to
its lowest setting (fully counterclockwise). Start the
T/Pump and circulate the solution for one hour. Drain the solution and
refill the pump with distilled water. Using distilled water retards algae
growth and mineral buildup.
Change the distilled water monthly or more often depending upon use.
For best results use only GAYMAR T/Pads®or Mul••T••Pads®. The unique
button design allows water to flow and provides trouble free operation
when the pad is folded. This reduces the number of different sizes of pads
your facility must keep in inventory. The T/Pads can be interconnected to
provide therapy to more than one body site at a time (see fig. 1, p. 3). For
a brochure listing the various T/Pads, contact the GAYMAR Customer
Service Department (see inside cover for telephone numbers).
An optional bed bracket (model TP20A) is available to mount the T/Pump
on the footboard of a bed.
Storage (Short term)
Storage (Long term)
Draining
Cleaning
Pads / Accessories
STORAGE/CLEANING
SHUTDOWN PROCEDURE 1. Turn off pump before disconnecting pad. Close hose clamps. To
prevent water spillage, always disconnect pad from pump with
connectors raised above the level of the pad and pump.
2. Connect the T/Pad Clik-Tite connectors together.
3. Connect the ends of the T/Pump connector hose together.
STORAGE AND CLEANING

REFERENCE PRINT
SERVICE MANUAL
T/PUMP (TP400 Series)
8
There are four devices that control the operation of the heater in the
GAYMAR T/Pump:
•The temperature controller is thermistor actuated (fig. 4, item 1, p. 9).
This controller is adjustable over a temperature range of 85°F to 105°F
(29.4°C to 40.6°C). The desired water temperature is set with a special
removable key (fig. 4, item 7). To prevent unauthorized temperature
setting changes, remove the key after the temperature has been set.
•The manifold backup limit thermostat (fig. 4, item 9) is mounted on the
brass manifold block (fig. 4, item 8). This thermostat senses water
temperature flowing to the pad and will shut off the pump and heater
and activate the OVER TEMP light if the water temperature exceeds
specific limits. The purpose of the manifold backup limit thermostat is to
prevent the pump from providing water at too high a temperature to
the pad.
•The well backup limit thermostat (fig. 4, item 5) is mounted on the brass
plate (fig. 4, item 11) that extends along and under the heater (fig. 4,
item 4) near the bottom of the reservoir. This thermostat senses water
temperature in the reservoir and will shut off the pump and heater and
activate the OVER TEMP light if the reservoir temperature exceeds
specific limits. The purpose of the well backup limit thermostat is to
both prevent the pump from providing water at too high a temperature
to the pad and to protect the pump from high temperature damage due
to a low water level.
•The tip-over switch (fig. 4, item 2; see also fig. 11, item 64, p. 27) is
mounted on the PC board. This mercury-type switch will shut off the
heater if the pump is tipped more than 45° from the vertical position.
NOTE: The tip-over switch does not shut off the pump
motor or activate the OVER TEMP light.
The pump (fig. 4, item 12) is a sump configuration driven by an impedance
protected, shaded pole AC motor (fig. 4, item 6).
The return hose fitting (fig. 4, item 10) is machined internally to act as an
orifice. This maintains a back pressure in the pad to make it resistant to
flow restrictions.
WATER TEMPERATURE
CONTROL
THEORY OF OPERATION
FLUID SYSTEM