Gentherm Electri-Cool II User manual

Technology to the next degree™
ELECTRI-COOL® II
OPERATION AND TECHNICAL MANUAL
Model 767 Localized Cooling System
Gentherm Medical, LLC • 12011 Mosteller Road Cincinnati, Ohio 45241, U.S.A. www.gentherm.com

Gentherm Customer Relations
Gentherm Medical, LLC
Telephone [phone]
Toll-Free 1-800-989-7373
Fax [phone]
24-Hour Clinical Support 1-513-460-2038
Medical Technical Support 1-888-437-5608
Email [email protected]
Website: https://www.gentherm.com
Mailing Address: 12011 Mosteller Road
Cincinnati OH 45241
USA
Electri-Cool® II is a registered trademark of Gentherm Medical, LLC, Cincinnati, Ohio, USA.
© 2021, Gentherm Medical, LLC All rights reserved.
All other trademarks are the property of their respective owners.
Part No. 56269 Rev. V

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Electri-Cool II Model 767SECTION TITLE
Contents
1.0 Introduction ..............................................................1
1.1 Receiving and Inspection/ Important Safety Information .............................1
1.2 General Safety Precautions .......................................................1
1.3 General Product Description ......................................................1
1.4 Indications for Use ..............................................................2
1.5 Contraindications ...............................................................2
1.6 Transporting and Shipping .......................................................2
2.0 General Safety Precautions ................................................ 2
3.0 Warnings.................................................................3
4.0 Cautions .................................................................3
5.0 Symbols on the Device and in the Manual .................................... 5
6.0 Serial Number ............................................................7
7.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
7.1 Receiving Inspection and Setup .................................................. 7
8.0 Technical Help ............................................................7
9.0 Authorized European Representative.........................................7
10.0 Introduction ............................................................. 8
10.1 Before you call for service..........................................................8
11.0 Setup................................................................... 9
11.1 Equipment Set-Up ..............................................................9
11.2 Mounting the unit to a bed bracket ................................................9
11.3 Reservoir Filling Instructions .................................................... 10
11.4 Startup Instructions ............................................................ 10
11.5 Setting Temperature ........................................................... 10
11.6 Accessories.................................................................... 12
11.7 Pad Instructions ............................................................... 13
11.8 Disposal ...................................................................... 13
11.9 Cleaning (External)............................................................. 13
11.10 Storage ....................................................................... 14
12.0 Electromagnetic Emissions ................................................14
13.0 Maintenance ............................................................18
13.1 Overview ...................................................................... 18

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13.2 Inspection Frequency .......................................................... 18
13.3 Exterior Physical Inspection & Cleaning........................................... 18
13.4 Draining the Reservoir .......................................................... 18
14.0 Air Filter Inspection and Replacement.......................................19
14.1 Remove the Filter Retainer .....................................................20
15.0 Draining the Reservoir ................................................... 22
16.0 Troubleshooting Guide ................................................... 24
16.1 General .......................................................................24
16.2 Indicator Specifics .............................................................25
17.0 Service ................................................................ 26
18.0 ECII Interior Access...................................................... 27
18.1 Flow Test......................................................................28
18.2 Water Leak Test ................................................................28
18.3 Temperature Test ..............................................................28
18.4 Low Water Switch/Indicator Test .................................................29
18.5 Leakage Current Test ...........................................................30
18.6 Ground Continuity Test .........................................................30
18.7 Water Temperature Low-Limit Thermistor Test.....................................30
18.8 Internal Physical Inspection ..................................................... 31
19.0 Preventive Maintenance for Service Personnel............................... 33
20.0 Rear Enclosure and Reservoir Lid Replacement.............................. 38
20.1 Rear Enclosure and Reservoir Lid Removal .......................................39
20.2 Rear Enclosure and Reservoir Lid Installation ..................................... 41
21.0 Front Enclosure Replacement............................................. 43
21.1 Front Enclosure Removal .......................................................44
21.2 Front Enclosure Installation .....................................................45
22.0 Bottom Enclosure Replacement ........................................... 47
22.1 Bottom Enclosure Removal .....................................................48
22.2 Bottom Enclosure Installation ...................................................49
23.0 Equipotential Grounding Stud Replacement ................................ 50
23.1 Grounding Stud Removal .......................................................50
23.2 Grounding Stud Installation ..................................................... 51
24.0 Membrane Panel Replacement ............................................ 53
24.1 Membrane Panel Removal ......................................................54
24.2 Membrane Panel Installation....................................................55

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Electri-Cool II Model 767SECTION TITLE
25.0 Float Switch Replacement ................................................ 56
25.1 Float Switch Removal ..........................................................57
25.2 Float Switch Installation ........................................................58
26.0 Reservoir Replacement ...................................................61
26.1 Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
26.2 Reservoir Installation...........................................................63
27.0 Pump Replacement ..................................................... 64
27.1 Pump Removal ................................................................65
27.2 Pump Installation ..............................................................68
28.0 Quick Disconnect Panel Mount Couplings Replacement........................71
28.1 Quick Disconnect Removal ......................................................72
28.2 Quick Disconnect Installation.................................................... 74
29.0 Fuse Replacement .......................................................77
29.1 Fuse Removal .................................................................78
29.2 Fuse Installation ...............................................................79
30.0 Power Inlet and Wire Harness Replacement ................................. 80
30.1 Power Inlet Removal ........................................................... 81
30.2 Power inlet Installation .........................................................84
31.0 Control Board Replacement .............................................. 87
31.1 Control Board Removal .........................................................88
31.2 Control Board Installation.......................................................89
32.0 Power Supply Replacement............................................... 90
32.1 Power Supply Removal ......................................................... 91
32.2 Power Supply Installation .......................................................93
33.0 Thermoelectric (TE) Module Replacement .................................. 96
33.1 TE Module Removal............................................................97
33.2 TE Module Installation..........................................................99
34.0 Fan Motor Replacement ..................................................101
34.1 Fan Motor Removal ...........................................................102
34.2 Fan Motor Installation .........................................................103
35.0 Fan Guard Replacement................................................. 106
35.1 Fan Guard Removal ........................................................... 107
35.2 Fan Guard Installation ..........................................................110
36.0 Specifications ..........................................................113
36.1 Expected Service LIfe ..........................................................114
36.2 Replacement Parts.............................................................118

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37.0 Fluid Circuit Disinfection/Dry Storage Procedure ........................... 122
37.1 Draining the Electri-Cool II .....................................................122
37.2 Chemical Cleaning Circulation Chart ............................................122
37.2.1 Disinfection/Dry Storage Procedure.............................................122
38.0 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
38.1 General Safety and Electrical Safety.............................................124

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Electri-Cool II Model 767SECTION TITLE
List of Figures
Figure 1 Mounting the unit to a bed bracket ......................................9
Figure 2 Mounting the bed bracket to rear enclosure ..............................9
Figure 3 Electri-Cool II Membrane Control Panel .................................11
Figure 4 Step 1 Unplug power cord.............................................20
Figure 5 Step 2 Pry off retainer ................................................20
Figure 6 Step 3 Discard used filter .............................................20
Figure 7 Step 4 Place filter in retainer .......................................... 21
Figure 8 Step 5 Align tabs to slots ............................................. 21
Figure 9 Step 6 Press retainer into place........................................ 21
Figure 10 Step 1 Unplug power from mains ....................................22
Figure 11 Step 3 Open reservoir lid .............................................22
Figure 12 Step 4 Tip unit forward ...............................................22
Figure 13 Control board diagram................................................32
Figure 14 Detail A Operate Position .............................................32
Figure 15 Detail A Test Position .................................................32
Figure 16 Exploded view with callouts ...........................................35
Figure 17 Step 1 Unplug power cord.............................................39
Figure 18 Step 3 Remove two handle screws .....................................39
Figure 19 Step 4 Remove two base screws .......................................39
Figure 20 Step 5 Remove collar ................................................40
Figure 21 Step 6 Lift rear enclosure with lid up and away ..........................40
Figure 22 Step 1 Install enclosure and lid ........................................ 41
Figure 23 Step 2 Install reservoir collar .......................................... 41
Figure 24 Step 3 Install two base enclosure screws. ............................... 41
Figure 25 Step 4 Install two handle screws .......................................42
Figure 26 Step 2 Remove four screws ...........................................44
Figure 27 Step 4 Remove front enclosure ........................................44
Figure 28 Step 5 Disconnect ribbon cable .......................................44
Figure 29 Step 3 Install front enclosure. .........................................45

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Figure 30 Step 5 Reconnect ribbon cable........................................45
Figure 31 Step 5 Install front enclosure..........................................46
Figure 32 Step 5 Remove rubber feet ...........................................48
Figure 33 Step 1 Install feet ....................................................49
Figure 34 Step 2 Apply the BF label.............................................49
Figure 35 Step 3 Apply the GTIN label...........................................49
Figure 36 Step 1 Remove 1st Keps nut ...........................................50
Figure 37 Step 2 Remove ground wire and second Keps nut .......................50
Figure 38 Step 1 Insert stud .................................................... 51
Figure 39 Step 2 Add the green and gold ring .................................... 51
Figure 40 Step 3 Install Keps nuts 1 & 2..........................................52
Figure 41 Step 5 Attach ground wire and second Keps nut .........................52
Figure 42 Step 3 Unplug ribbon cable ...........................................54
Figure 43 Step 4 Push flat screwdriver through cable slot from the inside ...........54
Figure 44 Step 1 Thread cable through slot.......................................55
Figure 45 Step 4 Connect ribbon cable ..........................................55
Figure 46 Step 3 Disconnect J7 .................................................57
Figure 47 Step 4 Loosen reservoir insulation .....................................57
Figure 48 Step 5 Unscrew float switch mounting nut ..............................57
Figure 49 Step 1 GEMS orientation ..............................................58
Figure 50 Step 2 Thread wires through gasket ....................................58
Figure 51 Thread connector and wires through reservoir ...........................58
Figure 52 Step 4 Secure float switch mounting nut................................59
Figure 53 Step 5 Loosen reservoir insulation .....................................59
Figure 54 Step 6 Route wiring behind bracket ....................................59
Figure 55 Step 7 Attach connector to J7..........................................60
Figure 56 Step 5 Loosen two hose clamps .......................................62
Figure 57 Step 6 Remove tubing................................................62
Figure 58 Step 1 connect tubing to reservoir with clamps ..........................63
Figure 59 Step 3 Float switch wires position ......................................63
Figure 60 Step 4 Connect float switch to J7.......................................63

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Figure 61 Step 3 Unplug pump wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 62 Step 4 Remove the wire tie............................................65
Figure 63 Step 5 Remove EMI suppressor .......................................65
Figure 64 Step 7 Remove discharge tubing.......................................66
Figure 65 Step 5 Loosen two hose clamps .......................................66
Figure 66 Step 6 Unscrew pump bracket from base enclosure......................66
Figure 67 Step 8 Remove inlet tubing ...........................................67
Figure 68 Step 1 Remove pump from bracket.....................................67
Figure 69 Step 1 Mount pump to bracket.........................................68
Figure 70 Step 2 Mount bracket to base .........................................68
Figure 71 Step 3 slide tubing onto new pump ....................................68
Figure 72 Step 4 Tighten the hose clamps........................................69
Figure 73 Step 5 Install EMI suppressor .........................................69
Figure 74 Step 6 Wire tie below EMI suppressor ................................69
Figure 75 Step 7 Secure wires to bracket .........................................70
Figure 76 Step 8 Route wires behind bracket .....................................70
Figure 77 Step 9 Connect power wire connector to J5 .............................70
Figure 78 Step 4 Tubing at 90 degree elbow .....................................72
Figure 79 Step 5 Remove tubing from pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 80 Step 6 Slide retainer nuts up .......................................... 73
Figure 81 Step 7 Pull couplings out of enclosure .................................73
Figure 82 Slide retainer nuts onto tubing ........................................ 74
Figure 83 Step 6 Extend tubing through enclosure................................74
Figure 84 Step 7 Insert couplings into hose ......................................75
Figure 85 Step 8 Turn and align couplings .......................................75
Figure 86 Step 9 Tighten retaining nuts..........................................76
Figure 87 Step 11 Tape the exposed clamps ......................................76
Figure 88 Step 12 Apply electrical tape around insulation .......................76
Figure 89 Step 1 Unplug power .................................................78
Figure 90 Step 2 Open fuse door ...............................................78
Figure 91 Step 3 Note direction arrows ..........................................78

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Figure 92 Step 1 Place fuses into holders ........................................79
Figure 93 Step 2 Match arrow direction ..........................................79
Figure 94 Step 3 Locking tabs ..................................................79
Figure 95 Step 3 Plastic power inlet shroud ...................................... 81
Figure 96 Step 4 Remove retaining Keps nut and ground wires ..................... 81
Figure 97 Step 5 Disconnect harness from the power supply . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 98 Step 6 Remove suppressor............................................82
Figure 99 Step 7 Remove retaining screws .......................................83
Figure 100 Step 8 Power inlet removal 2 .........................................83
Figure 101 Step 2 Install power inlet .............................................84
Figure 102 Step 3 Connect control board wires to J2 ...............................84
Figure 103 Step 4 Install EMI suppressor .........................................84
Figure 104 Step 5 Route wire harness connector behind bracket.....................85
Figure 105 Step 6 Connect power supply .........................................85
Figure 106 Step 7 Attach all grounding wires ......................................85
Figure 107 Step 8 Reinstall plastic power inlet shroud..............................86
Figure 108 Step 3 Disconnect all 5 connectors.....................................88
Figure 109 Step 4 Remove three plastic screws ....................................88
Figure 110 Step 5 Remove three plastic washers (one shown) .......................88
Figure 111 Step 1 Remove three plastic washers (one shown) .......................89
Figure 112 Step 2 Reinstall three plastic screws ...................................89
Figure 113 Step 3 Connect all 5 connectors .......................................89
Figure 114 Step 4 Unscrew power supply from front bracket ........................ 91
Figure 115 Step 5 Control board power wire harness ............................... 91
Figure 116 Step 6 Remove Phillips screws from rear braket. ........................92
Figure 117 Step 7 Disconnect power supply wires to power inlet .....................92
Figure 118 Step 8 Remove wire tie on power supply................................92
Figure 119 Step 1 Connect power supply wires from power inlet .....................93
Figure 120 Step 2 Install two truss-head screws on rear bracket .....................93
Figure 121 Step 3 Connect fan wires to the power supply ...........................93
Figure 122 Step 4 Detail ........................................................94