T/PUMP® - Instrulife
Contents
1. 8 Manifold backup limit thermostat TE 5 Well backup limit thermostat 1 PC board 3 Temperature Temp controller setting key TOP 4 Heater 11 Pump E 10 Brass plate heat shield BOTTOM STORAGE CLEANING SERVICE MANUAL TP472 TIPUMP Storage Short term 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 Storage Long term Disconnect pad Connect ends of the connector hose together Open hose clamps Add 1 4 ounce GAYMAR catalog REF 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 Draining Disconnect the T Pump from AC power 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 Cleaning Unplug the T Pump prior to cleaning To clean the external surfaces use a non abrasive cleaning solution such as warm soapy water and a damp cloth To clean th2. 21 6 FUNCTIONAL CHECK TEST DIAGRAM 22 7 CIRCUIT DIAGRAM FOR T PUMP 23 8 CIRCUIT DIAGRAM FOR TPCI TEST COVER 24 9 EXPLODED VIEW 25 10 PC BOARD 29 SAFETY PRECAUTIONS SERVICE MANUAL TP472 TIPUMP DANGER Risk of electric shock Disconnect power before servicing the T Pump WARNING This device pumps warmed water through a pad Set pad tem perature only as prescribed by and under the guidance of a physician Monitor the patient s temperature and skin condition every 20 minutes or as directed by a physician Failure to adhere to these warnings could result in patient injury The following Groups Conditions require additional surveillance Group Condition at risk Potential injury Pediatric patients Hyperthermia hypothermia Patients with impaired circulation Areas of application are under pressure In combination with topical solutions Chemical whose toxicity may be affected by the injury application of heat In combination with other heat sources Thermal injury 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 S
3. KC KAC Fe mee pma r Fo remm ras e omon e eses mess em Pie fossa fowo C ee EA Cw osti MN te ren SNOT asee ANTE Pa msan ere phe 62536607 well backup limit thermostat is part of the tray assembly Do not attempt to drill out the old thermostat A leakproof installation is not possible Install tray assembly see p 17 26 SERVICE MANUAL REPLACEMENT PARTS TP472 TIPUMP Item 25 09808 000 Water Level Label included with item 24 26 90385 000 Suction Cup 27 10184 000 ES Ratings Label 81002 00 EZ Tubing 1 4 ID x 9 cm long P N Description 28 eo 29 03394 00 Manifold Fitting 03881 00 ES Brass Bearing Washer 90342 00 EX Switch 250V see note below 30 99 UJ 2 mas ora ungana _ seam rom KE 3 34 35 08086 000 Hose Assembly includes items 38 and 39 2 Screw 4 40 x 3 8 SST 36 91275 027 37 03975 00 EX Male Clik Tite included with item 35 03884 000 EZ Female Clik Tite included with item 35 0 38 03887 000 39 40 09667 000 Power Entry Module Fuseholder 90695 021 2 Fuse Power Cord Continental Europe 002 Power Cord United Ki
4. ES 38 D 4 i Em ER Z dai pl sa U 13A NHS X388DEv3 ler mE 9 D I ps D amp 400 8102 WHC 591 i3 EU i AHn2H3 NEUE 1 5 on emm 23 CIRCUIT DIAGRAMS TEST COVERS SERVICE MANUAL TP472 TIPUMP Figure 8 CIRCUIT DIAGRAM FOR TPCI TEST COVER PIN 06520 000 to connect refer to figure 5 LIMIT THERMOSTAT PRIMARY TEST COVER SHORTING SWITCH SHORTING SWITCH OFF spor SPDT 52 INDICATOR S1 am A3 T QU AAN ANN 49 WELL MANIFOLD THERMOSTAT LED THERMOSTAT LED YEL vio ORG RED BLU INSULATED 27 Va ALLIGATOR E 171 GLIP YEL VIO ORG PC RED BLU HEATER BOARD WELL MANIFOLD TEMPERATURE THERMOSTAT THERMOSTAT CONTROLLER N NE NI L ZPUMP OVER TEMP LIGHT 115 VAC TO MOTOR COMMON 24 EXPLODED VIEW 20990 Figure 9 EXPLODED VIEW SERVICE MANUAL TP472 TIPUMP 52 see figure 10 55 5 25 39 38 34 33 32 28 27 26 REPLACEMENT PARTS PEE TP472 TIPUMP ls erna estas NN
5. 1500 ml maximum Use only an international harmonized 3 wire cordset using cordage approved to HD 21 conductor size 1 00 mm 5x20 mm 1 6 Type Sheet 111 220 240 50 Hz 1 6A 15 6 C to 32 2 C Type Class 1 grounded equipment suitable for continuous operation Not classified for protection against harmful ingress of liquid Equipment not suitable for use in the presence of a flammable anaesthetic mixture with air or with oxygen or nitrous oxide THEORY OF OPERATION SERVICE MANUAL TP472 TIPUMP WATER TEMPERATURE CONTROL FLUID SYSTEM There are four devices that control the operation of the heater in the GAYMAR T Pump The temperature controller is thermistor actuated fig 3 item p 7 This controller is adjustable over a temperature range of 30 to 41 The desired water temperature is set with a special removable key fig 3 item 3 To prevent unauthorized temperature setting changes remove the key after the temperature has been set The manifold backup limit thermostat fig 3 item 8 is mounted on the brass manifold block fig 3 item 7 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
6. Thermostat Test as outlined in the FUNCTIONAL CHECK pp 12 13 Record all results when recalibrating Apply new vinyl seal after the trim pot has been adjusted properly TROUBLESHOOTING SERVICE MANUAL TP472 TIPUMP PROBLEM POSSIBLE CAUSE REMEDY OVER TEMP light is on Pad or hose is kinked Hose clamps are closed Turn switch off unplug pump and dump water out Unkink pad and or hose Open hose clamps Refill with 2 level is n room temperature distilled water to proper level Str ever IS OW OF Teseryolrsisempty Plug pump in turn switch on and wait 40 minutes 3 filled with water that is too hot it must be below 24 4 One ofthe backup limit thermostats has failed Unplug pump and install a test cover Determine which thermostat has failed Refer to Backup Limit Thermostat Tests p 12 Replace thermostat p 17 5 PC board temperature controller has failed Unplug pump install test cover and perform Calibration pp 18 19 Replace PC board as required pp 16 17 6 Motor failed Replace motor T Pump will not pump Water level is low or reservoir is empty Refill with room temperature distilled water to proper ON OFF switch pilot light level is lit Tr 2 OVER TEMP light is on Refer to OVER TEMP section above T Pump will not pump The switch may not be fully engaged The light on the switch should be lit Verify that the ON OFF switc
7. T PAD Mul T Pad and Clik Tite are registered U S Patent and Trademark Office U S PATENT 4 068 870 2001 Gaymar Industries Inc All rights reserved www gaymar com SERVICE MANUAL TP472 TIPUMP CONTENTS CONTENTS SAFETY 2 INTRODUCTION 3 FEATURES P 4 SPECIFICATIONS eese sees eee 4 44 44 5 THEORY OF OPERATION 1 1 0 10 044 4 4 6 STORAGE 0 4 00 2 9 8 FUNCTIONAL CHECK AND SAFETY INSPECTION 9 INSPECTION FORM 2 1 14 DISASSEMBLY REASSEMBLY 15 CALIBRATION 4 20 14 1 18 TROUBLESHOOTING 2 21 0 1 0 4444141 444 1 1 20 REPLACEMENT PARTS LISTS 26 ILLUSTRATIONS T PUMP HEAT THERAPY SYSTEM 3 2 TIPUMP FEATURES SPECIFICATIONS 4 3 TIPUMP 7 4 t 10 5 TPCI TEST COVER 4 0 242
8. backup limit thermostat fig 3 item 5 is mounted on the brass plate fig 3 item 10 that extends along and under the heater fig 3 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 3 item 2 see also fig 10 4 p 29 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 3 item 11 p 7 is a sump configuration driven by an impedance protected shaded pole AC motor fig 3 item 6 The return hose fitting fig 3 item 9 is machined internally to act as an orifice This maintains a back pressure in the pad to make it resistant to flow restrictions SERVICE MANUAL TIPUMP COMPONENTS TP472 TIPUMP FIGURE 3 TIPUMP COMPONENTS 7 Brass manifold block 6 Pump motor 9 Return hose fitting 4 Heater
9. paying particular attention to test setups Any deviation from the setups procedures or test equipment may result in incorrect or mislead ing results Before making any repairs be sure to recheck your test setup procedure and test equipment A DANGER Risk of electric shock Disconnect power before servicing the 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 after making repairs and before returning the T Pump to patient use Document your findings on the INSPECTION FORM p 14 Improper repair may result in death or serious injury equipment damage or malfunction CAUTION Do not perform any powered tests with the reservoir empty Damage to the T Pump may result To assure the optimum performance dependability and safety the following should be performed once a year or as specified in the facility s preventive maintenance program and after making repairs TPT9 GAYMAR Flow and Temperature Tester 2 52 1 30 cm long 7 5 immersion T Pad Any GAYMAR 12 or 22 series T Pad GAYMAR T Pump Test Cover Ground Resistance Tester Cur
10. test cover will turn off If the OVER TEMP light does not light and a thermo stat has tripped replace the light Either the MANIFOLD or WELL light on the test cover will be lit or both lights will be off depending on which thermostats have tripped If the manifold thermostat light is on then the manifold thermostat has opened The temperature recorded must be between 43 3 C to 47 2 C If the thermostat operates outside its intended range it must be replaced see page 17 Proceed to step 3 p 13 If the well thermostat light is on then the well thermostat has opened The temperature recorded must be between 43 3 to 50 If the thermostat operates outside its intended range it must be replaced see page 17 Proceed to step 3 p 13 If neither light is on then both thermostats have opened at the same temperature To confirm this toggle the thermostat shorting switch to the MANIFOLD position The MANIFOLD light should be on Next toggle switch to the WELL position The WELL light should be on If either thermostat opens outside its intended range as defined above it must be replaced see page 17 Proceed to step 4 p 13 SERVICE MANUAL TP472 TIPUMP FUNCTIONAL CHECK 10 LEAK TEST COVER AND FILL NECK GASKET REINSTALLATION 3 To test the remaining thermostat toggle the limit thermostat shorting switch to the position corresponding to the non tripped thermostat This will short out the
11. the smallest hole 2 Motor is malfunctioning See 1 above If flow path is clear replace motor Current leakage is too I Heater will be the most probable cause Disconnect heater and check again Replace heater if high necessary If current leakage remains high continue disconnecting components until fault is located Resistance to ground I Earth conductor connections within pump Check that connections are tight If problem persists failure greater than check grounding wire to each component for continuity 0 5 ohm Water leaks from The T Pump must always be connected to a T Pad or the hose ends must be joined Clik Tite connector together to prevent water flow leakage If the connector leaks check for I Damaged ring If defective replace Clik Tite connector 2 Locking ring on Clik Tite connector is not Snap Clik Tite locking ring shut snapped into place see fig p 3 SERVICE MANUAL TP472 TIPUMP TPCI TEST COVERS Figure 5 TPCI TEST COVER CAUTION Route wires as shown to avoid interference with T Pump fan motor 500 ohm Trim Pot R3 INSIDE COVER NOTE Alwa
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13. AFETY INSPECTION pp 9 13 after making repairs and before returning the T Pump to patient use Document your findings on the INSPECTION FORM 14 Improper repair may result in death or serious injury equipment damage or malfunction CAUTION Do not perform any powered tests with the reservoir empty Damage to the T Pump may result SERVICE MANUAL INTRODUCTION TP472 TIPUMP Figure 1 TIPUMP HEAT THERAPY SYSTEM Cord Hose strap Carry handle Overtemp light Power entry module and Operating water fuseholder level indicator Temperature setting key Multiple Pads Single Pad 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 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 T Pads can be interconnected to provide therapy to more than one body site at a time FEATURES SERVICE MANUAL TP472 TIPUMP Figure 2 TIPUMP FEATURES SPECIFICATIONS Contraindications Foldaway Carry Handle pullout proof Power Entry Mod
14. AL CHECK SERVICE MANUAL TP472 TIPUMP 7 8 9 FLOW RATE TEST OPERATING TEMPERATURE TEST BACKUP LIMIT THERMOSTAT TEST Be sure the pad is flat and warm approximately 41 and at the same level as the pump Top of TPT9 float see fig 6 p 22 should read at least 30 Iph Record reading NOTE If flow is below 30 Iph refer to TROUBLESHOOTING section p 20 Make sure temperature is set to maximum 41 on dial Allow unit to come to a steady temperature approximately thirty 30 minutes To ensure accurate temperature readings add a small amount of water to TPT9 well Insert thermometer in TPT9 well Take readings every thirty 30 seconds for five 5 minutes for a total of ten 10 readings The average of these readings should be 41 1 C Record the average value If the unit is out of calibration refer to CALIBRATION section p 18 Do not let the pump cool down Proceed directly to Backup Limit Thermostat Test With the pump operating properly at 41 1 move the primary shorting switch to the SHORT position see fig 5 p 21 This will short out the temperature controller and allow the pump to continue heating to the trip point of the backup limit thermostat s Carefully observe the rising temperature and record the highest reading When a thermostat opens the pump will turn off the OVER TEMP light will be lit and the HEATER INDICATOR light on the
15. GAYMAR REF TP472 Heat Therapy System SERVICE MANUAL P N 11205 000 5 01 SERVICE MANUAL TP472 TIPUMP BEFORE YOU BEGIN RECEIVING INSPECTION WARRANTIES READ AND UNDERSTAND THIS TIPUMP SERVICE MANUAL AND ALL PRECAUTIONS SEE PAGE 2 PRIOR TO SERVICING THE TIPUMP The purpose of this manual is to provide operation service and repair information for GAYMAR heat therapy pumps Only qualified medical service personnel should repair the T Pump in accordance with the TP472 T Pump Service Manual Contact your local dealer or Gaymar s Technical Service Department for assistance Telephone 716 662 8636 Fax 716 662 0730 Upon receipt unpack the T Pump Save all packing material Perform a visual and mechanical inspection for concealed damage If any damage is found notify the carrier at once and ask for a written inspection Photo graph any damage and prepare a written record Failure to do so within 15 days may result in loss of claim Contact your local dealer for assistance The TP472 T Pump is warranted free of defects in material and workmanship for a period of one 1 year under the terms and conditions of the Gaymar warranty in place at the time of purchase A copy of the warranty is available upon request Gaymar disclaims all implied warranties including but not limited to the implied warranties of merchantability and of fitness for a particular purpose T PUMP
16. UMP AYLNA MIIA avid G INGOW AYLNA LNO3J 2 YWIMOd WOY YIMOd HO 7 1 YOUMS 39HvH2JSIG OILVLSOHLIFII iN3A3ug 8959185 INGON ALN MIA MalA INO OL NOISIAOHd G3HSIJdAO22v 38 TIvHs 0410 SIHL 40 SNITGNVH 39HYH2SIG JILVISOHLI23313 WOHJ vy EINIR 39vWva OL 37811435515 3uv 1 012 JHL cNonnvao s W LHM 18 um 8 NOISIA3H 51860192 S9NIMVHG i dA HVAAVS OL Sa3lv13HHO2 SIHL 32N3H3d3H IOHL10N 5537 SavHvdOHJIN NI SHV SHOLIIVAVI I310N SSJINN NOSHVI XS SHV SHOLSIS3H 11 Z SNHO NI SYV S32ONVLISIS3H 11 S310N hR AYLNA 3A 7 YOUMs 198107 Y3A Od WOW Nug A077 u21IMS ee o 277772272 d d 2 13A NHS i iE ac 4 4 4 1 D zr 13A NH8 isl 71 gt 551 137NI S l NOLL2V dVNS v d ES 304JINVIN he LVLSONHIHL H
17. e 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 REF 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 Pads Accessories For best results use only GAYMAR T Pads 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 p 3 For a brochure listing the various T Pads contact your local GAYMAR dealer An optional bed bracket model TP20A is available to mount the T Pump on the footboard of a bed SERVICE MANUAL TP472 TIPUMP FUNCTIONAL CHECK FUNCTIONAL CHECK amp SAFETY INSPECTION INTERVAL REQUIRED TOOLS A This section is designed to provide a complete check of all pump param eters The order of tests should be followed so that the functional testing can be completed in the least possible time Follow the FUNCTIONAL CHECK AND SAFETY INSPECTION procedures carefully
18. er be sure the fill neck gasket fig 9 item 6 p 25 is in place Push cover down as tightly as possible Hold in place when tightening cover screws This completes the FUNCTIONAL CHECK procedure Return pump to service if it is operating properly or proceed to the DISASSEMBLY REASSEMBLY section pertaining to the problem s INSPECTION FORM SERVICE MANUAL TP472 TIPUMP Inspection forms vary from hospital to hospital The following sample form is intended as a guide so that the important parameters are recorded SERVICE MANUAL DISASSEMBLYIREASSEMBLY TP472 TIPUMP DANGER Risk of electric shock Disconnect power before servicing the T Pump 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 9 13 after making repairs and before returning the T Pump to patient use Document your findings on the INSPECTION FORM p 14 Improper repair may result in death or serious injury equipment damage or malfunction CAUTION Do not perform any powered tests with the reservoir empty Damage to the T Pump may result NOTE All wires are terminated with slip on connectors When text says remove wire the slip on connector is to be removed from the mating lug on the specific item COVER I Unscrew fill cap valve assembly fig 9
19. g 9 item 45 Use caution to be sure no strain is put on thermistor leads fine white wires Carefully remove the thermistor capsule from the manifold To avoid damaging the thermistor do not pull on the wires A dental pick or scribe can be used to pry the capsule out of the hole SERVICE MANUAL TP472 TIPUMP DISASSEMBLYIREASSEMBLY MANIFOLD BACKUP LIMIT THERMOSTAT WELL BACKUP LIMIT THERMOSTAT TRAY On reassembly put a small quantity of silicone heat sink compound Dow Corning 340 or equivalent around the thermistor capsule Carefully insert the thermistor capsule into the hole on the brass manifold block To avoid damaging the thermistor do not push on the wires The capsule may be seated by placing needle nose pliers or tweezers on the edge of the capsule The remainder of the reassembly is the reverse of the above Upon inserting the P C Board the potentiometer shaft fig 9 item 49 must be in the vertical position to mate with the slot in the temperature indicator fig 9 item 37 Refer to CALIBRATION procedures pp 18 19 Remove the two 2 wire lugs Note the position of the color coded wires Facing the front of the T Pump the purple wire goes on the left hand lug and the orange wire goes on the right hand lug Remove the two 2 screws retaining the thermostat to the brass manifold block Reassembly is the reverse of the above Always be sure to check the back
20. h pilot light switch is fully engaged in the ON position does not light 2 Power cord is not fully inserted into power Insert the plug fully into the receptacle and power entry entry module or grounded receptacle module 3 Fuse is blown Inspect for broken or disconnected internal wiring Check for shorted components 4 Damaged cord or plug Check plug terminals Check power cord continuity to breaker NOTE Flex cord while checking continuity Replace power cord assembly as required T Pump pumps OK but I Unit is tipped Place unit on level surface will not heat 2 Heater is not receiving power or is defective Check if setpoint has been set too low Remove cover and check power to heater If power is present heater is probably defective Cold heater resistance is approximately 155 ohms Replace if required If there is no power at heater terminals replace PC board 3 OVER TEMP light is on Refer to OVER TEMP section above T Pump pumps OK but I ON OFF switch defective Replace ON OFF switch ON OFF switch pilot light NOTE Neon pilot light is not replaceable does not light Flow rate is less than I Flow path is restricted or obstructed Be sure pump is at same level as pad pad is flat and 30 Iph water temperature is 41 Flow is specified under these conditions Look for obstructions in the flow path Open hose clamps The orifice in the return hose fitting fig 9 item 43 p 25 is
21. imary shorting switch fig 5 on the test cover must be in the OPEN position The backup limit thermostat shorting switch fig 5 must be in the OPEN position Turn unit on and allow to come to a steady temperature approxi mately thirty 30 minutes The HEATER INDICATOR on the cover should be on whenever the heater is on NOTE Flow must be 30 minimum If not refer to TROUBLESHOOTING p 20 Start recording the temperature readings every thirty 30 seconds for five 5 minutes for a total of ten 10 readings The average of these readings should be 41 1 If not it will be necessary to adjust the R3 trim pot fig 5 This is accomplished by inserting an insulated alignment tool through the small hole in the left side of the test cover Turn the potentiometer screw clockwise to increase the water temperature Turn the screw counterclockwise to decrease the water temperature Do not force the adjusting screw past its stops After the final adjustment is made let the unit run for one half hour and recheck the calibration as described in step 9 The bandwidth should not exceed 1 Bandwidth is the difference between the maximum and minimum temperature excursions If the OVER TEMP light is activated during the calibration adjustment the water must be replaced with water 24 or less and the calibration procedure repeated Without letting the pump cool proceed directly to the Backup Limit
22. item p 25 and remove Unscrew plastic retainer 2 Remove the four screws which retain the cover two on each end of the pump NOTE When reinstalling the cover do not forget to replace the fill neck gasket fig 9 item 6 MOTOR Place screwdriver under fan hub fig 9 item 7 p 25 and twist to remove fan NOTE When replacing the fan make sure the hub is flush with top of motor shaft 2 Remove green w yellow stripe ground wire and orange and blue power wires NOTE To prevent breaking the motor lugs support them when removing the slip on lugs 3 Remove the four retaining screws and washers on the top face of the motor DISASSEMBLYIREASSEMBLY SERVICE MANUAL TP472 TIPUMP HEATER PC BOARD It is necessary to remove the reservoir to remove the motor Remove the eight 8 screws located around the inside wall of the tray NOTE It is not necessary to remove the front label fig 9 item 34 The front label is attached only to the tray and will slip off the reservoir Gently separate the reservoir from the tray Do not damage the large O ring that seals the tray and reservoir Turn the tray on its backside front label up Place a screwdriver against the white impeller in the bottom of the pump housing to prevent the impeller from turning and remove the screw retaining the impeller It is not necessary to remove the bottom housing fig 9 item 21 of the pump The impelle
23. ng material e g cloth or towel 5 Set both test cover switches to the OPEN position 4 GROUND RESISTANCE DANGER CHECK Risk of electric shock Be sure unit is unplugged when performing ground resistance test Use a ground resistance meter to measure the resistance between the ground pin on the power entry module fig 9 item 40 p 25 and the brass manifold block fig 9 item 45 Contact is available through the hole where the hoses connect to the pump This value should not be more than 0 5 ohm 5 CURRENT LEAKAGE It will be convenient to check current leakage at this point since the unit is CHECK full and connected to a pad Measure the maximum current leakage in all combinations of heater ON or OFF and power switch ON or OFF Access to chassis ground for current leakage testing is available through the hole where the hose connects to the pump The highest reading is typically less than 30 microamperes The maximum allowable reading is 100 microamperes Record the highest reading 2 Disconnect leakage meter setup 6 TIP OVER SWITCH Check the tip over switch at this point since the test cover is on CHECK and the unit is full Set temperature to maximum 41 on dial The heater indicator fig 5 p 21 will be on Tip the unit approxi mately 45 If the heater indicator goes out the tip over switch is operating If not repair or replace the PC board p 16 Record results FUNCTION
24. ngdom PC003 Power Cord Australia 42 004 Power Cord Switzerland PC005 ES Power Cord 006 Power Cord Denmark 007 Power Israel The large 250V switch used on the TP472 T Pump is no longer available When replacing this switch replace the tray assembly item 15 which includes the smaller switch 36 PCO001 2 004 005 006 007 REPLACEMENT PARTS SERVICE MANUAL TP472 TIPUMP OC a omen ones ACI opoo eene eposa eee Ce essere 1 PowmonaeSak Cs mme a ree X _ 81 1 ren tt ah on NOT ARCA SERRATE ACO powo GE pore e 00 ope pom e aer Om _ ome Taste 28 SERVICE MANUAL PC BOARD TP472 TIPUMP Figure 10 PC BOARD 12 13 12 3 ES 90586 000 Silicon Controlled Rectifier CR6CM 12 Heat Sink Included with item 52 AVAILABLE SEPARATELY Dmm eee _ 0 Fem Premier peee ENGIN SES a pemn nn os _ Ft _ a room po Jeera aso Authorized CE representative Europe INVATECH GmbH amp Co Wandsbeker K nigstraBe 27 29 D 22041 Hamburg Germany GAYMAR GAYMAR INDUSTRIES INC 10 Centre Drive Orchard Park NY 14127 2295 USA Phone 716 662 8636 FAX 716 662
25. previously opened thermostat and allow the unit to continue heating Both thermostat indicator lights should be off and the HEATER INDICATOR light should be on Carefully observe the rising temperature and record the highest reading When the water temperature rises to the trip point of the remaining thermostat the OVER TEMP light will be on the pump will turn off the heater indicator light will turn off and the appropriate thermostat light will be on If the manifold thermostat light is on then the manifold thermostat has opened The temperature recorded must be between 43 3 C to 47 2 C If the thermostat operates outside its intended range it must be replaced see page 17 If the well thermostat light is on then the well thermostat has opened The temperature recorded must be between 43 3 C to 50 If the thermostat operates outside its intended range it must be replaced see page 17 4 Unplug the unit remove the test cover and proceed to LEAK TEST Immediately upon completion of Backup Limit Thermostat Test reinstall fill cap tightly Put your finger over the hole in the cap and tilt unit toward you so the front is down Hold for three 3 minutes 2 Return the unit to upright position and carefully check inside of tray and reservoir tray joint for leaks Repeat process turning pump on back face If leakage is found refer to the DISASSEMBLY REASSEMBLY section pp 15 17 and correct problem When reinstalling cov
26. ps of oil to the bearing housing of the motor located below the fan Using a micro oiler apply a similar amount to the lower bearing at the location indicated in figure 4 apply 4 drops oil to vent hole N Manufacturer ID apply similar amount inside lower end cap early design oiler tube Figure 4 PUMP MOTOR NOTE Early versions of the pump motor have an oiler tube which does not effectively distribute oil to the lower bearing Do not use the oiler tube to apply oil to the lower bearing Use a micro oiler to apply oil directly to the locations shown in figure 4 SERVICE MANUAL FUNCTIONAL CHECK TP472 TIPUMP 3 TPCI TEST COVER When connecting the test cover do not remove any wiring connections INSTALLATION in the T Pump Simply clip the test cover alligator clips onto terminals with the same color wire 2 Connect test cover see fig 5 p 21 and fig 8 p 24 Always match the color of wiring connections to the color of T Pump wiring Be sure to keep wires away from fan Install test cover Be sure to push cover on tightly It is not necessary to install screws 3 Connect pump with test cover pad and TPT9 flow temp tester see fig 6 p 22 Be sure the 9 is connected to the supply side of the T Pump before the pad 4 Fill unit with room temperature distilled water and replace fill cap Connect any 12 or 22 series T Pad Place pad on an insulati
27. r may now be slipped off the shaft Return the tray assembly to an upright position The motor may be removed by lifting straight up Center the new motor seal gasket over opening and insert new motor through seal Replace impeller onto shaft and secure motor Do not overtorque the four 4 motor mounting screws Torque value is 6 9 to 9 2 cm kg If tray inserts are loose or motor mounts are worn a new tray with sensor bracket should be installed Remove the ground wire green w yellow stripe and the two 2 heater wires red and blue NOTE On reassembly the red wire goes on to the front post of the heater Remove the three 3 nuts retaining the heater The screws are retained in the tray The heater can then be removed by raising and tilting the top of the heater toward the left side of the T Pump Reassembly is the reverse of the above Do not forget to install heater gasket fig 9 item 11 p 25 Using the plastic key fig 3 item 3 p 7 turn the temperature indicator to the eleven o clock position The slotted coupling should then be positioned with the slot opening up Cut the plastic tie holding the wire bundle to the PC board Remove the red orange and blue wires from the PC board Remove the two screws fig 9 items 53 amp 54 p 25 retaining the PC board The board can then be raised from the tray exposing the thermistor probe assembly in the brass manifold block fi
28. rent Leakage Meter Distilled Water 2 liters approximate Synthetic Oil Anderol 465 GAYMAR P N 77137 000 INSPECTION FORM p 14 SERVICE MANUAL TP472 TIPUMP FUNCTIONAL CHECK I PHYSICAL CONDITION Examine the line cord along its entire length for physical damage such CHECK as cuts or cracked insulation A damaged line cord should be replaced rather than repaired 2 Operate switches and control settings at all positions If defective replace 3 Visually inspect pump Check for cracked or damaged plastic parts Be sure unit is unplugged Remove retainer cap Remove four 4 screws holding cover and remove cover Be sure not to lose fill neck gasket Perform visual inspection of all internal parts Remove any accumulated dirt with a vacuum cleaner or compressed air hose Leave cover off for balance of inspection 4 Check Clik Tite connectors for cracks or missing O rings Replace connectors if necessary 2 MOTOR LUBRICATION Locate the motor manufacturer s ID on the top bearing housing If the pump motor is by Jakel no oiling is required If the pump motor is by Uppco proceed with the following oiling instructions 2 Oil the pump motor every 6 months with Anderol 465 GAYMAR P N 77137 000 or equivalent to extend the life of the T Pump motor Do not use a petroleum based oil since it will leave a residue as it breaks down causing the motor to seize Add four 4 dro
29. result in death or serious injury equipment damage or malfunction CAUTION Do not perform any powered tests with the reservoir empty Damage to the T Pump may result CALIBRATION 9 GAYMAR Flow and Temperature Tester EQUIPMENT TPC GAYMAR T Pump Test Cover Thermometer 2 C to 52 C 1 accuracy 30 cm long 7 5 cm immersion Insulated alignment tool T Pad Any GAYMAR 12 or 22 series The calibration should be performed in a temperature controlled room between 21 C and 24 C CALIBRATION 1 Remove the pump cover by removing the two 2 screws at each end of the pump The fill cap valve assembly can be removed by unscrewing the cap and plastic retainer The cover is now free to be removed 2 Carefully remove the vinyl seal from the R3 trim pot fig 10 item 3 p 29 located at the top right corner of the printed circuit board 3 Install test cover See FUNCTIONAL CHECK p 11 and fig 5 p 21 4 Connect pump pad and TPT9 Flow and Temperature Tester according to fig 6 p 22 SERVICE MANUAL TP472 TIPUMP CALIBRATION Fill pump with room temperature distilled water Set Temp Dial to 41 maximum NOTE Be sure the temperature dial is always set to the maximum clockwise position when making calibration measurements and adjustments The pr
30. ule Twin 3 meter long Leakproof Pump Hose Assembly Clik Tite Connectors Temperature Setting Indicator key operated gr Temperature Setting Key FEATURES Serial Number 2 lt lt Temperature Setpoint Range Tip over Switch OVER TEMP Light OVER TEMP Safety Thermostats Operating Water Level Indicator Cord Hose Strap Temperature Set Point Scale Vented Leakproof Cap with Plastic Retainer Illuminated ON OFF Switch Durable Thermoplastic Case Extra Capacity Reservoir 1500 ml Operating Water Level Indicator Nonmarking Suction Cups Over Temp Light 30 41 exiting water temperature from pump accuracy 1 C at 41 C Key operated to prevent tampering Turns heater off if pump is tipped NOTE This does not activate the OVER TEMP light Indicates the pump and heater have been turned off This light is activated by the two OVER TEMP safety thermostats Refer to the TROUBLESHOOTING section Either of two limit thermostats will shut off pump and heater if the high temperature limit is exceeded The OVER TEMP light will glow Refer to TROUBLESHOOTING section Clear window allows viewing of the reservoir water level SERVICE MANUAL TP472 TIPUMP SPECIFICATIONS SPECIFICATIONS Reservoir capacity Detachable power cord Fuses Voltage Frequency Current Ambient operating temperature Classification IPXO
31. up limit thermostats according to the FUNCTIONAL CHECK pp 12 13 NOTE Do not attempt to replace the well thermostat To insure proper operation of this thermostat it is riveted and sealed to the tray assembly Experience has proven that it cannot be successfully replaced If this item is defective replace the entire tray assembly fig 9 item 15 p 25 Remove the eight 8 screws fig 9 item 14 p 25 around the inside wall of the tray Gently pry the reservoir from the tray Remove all components including seal bushing and clips from the old tray and reinstall into the new tray assembly Attach the reservoir to the tray Check that the reservoir ring seal fig 9 item 16 is properly located in the groove in the tray Install the eight 8 screws torqued to approximately 6 cm kg Always be sure to check the backup limit thermostats according to the FUNCTIONAL CHECK pp 12 13 CALIBRATION SERVICE MANUAL TP472 TIPUMP DANGER Risk of electric shock Disconnect power before servicing the T Pump WARNING Only qualified medical service personnel should repair the Improper repair may result in death or serious injury equipment damage or malfunction Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION pp 9 13 after making repairs and before returning the T Pump to patient use Document your findings on the INSPECTION FORM p 14 Improper repair may
32. ys match color of wiring connections to color of T Pump wiring Insulated Alignment Tool Heater Indicator Access Hole for Calibration Primary Shorting Limit Thermostat Shorting Switch Switch used to disable the A Switch is open in the temperature center position controller B To bypass a thermostat move the switch to the light that is out and test the other thermostat 21 TEST SETUP SERVICE MANUAL TP472 TIPUMP Figure 6 FUNCTIONAL CHECK TEST DIAGRAM ogo 09 T Pad size 12 or 22 Be sure pad is flat and at same level as pump S 0 f Se T TFCI Fill well with water 1 1 before inserting TPCI Test Cover thermometer installed TPT9 30 8 gph TP472 minimum L N T Pump Read at top of float il 6 Male Clik Tite Fitting and tube connector closest to front Plug into a properly black O ring of T Pump grounded outlet NOTE If the flow meter is connected in reverse no flow will be noted on the flow meter Change the pump connections so that the male fitting with black O ring is on the supply side 22 CIRCUIT DIAGRAM TIPUMP SERVICE MANUAL TP472 TIP
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