T/PUMP® - Frank`s Hospital Workshop
Contents
1. TPC 1 500 ohm Trim Pot CALIBRATION e Access Hole for Calibration Limit Thermostat Shorting Switch A Switch is open in center INSIDE COVER aa Shorting position 2 2 To short thermostat move Ir controller the switch to the light that is out and test the other thermostat SERVICE MANUAL TP500 TP500C T PUMP TEST SETUP Figure 8A FUNCTIONAL CHECK TEST DIAGRAM TP500 NOTE If the flow meter is connected in reverse the flow meter will indicate no flow Reverse the pump connections so that the male fitting with black O ring is on the supply side TFCI Fill well with water before inserting thermometer TPT9 9 GPH minumun Read at top 9 T Pad size 12 or 22 Be sure pad is flat and at same level as pump o NS TPCI Test Cover installed TP500 T Pump iO of float 11 V Male Clik Tite connector black O ring Fitting and tube closest to front of T Pump Plug into a properly grounded outlet Figure 8B FUNCTIONAL CHECK TEST DIAGRAM TP500C NOTE If the flow meter is connected i2. ORG RED BLU INSULATED 7 ALLIGATOR 13 V 10 5 V 5 11 V ELIP TYP 1 YEL bay on PC RED BLU HEATER rar ot BOARD WELL MANIFOLD TEMPERATURE THERMOSTAT THERMOSTAT CONTROLLER N RE T PUMP OVER TEMP LIGHT 115 VAC TO MOTOR COMMON SERVICE MANUAL TP500 TP500C T PUMP EXPLODED VIEW Figure 11 EXPLODED VIEW 42 21 22 23A 24 25 top and bottom 26 27 28 29 B 30 4iB 0 38A38 SERVICE MANUAL TP500 TP500C T PUMP REPLACEMENT PARTS Item P N Qty Description 04553 001 Cap Valve Assembly 2 77875 000 Handle Replacement Kit Included with item 4 3 08632 000 Instruction Label Included with item 4 4 08087 000 Cover Assembly includes items 2 3 58 and 59 5 90085 033 4 Fastener Clip Included with item 4 6 03650 000 Fill Gasket 7 04152 000 Fan 8 77121 000 Motor Kit includes item 13 9 91190 002 3 Nut 6 32 SST 10 04013 000 Heater 120V 05069 000 2 Heater Gasket 12 90085 003 OVER TEMP Light Clip 13 04877 000 Motor Seal Gasket included with item 8 14 90085 041 Circuit Breaker Clip 15 91272 0011 8 Screw 6 20 x 5 8 type B SST 09019 000 UL Label TP500 included with item 17 i 10408 000
3. 4 Visuallyinspect pump Check for crackedor damegedplasticparts Be sureunit is unplugged Remove retainer cap Remove four 4 screws holding cover and remove cover surenot to lose fill neck gasket Performvisual inspecticnof all intemal parts accumulated dirt witha vacuumcleaner or compressedairhose Leave coveroff forbalanceof inspectian 5 Checkcomectors for cracks missingOrings or other damage Replace connectors if necessary MOTOR LUBRICATION 1 Locate themotormanufacturer s IDon the top bearinghousing If thepumpmotor isby Jakel nooiling is required If thepumpmotor isbyUpoco proceedwiththe followingoiling instructions 2 Oil the pump motor every 6 months with Anderol 465 GAYMAR P N77137 000 or equivalent toextend the life of the T Pumpmotor Anderol 465 isasyntheticoil Donot useapetroleum basedoil since itwill leavearesidueas it breaks down causingthemotortoseize Add four 4 drops of oil tothe vent hole inthe bearing housing of the motor locatedbelowthe fan Usingamicrooiler applya similar amount tothe lowerbearingat the location indicated in figure 6 apply 4 drops oil to vent hole NOTE Early versions of the pump motor have an oiler tube which does Manufacturer not effectively distribute ID oil to the lower bearing apply similar amount inside lower end cap Do not use the oiler tube to apply oil to the lower bearing Usea micro oiler to apply oil directly to the location
4. UL Label TP500C included with item 17 78009 000 Tray w Sensor Brkt Thrmostat TP500 includes items 16 18 37 78009 001 Tray w Sensor Brkt Thrmostat TP500C includes items 16 18 37 18 08242 000 Warning Caution Label included with item 17 19 07968 000 Reservoir Seal 20 90018 061 4 Screw 6 32 x 1 2 SST 2 03567 000 Pump Housing 22 03611 000 Impeller 23A 90018 057 2 Screw pan head 6 32 x 1 4 SST 23B 91454 052 2 Screw fillister head 6 32 x 1 4 SST Thewellbackuplimit thermostat ispart of the trayassenbly Donot attempt to drill out the old thermostat leakproof installation is not possible Install trayassenbly seep 18 REPLACEMENT PARTS SERVICE MANUAL TP500 TP500C T PUMP Item P N Qty Description 24 03568 000 Bottom Housing 25 90514 01 6 Screw 6 20 x 5 8 type BT SST 26 Serial Number Label included with item 28 NOT AVAILABLE SEPARATELY 27 08090 000 Hospital Identification Label included with item 28 28 77867 000 Reservoir Replacement Kit includes items 26 27 29 29 04257 001 Water Level Label included with item 28 30 90385 000 4 Suction Cup 3 81002 000 Tubing 1 4 ID x 3 1 2 long 32 90500 000 Circuit Breaker w Clip 33 03394 000 2 Manifold Fitting 34 03881 000 Brass Bearing Washer 35 78301 000 Switc
5. Inspect hose connections and connectors 4 Measure ground resistance lt 0 5 ohm indicate value 5 Measure current leakage lt 100 pA indicate value 6 Check tip over switch 7 Measure flow gt 9 gph 34 Iph indicate value 2 3 Connect TPC1 test cover match wire colors of connections 8 Measure operating temperature 107 F 27 indicate average Record manifold backup limit thermostat trip point 110 F to 117 F 43 3 C to 47 2 C indicate value Record well backup limit thermostat trip point 110 F to 122 F 43 3 C to 50 C indicate value OVER TEMP light operates 10 Check for leakage 11 Reinstall cover and the fill neck gasket SERVICE MANUAL DISASSEMBLY REASSEMBLY TP500 TP500C T PUMP A DANGER Risk of electric shock Disconnect power before servicing the T Pump WARNING Only qualifiedmedical servicepersonnel 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 10 14 aftermakingrepairsandbeforeretumingtheT Purpto patient use Document your findings on the INSPECTION FORM p 15 Improper repairmay result in death or serious injury equipment damage ormalfunction A CAUTION Donot performany powered tests with the reservoir empty Damage to the T Pump may result NOTE Allwiresareterminatedwithslip ocoamectors When text says r
6. 5 Unkinkpadandhose Openhose clamps Open the fill cap on top of the pump Fill the pump with room temperature i e not hot distilledwater tothe operating level indicatedonthe side of the pump NOTE Using tap water will decrease the life of the pump Insert temperature settingkey Set temperature as prescribedby the physician Remove key toprevent tampering Plug the pump into a properly groundedoutlet Turnonthe power switch The selectedwater temperature will be reached inapproximately 20minutes If the water level drops belowthe operating level addwater overfill Overfilling can result in reducedpumpmotor life Apply T Padtothepatient FollowT Padinstructicns For specifiedperformance keep the pump at or above the level of the pua If thepunp isplacedbelowthepad s waterwill drain into the pump when it is shut off If thepumphasbeenoverfilledorifmultiplepads are comnected excess water can leak out onto the floor or cause reducedmotor life Turnoff pump before disconnectingpad Closeall hose clamps Toprevent water spillage always disconnect pad frompump with connectors raised above the level of the padandpunp Connect the T Pad Clik Tite connectors together where applicable Connect the ends of the T Pump connector hose together TP500anly SERVICE MANUAL TP500 TP500C T PUMP STORAGE CLEANING Storage Short term Storage Long term Cleaning Pads Accessories D
7. CHECK full andcomectedtoapad 1 Measurethemaximumcurrent leakage inall 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 tothepump Thehighest reading is typically less than 30 microamperes Themaximumallowable reading is 100 microamperes Record the highest reading 2 Disconnect leakagemeter setup TIP OVER SWITCH CHECK 1 Checkthetip overswitchat thispoint sincethetest coverison andtheunitis full Set temperature tomeximum 107 F endial The heater indicator fig 7 p 22 willbeqn Tiptheunit aproxi mately45 If theheater indicatorgoesout thetip overswitchis operating Ifnot repairor replace the p 17 Record results SERVICE MANUAL TP500 TP500C T PUMP FUNCTIONAL CHECK FLOW RATE TEST 1 Besurethepadis flat andwam approximately 107 F andat the same level thepump Topof TPT9 float see fig 8 p 23 shouldreadat least Record reading NOTE If flowis below 9 gph refer to TROUBLESHOOTING section p 21 OPERATING 1 Make sure temperature is set tomaximum 107 F ondial Allowunit TEMPERATURE TEST tocametoa steady temperature approximately thirty 30 minutes 2 Toensureaccurate temperature readings adda small amount of water toTPT9 well Insert thermometer in PT9 well 3 Take readings every thirty 30 seconds for five 5 minutes foratotal of ten 10
8. or MuleTePads The unique buttondesignallows water to flowandprovides trouble free operation when thepad 15 folded This reduces the number of different sizes of pads your facilitymust keep in inventory The T Pads canbe interconnected on model TP500 only toprovide therapy tomore than one body site at a time seefig 1 p 2 Forabrochurelistingthevariouspads contact the GAYMAR Customer Service Department see inside cover for telephone nnbers Anoptional bedbracket model TP20A is available tomount the T Pump on the foothoard of a bed THEORY OF OPERATION SERVICE MANUAL TP500 TP500C T PUMP WATER TEMPERATURE CONTROL FLUID SYSTEM There are four devices that control the operationof theheater inthe GAYMAR T Pump Thetemperaturecontrolleristhermistoractuated fig 5 iteml 9 Thiscontrollerisadjustableovera temperature range of 85 F to 107 F 29 49Cto41 79C Thedesiredwater temperature is set witha special removablekey fig 5 item7 Toprevent unauthorized temperature setting changes remove the key after the temperature has been set Themanifoldbackup limit thermostat fig 5 item9 ismountedon the brassmanifoldblock fig 5 item8 This thenrostat senses water temperature flowing to the padandwill shut off the pump and heater andactivate the OVER TEMP light if the water temperature exceeds specific limits Thepurposeof themani foldbackup limit thenrostat is to prevent the pump fromprovidingwater
9. readings The average of these readings shouldbe 107 F 42 F Recordtheaveragevalue If theunit isoutof calibration referto CALTBRATTONsecticn 19 4 Donotlet the pump cool down Proceed directly to Backup Limit Thermostat Test BACKUP LIMIT 1 Withthe pump operating properly at 107 F 2 F move the primary THERMOSTAT TEST shorting switch to the SHORTposition see fig 7A 7B p 22 Thiswill short out the temperature controller andallowthe pump to continue heatingtothe trippoint of thebackuplimit themmostat 2 Carefullycbserve the rising temperature and record the highest reading Whena thermostat opens the pump will tumoff the OVER TEMPlightwillbelit andthe HEATER INDICATOR light onthe test coverwillturnoff If the OVERTEMPlight doesnot light anda them stat has tripped replace the light Either the MANIFOLDor WELL light enthetest coverwillbelitorbothlightswillbeoff dependingcn which thermostats have tripped Tfthemanifoldthemostat light ison then themani foldthenrostat has opened The temperature recorded must be between 110 F to 117 F 43 3 Cto47 2 C the thermostat operates outside its intended range itmust be replaced see page 18 Proceedtostep3 Ifthewellthemvostat light isan then thewell themostat has opened The temperature recordedmust be between 110 F to 122 F 43 39 50 C the thermostat operates outside its intended range it must be replaced see page 18 Proceed
10. at toohigha temperature to thepad The well backup limit thermostat fig 5 item5 ismountedonthebrass plate fig 5 item11 that extends alangandunder theheater fig 5 item4 near thebottomof the reservoir This thermostat senses water temperature inthe reservoir andwill shut off the pump and heater and activate the OVER TEMP light if the reservoir temperature exceeds specific limits Thepurposeof thewell backup limit thermostat is to both prevent the pump fromproviding water at toohigha temperature to the pad and to protect the pump fromhigh temperature damage due toa lowwater level Thetip over switch fig 5 item2 seealsofig 12 iteme4 p 27 is mountedon the PCboard Thismercury type switch will shut off the heater if thepump is tippedmore than 45 fromthevertical position NOTE The tip over switch does not shut off the pump motor or activate the OVER TEMP light Thepump fig 5 item12 isasumpconfiguration drivenby an impedance protected shadedpoleACmotor fig 5 item6 Theretumbosefitting fig 5 item10 ismachinedintemallytoactasan orifice Thismaintains abackpressure in thepadtomeke it resistant to SERVICE MANUAL T PUMP COMPONENTS TP500 TP500C T PUMP FIGURE 5 COMPONENTS 3 Serial number ID label 6 Pump motor 8 Brass manifold block 10 Return hose fitting 9 Manifold backup limit thermostat 2 Tip over switch 1 PC Board 5 Well backup limit thermostat 4 Heat
11. following shouldbeperformedonceper year oras specifiedinthe facility s preventivemaintenance program andaftermakingrepairs REQUIRED TOOLS TPT9 GAYMAR Flow and Temperature Tester When testing TP500C use alsoan AdaptorHose Assembly P N 77926 000 Thermometer 30 F to125 F 2 C to 52 C 1 C accuracy 12 lang 3 immersion e g Brooklyn Thenmameter 73544 or equivalent Brooklyn Thermometer Co Farmingdale NY 11735 T Pad Any GAYMAR 12 or 22 series T Pad or TP612 or TP622 padas applicable GAYMAR T Pump Test Cover Ground Resistance Tester Current Leakage Meter DistilledWater 21iters apgoroximete SyntheticOil Anderol 465 GAYMAR P N 77137 000 INSPECTION FORM p 15 10 SERVICE MANUAL FUNCTIONAL CHECK TP500 TP500C T PUMP PHYSICAL CONDITION 1 Examinethelinecordalongitsentire length forphysical damage such CHECK as cuts or cracked insulation Adamaged line cord shouldbe replaced rather than repaired Check the qualityof the strainreliefs at bothends of the Linecord 2 Examinetheplugo the line cordtobe sure it is ingoodcondition If unit has non moldedtype plug open plug and check for wire breakage and loose temminal screw s T defective replacewithahogpital grade plug Torque terminal screw 5 andoutside housing screws to12 in lbs 3 Qoerateswitchesandcontrol settingsatall positions Ifdefective replace
12. 3 14 NOTE Do not attempt to replace the well thermostat To insureproper qperaticnof this thenrostat it isrivetedandsealed tothe tray asserbly Experiencehas proven that it cannot be successfully replaced If this itemis defective replace the entire tray assembly fig 11 item17 p 26 Remove the eight 8 screws fig 11 item15 p 26 around the inside wallof thetray Gentlyprythereservoirfromthetray Remove all components includingseal bushing andclips fromtheold trayand reinstall intothenewtrayassenbly Attach the reservoir tothe tray Check that the reservoir ring seal fig 11 item19 p 26 isproperly located inthegroove inthetray Install theeight 8 screws torquedtoaporaximately 6 in 1bs Always sure to check the backup limit thermostats according to the FUNCTIONAL CHECK pp 13 14 SERVICE MANUAL TP500 TP500C T PUMP CALIBRATION A DANGER Risk of electric shock Disconnect power before servicing the T Pump A WARNING e Onlyqualifiedmedical servicepersamel should repair the T Pump Improper repair may result in death or serious injury equipment damage or malfunction e Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION 10 14 aftermakingrepairs andhefore retumingtheT Purpto patient use Document your findings on the INSPECTION FORM p 15 Improper repairmay result in death or serious injury equipment damage ormalfunction A CAUTION Donot performany powered tes
13. GAYMAR T PUMP TP500 TP500C Heat Therapy System LISTED 3041 STANDARD NORME C22 2NO 125 RISK C CLASS CATEGORIE DE RISQUES NO 2G SERVICE MANUAL P N11950 000 9 03 CONTENTS SERVICE MANUAL TP500 TP500C T PUMP BEFORE YOU BEGIN CONTENTS Read and understand this T PUMP SERVICE MANUAL and all PRECAUTIONS see page 1 prior to servicing the T Punp The purpose of thismanual is toprovide operation service and repair information for GAYMAR heat therapy pups RECEIVING INSPECTION Check the shipping carton for damage immediately upon receipt If package damage is discovered the device shouldbe unpackedwith the carrier s agent present Any claims for shortage or damage must be filedwiththedeliveringcarrierby thepurchaser Do not return pumps damaged in shipment to GAYMAR without contactingour Technical Service Department for advice see phone numbers below If damaged goods are returned to GAYMAR without notifyingthe carrier AYMAR will assume the repairs will bemade at the customer s expense H Colder style Connectors T Pump Components TO RETURN PUMPS TO FACTORY FOR REPAIR OR EXCHANGE 1 Test Covers Merchandise returned to GAYMAR must be Functional Check Test Diagram accompanied by a Return Goods Number RGH Circuit Diagram for T Pump issued by GAYMAR authorizing goods tobe Circuit Diagramfor 1 Test Cover returmed Call Customer Service or Technical Exploded View o
14. IOVdVO TIV SSAINN NO8WVO 6 5 51544 TIV SWHO SAONVLSISSY 11 SALON 06 zr a 015 ZOObNL H ziaig 59000 Q 20 v E4 9 2 781 ASSV H 8 9 L dW3LY3A0 isa 8 AYNOYIN LLL Uy IGNI as n ei 19 H 3 E osia osia 2 Ar NOILOV dVNS NOLLOV dVNS er annd Q 104INVW NIM 1409138 1VISOWMHSHL 1VlSOWMH3SHL 5 5 zs epa i 5 eu LL abus o o VE E 002 39NVHO 13101A MOTISA _ i EL 100PNL 9486 VA 5 Ab vH o K olo rl n ania HOLIMS 24 SERVICE MANUAL TP500 TP500C T PUMP CIRCUIT DIAGRAMS TEST COVERS Figure 10A CIRCUIT DIAGRAM FOR TPC1 TEST COVER To connect refer to figure 7A LIMIT THERMOSTAT PRIMARY TEST OVER SHORTING SWITCH SHORTING SWITCH OFF SPDT 516 SPDT 52 INDICATOR 51 ANN 59 FON WELL MANIFOLO THERMOSTAT LED THERMOSTAT LED YEL
15. OPERATING INSTRUCTIONS T Pumps are suppliedwith one of two types of hose connectors TP500 T Pumps have Clik Tite connectors TP500C T Pumps have Colder style connectors CLIK TITE CONNECTORS on TP500 ToattachClik Tite connectors fromhose to pad 1 Insertmalefittirgsintofemlefittirngswith atwistingmotian figs 3Aand3B 2 Whenfittingsarefullyinserted snaplocdking ringintoplace figs 3Cand3D 3 Todisconnect simply reverse the procedure 4 Toopenor close the hose pinch clamps Openthe clamp by pushing the serrated fig 35 e Closethe clampby pressing the clamp together fig 3F NOTE Refertofigurel p 2 and item 9 p 6 when connecting multiple pads COLDER STYLE CONNECTORS on TP500C 1 ToattachColder style connectors toapad push themale coupling onto the female cou pling When youhearanaudible click the comectorsare joined fig 4A 2 Todiscamect Colder stylecomectors press downonthe thumb tab of the female coupling Thecouplingswillpartiallydisoamect Pull the malecouplingaut fullytodiscamect fig 4B Figure 4Colder style Camectors OPERATING INSTRUCTIONS SERVICE MANUAL TP500 TP500C T PUMP START UP PROCEDURE SHUTDOWN PROCEDURE Before filling always attachaT Pad tothe T Pump connector hose see figs 3and4 p
16. Tests p 13 Replace thermostat p 18 Unplug pump install test cover and perform Calibration pp 19 20 Replace PC board as required pp 17 18 Refill with room temperature distilled water to proper level Refer to OVER TEMP section above The light on the switch should be lit Verify that the switch is fully engaged in the ON position Insert the plug fully into the receptacle Unplug T Pump Determine cause Reset breaker Check plug terminals Check power cord continuity to breaker NOTE Flex cord while checking continuity Replace power cord assembly as required Place unit on level surface 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 80 ohms Replace if required If there is no power at heater terminals replace PC board OVER TEMP light is on ON OFF switch defective Flow path is restricted or obstructed Motor is malfunctioning Heater will be the most probable cause Cord or plug connection s will be most probable cause Refer to OVER TEMP section above Replace ON OFF switch NOTE Neon pilot light is not replaceable Be sure pump is at same level as pad pad is flat and water temperature is 107 F Flow is specified under these conditions Look for obstructions in the flow path Open hose clam
17. ay result in death or serious injury equipment damage ormalfunction e Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION pp 10 14 aftermakingrepairs andbefore returning the T Pump topatient use Document your findings on the INSPECTION FORM p 15 Improper repairmay result indeathor serious injury equipment damage or malfunction A CAUTION Donot performany powered tests with the reservoir empty Damage to the T Pump may result SERVICE MANUAL INTRODUCTION TP500 TP500C T PUMP MultiplePads Figure 1 T Pump Heat Therapy System Heat therapyiseffectiveinthedilatianofbloodvessels thereby increasing the blood flowto the heatedarea Heat therapy has avarietyof uses the most commonbeing treatment of aches andpains in joints andmuscles The GAYMAR T Pump Heat Therapy System provides means of applyingheat therapy by supplying temperature controlledwater througha connector hose toa Gaymar T Pad The hose is terminated in easy to use Clik Tite orColder stylecamectors The T Padprovides the interface for delivering the heat therapy The uniquebuttondesignallows water to flowandprovides trouble free operation when the pad is folded This reduces the number of pads your facilitymust keep in inventory Thepads areapoliedtothepart of the body requiringheat therapy andthe circulatingwatermaintains thepadat the set point temperature The temperature setpoint is key o
18. e bottomhousing fig 11 item24 p 26 of the pump 7 The impellermaynowbe slippedoff the shaft Return the tray assembly toanupright position Themotormaybe removedby lifting straight up 8 Center the newmotor seal gasket over opening and insert newmotor through seal Replace impeller canto shaft andsecuremotor 9 Donot overtorque the four 4 motormounting screws Torque value is 6to8in lbs 10 If tray inserts are loose ormotormounts are worn anewtraywith sensorracket shouldbe installed HEATER 1 Removethegroundwire green andthe twoheaterwires redandblue NOTE Onreassembly the redwire goes onthe front post of the heater 2 Removethethree 3 nuts retaining theheater The screws are retained inthe tray The heater can thenhbe removedby raisingandtilting the top of the heater toward the left side of theT Pump 3 Reassembly isthe reverse of the above 4 Donot forget toinstallheatergasket fig 11 item11 p 26 PC BOARD 1 Usingtheplastickey fig 5 item7 p 9 tumnthetenperature indicator totheeleveno clockpositian The slotted coupling should thenbe positionedwith the slotopeningup 2 Cuttheplastictie holding the wire bundle to the PCboard Remove the red orange andblue wires fromthe PCboard 3 Remove the two screws fig 11 items 56 amp 57 p 26 retaining the board Theboardcanthenbe raised fromthe tray exposing the ther mistorprobeassenbly inthebrassmanifoldblock fig 11 item47 26 U
19. emove wire the slip onconnector is tobe removed fromthe mating lugonthe specific item COVER 1 Unscrewfill cap valveassenbly fig 11 item1 p 26 andremove Unscrewplasticretainer 2 Remove the four screws which retain the cover two on each end of the pump NOTE When reinstalling the cover donot forget toreplace the fill neckgasket fig 11 item6 MOTOR 1 Placeascrewdriverunder fanhub fig 11 item7 26 andtwist to remove fan NOTE When replacing the fan make sure the hub is flushwith top of motor shaft 2 Remove green ground wire and orange and blue power wires NOTE Toprevent breaking the motor lugs support themwhen removingtheslip oilugs 3 Remove the four retaining screws and washers on the top face of the motor 16 SERVICE MANUAL TP500 TP500C T PUMP DISASSEMBLY REASSEMBLY 4 Itisnecessary to remove the reservoir to remove the motor Remove the eight 8 screws locatedaround the insidewall of thetray NOTE It isnot necessary to remove the front label fig 11 item37 26 The front label isattachedonly tothe trayandwill slipoff the reservoir 5 Gently separate the reservoir fromthe tray Donot damage the large ringthat seals the trayandreservoir 6 Tumthetraymitshackside front labelup Placea screwdriveragainst the white impeller in the bottomof the pump housing toprevent the impeller fromtumingand remove the screwretaining the impeller It is not necessary to remove th
20. ept for such warranty GAYMAR disclaims all other express and or implied warranties including but not limited to the impliedwarranties of merchantability and of fitness for aparticular purpose 11 labor performedand parts provided free of charge for aperiodof one 1 full year fromthe date of purchase provided the equipment is returned withprior authorization prepaid to an authorized GAYMAR service centeror the factory Free replacement of product where defects inmaterials and or workmanship are evident at time of delivery provided the product is retumedwithpriorauthorization prepaid toGAYMAR Industries Free replacement of product where defects inmaterials and or workmanship occur within 90 days fromdate of delivery provided the product is returned with prior authorization prepaid to GAYMAR Idrtriss Defectivepartswillbe exchanged free of charge where defects inmaterials and or workmanship occur within 90 days fromdate of delivery provided the parts are returned with prior authorization prepaid to GAYMAR Idertriss Forpriorauthorizationcnall itemshbeing retumedto the factory and for a Return Goods Number RGH call Customer Service at 716 662 2551 1 800 828 7341 30 GAYMAR GAYMAR INDUSTRIES INC 10 Centre Drive Orchard Park NY 14127 2295 Phone 1 800 828 7341 716 662 2551 e T PUMPS AND T PADS 1 800 993 7890 ARE MADE IN THE USA 716 662 0748
21. er temperature controller TOP wirehamessrenovedfarclarity 7 Temperature setting key 4 Heater Brass plate 12 P heat shield BOTTOM FUNCTIONAL CHECK SERVICE MANUAL TP500 TP500C T PUMP FUNCTIONAL CHECK amp This section is designed toprovide a complete check of all pump param SAFETY INSPECTION eters Theorderof tests shouldbe followedso that the functional testing canbe completedinthe least possible time Follow the FUNCTIONAL CHECK AND SAFETY INSPECTION carefully payin particularattentiantotest setups Anydeviation fronthe setups procedures or test equipment may result in incorrect ormisleadingresults Beforemakingany repairs be sure to recheck your test setup procedure andtest equipment A DANGER Riskof electric shock Disconnect power before servicing the T Pump A WARNING Onlyqualifiedmedical servicepersonnel should repair the T Pump Improper repair may result in death or serious injury equipment damage or malfunction e Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION aftermaking repairs andbefore retuumingtheT Purmptopatient use Document your findings on the INSPECTION FORM p 15 Improper repairmay result in death or serious injury equipment damage or malfunction A CAUTION Donot performany powered tests with the reservoir empty Damage to the T Pump may result INTERVAL Toassure the optimumperformance dependabilityand safety the
22. esmallbuttonin the centerwill extend1 4 exposingawhiteband Refer to the TROUBLESHOOTING section OVER TEMP Either of two limit themmostats will shut off pumpandheater Safety if thehigh temperature limit is exceeded The OVER TEMP Themostats light will glow Refer to the TROUBLESHOOTING section SPECIFICATIONS SERVICE MANUAL TP500 TP500C T PUMP SPECIFICATIONS Size 8 1 a x 5 g x 6 1 4 20 6cmx14 3cmx15 9 cm Weight empty 51bs 20z 2 3 kg Reservoircapacity 510z 1500ml maximum Flowrate 9 gph 34 1ph minimumwithpad attached Ambient operating 60 F to 90 F 15 6 Cto32 29 C temperatures Storagetemperatures 30 Fto160 F 34 4 Cto71 1 C empty Temperature set point 85 Fto1079F 29 49Cto41 79C rame Average operating 2 Fat 107 F setting temperature accuracy Power cord 18 AWG 3 conductor 9 ft 274 Type SJT with molded hospitalgradeplug Circuitbreaker 3 amperes ist backup Limit Bimetallic trippoint fixed thermostat 110 F to 117 F 43 39 47 29 manifoldmounted 2ndbackup Limit Bimetallic trippoint fixed thermostat 110 F to 122 F 43 39 50 C well mounted Current leakage 100 microamperes maximum Groundresistance 0 5 ohmmaximum Electrical requirerents Voltage VAC 120 Frequency Hz 60 Current amps 18 Power req d watts 200 Safetyaparovals Tested to UL 544 and CSA 22 2 No 125 SERVICE MANUAL TP500 TP500C T PUMP
23. f T Pump ae 5 716 662 2551 1 800 828 7341 Advisemodel serial number andnatureof problem You will be given a Return Goods Number RG The serial number is on the back of the T Pump seefigure2 p 3 T PUMP T PAD MuleTePad Clik Tite andGaymar are registered trademarks of Gaymar Industries Inc U S PATENT 4 068 870 92001 Gaymar Industries Inc All rights reserved www gaymar com SERVICE MANUAL SAFETY PRECAUTIONS TP500 TP500C T PUMP A DANGER Riskof explosion Donot use inthe presence of flammable aresthstics Riskof electric shock Disconnect power before servicing the T Pump A WARNING e This device pumps warmed water throughapad Set pad temperature only as prescribedby andunder the guidance of a physician Monitor thepatient stemperatureandskincondition every 20 minutes or as directedbya physician Failure to adhere to these warnings could result inpatient injury The followingGroups Conditicns requireacdditianal surveillance Group Condition at risk Potential injury Pediatric patients Hyperthermia hypothermia Areas of application are under pressure Ischemia In combination with topical solutions whose toxicity Chemical may be affected by the application of heat In combination with other heat sources Thermal injury Patients with impaired circulation Ischemia Onlyqualifiedmedical servicepersonnel shouldrepairthe T Pump Improper repair m
24. h Kit 120V 91282 007 OVER TEMP Lamp with clip 37 11184 000 Front Label included with item 17 38A 08086 000 Hose Assembly TP500 includes items 41 and 41B 38B 08648 000 Hose Assembly TP500C includes item 42 39 91275 027 2 Screw 4 40 x 3 8 SST 40 03975 000 Indicator 4 A 03887 000 Male Clik Tite included with item 38A 41 03884 000 Female Clik Tite included with item 38A sa muse em Sorte Smee Tt 43 90076 018 Strain Relief Bushing 44 78315 000 Power Cord Kit with molded plug 45 03989 000 Hose Fitting orificed 46 03988 000 Hose Fitting no orifice 47 03983 000 Brass Manifold Block 48 03381 000 Manifold Gasket 49 90255 000 Plug replacement 8 SERVICE MANUAL TP500 TP500C T PUMP REPLACEMENT PARTS ot NTT 03661 000 Temperature Adjusting Key NOT SHOWN 61 TFCI Thermometer NOT SHOWN 62 TPCI Test Cover NOT SHOWN 63 TPT9 Flow and Temperature Test Tool NOT SHOWN 64 77926 000 Hose Adaptor Assembly see figure 8B WARRANTIES SERVICE MANUAL TP500 TP500C T PUMP WARRANTIES PUMP PAD SINGLE PATIENT USE PAD REUSABLE PARTS GAYMAR equipment and products are warranted against defects in material andworkmanship under normal use and operation fromthe date of purchase for the time periods listedbelow for the respective equipment and products Exc
25. ion Thebackup limit thermostat shorting switch fig 7 7 must be inthe OPENpositicn Turnunit on and allowto came toa steady temperature approxi matelythirty 30 minutes The HEATER INDICATOR on the cover should on whenever the heaterisan NOTE Flowmust 9gph minimum Ifnot refer to TROUBLESHOOTING p 21 Start recording the temperature readings every thirty 30 seconds for five 5 minutes foratotal of ten 10 readings Theaverageof these readings shouldbe 107 F 2 F Ifnot it will benecessary toadjust the R3trimpct fig 7A 7B p 22 This isaccomplishedby insertingan insulatedaLignment tool through the srallbole inthe left sideof the TECI test cover Turm the potentiometer screw clockwise to increase the water temperature Tum the screw counterclockwise to decrease the water temperature Do not force the adjusting screwpast its stops After the final adjustment ismade let the unit run forme half hour and recheck the calibrationas described instep 9 The bandwidth shouldnot exceed 2 F Bandwidth is the difference between the maximum andminimum temperature excursions If the OVER TEMP light isactivatedduring the calibratioadjustment thewatermust be replacedwithwater 75 F or less and the calibrationprocedure repeated Without letting the pump cool proceeddirectly to the Backup Limit Thermostat Test as outlined in the FUNCTIONAL CHECK p 13 Applyblue torque seal after the trimpot has been adju
26. isconnect pad Connect ends of the connector hoses together where applicable Openhose clamps Leave water inthe reservoir Toprevent hosekinks coil thehose rather than folding it Fasten the hose andcordwithstrap Connect pad Open hose clamps Add 1 4 ounce GAYMAR MTA33 germicidal or equivalent towater already inreservoir Runfortwo 2 minutes Drainpump Close hose clamps Disconnect pad To prevent hose kinks coil thehose rather than foldingit Fastenthehoseandcordwith strap and store pump Unplug the power cord Disconnect the pador hoses fromone another keeping hoses at or above the level of the T Pump Remove the fill cap and invert the T Pumpover a sink Whenall fluidhas drained fromthe hoses andreservoir replace the fill capandconnect the hoses together where Unplug the power cord Tocleanthe extemal surfaces useanon abrasivecleaningsoluticn such aswarm soapywater andadamp cloth Tocleanthe fluidsystem drainthepurp Fill the reservoir tothe grat ing level indicated on the side of the pump Add 1 4 ounce GAYMAR catalogMI233 germicidal or equivalent Set the temperature indicator to its lowest setting fullycounterclockwise Start theT Pumpandcirculate the solution for one hour Drainthe solutionand refill thepumpwith distilledwater Usingdistilledwater retards algaegrowthandmineral Change the distilledwater monthly ormore often depending upon use For best results use only GAYMAR T Pads
27. n reverse the flow meter will indicate no flow Reverse the pump hose connections to change the direction of flow TFCI Fill well with water before inserting thermometer TPT9 9 GPH minumum ono ono 020 09o 00 T Pad size 12 or 22 Be sure pad is flat and at same level as pump o oc 9 TPCI Test Cover installed TP500C Read at top of float Adaptor Hose Assembly P N 77926 000 Fitting and tube closest to front of T Pump Plug into a properly grounded outlet SERVICE MANUAL TP500 TP500C T PUMP CIRCUIT DIAGRAM T PUMP MATA bra mall MATA 9101 LHM M8 X18 TSA MATA LNOUT O 5 MAIA 7 yams eT OL NOISIAOYd ALVNOAG V A INO GSHSINdNOOOV 5 Say TIVHS LONGOdd SIHL 398VHOSIG OILVLSOYLOATA 39VIAVG 318114422506 SANENASSV WNLOV JHL NOILNYO SNIMVGO HVINAVO S31VT3HHOO SIHL HON383H3 ANON NOISIA3H 000 8861 GALON SSF INN SAVEVAONOIN NI FeV SHOL
28. perated to prevent tampering The T Pads canbe interconnected onmodel TP500 only toprovide therapy tomore thanone body siteat atime SERVICE MANUAL TP500 TP500C T PUMP FEATURES Cord Hose Strap Serial Number Vented Leakproof Fold Hospital Cap with Gare Handle Operating Identification Label Plastic Retainer Illuminated pullout proof Instructions ON OFF Switch Power Cord with Molded Durable Hospital Grade Thermoplastic Plug Case Circuit Breaker Twin 10 long Leakproof Pump Hose Assembly ED Capacity with 2 types of eservoir Connectors 1500 ml 51 oz available see figures 3 amp 4 Operating Water Level Indicator TEMPERATURE SETTING Indicator key operated Nonmarking Suction Cups TEMPERATURE Dual Temperature SETTING Key Set Point Scale C F OVER TEMP Light Figure 2 T Punp Features FEATURES AttachedHose 10 305 dual hose Connectors allowpads tobe connectedto the pump see figs 3and4 p 5 Tip over Tumsheateroff ifpumpistipped Switch NOTE This does activate the OVER TEMP light Hospital ID Alakel is providedon the back of the T Pump for your Label convenience Usea felt tiporball point pen toaddany OVER TEMP Indicates the pump and heater have been turned off Ligt This light is activatedby the two OVER TEMP safety themmostats Refer to the TROUBLESHOOTING section CircuitBreaker Whenthecircuitbreakertrips th
29. ps The orifice in the return hose fitting fig 5 item 10 p 9 is the smallest hole See 1 above If flow path is clear replace motor Disconnect heater and check again Replace heater if necessary If current leakage remains high continue disconnecting components until fault is located Check that connections are tight applies to older style non molded type plugs Disconnect power lead at circuit breaker and switch Measure resistance of power cord alone Replace if necessary If problem persists check grounding wire to each component for continuity Water leaks from Connecto Clik Tite Connector r 1 Damaged ring Locking ring on Clik Tite connector is not snapped into place see fig 3 p 5 If defective replace Clik Tite connector Snap Clik Tite locking ring shut Colder style Connector The couplings are not securely connected Push the male and female ends together until you hear a click If it still leaks replace connector SERVICE MANUAL 1 TEST COVERS TP500 TP500C T PUMP Figure 7A NEW STYLE 1 TEST COVER A CAUTION NOTE Route 1 wires as shown to avoid Always match color of 1 wiring interference withT Pump fanmotor connections tocolorof T Pumpwiring m Insulated Alignment 2 Tool H Heater Indicator
30. s shown in figure 6 early design d oiler tube Figure 6 PUMP MOTOR SERVICE MANUAL FUNCTIONAL CHECK TP500 TP500C T PUMP TPC1 TEST COVER 1 Whenconnectingthe test cover donot remove any wiring connec INSTALLATION timsintheT Pump Simplyclipthetestooveralligatorclipsonto temninalswiththe same colorwire 2 Connect test cover see fig 7A 7B 22 and10A 10B p 25 Always match the color of TEC1 wiring connections to the color of T Pumpwiring Be suretokeepwires away fronfan Install test cover Besuretopushooverantightly It isnotnecessary to install screws 3 Connect pumpwithtest cover pad flow temp tester and adaptor hose if required see fig 8 p 23 BesuretheTPI9is connected to the supply side of the T Pump before the pad 4 Filluitwithroontenperaturedistilledwaterandreplace fill cap Comect pad Placepadonaninsulatingmaterial e g clothortowel 5 Set bothtest cover switches tothe OPENposition GROUND RESISTANCE DANGER CHECK Riskof electric shock Be sure unit is unplugged when performing thegroundresistancetest 1 Useagroundresistance meter tomeasure the resistance between the groundpinontheplugandthebrassmanifoldblock fig 11 item47 Contact is available through the hole where the hoses connect to the pump This value shouldnot be more than 0 5 ohm CURRENT LEAKAGE Tt will beconvenient tocheck current leakageat thispoint sincetheunit is
31. secautiontobe ssurenostrainisputonthen stor leads fine whitewires 4 Carefully remove the themnistor capsule fromthemanifold Toavoid damaging the thermistor donot pull onthewires Adental pickor scribe canbeusedtopry the capsule out of thehole 17 SERVICE MANUAL DISASSEMBLY REASSEMBLY TP500 TP500C T PUMP MANIFOLD BACKUP LIMIT THERMOSTAT WELL BACKUP LIMIT THERMOSTAT TRAY Onreassembly put asmall quantity of silicone heat sink compound Dow Coming 340 or equivalent around the thermistor capsule Carefully insert the thermistor capsule into theholeonthebrass manifoldblock Toavoiddamaging the thermistor donot pushon the wires The capsulemay be seatedbyplacingneedlenosepliersor tweezers on the edge of the capsule The remainder of the reassembly is the reverse of the above Upon insertingtheP C Board thepotentiameter shaft fig 11 item52 26 must be inthe vertical position tomatewith the slot inthe temperature indicator fig 11 item40 26 Refer to CALIBRATION procedures 19 20 Remove the two 2 wire lugs Note the positionof the color coded wires Facing the front of the T Pump thepurplewiregoes on the left hand lug andthe orange wire goes on the right hand lug Remove the two 2 screws retaining the thermostat tothe brass manifoldblack Reassenbly is the reverse of the above Always sure to check the backup limit thermostats according to the FUNCTIONAL CHECK pp 1
32. stedproperly 20 SERVICE MANUAL TP500 TP500C T PUMP TROUBLESHOOTING PROBLEM POSSIBLE CAUSE REMEDY OVER TEMP light is on T Pump will not pump ON OFF switch pilot light is lit T Pump will not pump ON OFF switch pilot light does not light T Pump pumps OK but will not heat T Pump pumps OK but ON OFF switch pilot light does not light Flow rate is less than 9 gph Current leakage is too high Resistance to ground failure greater than 0 5 ohm Pad or hose is kinked Hose clamps are closed Water level is low or reservoir is empty Pump is filled with water that is too hot it must be below 75 F One of the backup limit thermostats has failed PC board temperature controller has failed Water level is low or reservoir is empty OVER TEMP light is on The ON switch may not be fully engaged The electrical cord is not plugged into a grounded electrical receptacle Check circuit breaker If center button has moved forward exposing white band breaker has tripped Damaged cord or plug or break in continuity between cord and breaker Unit is tipped Turn switch off unplug pump and dump water out Unkink pad and or hose Open hose clamps Refill with room temperature distilled water to proper level Plug pump in turn switch on and wait 40 minutes Unplug pump and install a test cover Determine which thermostat has failed Refer to Backup Limit Thermostat
33. t be between 110 F to 122 F 43 39C to 50 the thermostat operates outside its intended range it must be replaced see page 18 4 Unplugtheunit remove the test cover and proceed to LEAK TEST 1 Inmediatelyupon completionof Backup Limit Thermostat Test reinstall fill captightly Put your fingerovertheholeinthecapandtilt unit toward you so the front is down Hold for three 3 minutes 2 Retumtheunit toupright positicoandcarefully check insideof tray andreservoir tray joint for leaks Repeat process tumingpump onback face If leakage is found refer tothe DISASSEMBLY REASSEMBLY section 16 18 andcorrect Whenreinstallingcover besurethe fillneckgasket fig 11 item6 p 26 isinplace Pushooverdownas tightlyaspossible Holdinplacewhen tighteningcoverscrews This completes the FUNCTIONAL CHECKprocedure Return pumptoservice if it isqperatingproperly orproceedtothe DISASSEMBLY REASSEMBLY sectionpertaining totheproblem s 14 SERVICE MANUAL TP500 TP500C T PUMP INSPECTION FORM Inspectianfommevaryfranbospitaltohospital The following sample formis intendedas a guide sothat the important parameters are recorded T Pump Functional Check and Safety Inspection Form Date Model Number Serial Number Item Value OK Action Action Taken Needed check one 1 Inspect physical condition line cord plug housing o Inspect electrical compartment switches fuse circuit breaker
34. to step3 Ifneitherlightison thenboththemostats have openedat the same temperature Toconfimmthis toggle the thermostat shorting switch tothe MANIFOLDposition The MANIFOLD light shouldbe on Next toggle switch tothe WELLposition The WELL light shouldbe on If either thermostat opens outside its intended range as defined above it must be replaced see page 18 Proceed to step4 FUNCTIONAL CHECK SERVICE MANUAL TP500 TP500C T PUMP LEAK TEST COVER AND FILL NECK GASKET REINSTALLATION 3 Totest theremainingthemostat toggle the Limit themostat shorting switch tothe position corresponding to thenon tripped thermostat This will short out the previously opened thermostat andallowthe unit tocontinueheating Boch themostat indicator lights shouldbeoff and the HEATER INDICATOR light shouldbe on Carefully observe the rising temperature and record the highest reading When the water temperature rises tothe trippoint of the remaining themrostat the OVER TEMP Light will thepumpwill tumoff theheater indicator light will timoff andtheaporooriate themostat lightwillbean e T themanifoldthenmstat light isan thenthemanifoldthemostat has opened The temperature recorded must be between 110 F to 117 F 43 3 Cto47 2 C the thermostat operates outside its intended range itmust be replaced see page 18 e Tfthewell themostat light ison thenthewell themostat has opened The temperature recordedmus
35. ts with the reservoir empty Damage to the T Pump may result CALIBRATION UPTO 999m GAYMAR Flow and Temperature Tester Adaptor Hose Assembly P N 77926 000 TBCL GAYMAR T Pump Test Cover TECI eem Thermometer 30 F to 125 F 2 C to 52 C 1 C accuracy 12 long 3 inmersicn e g Brooklyn Thermometer 73544 or equivalent Tnsulatedalignment tool T Pad Any GAYMAR 12 or 22 series T Pad or TP612 or TP622 pad as applicable The calibration shouldbe performed ina temperature controlled roam between 70 F and 75 F CALIBRATION 1 Remove the pump cover by removing the two 2 screws at each end of the pump The fill cap valve assembly canbe removedbyunscrewing the capandplastic retainer The cover is now free tobe removed 2 Carefullyremove theblue torque seal fromtheR3 trimpot fig 12 item 63 p 27 locatedat the topright comerof theprintedcircuit board 3 Install test cover See FUNCTIONAL CHECK p 12 and figures 7 7 CALIBRATION SERVICE MANUAL TP500 TP500C T PUMP Connect pump pad TPT9 f1ow temp tester and adaptor hose assem blyifrequired seefig 8 p 23 Fillpumpwithroomtemperaturedistilledwater Set Temp Dial to 107 F maximum NOTE Besurethetenperaturedial is always set tothe maximum clockwise position when making calibrationmeasurements andadjustments The primary shorting switch fig 7A 7B p 22 mthe test covermust be inthe OPENposit
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