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®

P/N 11205-000 5/01

T/PUMP®

REF TP472Heat Therapy System

SERVICE MANUAL

SERVICE MANUALTP472 T/PUMP

BEFORE YOU BEGIN . . .

T/PUMP, T/PAD, Mul•T•Pad, and Clik-Tite are registered in U. S. Patent and Trademark Office. U. S. PATENT 4,068,870© 2001. Gaymar Industries, Inc. All rights reserved. www.gaymar.com

READ AND UNDERSTAND THIS T/PUMP SERVICEMANUAL AND ALL PRECAUTIONS (SEE PAGE 2) PRIORTO SERVICING THE T/PUMP.

The purpose of this manual is to provide operation, service, and repairinformation for GAYMAR heat therapy pumps.

Only qualified medical service personnel should repair the T/Pump, inaccordance with the TP472 T/Pump Service Manual. Contact your localdealer 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 avisual and mechanical inspection for concealed damage. If any damage isfound, 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 15days may result in loss of claim.

Contact your local dealer for assistance.

RECEIVING INSPECTION

WARRANTIES The TP472 T/Pump is warranted free of defects in material andworkmanship for a period of one (1) year, under the terms and conditionsof the Gaymar warranty in place at the time of purchase. A copy of thewarranty is available upon request. Gaymar disclaims all implied warrantiesincluding, but not limited to, the implied warranties of merchantability andof fitness for a particular purpose.


1

CONTENTS

ILLUSTRATIONS

SAFETY PRECAUTIONS .......................................................... 2

INTRODUCTION....................................................................... 3

FEATURES .................................................................................. 4

SPECIFICATIONS ...................................................................... 5

THEORY OF OPERATION ....................................................... 6

STORAGE / CLEANING ............................................................ 8

FUNCTIONAL CHECK AND SAFETY INSPECTION ......... 9

INSPECTION FORM ................................................................ 14

DISASSEMBLY / REASSEMBLY ............................................. 15

CALIBRATION ......................................................................... 18

TROUBLESHOOTING ............................................................ 20

REPLACEMENT PARTS LISTS .............................................. 26

1 T/PUMP® HEAT THERAPY SYSTEM ...................................... 3

2 T/PUMP FEATURES/SPECIFICATIONS ................................ 4

3 T/PUMP COMPONENTS .......................................................... 7

4 MOTOR...................................................................................... 10

5 TPC1 TEST COVER ................................................................. 21

6 FUNCTIONAL CHECK TEST DIAGRAM ............................ 22

7 CIRCUIT DIAGRAM FOR T/PUMP ....................................... 23

8 CIRCUIT DIAGRAM FOR TPC1 TEST COVER ................... 24

9 EXPLODED VIEW OF T/PUMP ............................................. 25

10 PC BOARD ASSEMBLY........................................................... 29

CONTENTS


• Risk of electric shock. Disconnect power before servicingthe T/Pump.

DANGER

SAFETY PRECAUTIONS

2

• Do not perform any powered tests with the reservoir empty.Damage to the T/Pump may result.

CAUTION

WARNING

• This device pumps warmed water through a pad. Set pad tem-perature only as prescribed by and under the guidance of aphysician. Monitor the patient's temperature and skin conditionevery 20 minutes or as directed by a physician. Failure toadhere to these warnings could result in patient injury.

The following Groups/Conditions require additional surveillance:

• Only qualified medical service personnel should repair theT/Pump. Improper repair may result in death or seriousinjury, equipment damage, or malfunction.

• Always perform the FUNCTIONAL CHECK AND SAFETYINSPECTION (pp. 9-13) after making repairs and before returningthe T/Pump to patient use. Document your findings on theINSPECTION FORM (p. 14). Improper repair may result indeath or serious injury, equipment damage, ormalfunction.

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INTRODUCTION

3

The Gaymar T/Pump Heat Therapy System provides a means of applyingheat therapy by supplying temperature-controlled water through aconnector 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. Theunique button design allows water to flow and provides trouble-freeoperation when the pad is folded. The pads are applied to the part of thebody requiring heat therapy, and the circulating water maintains the padat the set point temperature.

The T/Pads can be interconnected to provide therapy to more than onebody site at a time.

Single Pad

Multiple Pads

Figure 1 - T/PUMP HEAT THERAPY SYSTEM


Temperature 30-41°C, exiting water temperatureSetpoint Range from pump; accuracy, ±1°C at 41°C.

Key-operated to prevent tampering.

Tip-over Turns heater off if pump is tipped.Switch NOTE: This does not activate the

OVER TEMP light.

OVER TEMP Indicates the pump and heater haveLight been turned off. This light is activated

by the two OVER TEMP safetythermostats. Refer to theTROUBLESHOOTING section.

OVER TEMP Either of two limit thermostats willSafety shut off pump and heater ifThermostats the high temperature limit is

exceeded. The OVER TEMP light willglow. Refer to TROUBLESHOOTINGsection.

Operating Clear window allows viewing of theWater Level reservoir water level.Indicator

FEATURES

FEATURES

4

Figure 2 - T/PUMP FEATURES / SPECIFICATIONS


SPECIFICATIONS

SPECIFICATIONS

5

Reservoir capacity 1500 ml maximum

Detachable Use only an internationalpower cord (harmonized) 3-wire cordset

using cordage approved toHD-21 conductor size1.00 mm2

Fuses 5x20 mm, 1.6A, Type “T”Sheet 111

Voltage ~220-240

Frequency 50 Hz

Current 1.6A

Ambient operating 15.6°C to 32.2°Ctemperature

Classification Type B, Class 1, groundedequipment suitable forcontinuous operation. Notclassified for protection againstharmful ingress of liquid.

Equipment not suitable foruse in the presence of aflammable anaesthetic mixturewith air or with oxygen ornitrous oxide.

IPXO


6

There are four devices that control the operation of the heater in theGAYMAR T/Pump:

• The temperature controller is thermistor actuated (fig. 3, item 1, p. 7).This controller is adjustable over a temperature range of 30°C to 41°C.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 thebrass manifold block (fig. 3, item 7). This thermostat senses watertemperature flowing to the pad and will shut off the pump and heaterand activate the OVER TEMP light if the water temperature exceedsspecific limits. The purpose of the manifold backup limit thermostat is toprevent the pump from providing water at too high a temperature tothe pad.

• The well backup limit thermostat (fig. 3, item 5) is mounted on the brassplate (fig. 3, item 10) that extends along and under the heater (fig. 3,item 4) near the bottom of the reservoir. This thermostat senses watertemperature in the reservoir and will shut off the pump and heater andactivate the OVER TEMP light if the reservoir temperature exceedsspecific limits. The purpose of the well backup limit thermostat is toboth prevent the pump from providing water at too high a temperatureto the pad and to protect the pump from high temperature damage dueto a low water level.

• The tip-over switch (fig. 3, item 2; see also fig. 10, item 4, p. 29) ismounted on the PC board. This mercury-type switch will shut off theheater if the pump is tipped more than 45° from the vertical position.

NOTE: The tip-over switch does not shut off the pumpmotor or activate the OVER TEMP light.

The pump (fig. 3, item 11, p. 7) is a sump configuration driven by animpedance protected, shaded pole AC motor (fig. 3, item 6).

The return hose fitting (fig. 3, item 9) is machined internally to act as anorifice. This maintains a back pressure in the pad to make it resistant toflow restrictions.

WATER TEMPERATURECONTROL

THEORY OF OPERATION

FLUID SYSTEM


7

T/PUMP COMPONENTS

FIGURE 3 - T/PUMP COMPONENTS

TOP

BOTTOM

[11] [10]


Disconnect pad. Connect ends of the connector hoses together. Openhose clamps. Leave water in the reservoir. To prevent hose kinks, coil thehose rather than folding it. Fasten the hose and cord with strap.

Disconnect pad. Connect ends of the connector hose together. Open hoseclamps. Add 1/4 ounce GAYMAR catalog REF MTA33 germicidal orequivalent to water already in reservoir. Run for two (2) minutes. Drainpump. To prevent hose kinks, coil the hose rather than folding it. Fastenthe hose and cord with strap and store pump.

Disconnect the T/Pump from AC power. Disconnect the pad or hosesfrom 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 hasdrained from the hoses and reservoir, replace the fill cap and connect thehoses together.

Unplug the T/Pump prior to cleaning.

To clean the external surfaces, use a non-abrasive cleaning solution (suchas warm soapy water) and a damp cloth.

To clean the fluid system, drain the pump. Fill the reservoir to the operat-ing level indicated on the side of the pump. Add 1/4 ounce GAYMARcatalog REF MTA33 germicidal or equivalent. Set the temperature indicatorto its lowest setting (fully counterclockwise). Start the T/Pump andcirculate the solution for one hour. Drain the solution and refill the pumpwith distilled water. Using distilled water retards algae growth and mineralbuildup.

Change the distilled water monthly or more often depending upon use.

For best results use only GAYMAR T/Pads® or Mul•T•Pads®. The uniquebutton design allows water to flow and provides trouble free operationwhen the pad is folded. This reduces the number of different sizes of padsyour facility must keep in inventory. The T/Pads can be interconnected toprovide therapy to more than one body site at a time (see fig. 1, p.3). For abrochure listing the various T/Pads, contact your local GAYMAR dealer.

An optional bed bracket (model TP20A) is available to mount the T/Pumpon the footboard of a bed.

Storage (Short term)

Storage (Long term)

Draining

Cleaning

Pads / Accessories

STORAGE / CLEANING

8


FUNCTIONAL CHECK &SAFETY INSPECTION

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 testingcan be completed in the least possible time.

Follow the FUNCTIONAL CHECK AND SAFETY INSPECTION procedurescarefully, paying particular attention to test setups. Any deviation from thesetups, 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.

Risk of electric shock. Disconnect power before servicing theT/Pump.

• 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 INSPECTIONafter making repairs and before returning the T/Pump to patientuse. Document your findings on the INSPECTION FORM(p. 14). Improper repair may result in death or seriousinjury, equipment damage, or malfunction.

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, thefollowing should be performed once a year (or as specified in thefacility's preventive maintenance program) and after making repairs.

TPT9 ------------------------- GAYMAR Flow and Temperature Tester

TFC1 ------------------------- Thermometer, -2°C to 52°C, 1°C accuracy,

30 cm long, 7.5 cm immersion

T/Pad ------------------------- Any GAYMAR “12” or “22” series T/Pad

TPC1 ------------------------- GAYMAR T/Pump Test Cover

Ground Resistance Tester

Current Leakage Meter

Distilled Water ------------- 2 liters (approximate)

Synthetic Oil ---------------- Anderol 465 (GAYMAR P/N 77137-000)

INSPECTION FORM -------- (p. 14)

DANGER

WARNING

CAUTION

INTERVAL

REQUIRED TOOLS

FUNCTIONAL CHECK

9


FUNCTIONAL CHECK

10

1. PHYSICAL CONDITIONCHECK

2. MOTOR LUBRICATION

1. Examine the line cord along its entire length for physical damage, suchas cuts or cracked insulation. A damaged line cord should be replacedrather 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 neckgasket.) Perform visual inspection of all internal parts. Remove anyaccumulated dirt with a vacuum cleaner or compressed air hose. Leavecover off for balance of inspection.

4. Check Clik-Tite connectors for cracks or missing O rings. Replaceconnectors if necessary.

1. 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 motoris by Uppco, proceed with the following oiling instructions.

2. Oil the pump motor every 6 months with Anderol #465 (GAYMARP/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 itbreaks down, causing the motor to seize. Add four (4) drops of oil tothe bearing housing of the motor located below the fan. Using a microoiler, apply a similar amount to the lower bearing at the locationindicated in figure 4.

Figure 4 - PUMP MOTOR

NOTE: Early versions ofthe pump motor have anoiler tube which doesnot effectively distributeoil to the lower bearing.Do not use the oilertube to apply oil to thelower bearing. Use amicro oiler to apply oildirectly to the locationsshown in figure 4.


11

FUNCTIONAL CHECK

1. When connecting the test cover do not remove any wiring connectionsin the T/Pump. Simply clip the test cover alligator clips onto terminalswith the same color wire.

2. Connect TPC1 test cover (see fig. 5, p. 21 and fig. 8, p. 24). Alwaysmatch the color of TPC1 wiring connections to the color ofT/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 TPT9 is connected to the supply side of theT/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 insulatingmaterial (e.g., cloth or towel).

5. Set both test cover switches to the OPEN position.

Risk of electric shock. Be sure unit is unplugged when performingground resistance test.

1. Use a ground resistance meter to measure the resistance between theground pin on the power entry module (fig. 9, item 40, p. 25) and thebrass manifold block (fig. 9, item 45). Contact is available through thehole where the hoses connect to the pump. This value should not bemore than 0.5 ohm.

It will be convenient to check current leakage at this point since the unit isfull and connected to a pad.

1. Measure the maximum current leakage in all combinations of heater“ON” or “OFF” and power switch “ON” or “OFF.” Access to chassisground for current leakage testing is available through the hole wherethe hose connects to the pump. The highest reading is typically lessthan 30 microamperes. The maximum allowable reading is 100microamperes. Record the highest reading.

2. Disconnect leakage meter setup.

1. Check the tip-over switch at this point, since the test cover is onand the unit is full. Set temperature to maximum (41°C) 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 isoperating. If not, repair or replace the PC board (p. 16). Recordresults.

3. TPC1 TEST COVERINSTALLATION

DANGER4. GROUND RESISTANCECHECK

5. CURRENT LEAKAGECHECK

6. TIP-OVER SWITCHCHECK


FUNCTIONAL CHECK

1. Be sure the pad is flat and warm (approximately 41°C) and at the samelevel as the pump. Top of TPT9 float (see fig. 6, p. 22) should read atleast 30 lph. Record reading.

NOTE: If flow is below 30 lph, refer to TROUBLESHOOTING section(p. 20).

1. Make sure temperature is set to maximum (41°C) on dial. Allow unit tocome to a steady temperature, approximately thirty (30) minutes.

2. To ensure accurate temperature readings, add a small amount of waterto TPT9 well. Insert thermometer in TPT9 well.

3. Take readings every thirty (30) seconds for five (5) minutes for a totalof ten (10) readings. The average of these readings should be 41°C±1°C. Record the average value. If the unit is out of calibration, refer toCALIBRATION section (p. 18).

4. Do not let the pump cool down. Proceed directly to Backup LimitThermostat Test.

1. With the pump operating properly at 41°C ±1°C, move the primaryshorting switch to the SHORT position (see fig. 5, p. 21). This will shortout the temperature controller and allow the pump to continue heatingto the trip point of the backup limit thermostat(s).

2. Carefully observe the rising temperature and record the highestreading. When a thermostat opens, the pump will turn off, the OVERTEMP light will be lit, and the HEATER INDICATOR light on the testcover 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 lighton the test cover will be lit or both lights will be off, depending onwhich thermostats have tripped.

• If the manifold thermostat light is on, then the manifold thermostathas opened. The temperature recorded must be between 43.3°C to47.2°C. If the thermostat operates outside its intendedrange, it must be replaced (see page 17). Proceed to step 3,p.13.

• If the well thermostat light is on, then the well thermostat hasopened. The temperature recorded must be between 43.3°C to50°C. 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 sametemperature. To confirm this, toggle the thermostat shorting switchto the MANIFOLD position. (The MANIFOLD light should be on.)Next, toggle switch to the WELL position. (The WELL light should beon.) If either thermostat opens outside its intended range asdefined above, it must be replaced (see page 17). Proceed tostep 4, p. 13.

12

7. FLOW RATE TEST

8. OPERATINGTEMPERATURE TEST

9. BACKUP LIMITTHERMOSTAT TEST


13

3. To test the remaining thermostat, toggle the limit thermostat shortingswitch to the position corresponding to the non tripped thermostat.(This will short out the previously opened thermostat and allow theunit to continue heating.) Both thermostat indicator lights should be offand the HEATER INDICATOR light should be on. Carefully observe therising temperature and record the highest reading. When the watertemperature rises to the trip point of the remaining thermostat, theOVER TEMP light will be on, the pump will turn off, the heater indicatorlight will turn off, and the appropriate thermostat light will be on.

• If the manifold thermostat light is on, then the manifold thermostathas opened. The temperature recorded must be between 43.3°Cto 47.2°C. If the thermostat operates outside its intendedrange, it must be replaced (see page 17).

• If the well thermostat light is on, then the well thermostat hasopened. The temperature recorded must be between 43.3°C to50°C. If the thermostat operates outside its intendedrange, it must be replaced (see page 17).

4. Unplug the unit, remove the test cover and proceed to LEAK TEST.

1. Immediately upon completion of Backup Limit Thermostat Test,reinstall fill cap tightly. Put your finger over the hole in the cap and tiltunit toward you so the front is down. Hold for three (3) minutes.

2. Return the unit to upright position and carefully check inside of trayand reservoir tray joint for leaks. Repeat process turning pump on backface. If leakage is found, refer to the DISASSEMBLY/REASSEMBLY section(pp. 15-17), and correct problem.

When reinstalling cover, be sure the fill neck gasket (fig. 9, item 6, p. 25) isin place. Push cover down as tightly as possible. Hold in place whentightening cover screws.

This completes the FUNCTIONAL CHECK procedure. Return pump toservice if it is operating properly, or proceed to the DISASSEMBLY/REASSEMBLY section pertaining to the problem(s).

FUNCTIONAL CHECK

10. LEAK TEST

11. COVER AND FILLNECK GASKETREINSTALLATION


INSPECTION FORM

14

Inspection forms vary from hospital to hospital. Thefollowing sample form is intended as a guide so that theimportant parameters are recorded.


15

DISASSEMBLY/REASSEMBLY





NOTE: All wires are terminated with slip-on connectors. Whentext says “remove wire,” the slip-on connector is to be removedfrom the mating lug on the specific item.

1. Unscrew fill cap/valve assembly (fig. 9, item 1, p. 25) and remove.Unscrew plastic retainer.

2. Remove the four screws which retain the cover, two on each end ofthe pump.

NOTE: When reinstalling the cover, do not forget to replace the fillneck gasket (fig. 9, item 6).

1. Place a screwdriver under fan hub (fig. 9, item 7, p. 25) and twist toremove fan.

NOTE: When replacing the fan, make sure the hub is flush with top ofmotor shaft.

2. Remove green (w/yellow stripe) ground wire and orange and bluepower wires.

NOTE: To prevent breaking the motor lugs, support them whenremoving the slip-on lugs.

3. Remove the four retaining screws and washers on the top face of themotor.

DANGER

WARNING

CAUTION

COVER

MOTOR


16


4. It is necessary to remove the reservoir to remove the motor. Removethe 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 thereservoir.

5. Gently separate the reservoir from the tray. Do not damage the largeO ring that seals the tray and reservoir.

6. Turn the tray on its backside (front label up). Place a screwdriveragainst the white impeller in the bottom of the pump housing toprevent the impeller from turning and remove the screw retaining theimpeller. It is not necessary to remove the bottom housing (fig. 9, item21) of the pump.

7. The impeller may now be slipped off the shaft. Return the tray assemblyto an upright position. The motor may be removed by lifting straightup.

8. Center the new motor seal gasket over opening and insert new motorthrough seal. Replace impeller onto shaft and secure motor.

9. Do not overtorque the four (4) motor mounting screws. Torque valueis 6.9 to 9.2 cm-kg.

1. Remove the ground wire (green w/yellow stripe) and the two (2)heater wires (red and blue). NOTE: On reassembly, the red wiregoes on to the front post of the heater.

2. Remove the three (3) nuts retaining the heater. The screws areretained in the tray. The heater can then be removed by raising andtilting the top of the heater toward the left side of the T/Pump.

3. Reassembly is the reverse of the above.

4. Do not forget to install heater gasket (fig. 9, item 11, p. 25).

1. Using the plastic key (fig. 3, item 3, p. 7), turn the temperature indicatorto the eleven o'clock position. The slotted coupling should then bepositioned with the slot opening up.

2. Cut the plastic tie holding the wire bundle to the PC board. Removethe red, orange, and blue wires from the PC board.

3. Remove the two screws (fig. 9, items 53 & 54, p. 25) retaining the PCboard. The board can then be raised from the tray, exposing thethermistor probe assembly in the brass manifold block (fig. 9, item 45).Use caution to be sure no strain is put on thermistor leads (fine whitewires).

4. Carefully remove the thermistor capsule from the manifold. To avoiddamaging the thermistor, do not pull on the wires. A dental pick orscribe can be used to pry the capsule out of the hole.

HEATER

PC BOARD

10. If tray inserts are loose or motor mounts are worn, a new tray with sensor bracket should be installed.


17


5. 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 brassmanifold block. To avoid damaging the thermistor, do not push on thewires. The capsule may be seated by placing needle nose pliers ortweezers on the edge of the capsule.

6. The remainder of the reassembly is the reverse of the above. Uponinserting the P. C. Board, the potentiometer shaft (fig. 9, item 49) mustbe in the vertical position to mate with the slot in the temperatureindicator (fig. 9, item 37). Refer to CALIBRATION procedures(pp. 18-19).

1. Remove the two (2) wire lugs. Note the position of the color codedwires. Facing the front of the T/Pump, the purple wire goes on the lefthand lug, and the orange wire goes on the right hand lug.

2. Remove the two (2) screws retaining the thermostat to the brassmanifold block.

3. Reassembly is the reverse of the above.

4. Always be sure to check the backup limit thermostats according to theFUNCTIONAL CHECK (pp. 12-13).

NOTE: Do not attempt to replace the well thermostat.To insure proper operation of this thermostat, it is riveted andsealed to the tray assembly. Experience has proven that it cannot besuccessfully replaced. If this item is defective, replace theentire tray assembly (fig. 9, item 15, p. 25).

1. Remove the eight (8) screws (fig. 9, item 14, p. 25) around the insidewall of the tray. Gently pry the reservoir from the tray.

2. Remove all components including seal, bushing, and clips from the oldtray and reinstall into the new tray assembly.

3. 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.

4. Always be sure to check the backup limit thermostats according to theFUNCTIONAL CHECK (pp. 12-13).

MANIFOLD BACKUPLIMIT THERMOSTAT

WELL BACKUPLIMIT THERMOSTAT

TRAY


18





TPT9 ---------------------------- GAYMAR Flow and Temperature Tester

TPC1 ---------------------------- GAYMAR T/Pump Test Cover

TFC1 ---------------------------- Thermometer, -2°C to 52°C, 1°C 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.

1. Remove the pump cover by removing the two (2) screws at each endof the pump. The fill cap/valve assembly can be removed by unscrewingthe 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 Testeraccording to fig. 6, p. 22.

DANGER

WARNING

CAUTION

CALIBRATION

CALIBRATIONEQUIPMENT

CALIBRATION


CALIBRATION

19

5. Fill pump with room temperature distilled water.

6. Set Temp Dial to 41°C (maximum).

NOTE: Be sure the temperature dial is always set to themaximum clockwise position when making calibrationmeasurements and adjustments.

7. The primary shorting switch (fig. 5) on the test cover must be in theOPEN position. The backup limit thermostat shorting switch (fig. 5)must be in the OPEN position.

8. 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 theheater is on.

NOTE: Flow must be 30 lph, minimum.If not, refer to TROUBLESHOOTING (p. 20).

9. Start recording the temperature readings every thirty (30) seconds forfive (5) minutes for a total of ten (10) readings. The average of thesereadings should be 41°C ±1°C. If not, it will be necessary to adjust theR3 trim pot (fig. 5). This is accomplished by inserting an insulatedalignment tool through the small hole in the left side of the TPC1 testcover. Turn the potentiometer screw clockwise to increase the watertemperature. Turn the screw counterclockwise to decrease the watertemperature.

Do not force the adjusting screw past its stops.

10. After the final adjustment is made, let the unit run for one-half hourand recheck the calibration as described in step 9. The bandwidthshould not exceed 1°C. Bandwidth is the difference between themaximum and minimum temperature excursions. If the OVER TEMPlight is activated during the calibration adjustment, the water must bereplaced with water 24°C or less and the calibration procedurerepeated.

11. Without letting the pump cool, proceed directly to the Backup LimitThermostat 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.


20

TROUBLESHOOTING

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21

TPC1 TEST COVERS

Figure 5 - TPC1 TEST COVER

CAUTIONNOTE:

Always match color of TPC1 wiringconnections to color of T/Pump wiring.

Route TPC1 wires as shown to avoidinterference with T/Pump fan motor.


22

TEST SETUP

Figure 6 - FUNCTIONAL CHECK TEST DIAGRAM


23

Figure 7 - CIRCUIT DIAGRAM

CIRCUIT DIAGRAM, T/PUMP

AT

TE

NT

ION

Sta

tic-S

ensi

tive

Dev

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FRO

NT

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(220

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Figure 8 - CIRCUIT DIAGRAM FOR TPC1 TEST COVER (P/N 06520-000; to connect, refer to figure 5)

24

CIRCUIT DIAGRAMS, TEST COVERS


25

EXPLODED VIEW

Figure 9 - EXPLODED VIEW


REPLACEMENT PARTS

* The 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).

metI N/P ytQ noitpircseD

1 300-35540 1 ylbmessAevlaV/paC

2 1 ]4metihtiwdedulcnI[eldnaH

3 000-21890 1 ]4metihtiwdedulcnI[lebaLnoitacidniartnoC

4 000-59690 1 ]5dna,3,2smetisedulcni[ylbmessArevoC

5 330-58009 4 ]4metihtiwdedulcnI[pilCrenetsaF

6 000-05630 1 teksaGlliF

7 000-25140 1 naF

8 000-69087 1 ]31metisedulcni[tiKrotoM

9 200-09119 3 TSS23-6,tuN

01 000-36690 1 retaeH

11 000-96050 2 teksaGretaeH

21 300-58009 1 pilCthgiLPMETREVO

31 000-77840 1 ]8metihtiwdedulcni[teksaGlaeSrotoM

41 110-27219 8 TSS,Bepyt,"8/5x02-6,wercS

51 000-08087 1 ]43dna13metisedulcni[*tatsomrehT,tkrBrosneS/wyarT

61 000-86970 1 laeSriovreseR

71 950-81009 4 TSS,"8/3x23-6,wercS

81 000-76530 1 gnisuoHpmuP

91 000-11630 1 rellepmI

02 750-81009 1 TSS,"4/1x23-6,wercS

12 000-86530 1 gnisuoHmottoB

22 110-41509 6 TSS,TBepyt,"8/5x02-6,wercS

32 1 ]YLETARAPESELBALIAVATON;4meti/wdedulcni[lebaLrebmuNlaireS

42 000-31187 1 ]72dna,62,52,32,61smetisedulcni[)tiKtnemecalpeR(riovreseR

26


27

REPLACEMENT PARTS


52 000-80890 1 ]42metihtiwdedulcni[lebaLleveLretaW

62 000-58309 4 puCnoitcuS

72 000-48101 1 lebaLsgnitaR

82 000-20018 1 gnolmc9xDI"4/1,gnibuT

92 000-49330 2 gnittiFdlofinaM

03 000-18830 1 rehsaWgniraeBssarB

13 400-24309 1 ]wolebetonees[*)V052(hctiwS

23 310-28219 1 pilchtiwpmaLPMETREVO

33 000-16630 1 yeKtsujdAerutarepmeT

43 000-38111 1 ]51metihtiwdedulcni[lebaLtnorF

53 000-68080 1 ]93dna83smetisedulcni[ylbmessAesoH

63 720-57219 2 TSS,"8/3x04-4,wercS

73 000-57930 1 rotacidnI

83 000-78830 1 ]53metihtiwdedulcni[etiT-kilCelaM

93 000-48830 1 ]53metihtiwdedulcni[etiT-kilCelameF

04 000-76690 1 redlohesuF/eludoMyrtnErewoP

14 120-59609 2 esuF

24

100CP 1 )eporuElatnenitnoC(droCrewoP

200CP 1 )modgniKdetinU(droCrewoP

300CP 1 )ailartsuA(droCrewoP

400CP 1 )dnalreztiwS(droCrewoP

500CP 1 )ylatI(droCrewoP

600CP 1 )kramneD(droCrewoP

700CP 1 )learsI(droCrewoP

.elbaliavaregnolonsipmuP/T274PTehtnodesuhctiwsV052egralehT*hcihw)51meti(ylbmessayartehtecalper,hctiwssihtgnicalpernehW

.hctiwsrellamsehtsedulcni


REPLACEMENT PARTS

28


34 000-98930 1 )decifiro(gnittiFesoH

44 000-88930 1 )ecifiroon(gnittiFesoH

54 000-38930 1 kcolBdlofinaMssarB

64 000-18330 1 teksaGdlofinaM

74 000-63409 1 rehsaWerbiF

84 510-58009 1 pilCrenetsaF

94 000-96930 1 tfahSretemoitnetoP

05 000-35087 1 )dlofinam(tatsomrehTtimiLpukcaB

15 000-26409 2 recapS

25 000-07877 1 rotsimrehtsedulcni,ylbmessAdraoBCP

35 400-93109 2 lanretnI,rehsawkcoL

45 520-81009 2 TSS,"4/1x04-4,wercS

55 ]YLETARAPESELBALIAVATON.4metihtiwdedulcnI[partSesoH

65 100-94890 1 ediSrewoProtalusnI

75 000-94890 ediSlliFrotalusnI

85 250-45419 2 TSSGL"4/1x23-6DHretsilliF-wercS

95 000-79001 1 gniniateR,pilC

1CFT 1 ]NWOHSTON[retemomrehT

1CPT 1 ]NWOHSTON[revoCtseT

9TPT 1 ]NWOHSTON[looTtseTerutarepmeTdnawolF

A02PT 1 tekcarBdeB


29

PC BOARD

Figure 10 - PC BOARD


1 000-68509 1 21-MC6RCreifitceRdellortnoCnociliS

2 ]YLETARAPESELBALIAVATON.25metihtiwdedulcnI[kniStaeH

3 810-82709 1 retemoitnetoP

4 000-17930 1 hctiwSyrucreM

5 193-29009 1 %1,W8/1,mho528,rotsiseR

6 100-23760 1 rotsimrehT

7 721-82709 1 retemoitnetoP

8 130-68809 1 E9503ACCI

9 200-71709 1 419N1,edoiD

01 060-10709 1 V05,fµ001,roticapaC

11 144-29009 1 %5,W5,mhoK81,rotsiseR

21 000-07877 1 ylbmessAdraoBCP

31 421-10709 1 V052,fµ1.0,roticapaC

1 2 3

4

5

6

78

9

10

11

12 13

Authorized CE representative(Europe):

INVATECH GmbH & Co.Wandsbeker Königstraße 27-29D 22041 Hamburg, Germany

®

GAYMAR INDUSTRIES, INC.

10 Centre DriveOrchard Park, NY

14127-2295USA

Phone:(716) 662-8636

FAX:(716) 662-0730

t/pump - stryker corporation · t/pump components figure 3 - t/pump components top bottom [11] [10]...

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