Gaymar TC3003 User guide

Thermacare® REF TC3003

Convective Warming System

Service Manual

P/N: 11898000 Rev. A 3/10

Before you begin . . .

Important

• Refer to the TC3003 Convective Warming

System Operating Manual for detailed
operating instructions. Read and understand
the Operating Manual and all precautions prior
to using the Convective Warming System.

• Review the SAFETY PRECAUTIONS (see page

2) prior to servicing the Convective Warming
Unit (Power Unit).

• For technical assistance, contact your local
dealer.

NOTE: Extremely high storage temperatures
(such as those found in rail cars or automobile
trunks on hot summer days) can cause the
thermostats within this device to actuate. Should
this occur, the REMOVE FROM USE indicator will
light when the Power Unit is turned on. If this
happens, the thermostats must be manually
reset. Refer to section 7, Functional Check and

Safety Inspection.

Symbols used within this manual:

Attention: consult accompanying
documents

Dangerous voltage

Protective earth (ground)

Type BF applied equipment

Off-on switch

Fan only (no heat)

32°C

16°C - 29°C

38°C

43°C

46°C

REMOVE FROM USE
(indicator light, amber color)

Do not use in operating room
(OR) or Intensive Care Unit (ICU)

Ambient operating temperature

Table of Contents

Contents

Section Introduction Page

1.0 Safety Precautions .............................................................. 2

2.0 Repair Policy / Return Authorization ..................................... 3

3.0 Specifications...................................................................... 4

4.0 Theory of Operation ............................................................. 5

5.0 Controls and Indicators ........................................................ 7

6.0 Preventive Maintenance ....................................................... 7

7.0 Functional Check and Safety Inspection ............................... 8

8.0 Inspection Form ................................................................ 16

9.0 Troubleshooting................................................................. 19

10.0 Repair Procedures ............................................................. 21

11.0 Drawings/Parts List ........................................................... 24

12.0 TC20 Test Tool Schematic ................................................. 27

13.0 Wiring Diagram ................................................................. 28

Illustrations

Figure Description Page

1 Convective Warming System ...............................................5

2A/B Power Unit Mounting ...........................................................5

3 Pole Mounting Height Limit ................................................. 5

4 Operator Control Panel ........................................................6

5 TC20 Test Tool ....................................................................9

6 Temperature Sensor Location .............................................10

7 Troubleshooting Chart - NO HEAT .......................................19

8 Troubleshooting Chart - NO AIR FLOW................................20

9 Drawing/Parts List .............................................................24

10 Drawing/Parts List .............................................................25

11 Drawing/Parts List .............................................................26

11a Power Cord Plugs ..............................................................27

12 TC20 Test Tool Schematic ..................................................27

13 Wiring Diagram ..................................................................28

Tables

Table Description Page

1 Air Temperatures ................................................................. 4

2 Functional Check/Inspection Form.......................................16

1

Section 1 - Safety Precautions

1.0 Safety Precautions

Review the following SAFETY PRECAUTIONS prior
to testing the Power Unit.

DANGER

• Explosive hazard. Do not use in the
presence of flammable anesthetics.

• Risk of electric shock. Disconnect power
before servicing the TC3003 Power Unit.

WARNING

This device generates heated air flow.
Excessive heat could cause thermal
stress or skin lesions. Failure to follow
these precautions could result in death or
serious injury:

• Use this system only under direction of a

physician. Read and understand the

Operating Manual, Quilt Instructions for
Use, and all precautions before using.

• Repairs should be performed only by
qualified personnel such as certified
biomedical electronics technicians or
certified clinical engineers familiar with
repair practices for servicing medical
devices, and in accordance with the

Service Manual. Damage to the Power
Unit or malfunction could otherwise
result.

• Always perform the FUNCTIONAL
CHECK AND SAFETY INSPECTION after
making repairs and before returning the
Power Unit to patient use. Document
your findings on the INSPECTION
FORM. Improper repair may result in
death or serious injury, equipment
damage, or malfunction.

(continued next column)

WARNING

• After performing the thermostat test
procedure, verify that the TC20 Test Tool
or any installed test jumpers have been
removed before returning the Power Unit
to patient use.

Failure to remove the TC20 Test Tool or
test jumpers may result in death, serious
injury or equipment malfunction.

• Always unplug the Power Unit before
attaching or removing the TC20 Test Tool
or test jumpers and when resetting
thermostats. Failure to unplug the Power
Unit could result in electrical shock and
cause death or serious injury.

• Use only Gaymar replacement par ts as
identified in the parts lists (pp. 24-27). Use
of substitute parts could lead to power
unit malfunction or patient injury.

• The Temperature Control PC Board is
pre-set at the factory. Do not attempt to
calibrate it. Adjustment of the Control PC
Board in the field could result in patient
injury.

• Use care when resetting the thermostats.
Excessive force (force greater than 5
pounds) can damage the overtemp
protection device and/or inadvertently
alter the trip temperature of the device.

CAUTION

• U. S. Federal law restricts this device to
sale by or on the order of a physician.

• For grounding reliability, plug only into a

properly grounded outlet.

• The HEPA filter must be installed correctly.
Failure to install the filter correctly will
prevent it from functioning properly and
could allow unfiltered air to reach the
patient.

• When using an I. V. pole, do not mount the

Power Unit higher than 1 meter. Otherwise,
the Power Unit could tip over.

2

Section 2 - Repair Policy

2.0 Repair Policy

For customers who repair Gaymar Power Units at
their location, this manual contains information to
allow a qualified biomedical technician to make
necessary repairs.

2.1 Limited Warranty

The Thermacare TC3003 Power Unit is warranted
free of defects in material and workmanship under
normal use and operation for a period of two
years, under the terms and conditions of the
Gaymar warranty in place at time of purchase.
During the warranty period, Gaymar will repair or
replace at its sole option, free of charge, any
defective parts or products returned with prior
authorization prepaid to Gaymar Industries.
Consumable items such as filters are excluded.
The full warranty is available from Gaymar upon
request.

Warranty does not cover products abused,
misused, or altered outside the factory. There are
no obligations on the part of Gaymar for
consequential damages arising out of or in
connection with the use or performance of the
product. Gaymar disclaims all implied warranties
including, but not limited to, the implied warranties
of merchantability and of fitness for a particular
purpose.

2.4 Return Authorization

Please contact your local dealer.

2.2 In-Warranty Repairs

All in-warranty field repairs must be authorized by
Gaymar's Export Department before proceeding.

2.3 Out-of-Warranty Repairs

If the Power Unit becomes inoperative and the
cause cannot be determined, the complete Power
Unit may be returned to the factory for servicing at
the purchaser's expense. Please contact
Gaymar's Export Department to obtain a returned
goods (“RG”) number prior to returning
equipment.

3

Section 3 - Specifications

3.0 Specifications

3.1 Physical

Dimensions 42 cm x 28 cm x 27 cm
Weight 6.8 kg
Enclosure Thermoplastic
Filter HEPA filtration down to

0.2 micron particle size

3.2 Electrical

Classification Type BF, Class 1, grounded

equipment suitable for
continuous operation. Not
classified for protection against
harmful ingress of liquid.

Input 220-240 V (± 10%), 50 Hz,

7 amps max

Motor 1/25 HP, single phase
Heater 1200W heating element
Detachable Use only an International

Cord (Harmonized) three wire

cordset using cordage
approved to HD-21. Conductor
size is 1.0 mm
(H05VVF3G1.00)

Circuit Breaker 10 amp
Current Leakage (Earth) 100 microamps max.

(90 microamps typical)

Ground Resistance 0.15 ohms nominal;

Ambient Operating Temperature

16°C to 29°C

Temperature

Setting

Temperature

2

0.5 ohms maximum

Fan only

32°C

3.3 Temperature Settings

The air temperatures are identified on the
operator control panel and indicate the average
air temperature at the hose end using a Quilt.

NOTE: The air temperature around the patient
is affected both by the ambient room
temperature and the use of an insulating
blanket on top of the Quilt.

3.4 Safety System

Dual Patient Safety Temperature Limit
Thermostats

Either of two independently operating
thermostats will shut off the TC3003 at a
preset high limit temperature. The heater
element and blower will remain off until the
thermostat is manually reset.

HeaterOvertemp

Heater overtemp thermostat will shut off the
TC3003 in the event of a blower failure or
lack of air movement. The heater element
and blower will remain off until the
thermostat is manually reset.

High Temp Indicator

The REMOVE FROM USE indicator will light
on the front panel when a patient safety
thermostat or heater overtemp thermostat
has tripped. Also, the heating element and
blower will turn off.

HEPA Filter Interlock Switch

The REMOVE FROM USE indicator will light
on the front panel when the HEPA filter has
been installed incorrectly or is missing. Also,
the heating element and blower will turn off.

3.5 Quilts

38°C

43°C

46°C

Table 1 - Air Temperatures

4

All Quilts are made of a nonwoven layer bonded
to a plastic film.

Quilt material meets U. S. flammability standards:

• NFPA 702 “Normal Flammability”

• CPSC Part 1632

• California Title 19, Subchapter 7

Clear drape material meets NFPA 702 “Normal
Flammability.”

Section 4 - Theory of Operation

4.0 Theory of Operation

4.1 Convective Warming System

The Convective Warming System (fig. 1)
provides a continuous means of warming patients
to help prevent and/or treat hypothermia. The
system consists of a Convective Warming Unit
(Power Unit) and a disposable Quilt. A connecting
hose conducts heated air from the Power Unit to
the Quilt.

Figure 1 - Convective Warming System

4.2 TC3003 Power Unit

The TC3003 Power Unit provides a continuous
source of air to the Quilt. The Power Unit consists
of a HEPA filter, blower, heater, and temperature
controller. The Power Unit is a hand-carried
portable device which has dual mounting
provisions. It can hang on a bedrail or footboard
using the bedrail hooks on the back of the unit
(see fig. 2B). It can also mount to an I. V. pole or
optional accessory stand using the I. V. pole
clamp (see fig. 2A). Output air temperatures may
be set to one of five temperature settings:
fan only, 32°C, 38°C, 43°C, or 46°C.

IV Pole
Clamp

Figure 2A - I. V. Pole or Stand mounted

Bedrail
Hook

Figure 2B - Bed rail mounted

CAUTION

When using an I. V. pole, do not mount the
Power Unit higher than 1 meter (see fig. 3).

Otherwise, the Power Unit could tip over.

1 meter

maximum

Figure 3 - Pole mounting height limit

5

Section 4 - Theory of Operation (cont’d)

32°C

Ambient air is drawn in through air vents in the
bottom of the enclosure. Air passes through a
HEPA filter and across a 1200 watt, open coil
heater located in the inlet of a blower. Output air
temperature is monitored by a thermistor located
directly in the output air stream (plenum) and
provides feedback to the solid-state controller.
The controller compares the output air
temperature to the selected temperature and,
using an on-off control scheme, turns the heater
on or off accordingly. The maximum output air
temperature is limited not only by the control
system but by two redundant bimetallic latching
thermostats. These thermostats are located in the
output air stream and will interrupt power to both
the heater and the blower, and light the REMOVE
FROM USE indicator on the front panel should the
output air temperature exceed predetermined
limits. A similar thermostat located directly above
the heater is used to protect the internal
components in the event of a motor failure. It too
will interrupt power to the heater and blower and
light the REMOVE FROM USE indicator.

38°C 43°C 46°C

Figure 4 - Operator Control Panel

4.3 Quilts

The Quilts distribute air evenly over the covered

areas of the patient through openings in the
patient side of the Quilt. Quilts consist of layers
of plastic and nonwoven material bonded
together. Refer to the instructions enclosed with

each Quilt.

Air is delivered to the Quilt using a permanently
attached, flexible hose. The hose has a sleeve
which is stain resistant and easy to clean.

6

Section 5 - Controls and Indicators
Section 6 - Preventive Maintenance

5.0 Controls and Indicators

5.1 Power

An on/off circuit breaker is located on the front
of the unit in the bottom left corner. It controls
power to the entire unit. When switched to the
ON position, a power indicator in the switch will
light.

5.2 Control Panel

An operator control panel (fig. 4, p. 6) is
mounted at the top of the Power Unit:

• [Power Up] When the power unit is turned on,
the system defaults to the 32°C temperature
setting. A green light directly above the
selector switch will glow indicating the
selected temperature range.

• [Temperature Settings] Temperature settings
are selected by pressing the appropriate push­button -- fan only, 32°C, 38°C, 43°C, or 46°C.

• [Power Interruption] If electrical power is
interrupted momentarily, the existing
temperature setting will remain. If electrical
power remains off, the TC3003 will default to
the 32°C setting when power is restored.

A REMOVE FROM USE indicator will light:

• if a patient safety thermostat or heater
thermostat has tripped.

• if the HEPA filter has been installed incorrectly
or is missing.

The heating element and blower will automatically
turn off when these conditions occur.

6.0 Preventive Maintenance

6.1 HEPA Filter

Dirt that has accumulated on the internal HEPA air
filter will reduce the efficiency of the blower and
heater. Under normal use, replace the HEPA filter
every 1000 operating hours or 12 months,
whichever occurs first. Replace the filter only with
the Gaymar P/N listed (see parts list, fig. 9, p.24).

WARNING

Use only Gaymar replacement parts as
identified in the parts lists (pp. 24-27).

Use of substitute parts could result in
power unit malfunction or patient injury.

Refer to Functional Check, 7.6 Filter Switch Test
& Filter Replacement (p. 14) for instructions.

6.2 Blower

The blower motor and fan do not require
lubrication.

6.3 Enclosure Exterior

Clean the control panel and Power Unit exterior
with a soft cloth lightly dampened with a
nonstaining hospital disinfectant.

6.4 Quilts

Quilts are not sterile.
Quilts are intended for single patient use only.
Quilts should be discarded after use.

Small rips or tears in quilt material may be
temporarily fixed with adhesive tape.

6.5 Hose

Clean the hose with a soft cloth lightly dampened
with a nonstaining hospital disinfectant. Place the
connector hose under the bed rail hooks when not
in use.

6.6 Air Vents

Clean accumulated dirt from the air vents with a
vacuum cleaner.

7

Section 7 - Functional Check and Safety Inspection

7.0 Functional Check and Safety
Inspection

To assure optimum performance, dependability
and safety, perform FUNCTIONAL CHECK AND

SAFETY INSPECTION as follows:

• After repair, and every 12 months thereafter
— the FUNCTIONAL CHECK AND SAFETY
INSPECTION consists of all procedures

(sections 7.1 through 7.9).

If your facility's procedures call for more
frequent functional test and safety inspections,
note this fact on the INSPECTION FORM.

Inspection Form

An INSPECTION FORM (table 2, pp. 16-18) is
provided at the end of this section to facilitate
and document the inspection process.

Test Equipment

The following test equipment (or equivalent) is
required in order to perform the preventive
maintenance procedures:

• Digital air thermistor thermometer
(YSI 400 series)

Range: 10°C to 71°C
System accuracy: ± 0.6°C

• Temperature sensor
(P/N 77948-000)

NOTE:

1. Include the accuracy of the measuring

equipment when making judgments
about observed temperature readings.

2. Test Conditions: 230 VAC ± 2 ,

21°C-24°C ambient (with heater on); this
may require the use of a variable
transformer.

• #2 Phillips screwdriver

• Current Leakage / Ground Resistance Tester

• Model TC1050CE, TC2050CE, TC2052CE, or

TC2054CE Quilt

• Adhesive Tape

• TC20 Test Tool*, or two 16 gauge insulated
Test Jumpers

* The TC20 Test Tool is available from

Gaymar. This tool was designed to allow
for more convenient testing of the
thermostats and eliminate the need to
install jumpers. Contact Gaymar's
Technical Service Department for more
information.

• INSPECTION FORM (table 2, pp. 16-18)

Procedures

Perform the following procedures carefully,
paying particular attention to test setups. Any
deviation from the setups, procedures, or test
equipment may result in incorrect or
misleading results.

7.1 Enclosure

Examine the overall condition of the Power Unit
exterior:

1. Unplug the power unit.

2. Examine the enclosure, checking for cracks.

3. Check that exterior screws are tight.

4. Check that labelling and markings are

legible.

5. Clean accumulated dirt from the air vents

with a vacuum cleaner.

6. Check hose assembly for holes and broken

fittings. Replace if necessary.

7.2 Plug, Line Cord

Examine the plug and line cord:

1. Examine the attachment plug on the line cord

to be sure it is in good condition.

2. Examine the line cord along its entire length

for physical damage, such as cuts or
cracked insulation. Replace, rather than
repair, damaged line cords.

• Stopwatch

8

Section 7 - Functional Check and Safety Inspection (cont’d)

7.3 Power Switch

Check the power switch light:

1. Plug in the Power Unit. Turn the power switch
on.

2. Verify that the power switch is lit.

3. Verify the Power Unit starts in the 32°C heat
setting.

7.4 Temperature Settings Switches

Examine the overall condition of the
control panel:

1. Select each of the five temperature settings.
Verify that the appropriate indicator for each
lights.

7.5 Thermostat and REMOVE FROM

USE Alert

Test the Patient Limit Thermostats and REMOVE
FROM USE Alert.

The following procedure describes two different
approaches for measuring the trip points
(actuation temperatures) of the Power Unit's
patient limit thermostats. There are two patient
limit thermostats (item 18, fig. 11, p. 26) within
the Power Unit and each must be tested. The
TC20 Test Tool helps simplify these tests. Steps
1 to 20 (pp. 9-11) should be followed when a
TC20 Test Tool is available. For those facilities not
having access to a TC20, follow steps 21 to 50
(pp. 12-13).

NOTE: A third thermostat, the heater overtemp
thermostat (item 33, fig. 11, p. 26), is provided
to protect internal components in the event of a
motor blockage or failure. It does not need to
be function tested.

7.5.1 TC20 Test Tool Procedure
(steps 1 to 20) [see fig. 10, p. 25, for

TC20 Test Tool part number]

1. Unplug the Power Unit.

WARNING

Always unplug the Power Unit
before attaching or removing the
TC20 Test Tool and when resetting
thermostats. Failure to unplug the
Power Unit could result in
electrical shock and cause death
or serious injury.

2. Remove the six screws on the back of the
unit. Carefully separate the two halves of the
enclosure.

3. Connect the TC20 Test Tool (fig. 5) to the
5-pin field test connector on back of the PC
board and route the TC20 Test Tool cable out
through the opening in the bottom of the unit
(see fig. 10, p. 25). Close the two halves of
the enclosure and temporarily secure it
closed with adhesive (duct) tape. Plug in the
power unit.

S3S2

THERMOSTAT

BYPASS

OVERTEMP

HEAT

Figure 5 - TC20 Test Tool

(for schematic, see figure 12, p. 27)

9

Section 7 - Functional Check and Safety Inspection (cont’d)

Figure 6A - Hose detail, showing sensor location Figure 6B - Test setup

Figure 6 - Temperature sensor location

4. Set the two TC20 Test Tool toggle switches as
follows:

• THERMOSTAT BYPASS -- place in center

position;

• HEAT/OVERTEMP -- place in HEAT

position.

5. Locate the air temperature sensor at the center
of the end of the hose (fig. 6A). Secure the
sensor with adhesive tape. Verify that the

sensor is located at the center of the hose.

6. Connect the hose to a Model TC1050CE,
TC2050CE, TC2052CE, or TC2054CE Quilt
(fig. 6B).

7. Turn the Power Unit on. Select the 46°C
setting.

8. Run the Power Unit for 5 to 10 minutes at the
46°C setting. The temperature will oscillate.
During this time interval, familiarize yourself
with the following steps 9 through 14. Have a
stopwatch ready.

9. Place the HEAT/OVERTEMP switch to
OVERTEMP. The temperature should start to
increase. When the air temperature reaches
48°C, start the stopwatch.

10. Allow the Power Unit to heat until either the S2
or S3 Test Tool thermostat indicator is lit. Stop
the stopwatch and note the highest
temperature displayed. This is the upper limit
temperature for one of the thermostats.
Record the time and temperature on the
INSPECTION FORM.

Verify that the REMOVE FROM USE light is lit.

NOTE: It is acceptable if both thermostats
trip simultaneously, in which case the S2
and S3 indicators will both be off. If this
occurs, record the elapsed time and
temperature. Verify that the REMOVE FROM
USE indicator is lit. Verify that both the S2
and S3 indicators light by toggling the
THERMOSTAT BYPASS switch from the S2 to
S3 position. (If both thermostats have
tripped, skip steps 11-14 and proceed to
step 15.)

11. Switch the TC20 THERMOSTAT BYPASS to
whichever thermostat (S2 or S3) is lit. This
will short out the thermostat which opened
first so that the second thermostat can be
tested.

Switch the TC20 from OVERTEMP to HEAT to
allow the Power Unit to return to normal
operating temperature before testing the
second thermostat.

12. Run the Power Unit again for 5 to 10 minutes
in the 46°C setting. The temperature will
oscillate. Have a stopwatch ready.

13. Place the OVERTEMP/HEAT switch to
OVERTEMP. The temperature should start to
increase. When the air temperature reaches
48°C, start the stopwatch.

14. Continue to monitor the TC20 Test Tool until
the second thermostat indicator is lit. Stop the
stopwatch and note the highest temperature
displayed. This is the upper limit temperature

10

Section 7 - Functional Check and Safety Inspection (cont’d)

ARNING

for the other thermostat. Record the time and
temperature on the INSPECTION FORM (table
2, pp. 16-17). Plot these values on table 2, p.

18.

Verify that the REMOVE FROM USE light is lit.

15. Thermostat trip acceptance

Both thermostats must trip within the
acceptance window (see table 2, p. 18).
If this condition is not met, do not put the
Power Unit in service. Call Gaymar's Technical
Service Department for assistance (see inside
front cover for telephone numbers).

16. Unplug the power unit. Open the enclosure to
allow the Power Unit to cool for 5-10 minutes.

17. Locate the two patient limit thermostats (item
18, fig. 11, p. 26). Reset S2 by gently pressing
the center reset button.

WARNING

Use care when resetting the
thermostats. Excessive force (force

greater than 5 pounds) can damage
the overtemp protection device and/
or inadvertently alter the trip
temperature of the device.

NOTE: Use care when resetting the
thermostats since the power terminals are
delicate. Avoid flexing the terminals.
Thermostats with loose terminals should be
replaced and retested.

18. Press the center reset button of S3. Verify it
has reset (indicated by an audible "click" and
tactile feedback). If it "clicks", proceed to step

19.

If you don't hear a "click", then what was
assumed to be the patient limit thermostat S3
tripping was actually the heater overtemp
thermostat S4 in the same circuit. This will
rarely occur. If it has occurred, proceed as
follows:

a. Remove the filter retainer and nut.

Remove the filter. Jumper out the S4
thermostat. Replace the filter, filter
retainer and nut.

c. Bypass S2 by placing the

THERMOSTAT BYPASS switch in the
S2 position. Place the HEAT/
OVERTEMP Switch to OVERTEMP.
Allow the Power Unit to operate. When
the air temperature reaches 48°C,
start the stopwatch.

d. Allow the Power Unit to heat until the

S3 thermostat indicator is lit. Stop the
stopwatch and note the highest
temperature displayed. This is the
upper limit temperature for the S3
thermostat. Record the elapsed time
and temperature.

e. Verify that the REMOVE FROM USE

light is lit.

f. The S3 thermostat must trip within the

acceptance window (see table 2, p.

18). If this condition is not met, do not
put the Power Unit in service. Call
Gaymar's Technical Service
Department for assistance (see inside
front cover for telephone numbers).

g. Unplug the Power Unit.

h. Open the enclosure and allow the

Power Unit to cool for 5-10 minutes.

i. Remove the filter retainer and nut.

Remove the filter. Remove the jumper
from the S4 thermostat. Press the S4
reset button and insure it is reset.
Replace the filter, filter retainer, and
nut.

j. Reset both the S3 and S2 thermostats

by pressing their center reset buttons.
(The S2 thermostat may have
retripped.)

19. Remove the TC20 Test Tool.

WARNING

After performing the preceding test
procedure, verify that the TC20 Test
Tool and all jumpers have been
removed before returning the Power
Unit to patient use. Failure to do so

may result in death, serious injury,
or equipment malfunction.

b. Run the Power Unit for 5 to 10 minutes

in the 46°C setting.

20. Proceed to the FILTER SWITCH TEST

(section 7.6, p. 14).

11

Section 7 - Functional Check and Safety Inspection (cont’d)

7.5.2 ALTERNATE Test Jumper
Procedure (steps 21 to 50)

21. Unplug the Power Unit.

WARNING

Always unplug the Power Unit
before attaching or removing
jumpers and when resetting
thermostats. Failure to unplug the
Power Unit could result in
electrical shock and cause death or
serious injury.

22. There are two patient limit thermostats within
the Power Unit and each must be tested. One
16 gauge insulated stranded wire jumper with
alligator clips will be required. To help
remember to remove the test jumper, label a
LARGE, distinctive tag “REMOVE AFTER
TEST” and tie the tag to the jumper.

Remove the six screws on the back of the
unit. Install a jumper across thermostat S3
(item 18, fig. 11, p. 26). Temporarily secure
the two halves of the enclosure together with
adhesive (duct) tape.

23. Locate the air temperature sensor at the
center of the end of the hose (fig. 6A, p. 10).
Secure the sensor with adhesive tape. Verify

that the sensor is located at the center of
the hose.

26. Unplug the Power Unit. Carefully separate the

enclosure slightly.

27. Unplug the thermistor (item 13, fig. 10,
p. 25) from the back of the control board.

NOTE: The power resistor on the back side
of the PC board may be hot to touch.

28. Put the enclosure back together and secure it
with adhesive (duct) tape.

29. Plug in the Power Unit and turn it on. Leave
unit in 32°C temperature setting. Have a
stopwatch ready.

NOTE: Do not set the TEMPERATURE
SETTINGS switch to fan only since this
setting disables the heater.

30. The temperature should increase. When the
air temperature reaches 48°C, start the
stopwatch. The Power Unit will heat until the
S2 thermostat trips. When this happens, the
blower and heater will shut off. Stop the
stopwatch and note the highest temperature
displayed. This is the upper limit temperature
for thermostat S2. Record the time and
temperature on the INSPECTION FORM
(table 2, pp. 16-17).

31. Verify that the REMOVE FROM USE light is lit.

32. Unplug the Power Unit.

33. Open the enclosure and allow the Power Unit
to cool for 5-10 minutes.

34. Locate the two patient limit thermostats (item
14, fig. 11, p. 26). Gently press the reset
button in the center of each thermostat. Move
the jumper across thermostat S2.

24. Connect the hose to a Model TC1050CE,
TC2050CE, TC2052CE, or TC2054CE Quilt
(fig. 6B, p. 10).

25. Plug in the Power Unit and turn it on. Select
the 46°C setting. Run the Power Unit for 5 to
10 minutes. The temperature will oscillate.
During this time interval, familiarize yourself
with the following steps 26 through 31, so
that the procedure can be accomplished
quickly, without letting the Power Unit cool.

NOTE: Perform the following steps 26
through 31 as quickly as possible, to
prevent the Power Unit from cooling down:

12

WARNING

Use care when resetting the
thermostats. Excessive force (force

greater than 5 pounds) can
damage the overtemp protection
device and/or inadvertently alter
the trip temperature of the device.

NOTE: If both thermostats reset, both
thermostats have tripped. This is
acceptable.

Section 7 - Functional Check and Safety Inspection (cont’d)

NOTE: Use care when resetting the
thermostats since the power terminals are
delicate. Avoid flexing the terminals.
Thermostats with loose terminals should
be replaced and retested. Be certain the
thermostats have cooled for 5-10 minutes
before resetting.

NOTE: If thermostat S2 does not reset, the
heater overtemp thermostat has tripped. In
the unlikely event that this has occurred,
perform the following:
a) remove the filter retainer and nut;
b) remove the filter;
c) jumper the S4 heater overtemp
thermostat; and
d) replace the filter, filter retainer, and nut.
Return to step 25.

35. Reconnect the thermistor to the control
board.

36. Put the enclosure back together and secure it
with tape.

37. Plug in the Power Unit. Turn it on.

38. Run the Power Unit for 5-10 minutes in the
46°C setting to stabilize the system
temperature.

NOTE: Perform the following steps 39 through
44 as quickly as possible, to prevent the Power
Unit from cooling down:

39. Unplug the Power Unit. Carefully separate
the enclosure slightly.

40. Unplug the thermistor (item 13, fig. 10, p.

25) from the back of the control board.

and note the highest temperature displayed.
This is the upper limit temperature for that
thermostat. Record the time and temperature
on the INSPECTION FORM (table 2, p. 17).
Plot these values on table 2, page 18.

44. Verify that the REMOVE FROM USE light is lit.

45. Unplug the Power Unit.

46. Open the enclosure and allow the Power Unit
to cool for 5-10 minutes.

47. Thermostat trip acceptance

Both thermostats must trip within the
acceptance window (see table 2, p. 18).
If this condition is not met, do not put the
Power Unit in service. Call Gaymar's
Technical Service Department for assistance
(see inside front cover).

48. Remove the jumper from the patient limit
thermostat.

If a jumper was used on the S4 heater
overtemp thermostat, remove the filter
retainer, nut, and filter. Remove the jumper
from S4. Reset S4 (indicated by an audible
"click" and tactile feedback). Replace the
filter, filter retainer, and nut.

WARNING

After performing the preceding test
procedure, verify that all test jumpers
have been removed before returning
the Power Unit to patient use.

Failure to remove test jumper(s)
may result in death, serious injury,
or equipment malfunction.

41. Put the enclosure back together and secure it
with tape.

42. Plug in the Power Unit and turn it on. Leave
unit in 32°C temperature setting. Have a
stopwatch ready.

NOTE: Do not set the TEMPERATURE
SETTINGS switch to fan only since this
setting disables the heater.

43. The temperature should start to increase.
When the air temperature reaches 48°C, start
the stopwatch. Allow the Power Unit to heat
until thermostat S3 trips. Stop the stopwatch

49. Reconnect the thermistor connector to the
back of the control board.

(continued)

13

Section 7 - Functional Check and Safety Inspection (cont’d)

50. Reset the thermostats by gently pressing the
center reset buttons.

WARNING

Use care when resetting the
thermostats. Excessive force

(force greater than 5 pounds) can
damage the overtemp protection
device and/or inadvertently alter
the trip temperature of the device.

NOTE: Use care when resetting the
thermostats since the power terminals are
delicate. Avoid flexing the terminals.
Thermostats with loose terminals should
be replaced and retested.

7.6 Filter Replacement and Filter

Switch Test (every 12 months or 1000
operating hours, whichever occurs first)

1. Unplug the Power Unit. Separate the two

halves of the enclosure. Lay the Power Unit
on its back.

2. Remove the filter retainer and nut. Remove
the filter.

3. Put the enclosure back together and secure it
with tape.

4. Plug in the Power Unit. Turn it on. Verify that
the blower does not start and that the
REMOVE FROM USE light is lit.

5. A timer which counts total running hours is
located inside the Power Unit for use by
service personnel. Timer readings may be
used to track HEPA filter usage intervals. To
read the hour timer:

a. Unplug the Power Unit. Separate the

two halves of the enclosure again.
Locate the hour timer (see figure 10, p.

25). Plug in the Power Unit and turn it
on. Read the hour timer and record the
total running hours on the INSPECTION

FORM.

6. Unplug the Power Unit. Install filter. (Install
new filter every 1000 operating hours or 12
months, whichever occurs first.) Replace the
filter only with the Gaymar P/N listed (see
parts list, fig. 9, p.24). Record the hour timer
reading onto the new filter label. Reattach
filter and nut.

CAUTION

The HEPA filter must be seated
properly. Failure to install the filter

correctly will prevent it from
functioning properly, and could
allow unfiltered air to reach the
patient and cause injury.

7. Replace the six screws holding the
enclosure together.

7.7 Quilt Temperature

Verify temperature output at each heat setting:

1. Prepare the Power Unit test setup, if it has
not been previously prepared:

a. Locate the air temperature sensor at

the center of the end of the hose (fig.
6A, p. 10). Secure the sensor with
adhesive tape. Verify that the sensor

is located at the center of the hose.

b. Connect the hose to a Model

TC1050CE, TC2050CE, TC2052CE,
or TC2054CE Quilt (fig. 6B, p. 10).

c. Plug in the Power Unit and turn it on.

2. Set the TEMPERATURE SETTINGS switch to
32°C. Run the Power Unit for 5 minutes.
After 5 minutes, note the two highest and
two lowest temperature readings. Record the
average of these four temperatures on the
INSPECTION FORM (table 2, p. 17).

Allowable 32°C temperature:

30.6°C to 33.9°C average

b. Turn the Power Unit off.

14

Section 7 - Functional Check and Safety Inspection (cont’d)

3. Repeat step 2 for 38°C setting. Average

temperatures and record.

Allowable 38°C temperature:

36.1°C to 39.4°C average

4. Repeat step 2 for 43°C setting. Average

temperatures and record.

Allowable 43°C temperature:

41.7°C to 45.0°C average

5. Repeat step 2 for 46°C setting.

Allowable 46°C temperature:

44.7°C to 47.5°C average

6. If the temperatures in steps 2 through 5 are
not correct, do not put the Power Unit into
service. Call your local dealer for assistance.

7. Unplug the Power Unit.

7.8 Ground Resistance

Check grounding resistance:

7.10 Completing the Functional Check
and Safety Inspection

If the Power Unit has passed the FUNCTIONAL
CHECK AND SAFETY INSPECTION for all

requirements of procedures 7.1 through 7.9 , the
Power Unit should be considered operational and
suitable for return to service.

This completes the recommended FUNCTIONAL
CHECK AND SAFETY INSPECTION for the TC3003
series Power Unit.

1. Use a current leakage/ground resistance
tester to measure the resistance between the
grounding pin on the power entry module
and the I. V. pole clamp. An unplated area on
the underside of the I. V. pole clamp has
been provided for this test. Record the value.

2. The value should be less than 0.5 ohms.

7.9 Current Leakage

Measure current leakage:

1. Measure and record the maximum earth
current leakage (ground open). An unplated
area on the underside of the I. V. pole clamp
has been provided if needed for this test.
Measure at all combinations of:

• line polarity

• neutral open/closed

2. The current leakage should not exceed 100
microamperes in any condition.

15

Section 8 - Inspection Form

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16

Table 2 - Functional Check / Inspection Form (p. 1)

Section 8 - Inspection Form (cont’d)

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Table 2 - Functional Check / Inspection Form (p. 2)

17

Section 8 - Inspection Form (cont’d)

70

68

Fail (Thermostat trip point too high)

64

66

62

60

58

PASS (Safe range)

56

54

Hose output air temperature (°C)

Fail (Thermostat trip point too low)

50

52

Time (Seconds)

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

48

18

Table 2 - Functional Check / Inspection Form (p. 3)

Section 9 - Troubleshooting

WARNING

Always perform the FUNCTIONAL CHECK

AND SAFETY INSPECTION

after making
repairs and before returning the Power Unit
to patient use. Failure to perform the

FUNCTIONAL CHECK AND SAFETY
INSPECTION could result in patient injury.

SYMPTOM:

NO HEAT

DOES
QUILT

INFLATE?

In addition to the following troubleshooting
charts, refer to PREVENTIVE MAINTENANCE
(section 6, p. 7) and REPAIR PROCEDURES
(section 10, pp. 21-23).

NO

GO TO NO AIR FLOW

SYMPTOM

YES

PRESS

EACH SETTING

BUTTON. DOES

CORRESPONDING

LED LIGHT?

YES

UNPLUG UNIT;

MEASURE HEATER

RESISTANCE

IS

HEATER

RESISTANCE

BETWEEN 36.4

AND 40.2

OHMS?

YES

UNPLUG RT1
THERMISTOR

ASSY. TURN
POWER ON.

DOES

UNIT HEAT?

NO

NO

NO

TECHNICAL SERVICE

CALL TECHNICAL

SERVICE

REPLACE HEATER

SUSPECT PC

BOARD; CONTACT

YES

REPLACE RT1

THERMISTOR ASSY

Figure 7 - Troubleshooting Chart - NO HEAT

19

Section 9 - Troubleshooting (cont'd)

SYMPTOM:

NO AIR FLOW

ENSURE UNIT IS

PLUGGED IN

IS CIRCUIT

BREAKER LIT?

IS

RFU LIT?

UNPLUG

UNIT AND

OPEN IT

IS FILTER

INSTALLED

CORRECTLY?

YES

YES

YES

NO

NO

NO

UNPLUG UNIT; CHECK

CIRCUIT BREAKER

REPAIR/REPLACE

CALL TECH SERVICE

REINSTALL

FILTER

IS S2

OR S3

TRIPPED?

S4 HAS

TRIPPED

RESET S4

POWER UP

UNIT.

AIRFLOW?

NO

YES

YES

NO

RESET

S2, S3

IS THERE A
BLOCKED,BENT,
OR MISALIGNED

BLOWER WHEEL?

REPAIR/REPLACE

MOTOR

NO

IS RT1

THERMISTOR ASSY

CONNECTED?

YES

RUN UNIT IN

32°C SETTING

FOR 10 MINUTES

REMOVE BLOCKAGE;

YES

REPLACE/ALIGN
BLOWER WHEEL

PERFORM

FUNCTIONAL

CHECK

NO

RECONNECT RT1

THERMISTOR

POSSIBLE CONTROLLER

FAILURE; CALL TECH

ASSEMBLY

DOES RFU
REOCCUR?

SERVICE

YES

PERFORM

FUNCTIONAL

CHECK

PERFORM FUNCTION CHECK-­POSSIBLE CAUSES:

NO

1. TOO HIGH STORAGETEMP

2. UNIT OUT OF CAL.

3. LOW SPEC ON S2, S3

Figure 8 - Troubleshooting Chart - NO AIR FLOW20

Section 10 - Repair Procedures

10.0 Repair Procedures

WARNING

Use only Gaymar replacement parts as
identified in the parts lists (pp. 24-27).

Use of substitute parts could result in
power unit malfunction or patient injury.

To identify replacement parts, refer to figures
9-11 (pp. 24-27). To order replacement par ts,
contact Gaymar's Export Department:

Telephone: [phone]

Fax: [phone]

10.1 Replacing the Patient Limit
Thermostat(s) (S2 & S3)

To replace either thermostat (item 18, fig. 11):

1. Unplug the Power Unit.

2. Remove the six screws securing the
enclosure. Open the enclosure.

3. Carefully unplug the terminals from the
thermostat.

4. Remove the two #4 nuts from the
thermostat.

5. Replace the thermostat. Reinstall the nuts.

6. Carefully replace the terminals.

7. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).

4. Remove the ten screws securing the filter
inlet plate.

5. Remove the screw and lock washer securing
the ground wire to the backing plate.
Remove the two screws securing the
terminal block.

6. Carefully lift the filter inlet plate, exposing the
blower wheel.

7. Remove the blower wheel using
wrench through hole in one blade of blower
wheel.

8. Remove the two #6 screws holding the
heater to the motor bracket.

9. Disconnect the short wire from the heater to
the motor.

10. Remove the red heater wire from terminal
block location TB1-3 (refer to figure 11).
Remove cable ties.

11. Remove the heater.

12. Install the replacement heater.

13. Reroute the red wire through the 4-hole
grommet.

14. Reconnect both wires. Refer to TB1
designators in the schematic (figure 13) and
terminal block wiring designators in figure

11. Install cable ties.

15. Reinstall the blower wheel, making sure
there is 2.5 mm clearance between the
wheel and the blower inlet ring (see fig. 9).
(NOTE: the hex screw must be aligned with
the flat on the motor shaft.)

1

/8" hex

10.2 Replacing the Heater

To replace the heater (item 3, fig. 9):

1. Unplug the Power Unit.

2. Remove the six screws securing the
enclosure. Open the enclosure.

3. Remove the filter retainer and nut. Remove
the HEPA filter.

16. Place the filter inlet plate back on top of the
scroll. Secure the ten screws.

17. Replace the terminal block. Reconnect the
ground wire to the backing plate; make sure
the lock washer is reinstalled.

18. Replace the HEPA filter. Secure it with the
filter retainer and nut.

19. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).

21

Section 10 - Repair Procedures (cont’d)

10.3 Replacing the Thermistor
Assembly (RT1)

To replace the thermistor assembly (item 4, figs.
9-10):

1. Unplug the Power Unit.

2. Remove the six screws securing the
enclosure. Open the enclosure.

3. Unplug the thermistor assembly from the PC
board.

4. Cut the cable ties holding the thermistor wires
to the wire harness and enclosure standoff.
Be careful not to cut the insulation on the
standoff.

5. Remove the filter retainer and nut. Remove
the filter.

6. Remove the ten screws securing the filter
inlet plate.

7. Remove the two screws securing the terminal
block. Remove the screw and lock washer
securing the ground wire to the backing plate.

8. Depending on the method of mounting, either
use wire cutters to remove the spring clip, or
loosen the speed nut securing the thermistor
assembly to the filter inlet plate.

9. Replace the thermistor assembly. Secure it
with the new speed nut supplied with the
thermistor assembly.

10. Place filter inlet plate back on top of the
scroll. Secure the ten screws.

11. Replace the terminal block. Reconnect the
ground wire to the backing plate. Make sure
the lock washer is reinstalled.

12. Plug the thermistor assembly into the control
board. Use the cable ties supplied with the
thermistor assembly to hold the thermistor
wires to the PC board wire harness and
enclosure standoff.

13. Replace the HEPA filter. Secure it with the
filter retainer and nut.

14. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).

10.4 Replacing the motor

To replace the motor:

1. Unplug the Power Unit.

2. Remove the six screws securing the
enclosure. Open the enclosure.

3. Remove the filter retainer and nut. Remove
the filter.

4. Remove the ten screws securing the filter
inlet plate.

5. Remove the screw securing the ground wire
to the backing plate. Remove the two screws
securing the terminal block.

6. Carefully lift the filter inlet plate, exposing the
blower wheel.

7. Remove the blower wheel using a
wrench through hole in one blade of blower
wheel.

8. Cut wire tie holding wiring harness (fig. 11).

9. Unplug terminals from the motor.

10. Remove the two #8 screws and two #8 nuts
from the bottom of motor.

11. Loosen the two #8 screws on top of motor.
Slide filter support bracket off. Loosen
corresponding screws on new motor and
replace filter support bracket. Tighten
screws.

12. Remove and replace the motor.

13. Secure with mounting hardware.

14. Reconnect the terminals.

15. Secure wire harness to motor with a wire tie.

16. Reinstall the blower wheel, making sure there
is 2.5 mm clearance between the wheel and
the blower inlet ring (see fig. 9).
NOTE: the hex screw must be aligned with
the flat on the motor shaft.

17. Place the filter inlet plate back on top of the
scroll. Secure the ten screws.

18. Replace the terminal block. Reconnect the
ground wire to the backing plate; make sure
the lock washer is installed.

1

/8" hex

22

Section 10 - Repair Procedures (cont’d)

19. Replace the HEPA filter. Secure it with the
filter retainer and nut.

20. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).

10.5 Replacing the I. V. Pole Mount

Bracket

To replace the I. V. pole mount bracket:

1. Unplug the Power Unit.

2. Remove the six screws securing the
enclosure. Open the enclosure.

3. Remove the two screws securing the
terminal block from the backing plate.

4. Remove the two screws and the lock washer
holding the I. V. pole mount bracket to the
backing plate.

5. Remove the I. V. pole mount bracket from the
rear half of the enclosure.

6. Insert new I. V. pole mounting bracket into
rear half of the enclosure.

7. Replace the two screws and the lock washer
into the backing plate and I. V. pole mounting
bracket.

8. Replace the terminal block.

2. Remove the six screws securing the
enclosure. Open the enclosure.

3. Cut the four cable ties which secure the PC
board wires together.

4. Unplug the following wires from the PC
board assembly at the terminal block (item
30, fig. 11):

• Yellow wire from TB1-1C

• Gray wire from TB1-2C

• Red wire from TB1-3C

• White wire from TB1-4C

• Black wire from TB1-5C

5. Unplug the main harness (5-pin connector)
from PC board.

6. Unplug the 2-pin harness from the PC board.

7. Remove the six screws securing the PC
board assembly.

8. Remove the old PC board assembly and
install the new PC board assembly.

9. Reassemble in reverse order.

10. Perform the FUNCTIONAL CHECK AND

SAFETY INSPECTION (section 7, pp. 8-15).

9. Perform the FUNCTIONAL CHECK AND
SAFETY INSPECTION (section 7, pp. 8-15).

10.6 Temperature Control PC Board

WARNING

The Temperature Control PC Board is
pre-set at the factory. Do not attempt to
calibrate it. Adjustment of the Control
PC Board in the field could result in
patient injury.

To replace the P.C. board assembly
(item 11, fig. 10):

1. Unplug the Power Unit.

23

Section 11 - Drawings/Parts Lists

Item Description Part Number

1 HEPA filter 78018-000
2 Filter retainer nut 91396-005
3 Heater 78019-000
4 RT1 Thermistor assembly 77942-000
5 Blower wheel 91369-000
6 a. Clip 90228-004

b. Rachet 91428-002
7 Label, Caution 08985-000
8 Bed rail hook 77943-000

6a

6b

4

3

5

2.5 mm

2

7

8

24

1

Figure 9 - TC3003 Detail Drawing

Section 11 - Drawings/Parts Lists (cont’d)

12

4

TEST PLUG

HOUR TIMER

11

13

14

10

9

S3S2

Figure 10 ­TC3003 Detail Drawing

THERMOSTAT

BYPASS

OVERTEMP

HEAT

25

Section 11 - Drawings/Parts Lists (cont’d)

21

20

19

S2

S3

22

23

24

25

26

27

28

29

30

31

18

17

16

wire tie

ROTATION

32

33

S4

34

35

To release wires from
terminal block, insert a
small screwdriver in
slot nearest wire and
pull towards center.

26

Figure 11 - TC3003 Detail Drawing

Section 12 - TC20 Test Tool Schematic

PC001

PC004

PC006PC002 PC005 PC007PC003

Figure 11A - Power cord plugs

metInoitpircseDrebmuNtraPmetInoitpircseDrebmuNtraP

61eludomyrtnerewoP000-3998003noituaC,lebaL000-06990

71tikrotoM000-2208713kcolblanimreT000-64319

81)3S,2S(statsomrehttimiltneitaP500-3231923ylbmessapartsdroC000-19730

91ylbmessaesoH000-0597733)4S(tatsomrehtretaeH000-52087

02tnemecalperlebal,drac,tiK000-0118743hctiwskcolretnI000-57319

12)gnilebalsedulcni(tikgnisuohraeR200-8118753GL"2/14,gniveelS000-45018

22ylbmessapmalcelop.V.I000-41680--)eporuElatnenitnoC(drocrewoP100CP

32eohselggoT000-93419--)modgnIKdetinU(drocrewoP200CP

42knalB/keerG,noitacidniartnoC,draC000-77890--)ailartsuA(drocrewoP300CP

52hsinniF/hsidewS,noitacidniartnoC,draC000-67890--)dnalreztiwS(drocrewoP400CP

62hsinaD/hctuD,noitacidniartnoC,draC000-57890--)ylatI(drocrewoP500CP

72namreG/nailatI,noitacidniartnoC,draC000-47890--)kramneD(drocrewoP600CP

82eseugutroP/hsinapS,noitacidniartnoC,draC000-37890--)learsI(drocrewoP700CP

92hcnerF/hsilgnE,noitacidniartnoC,draC000-27890

(see Figures 11/11A)

ATTENTION

Static-Sensitive
Devices

27

Figure 12 - TC20 Test Tool Schematic

Section 13 - Wiring Diagram

28

ATTENTION

Static-Sensitive
Devices

Figure 13 - Wiring Diagram

Section 13 - Wiring Diagram (cont’d)

29

Gaymar Industries, Inc.

10 Centre Drive

Orchard Park, NY 14127-2295 USA

Telephone: [phone]
[phone]

Fax: [phone]
[phone]

www.gaymar.com

Gaymar and Thermacare trademarks are registered

in the US Patent and Trademark Office.

©2010. Gaymar Industries, Inc.

All rights reserved.