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 SERVICE MANUAL
Before you begin . . . SERVICE MANUAL
Medi-Therm® III
Medi-Therm® III

SAFETY PRECAUTIONS

WARNING CAUTION

• Repairs should be performed only by qualified Federal law restricts this device to sale by
personnel such as certified biomedical or on the order of a physician.
electronics technicians or certified clinical
engineers familiar with repair practices for
servicing medical devices, and in accordance
with the Medi-Therm® III Service Manual.
• Always perform the FUNCTIONAL CHECK
AND SAFETY INSPECTION (section 7.3, p. 20)
after making repairs and before returning the
Medi-Therm III machine to patient use.
Improper repair may result in death or
serious injury, equipment damage, or
malfunction.

RECEIVING INSPECTION
Upon receipt, unpack the Medi-Therm III machine. Save all Do not return the Medi-Therm III machine to
packing material. Perform a visual and mechanical Gaymar Industries without first contacting
inspection for concealed damage by removing the Gaymar's Technical Service Department for
wraparound from the chassis (see page 75). If any damage is assistance.
found, notify the carrier at once and ask for a written
inspection. Photograph any damage and prepare a written Telephone: Direct (716) 662-2551
record. Failure to do this within 15 days may result in loss Toll Free 1 800 828-7341
of claim.
IMPORTANT
Refer to section 7.0 of this Medi-Therm III Service Manual for Before operating the Medi-Therm III machine, remove
additional details. the compressor shipping braces. See p. 88, figure B.

OPERATING INSTRUCTIONS
For information on operating the Medi-Therm III machine,
refer to the Medi-Therm III Operator's Manual.

Medi-Therm and Clik-Tite are registered trademarks of Gaymar Industries, Inc.

©2007. Gaymar Industries, Inc. All rights reserved. www.gaymar.com
SERVICE MANUAL CONTENTS
Medi-Therm® III

CONTENTS
Section Description ................................................................................Page
1.0 PATIENT SAFETY ..................................................................... 1
2.0 MACHINE PRECAUTIONS ..................................................... 3
3.0 REPAIR POLICY ........................................................................ 4
3.1 In-Warranty Repairs ............................................................. 4
3.2 Out-of-Warranty Repairs ..................................................... 4
4.0 SPECIFICATIONS ..................................................................... 5
4.1 Physical Specifications .......................................................... 5
4.2 Thermal Specifications ........................................................ 5
4.3 Electrical Specifications ....................................................... 6
5.0 PROBE INFORMATION ........................................................... 7
6.0 THEORY OF OPERATIONS .................................................... 9
6.1 Machine ................................................................................. 9
6.2 Interconnections .................................................................. 11
6.3 Power Supply ........................................................................ 12
6.4 Machine Functions ............................................................... 12
7.0 FUNCTIONAL CHECK, SAFETY INSPECTION,
PREVENTIVE MAINTENANCE ............................................. 18
7.1 Receiving Inspection ............................................................ 18
7.2 Cleaning Procedures ........................................................... 18
7.3 Functional Check and Safety Inspection ........................... 20
7.4 Inspection Form ................................................................... 33
8.0 TROUBLESHOOTING & SERVICE MODES ........................ 34
8.1 Service Modes ...................................................................... 34
8.2 Troubleshooting Charts ...................................................... 38
9.0 REPAIR PROCEDURES ........................................................... 57
9.1 Refrigeration System .......................................................... 57
9.2 Replacing the Power Supply Board .................................... 59
9.3 Replacing the Control/Display Board ................................ 60
9.4 Replacing the Top Cover ..................................................... 61
9.5 Replacing Thermostats ....................................................... 62
9.6 Cleaning the Flow Switch ................................................... 63
9.7 Replacement Parts .............................................................. 64
9.8 Shipping/Repacking Instructions ........................................ 64
10.0 REFERENCE TABLES ............................................................... 65
10.1 Celsius-Fahrenheit Conversion .......................................... 65
10.2 Temperature vs. Resistance ................................................ 66
11.0 SERVICE INFORMATION ....................................................... 67

TABLES
Table Description ................................................................................Page
1 High Temperature Limits ......................................................... 25
2 RFU Error Codes ...................................................................... 35
3 Service Modes ........................................................................... 36
4 Celsius/Fahrenheit Conversion ................................................ 65
5 Temperature vs. Resistance ..................................................... 66
6A Operator Controls/Indicators ................................................. 68
6B Operator Controls/Indicators ................................................. 71
7 Parts List (base) ........................................................................ 77
8Parts List (head) ........................................................................................... 78
9Control/Display Board Parts List ................................................................ 85
10Power Supply Board Parts List ................................................................. 86

i
FIGURES SERVICE MANUAL
Medi-Therm® III

ILLUSTRATIONS
Figure Description .............................................................................. Page
1 Typical Water Warm-up Rate ................................................... 6
2 Typical Water Cooldown Rate ................................................. 6
3 Medi-Therm III System ............................................................ 8
4 MT590 Test Tool ....................................................................... 24
5 Initiating Service Mode 1 ........................................................ 35
6A/6L Troubleshooting Charts ........................................................... 38
6A Accessing RFU Codes ............................................................... 38
6B RFU Code 1 ............................................................................... 39
6C RFU Codes 2, 3, – , E, and L ...................................................... 40
6D RFU Codes 4, 5 .......................................................................... 41
6E RFU Codes 6, 7 .......................................................................... 42
6F RFU Code 8 ............................................................................... 43
6G RFU Code 9 ............................................................................... 44
6H RFU Code H (page 1 of 2) ........................................................ 46
6H RFU Code H (page 2 of 2) ........................................................ 47
6I Check Water Flow Alert is On (page 1 of 2) .......................... 48
6I Check Water Flow Alert is On (page 2 of 2) .......................... 49
6J Pump Motor Not Running ...................................................... 50
6K Water Won’t Heat in Auto or Manual Mode (page 1 of 2) ... 52
6K Water Won’t Heat in Auto or Manual Mode (page 2 of 2) ... 53
6L Water Will Not Cool (page 1 of 3) .......................................... 54
6L Water Will Not Cool (page 2 of 3) .......................................... 55
6L Water Will Not Cool (page 3 of 3) .......................................... 56
7 Flow Switch ............................................................................... 63
8 Circuit Boards and Connectors (head) .................................. 67
9A Operator Controls/Indicators ................................................. 68
9B Operator Controls/Indicators ................................................. 70
10 Heating Flow Diagram ............................................................. 72
11 Cooling Flow Diagram ............................................................. 72
12 Refrigeration Flow Diagram .................................................... 73
13 Test Setup .................................................................................. 74
14 Machine Disassembly ............................................................... 75
15 Parts Diagram (base) ............................................................... 76
16 Parts Diagram (head) ............................................................... 78
17 Thermostat Wiring Diagram ................................................... 79
18 System Wiring Diagram ........................................................... 81
19 Power Supply Board Schematic (sheet 1 of 3) ....................... 82
20 Control/Display Board Schematic (sheet 2 of 3) ................... 83
21 Control/Display Board Schematic (sheet 3 of 3) ................... 84
22 Control/Display Board .............................................................. 85
23 Power Supply Board ................................................................. 86
24 System Block Diagram ............................................................. 87
25 Shipping/Repackaging Instructions ......................................... 88

ii
SERVICE MANUAL PATIENT SAFETY
Medi-Therm® III

1.0 PATIENT SAFETY Use the Medi-Therm III Hyper/Hypothermia machine only under the direction
of a physician.

Review the following precautions and procedures prior to each application:

DANGER

Do not use the Medi-Therm III machine in the presence of

flammable anesthetics. Risk of explosion can result.

WARNING

• If the patient’s temperature is not responding or does not reach

the prescribed temperature in the prescribed time or deviates
from the prescribed temperature range, notify the attending
physician promptly. Failure to notify the physician promptly
may result in death or serious injury.

• Power interruption will cause the Medi-Therm III machine to go

into a standby mode, resulting in no therapy to the patient. Follow
instructions for desired mode to resume operation. Failure to
resume therapy could result in death or serious injury.

• The Medi-Therm III machine is provided with a means of

checking rectal/esophageal temperature probes. When performing
the probe check, use a disposable protective sheath (Becton-
Dickinson catalog 3700 oral sheath or equivalent) on the probe.
Failure to use sheath could result in cross-contamination.

• A physicians order is required for use of equipment. Check the

integrity of the skin according to department protocol when
regulating temperature with external devices. Frequency of
assessment and documentation will vary depending upon the
individual response of the patient. Failure to monitor patient
may result in skin damage or inappropriate patient
temperature.

PEDIATRICS—The temperatures of infants and children are more

responsive to surface heating and cooling than adults. The smaller
the patient, the more pronounced the effect because of the
patient’s higher ratio of skin contact area to body mass.

TEMPERATURE-SENSITIVE PATIENTS—Patients with impaired

peripheral blood circulation caused by vascular diseases and
patients who are incapacitated may be more sensitive to
temperature changes than patients with more normal circulation.

OPERATING ROOM PATIENTS—Patients with poor circulation

associated with inadequate heart function, reduction in blood volume,
and constriction of peripheral blood vessels may deviate from the
normal response to the external application of heat and cold.

1
PATIENT SAFETY SERVICE MANUAL
Medi-Therm® III

1.0 PATIENT SAFETY WARNING

(continued)
• Avoid placing additional heat sources between the patient and blanket/
body wrap. Skin damage can result.
Heat applied by the blanket/body wrap can result in a rise in skin
temperature at the areas of contact. The additional heat rise due to
electrosurgical currents flowing to the dispersive electrode could
be sufficient to cause tissue injury. Each thermal effect by itself may
be completely safe, but the additive effect may be injurious.1 Keep
additional heat sources from between the patient and the blanket/body
wrap.
• Prevent excessive and/or prolonged tissue pressure and shearing forces,
especially over boney prominences. Skin damage may result.
Localized skin injury due to tissue compressed between boney
prominences and fluid-filled channels has occurred during prolonged
cardiovascular procedures at water temperatures well below the
scientifically established epidermal burn injury threshold.2
Local ischemia can follow the application of pressures exceeding
capillary pressure resulting in tissue necrosis. This local effect may be
enhanced by generalized impairment of the circulation, local shearing
forces and increased metabolic demand because of temperature eleva-
tion. Pathological changes may begin in two (2) hours.
• Keep the area between the patient and the blanket/body wrap dry.
Excessive moisture may result in skin damage.
The application of heating or cooling may affect the toxicity of
solutions. Prep solutions have been reported to injure the skin when
allowed to remain between patients and water circulating heating
blankets/body wraps during prolonged procedures.3

CAUTION

• Place a dry absorbent sheet between the patient and the blanket
when using the plastic-like side of any blanket.
A dry absorbent sheet placed between the patient and the Hyper/
Hypothermia Blanket will absorb perspiration.Vinyl blankets and
body wraps with nonwoven fabric surfaces do not require an
absorbent sheet when using the nonwoven side toward the patient.
• Federal law restricts this device to sale by or on the order
of a physician.

REFERENCES
1 Gendron, F. G. Unexplained Patient Burns. chap. 5, p. 87, Quest Publishing Co., 1988.

2 Scott, Stewart M. Thermal Blanket Injury in the Operating Room. Arch. Surg., vol. 94, p. 181, Feb. 1967; Crino, Marjanne H. Thermal Burns
Caused by Warming Blankets in the Operating Room. Clinical Workshop, vol. 29, pp. 149-150, Jan-Feb 1980; Gendron, Francis G. Journal
of Clinical Engineering, vol. 5, no. 1, pp. 19-26, January-March 1980; Moritz, A. R. and Henriques, Jr., F.C. Studies of Thermal Injury II.The
Relative Importance of Time and Surface Temperature in the Causation of Cutaneous Burns. Am. J. Path., 23:695, 1947; Stoll, Alice M. and
Chianta, Maria A. Method and Rating System for Evaluation of Thermal Protection. Aerospace Medicine, vol. 40, no. 11, pp. 1232-1238,
Nov. 1969; Stewart, T. P. and Magnano, S. Burns or Pressure Ulcers in the Surgical Patient. Decubitus, vol. 1, pp. 36-40, 1988.

3 Llorens, Alfred S. Reaction to povidone-iodine surgical scrub, scrub associated with radical pelvic operation. Am. J. Obstet. Gynecol., pp.
834-835, Nov. 14, 1974; Hodgkinson, Darryl J., Irons, George B. and Williams, Tiffany J., Chemical Burns and Skin Preparation Solutions.
Surgery, Gynecology & Obstetrics, vol. 17 pp. 534-536, Oct. 1978.

2
SERVICE MANUAL MACHINE PRECAUTIONS
Medi-Therm® III

2.0 MACHINE DANGER

PRECAUTIONS
Disconnect power before servicing unit. Risk of electric shock.

WARNING

• 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 Medi-Therm III Service Manual.
Improper repair may result in death or serious injury, equipment damage,
or malfunction.
• Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION (section 7.3, p.
20) after making repairs and before returning the Medi-Therm III machine to patient
use. Improper repair may result in death or serious injury, equipment
damage, or malfunction.

• Some manufacturer’s patient probes may contain compensation resistors in series

with YSI 400 series thermistors. Do not use these probes with the Medi-Therm
III machine. Inaccurate patient temperature readouts will result and
inappropriate therapy may be delivered.
NOTE: Use only Gaymar probes or equivalent YSI 400 series probes approved for
use with medical devices.
(Refer to the list of recommended probes in section 5.0,
p. 7 PROBE INFORMATION.)

• All wire-lead, patient-connected transducer assemblies are subject to reading

error, local heating, and possible damage from high-intensity sources of RF energy.
Inadequately grounded electrosurgical equipment represents one such source, since
capacitively-coupled currents may seek alternate paths to ground through probe
cables and associated instruments. Patient burns may result.

If possible, remove the probe from patient contact before activating the surgical unit or
other RF source. If probes must be used simultaneously with electrosurgical apparatus,
hazards can be reduced by selecting a temperature monitoring point which is remote
from the expected RF current path to the ground return pad.
• Do not tip machine over without first draining the water out and unplugging the
power cord. Electrical shock or damage to the machine can result.

CAUTION
Add distilled water only. Failure to use distilled water may result in poor machine
performance.
• Do not use alcohol, since it is flammable. Alcohol may also accelerate blanket/body
wrap deterioration.
• Do not operate the machine without water, since damage to internal components
may result.
• Do not overfill. Overfilling may result in overflow because the water in the blanket/
body wrap drains back into the machine when the machine is turned off. Overfilling
may also result in splashing from the overflow tube during transport.

3
REPAIRS / WARRANTY SERVICE MANUAL
Medi-Therm® III

3.0 REPAIR POLICY The Medi-Therm III Hyper/Hypothermia machine is warranted free of defects
in material and workmanship for a period of two (2) years, under the terms
and conditions of the Gaymar warranty in place at the time of purchase. The
compressor portion of the machine carries a five (5) year prorated warranty.
The full warranty is available from Gaymar upon request. Medi-Therm III Hyper/
Hypothermia machines can be repaired at the factory or in the field. Upon
customer request, a shipping carton will be provided to safely return the machine
to Gaymar or a qualified Service Center.

For customers who repair Gaymar Medi-Therm III machines at their location, this
manual contains information to allow a qualified biomedical technician, familiar
with practices for servicing medical devices, to make necessary repairs. Service
training for the Hyper/Hypothermia machine is recommended and is available
from Gaymar. For specific details, contact your Gaymar representative or the
Technical Service Department at Gaymar. (See back cover of this manual for
Gaymar telephone numbers.)

3.1 IN-WARRANTY All in-warranty field repairs must be authorized by Gaymar’s Technical Service
REPAIRS Department before proceeding.

3.2 OUT-OF-WARRANTY The following repair options are available when local machine servicing is elected:
REPAIRS
I . Defective Component
Replacement parts can be ordered. Specify the Gaymar part number; refer to
the Parts Lists in section 11, pp. 76–88 of this manual.

2. Machine Repairs
If the Medi-Therm III machine becomes defective and the cause of the
problem cannot be determined, the complete machine can be returned to the
factory for servicing at the purchaser’s expense. This normally represents the
most expensive repair option.

Please contact Gaymar to obtain an RG (returned goods) number prior

to returning the machine.

4
SERVICE MANUAL SPECIFICATIONS
Medi-Therm® III

4.0 SPECIFICATIONS

4.1 PHYSICAL SPECIFICATIONS

MTA7900

37 in. high x 18-3/4 in. deep x 14 in. wide

Dimensions
(94.0 cm high x 47.6 cm deep x 35.6 cm wide)

141 lb (full); 121 lb (empty); shipping wt,136 lb

Weight
64.0 kg (full); 54.9 kg (empty); shipping wt, 61.7 kg

Normal Reservoir
Approximately 10 quarts (9-1/2 liters) distilled water
Operating Volume

Operating Ambient
15.6°C to 32.2°C (60°F to 90°F)
Temperature Range

Dead Head Pressure 9.0 psi max (62 kPa max)

Flow * 16 gph [gallons per hour] 60.6 liters/hour) *

* Minimum flow rate through a full size Gaymar Hyper/Hypothermia Blanket

4.2 THERMAL SPECIFICATIONS

44°C (111.2°F) to 49°C (120.2°F)

High Temperature Limits Fixed
(S2) & (S3) (Machine will go into REMOVE FROM USE NOW / MACHINE SHUTDOWN
condition and audible alarm will be on.)

-3°C (26.6°F) to +2.5°C (36.5°F)

Low Temperature Limits Fixed (S1)
(Machine will go into REMOVE FROM USE NOW / MACHINE SHUTDOWN
condition and audible alarm will be on.)

Add Water Alert Actuation Less than 8 quarts (7.6 liters) of water in the cold reservoir

Check Water Flow Alert Actuation 6 GPH

Check Probe Activation Temperature 29°C (84.2°F) or above 45°C (113°F)

(whenever probe is used)

Patient Temperature Control Range

for Automatic Mode 30°C (86.0°F) to 41°C (105.8°F)

Water Temperature Control

4°C (39.2°F) to 42°C (107.6°F)
Range for Manual Mode

5
SPECIFICATIONS SERVICE MANUAL
Medi-Therm® III

4.2 THERMAL SPECIFICATIONS (cont'd)

Figure 1—Typical water warm-up rate Figure 2—Typical water cooldown rate
(with full size blanket) (with full size blanket)

4.3 ELECTRICAL SPECIFICATIONS

MTA7900

±0.5°C, ±0.9°F
Patient Temperature Measurement Accuracy
(using Gaymar 400 series probe)

Display Accuracy ±0.3°C, ±0.5°F

Blanket Water Temperature 1°C, 1°F

Display Resolution
Patient Temperature 0.1°C, 0.1°F

±0.8°C, ±1.4°F
Blanket Water Temperature NOTE: At set points of 4°C to 6°C, this accuracy may not be
obtainable due to compressor control characteristics.
Controller Accuracy
Patient Temperature ±0.5°C, ±0.9°F

Chassis 100 microamps maximum

Current Leakage
Patient Probe 50 microamps maximum

Input Voltage 120V ± 10V

Frequency 60 Hz

Input Current 11.5A

UL416
Regulatory
CSA C22.2 No. 125

Meets EN60601-1-2:1993
Electromagnetic Compatibility (CISPR 11 Classified as Class A,
Group 1 ISM Equipment)

6
SERVICE MANUAL PROBE INFORMATION
Medi-Therm® III

5.0 PROBE Disposable Probes

INFORMATION
• DP400CE Disposable Rectal/Esophageal -
Adult/Small Child (3' [0.9 meters] long, requires adaptor);
YSI 400 series type

Probe Adaptor

• ADP10CE Reusable adaptor cable for DP400CE: connects Gaymar

disposable probe to Gaymar or Cincinnati Sub-Zero
control unit.

Reusable Probes

• PAT101 Patient probe—Rectal/Esophageal -

Adult (10' [3.0 meters] long);YSI 400 series type

• PAT102 Patient probe—Rectal/Esophageal -

Pediatric (10' [3.0 meters] long);YSI 400 series type

• PAT108 Patient probe—Skin surface (10' [3.0 meters] long);

YSI 400 series type

WARNING

Some manufacturer’s patient probes may contain compensation resistors

in series with YSI 400 series thermistors. Do not use these probes with
the Medi-Therm III machine.
Inaccurate patient temperature readouts will result and
inappropriate therapy may be delivered.

NOTE: Use only Gaymar probes or equivalent YSI 400 series probes
approved for use with medical devices.
(Refer to the list of recommended probes above.)

7
MEDI-THERM® III SYSTEM SERVICE MANUAL
Medi-Therm® III

Gaymar probe or equivalent YSI 400

series probe approved for use with
medical devices

/body wrap

Figure 3 - Medi-Therm III System

8
SERVICE MANUAL
Medi-Therm® III

6.0 THEORY OF The Gaymar Medi-Therm III machine provides a means of regulating patient
OPERATION, SYSTEM temperature by supplying temperature-controlled water through a connector
hose to a Gaymar Hyper/Hypothermia blanket/body wrap. The blanket/body wrap
provides an interface for heating or cooling the patient. A patient probe senses
patient temperature, which is displayed on the control panel. (See figure 3, p. 8.)

The Medi-Therm III machine controls output water temperature by mixing hot
and cold water using hot and cold solenoid valves under microcontroller control.
A circulating pump, heater and refrigeration unit are also utilized.

Bimetallic thermostats and associated backup circuitry limit output water

temperature independent of the microcontroller.

The feedback for control purposes depends upon the machine's operating mode.
The Medi-Therm III machine may be operated in one of three operating modes:

• In MANUAL mode, the operator sets the desired water temperature. A

temperature sensor within the machine monitors the water temperature
and the machine heats or cools the water as required to bring the water
temperature to the SET POINT temperature. The patient temperature may be
monitored by use of a patient probe connected to the patient probe jack on
the front of the unit.

• In AUTO mode, the Medi-Therm III machine automatically regulates the

patient's temperature to the selected SET POINT. The machine constantly
compares actual patient temperature with the SET POINT value, and
automatically adjusts the water temperature so that the desired patient
temperature is achieved.

• In MONITOR mode, the operator can monitor patient temperature through

the patient probe, without providing therapy.

Two gray hose sets are provided to connect multiple blankets and/or body wraps
in order to provide more body surface contact. Increased body surface contact
facilitates more efficient warming/cooling.

NOTE: When connecting a second blanket/body wrap to the Medi-Therm

III machine, check the water level prior to connecting the additional
blanket/body wrap.

Whenever the machine is on, 10 quarts of water are maintained cold in the cold
6.1 THEORY, water reservoir. A cold water reservoir probe provides temperature feedback to
MEDI-THERM III the microcontroller which cycles the refrigeration unit on at 5.8°C (42.5°F) and
MACHINE off at 3.3°C (38.0°F).

When the water requires cooling, water is pumped from the cold water reservoir.
When the water requires heating, a cartridge heater is used to quickly heat the
water.

9
 SERVICE MANUAL
Medi-Therm® III

6.1 THEORY OF WATER TEMPERATURE CONTROL

OPERATION, Hot and cold solenoid valves regulate the flow path by directing water
MEDI-THERM III returning from the blanket/body wrap to either the hot or cold water reservoir.
Regulating the flow path controls the temperature of water pumped to the
MACHINE (continued) blanket/body wrap. The microcontroller controls solenoid valve operation. Only
one valve may open at a time:

When the WARMING status light is lit, the hot solenoid valve is open.
Water returning from the blanket/body wrap circulates through the hot
water reservoir and is heated before being pumped back to the blanket/
body wrap. The heater, pump, and hot solenoid valve are energized. (See
fig. 10, p. 72.)
When the COOLING status light is lit, the cold solenoid valve is open.
Water returns from the blanket/body wrap to the cold water reservoir
and is replenished by chilled water from the cold water reservoir
before being pumped back to the blanket/body wrap. The pump and
cold solenoid valve are energized. (See fig. 11, p. 72.) The refrigeration
unit maintains the cold water reservoir temperature and operates
independently of the solenoid status.

When both the WARMING and COOLING lights are off, either the water
temperature is within 1°C (1.8°F) of the setpoint (in MANUAL mode) or the
patient temperature is within 0.5°C (0.9°F) of the setpoint (in AUTO mode).
Water temperature is controlled by alternating between heating and cooling (see
figures 10–11) with the heater cycled on and off as needed.

REFRIGERATION UNIT
The refrigeration circuit (see figure 12, p. 73) consists of two heat exchangers
operating at two pressures and two devices used to change these pressures. The
first of these devices is the compressor which changes the gas pressure from
low to high. The other device is the capillary tube which reduces the refrigerant
pressure from high to low.

Beginning the cycle at the capillary tube, high pressure liquid refrigerant flows
in the capillary tube and is discharged into the evaporator coil. The evaporator
coil, which is a heat exchanger, receives the refrigerant as a mixture of liquid and
vapor at a pressure low enough so that it boils and absorbs heat from the water
surrounding it.

The heated refrigerant vapor then leaves the evaporator coils, enters the suction
side of the compressor and is compressed, causing its pressure and temperature
to increase. The vapor, much warmer than the ambient air, travels to the
condenser.

The condenser is the other heat exchanger. The condenser fan draws the colder
ambient air over the condenser coils and removes the heat being carried by the
refrigerant and causes it to condense back into liquid refrigerant. This completes
the cycle and the high pressure liquid refrigerant is returned to the capillary tube
to be used over again. The temperature of the water surrounding the evaporator
coil (in the cold water reservoir) is controlled by the microcontroller. The
microcontroller senses the temperature with a cold water reservoir probe and
cycles the compressor relay on and off.

10
SERVICE MANUAL
Medi-Therm® III

6.1 THEORY OF BACKUP SYSTEMS

OPERATION, Backup systems within the Medi-Therm III machine limit the temperature of
MEDI-THERM III water exiting the machine to specified ranges in the event of a failure of the
control system including the microcontroller:
MACHINE (continued)
Maximum water temperature is limited by two bimetallic thermostats.
If either of these two thermostats is actuated, a REMOVE FROM USE NOW /
MACHINE SHUTDOWN circuit is triggered which:
• shuts down the pump and heater;
• lights the ALERT and the REMOVE FROM USE NOW / MACHINE
SHUTDOWN indicators; and,
• sounds the audible alarm.
In addition, if the microcontroller is operational, the compressor shuts down, the
displays blank, and the ALERT indicator and audible alarm turn on and off.

Minimum water temperature is limited by a bimetallic thermostat. If this

thermostat is actuated, a REMOVE FROM USE NOW / MACHINE SHUTDOWN
circuit is triggered, which in turn:

• shuts down the pump and heater;

• lights the ALERT and the REMOVE FROM USE NOW / MACHINE
SHUTDOWN indicators; and,
• sounds the audible alarm.
In addition, if the microcontroller is operational, the compressor shuts down,
the displays blank, and the ALERT indicator and audible alarm turn on and off.

6.2 SYSTEM See figure 8, p. 67 for base-to-head and control/display board-to-power supply
COMPONENT board connections; figure 18, p. 81 for system wiring diagram; figures 19–21,
INTERCONNECTIONS pp. 82–84 for electrical schematics; figures 22–23, pp. 85–86 for component
layouts and part designations; and figure 24, p. 87 for the system block diagram.

CONTROL/DISPLAY BOARD AND POWER SUPPLY BOARD

The Medi-Therm III machine uses two printed circuit boards (see figure 8, p. 67):

• The control/display board contains the microcontroller circuits, the

display circuits, and all other low voltage control circuits.
• The power supply board contains the power supply, the low voltage
to high voltage interface circuits, and the REMOVE FROM USE NOW /
MACHINE SHUTDOWN backup safety circuits.
The control/display board connects to the patient probe jack J1 via P2 at J2 and
to the digital control assembly panel via P4 at J4. All other connections from the
system’s peripheral devices to the control/display board are made through the
power supply board.

A 26-pin cable connects the control/display board via P1 at J1 to the power supply
board via P3 at J4.

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 SERVICE MANUAL
Medi-Therm® III

6.2 SYSTEM Four cables connect the components in the base of the machine to the PC boards
COMPONENT in the head (see figure 8, p.67):
INTERCONNECTIONS • A 9-pin connector P6 ties the water temperature probe RT2, cold
(continued) water reservoir probe RT1, flow switch S5, and level switch S4 to the
power supply board at J2 and ultimately to the control/display board.
• A 12-pin connector P7 ties the high voltage devices (pump, heater,
hot solenoid valve SV2, cold solenoid valve SV1, and refrigeration
compressor relay K1) to the interface circuits on the power supply
board, as well as thermostats S1, S2, and S3 to the high voltage backup
circuitry on the power supply board.
• A 6-pin connector P5 connects transformer T1 housed in the base
to the power supply circuitry at J3 on the power supply board.
• A chassis ground harness from the control/display board connects
to the chassis.

6.3 POWER SUPPLY See figure 18, p.81 for the system wiring diagram; figures 19–21, pp. 82–84 for the
electrical schematics; figures 22–23, pp. 85–86 for component layouts and part
designations; and figure 24, p. 87 for the system block diagram.

Power enters the Medi-Therm III machine through circuit breaker CB1 to feed
the refrigeration unit through relay K1. It also then enters the power supply board
at J1 to feed the hot solenoid valve, cold solenoid valve, heater and pump triacs,
the high voltage backup water temperature limiting circuits and transformer T1.

Power to drive the low voltage circuits on the control/display board is derived
from the machine’s power supplies which reside entirely on the power supply
board. The transformer T1 output is rectified and filtered to generate unregulated
positive and negative voltages. Q5, D1, L1 and associated components are
configured as a DC to DC switching regulator in a buck configuration yielding a
nominal output of +5.3 volts DC. Q6 is a linear regulator with a nominal output
of plus twelve (+12) volts DC, while Q7, also a linear regulator, delivers a nominal
output of minus twelve (-12) volts DC.

See figure 18, p. 81 for system wiring diagram; figures 19–21, pp. 82–84 for the
6.4 MACHINE electrical schematics; figures 22–23, pp. 85–86 for component layouts and part
FUNCTIONS designations; and figure 24, p. 87 for the system block diagram.

The U37 microcontroller is fully dependent on the code stored in the U31
EPROM. When the machine is on, the microcontroller continually cycles through
its main program loop to perform the following:
• Thermistor output measurement (see section 6.4.1, p. 13)
• Digital control panel input (section 6.4.2, p. 13)
• Display update (section 6.4.3, p. 13)
• Peripheral input (section 6.4.4, p. 14)
• Water/Patient temperature control (section 6.4.5, p. 15)
• Cold water reservoir temperature control (section 6.4.6, p. 16)
Backup water temperature limiting is achieved independently of the
microcontroller. (See section 6.4.7, p. 16.)

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SERVICE MANUAL
Medi-Therm® III

6.4.1 THERMISTOR Temperature measurement is achieved using 400 series thermistor beads located
OUTPUT in the water path (water temperature probe RT2), the cold water reservoir (cold
water reservoir probe RT1), and in the patient via the patient probe jack J1.
MEASUREMENT
Under microcontroller U37 control, each of the three beads is connected to the
current source circuitry (U38 and associated components) by a demultiplexor
U49. At the same time, the resulting output voltage created by the current
through the thermistor is presented to an amplifier circuit (U39 and associated
components) via multiplexor U50. The amplified voltage is then applied to a
voltage-to-frequency converter U24. A frequency up to 100kHz is presented to
port pin P3.5 of the microcontroller. The microcontroller converts the incoming
frequency to a temperature value.

At regular intervals two compensation resistors R13 and R12 are also processed
in the same manner. These compensation resistors are precision resistors with
values at each end of the probe temperature range of 0°C (32°F) to 50°C (122°F).
The values from the precision resistors are used to compensate for circuit drift.

User input is entered via a digital control panel. The input from the buttons is
6.4.2 DIGITAL CONTROL decoded by U45. The “data available” line of U45 is tied to the microcontroller
PANEL INPUT port pin P3.3. When a button press is decoded and debounced by U45, the
“data available” line goes high and the microcontroller responds by inputting the
decoded value.

For display of measured and set point temperatures, 7 segment LED displays are
6.4.3 DISPLAY UPDATE utilized:
• The set point display is driven by driver chip U48. The microcontroller
interfaces to it via the data bus at addresses 0FFF8H, 0FFF9H, 0FFFAH,
0FFFBH.
• The patient display is driven by driver chip U6. The microcontroller
interfaces to it via the data bus at addresses 0FFF4H, 0FFF5H, 0FFF6H,
0FFF7H.
• The water temperature display is driven by driver chip U5. The
microcontroller interfaces to it via the data bus at addresses 0FFECH,
0FFEDH, 0FFEEH, 0FFEFH.

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 SERVICE MANUAL
Medi-Therm® III

6.4.3 DISPLAY UPDATE All alarm and status indicators are lit by LED bars driven by inverter/driver IC’s:
(continued) • The alarm latch U53 is the interface between the microcontroller
and the ALERT, ADD WATER, CHECK PROBE, CHECK FLOW, REMOVE
FROM USE NOW / MACHINE SHUTDOWN, SELECT, °F and °C drivers
via the data bus at address 0FFBFH. A high signal written to the latch
by the microcontroller activates the individual inverter/drivers to
light the corresponding indicator.
• The mode display latch U54 is the interface between the
microcontroller and the COOLING,WARMING, FLOW-OK, AUTO,
MANUAL, and MONITOR drivers via the data bus at address 0FFDFH.
A high signal written to the latch by the microcontroller activates
the individual inverter/drivers.
• The control option display latch U64 is the interface between the
microcontroller and the GRADUAL, MODERATE, and RAPID drivers via
the databus at address FDFFH. A high signal written to the latch by
the microcontroller activates the individual drivers.
• The control latch U51 is the interface between the microcontroller
and the two leader light drivers via the data bus at address 0FF7FH.
When this latch is selected, a low signal on the data line from the
microcontroller causes a high signal on the latch output Therefore,
these two LED bar displays are “active low” in the eyes of the
microcontroller in contrast to all the other LED bar displays of the
machine.

The audible alarm is driven either by a high signal from the control latch U51
(from the microcontroller via the data bus at address 0FF7FH) or a high RFU
IN signal from Q10 on the power supply board. A low data line signal from the
microcontroller to U51 causes a high signal on the latch output. Therefore, the
alarm is “active low” in the eyes of the microcontroller. Transistor Q2 activates
the alarm.

6.4.4 PERIPHERAL INPUT The input buffer U55 is the interface between the microcontroller (via the data
bus at a “read” address of 0FFFEH) and the input signals from the flow switch S5
and the level switch S4 (which travel from the base through the power supply
board), the probe presence switch within the patient probe jack J1, and the
service mode button S3 on the control/display board. The lines to the buffer from
the peripheral devices are default high (via pull-up resistors).

The level switch S4 will pull its buffer input line low when it senses a sufficient
water level.

The flow switch S5 will pull its buffer input line low when it senses sufficient flow.

The probe presence switch within J1 will pull its buffer input line low when it
senses the presence of the patient probe.

Pressing the service mode switch S3 on the control/display board will pull its
buffer input line low.

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SERVICE MANUAL
Medi-Therm® III

6.4.5 WATER / PATIENT If the machine is in MANUAL mode, the water temperature as sensed by the
TEMPERATURE water temperature probe is used as the feedback signal for controlling the water
temperature to the MANUAL mode set point temperature.
CONTROL
If the machine is in AUTO mode, the patient temperature as sensed by the patient
probe connected to the patient probe jack is used as the feedback signal for
controlling the patient temperature to the AUTO mode set point temperature.
The machine accomplishes this by adjusting the water temperature. The water
temperature the machine uses in AUTO mode is dependent on the CONTROL
OPTION setting selected and if COOLING or WARMING is desired.
When COOLING the patient:
RAPID - the coldest water is used for cooling - as low as 4°C (39°F). This may
not be the most comfortable setting for the patient.
MODERATE - Water temperature is limited to 15°C (27°F) below the patient's
temperature. This will provide an improved comfort setting to the patient.
GRADUAL - Water temperature is limited to 10°C (18°F) below the patient's
temperature. This will provide the optimal comfort setting to the patient.
When WARMING the patient:
RAPID - the highest allowable water temperature is used for warming - as
high as 42°C (107.6°F). This is the fastest warming mode the machine can
provide.
MODERATE - The patient temperature will increase at a rate of 1°C (1.8°F)
in a period of 3 hours (0.33°C/Hr [0.6°F/Hr]).
GRADUAL - The patient temperature will increase at a rate of 1°C (1.8°F) in
a period of 6 hours (0.17°C/Hr [0.3°F/Hr]).
When WARMING a patient in MODERATE or GRADUAL modes, water
temperature is limited to a maximum of 42.0°C (107.6°F) and a minimum which
is determined by the current control option selected (15°C [27°F] below the
patient temperature in MODERATE mode and 1.0°C [18°F] below the patient
temperature in GRADUAL mode).
If the patient temperature deviates from the warming rate specified by the
CONTROL OPTION selected (Moderate and Gradual only) by 1.0°C (1.8°F) the
following will occur:
• the PATIENT temperature will flash;
• the ALERT led will flash; and;
• the audible alarm will toggle
Once the patient temperature returns to within 1.0°C (1.8°F) of the warming
rate specified by the CONTROL OPTION selected, the PATIENT temperature and
ALERT light will stop flashing and the audible will silence.
NOTE: If the control MODE or SET POINT is changed while this alarm is
occuring, the alarm will be reset.
For water temperature control, the microcontroller outputs a pulse train to
each solenoid valve and the heater. The pulse train duty cycle depends on the
magnitude and sense of the control signal calculated by the microcontroller.
That is, while the solenoids and heater are either on or off, the ratio of on time
to off time is proportional to the calculated control signal amplitude. For large
differences between set point and probe temperatures, the output to the cold
solenoid will be on and the output to the hot solenoid/heater combination will
be off, or vice-versa. For differences approaching zero, the output pulse train will
be applied to the hot solenoid and cold solenoid in a complementary fashion,
with the on times and off times automatically adjusted to maintain a probe

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 SERVICE MANUAL
Medi-Therm® III

temperature equal to the set point, or the output pulse train will be applied to the
heater (with the hot solenoid remaining open), with the on times and off times of
the heater automatically adjusted to maintain a probe temperature equal to the
set point.

The circulating pump is energized whenever the unit is in AUTO or

MANUAL modes.
The control latch U51 on the control/display board is the interface between the
microcontroller (via the data bus at address 0FF7FH) and the peripheral drivers
on the power supply board.
Interface circuitry on the power supply board consists of U1, U2, U7, U8, Q3, Q4,
Q8, Q9, and associated components. U1, U2, U7, and U8 are optically coupled
triac drivers used to control their respective triacs (Q3, Q4, Q8, and Q9); these
combinations provide electrical isolation between the low voltage microcontroller
control circuits and the line voltage circuits.
The heater, pump, hot solenoid valve, and cold solenoid valve are individually
controlled by the microcontroller through latch U51 on the control/display board.
A high signal on the data line from the microcontroller causes a low signal on the
appropriate output line of U51 which then sinks current from the power supply
board to activate the peripheral devices.

Pin 11 of U51 on the control/display board and U8 and Q9 of the power supply
board control the cold solenoid valve while pin 9 of U51 on the control/display
board and U7 and Q8 of the power supply board control the hot solenoid valve.
Pin 8 of U51 on the control/display board and U2 and Q4 of the power supply
board control the circulating pump. Pin 7 of U51 on the control/display board and
U1 and Q3 of the power supply board control power to the heater.

6.4.6 COLD WATER The control latch U51 on the control/display board is the interface between
the microcontroller (via the data bus at address 0FF7FH) and the refrigeration
RESERVOIR compressor relay driver on the power supply board. A high signal on the
TEMPERATURE appropriate data line causes a low signal at pin 6 of U51 on the control/display
CONTROL board, which then activates Q12 on the power supply board. Q12 on the power
supply board is the interface between the control/display board and the coil of
the power relay K1 located in the machine base. The microcontroller switches
power through the relay to the refrigeration compressor at cut-out and cut-in
temperatures of 3.3°C (38°F) and 5.8°C (42.5°F). These temperatures are sensed
by the cold water reservoir probe RTl located in the water reservoir. (See figure
12, p. 73.) Control of the cold water reservoir temperature takes place whenever
the machine is on.

6.4.7 BACK-UP WATER The power supply board includes the REMOVE FROM USE NOW / MACHINE
TEMPERATURE SHUTDOWN circuitry, which includes U3, U4, U5, U6, U9, U10, D2, D3, Q1, Q2,
LIMITING their interconnected components, and fixed, nonadjustable thermostats S2, S3,
and S1 located in the base. Under normal circumstances, Q1 and Q2 are kept
turned on by the action of R7, C10, and D4 and R5, C15, and D5 to complete
the conduction path for the heater and pump. If the water temperature falls into
the low temperature limit range, S1 will open. If the water temperature rises
into the high temperature limits ranges, S2 and/or S3 will open. (See section 4.2
Thermal Specification table, page 5, for the correct high or low temperature limits
with corresponding model number of your machine.) When any one of these
thermostats opens, it directly interrupts the circuit and shuts off the pump and

16
SERVICE MANUAL THEORY OF OPERATION
Medi-Therm® III

heater; at the same time, full line voltage will appear between J1-2 and J1-3. In this
6.4.7 BACK-UP WATER
case, U5 and U10 will be turned on by the action of R4, D3, and associated parts
TEMPERATURE while U3 and U9 will be turned on by the action of R6, D2, and associated parts.
LIMITING (continued) U5 prevents Q2 from turning on and U3 prevents Q1 from turning on even if the
open thermostat(s) closes again. The output of either U9 or U10, through buffer
Q10, signals the microcontroller that a thermostat has tripped and that a REMOVE
FROM USE NOW / MACHINE SHUTDOWN condition has resulted. Thus, should
any thermostat (S1, S2, or S3) trip, the heater and pump are shut off and the
microcontroller is notified.

On the control/display board, a high signal from Q10 of the power supply board
feeds Q2 to drive the audible alarm, feeds driver U62 to light the REMOVE FROM
USE NOW / MACHINE SHUTDOWN LED, and feeds driver U60 to light the ALERT
LED. All this is done independent of the microcontroller. This same signal is sent
to port pin P3.2 of the microcontroller Q3.

If the microcontroller is operational at the event of a high signal from Q10 of the
power supply board, the signal at P3.2 causes the microcontroller to shut off the
7 segment displays, flash the ALERT LED and light the REMOVE FROM USE NOW /
MACHINE SHUTDOWN LED, toggle the audible alarm, store the appropriate RFU*
code indicating the reason for the shutdown, turn off the heater and pump triacs
Q3 and Q4, turn off the solenoid triacs Q8 and Q9, and turn off the compressor
transistor Q12. Anytime the microcontroller goes into a shutdown condition it
also sends an output signal from port pin P3.4, through U40 of the control/display
board, to command, via Q11, U4, and U6 on the power supply board, a REMOVE
FROM USE NOW / MACHINE SHUTDOWN condition. The process of turning off
the heater and pump triacs Q3 and Q4 by the microcontroller removes power
from the REMOVE FROM USE NOW / MACHINE SHUTDOWN circuitry on the
power supply board which then allows the indicators on the control/display
board to toggle under microcontroller control. This shutdown condition by the
microcontroller program will remain until the machine is powered down. If, upon
machine turn on, the fault condition still exists, attempting to resume therapy
(which would turn on the pump and possibly heater) will replace power to
the REMOVE FROM USE NOW / MACHINE SHUTDOWN circuits on the power
supply board and cause the REMOVE FROM USE NOW / MACHINE SHUTDOWN
condition to recur.

Also, if during normal operation, the microcontroller senses internal problems, it

will attempt a shutdown as described above. (See table 2, section 8.1, p. 35.)

If the microcontroller is nonoperational at the event of a signal from Q10 of

the power supply board, the user is notified of the REMOVE FROM USE NOW /
MACHINE SHUTDOWN condition by the fact that the above mentioned indicators
are on continuously. In addition, there are separate, redundant circuits on the
power supply board, each triggered by any of the thermostats, that insure that
the pump and heater remain off even if the thermostat cools sufficiently to close
again. The REMOVE FROM USE NOW / MACHINE SHUTDOWN condition remains
latched and can be cleared only by an operator intervention in the form of turning
the machine circuit breaker off. If, upon machine turn on, the fault condition still
exists, attempting to resume therapy will cause the REMOVE FROM USE NOW /
MACHINE SHUTDOWN condition to recur.

* RFU = REMOVE FROM USE NOW / MACHINE SHUTDOWN

17
RECEIVING INSPECTION SERVICE MANUAL
& CLEANING PROCEDURES Medi-Therm® III

7.0 FUNCTIONAL CHECK, SAFETY INSPECTION, AND PREVENTIVE MAINTENANCE

7.1 RECEIVING Concealed Damage
INSPECTION After unpacking the Medi-Therm III machine, inspect the machine for concealed
damage. Save all packing material and carefully describe or photograph the
PROCEDURES
damage. Notify the carrier at once and ask for an inspection (in writing). Failure
to do this within 15 days may result in loss of claim. Do not return the machine to
GAYMAR — call Gaymar's Technical Service Department for advice.

Before placing the Medi-Therm III machine into service, perform a FUNCTIONAL
CHECK AND SAFETY INSPECTION (pp. 20 to 33).

IMPORTANT
Before operating the Medi-Therm III machine, remove the
compressor shipping braces. (See p. 88, figure B.)

7.2 CLEANING Fluid System

PROCEDURES Use distilled water to retard algae growth and mineral buildup. Change the
distilled water monthly or more often depending upon use.

The water circulation system, including reusable blankets, should be cleaned every
month to retard algae growth.

To clean the fluid system, drain the machine and prepare an algaecidal solution
according to manufacturer’s instructions. Use Gaymar product catalog MTA33.
Add the solution to the machine, attach blankets, set the machine in MANUAL
mode to a setpoint temperature of 10°C (50°F) and circulate the solution for 12
hours. Drain the solution and refill the machine with distilled water.

CAUTION

• Do not use bleach (sodium hypochlorite).

Bleach will damage the heating element in the machine,
which could result in excessive leakage current.

Compressor
Dirt that has accumulated on the condenser coils and cooling fins within the
machine will reduce the efficiency of the compressor and should be removed with
a vacuum cleaner or compressed air hose. This will require removal of the rear
baffle assembly. This should be checked monthly or more frequently depending
upon use. (See figure 14, p. 75.)

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SERVICE MANUAL CLEANING PROCEDURES
Medi-Therm® III

7.2 CLEANING Pump

PROCEDURES Pump motor should be oiled once a year with 3-4 drops of general purpose
(continued) motor oil in the locations identified on the pump label.

Panel Exterior
Clean the control panel and panel exterior with a cloth dampened with
isopropyl alcohol.

Reusable Blankets
Outside surfaces of standard reusable blankets may be cleaned with a damp
cloth and mild detergent to prevent algae growth. To clean the insides, attach the
blankets to the machine and follow instructions for section 7.2, p. 18, CLEANING
PROCEDURES, Fluid System.

NOTE: Exposure to harsh chemicals will cause blankets to lose flexibility and
resistance to cracking.

Probe Check Well

The Probe Check Well should be cleaned with a small tubular brush and
detergent, and then wiped with a commercial disinfectant.

WARNING
When performing the PROBE CHECK, use a disposable protective
sheath (Becton-Dickinson catalog 3700 oral sheath or equivalent)
on the probe.
Failure to use sheath could result in cross-contamination.

Connector Hoses
Clean connector hose sets with a damp cloth and mild detergent. Always wipe dry.

Probes
Do not autoclave. Clean with a damp cloth and mild detergent. Wipe dry.

Probes are made of PVC. If probe must be sterilized, use any cold sterilization
means except alcohol, which may accelerate probe deterioration. Always wipe dry.

If gas sterilization is necessary, probes should be handled like any other PVC
product. Probes are made of PVC.

Reusable probes may be cleaned with a damp cloth and mild detergent. Always
wipe dry. Exposure to harsh chemicals will cause probe to lose flexibility and
resistance to cracking.

Disposable probes should be discarded after use.

NOTE: Exposure to harsh chemicals will cause probe to lose flexibility and
resistance to cracking. Do not use damaged temperature probes.
Discard probes having visible pinholes, cracks or abrasions.

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FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK To assure the optimum performance, dependability and safety, the following should
AND SAFETY be performed every twelve (12) months or as specified in the facility's preventive
maintenance program.
INSPECTION
An Inspection Form is provided at the end of this section to facilitate and
document the inspection process. Lower case letters preceding the subheadings
within section 7.3 correspond to the lines on the INSPECTION FORM.

WARNING
Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION
after making repairs and before returning the Medi-Therm III machine to
patient use.
Improper repair may result in death or serious injury,
equipment damage, or malfunction.

Test Equipment The following test equipment (or equivalent) is required to perform the
Requirements preventive maintenance/functional check procedures:

• GAYMAR TPT9 Flowmeter/Temperature Tester

• GAYMAR TFC1 Thermometer (±1°C accuracy);
-2°C to +52°C range
• GAYMAR DBK9 Blanket Connector Hose
* • GAYMAR MT590 Test Tool, or
GAYMAR PRK2 Patient Temp Simulator Kit, or
Precision Decade Box (0-10K ohms, 0.2% accuracy, 1 ohm
increments)
• GAYMAR DHP901 or DHP813 Hyper/Hypothermia Blanket
* • GAYMAR MT590 Test Tool, or
6" (approximately 150 cm) Shorting Jumper
• Ground Resistance Checker
• Current Leakage Tester
• Static Control Wrist Strap

* The GAYMAR MT590 Test Tool is a dedicated test tool available from
Gaymar Industries. This tool was designed to allow for more convenient and
safer testing of the high temp backup thermostats by eliminating the need
to remove the lower wraparound cover and avoiding the use of a shorting
jumper that could be accidentally left inside the machine. In addition, the
test tool can be used to monitor input/output signals between the head and
base of the machine through the use of indicator lights. This feature can be of
great value during any troubleshooting process. This test tool also provides
a patient probe simulator which allows testing of the machine without a
precision decade box.

For more information on the MT590 Test Tool, contact the Gaymar
Technical Service Department.

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SERVICE MANUAL FUNCTIONAL CHECK AND
Medi-Therm® III SAFETY INSPECTION

7.3 FUNCTIONAL CHECK

DANGER
AND SAFETY
INSPECTION Disconnect power before servicing unit. Risk of electrical shock.
(continued)
Follow 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.

Before making any repairs, be sure to recheck your test setup, procedure, and test
equipment.

Test equipment should be calibrated in accordance with NIST (National Institute

of Standards and Technology) guidelines to insure accurate readings.

a) Condition of Chassis
The following inspections should be performed:
1. The chassis should be clean and relatively free of rust and corrosion.
2. Exterior screws should be tight.
3. Legends, markings, and operator instructions should be legible.
4. Dirt that has accumulated in vents and cooling fins within the
machine should be removed with a vacuum cleaner or compressed
air hose. This will require removal of the rear baffle assembly.
5. Check that the casters are tight and functioning properly.
6. The quick-disconnect fittings on the machine may become stiff and
difficult to engage. If so, apply a silicone-base lubricant to the inside
of the machine fittings and the outside of the blanket connector.
7. Clean the Probe Check Well according to the procedure described
in section 7.2, p. 19.
8. Inspect the fluid system for debris and any sign of algae growth.
Clean according to Cleaning Procedures, Fluid System (section 7.2).

b) Attachment Plug
Examine the attachment plug on the line cord to be sure that it is in
good condition.

c) Line Cord and Strain Reliefs

Examine the line cord along its entire length for physical damage, such as cuts
or cracked insulation. A damaged line cord should be replaced rather than
repaired. Check the quality of the strain reliefs at both ends of the line cord.

d) Circuit Breaker
A worn out circuit breaker can be responsible for intermittent shutoffs,
with no other apparent indications of failure.
Examine the physical condition of the circuit breaker, paying particular
attention to the push-on terminals at the rear of the breaker. Terminals
should be snug. Replace breaker and/or terminals if there is discoloration
or any indications of heating.
Cycle the switch on and off several times. The switch should have a
positive engagement (“click”) for the OFF and ON positions.

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FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK e) Condition of Lights and Alarm

AND SAFETY Plug in the Medi-Therm III machine and turn it on. Press and hold the
INSPECTION TEST LIGHTS button. The right and left halves of the display panel should
light and blank alternately (along with the audible alarm). The three status
(continued) legends (FLOW OK,WARMING, and COOLING), the ALERT legend and its
four (triangular) indicators, the three mode legends, SELECT heading
should be lit, and the three AUTO/CONTROL OPTION legends should be
lit. The three temperature displays should indicate “888”, “888.8”, and
“888.8”. The two temperature scale indicators (“°C” and “°F”) and the
two lines connecting SET POINT to both the WATER and PATIENT DISPLAY
should be lit. The audible alarm should sound. Replace any LED’s which
do not light.

f) Flow
To measure the machine’s flow rate and check the flow switch actuation,
perform the following:
1. Fill machine with distilled water until green band on float stem is
fully visible.
2. Connect the test setup shown in figure 13, p.74.
3. Turn machine on. Set machine in MANUAL mode.
4. Increase the temperature set point to light the WARMING status
light. Note the flow rate. The FLOW OK indicator should be lit.
5. Decrease the temperature set point to light the COOLING status
light. Note the flow rate. The FLOW OK indicator should be lit.
6. The flow rate in both modes should exceed 16 GPH
(60.6 liters/hr).
NOTE: If the unit has been completely drained, air can be
trapped in the pump causing the flow to be decreased.
To clear the air, turn the unit off, wait approximately
one minute, and start again from step 3.
7. Kink the hose to stop the flow. The CHECK WATER FLOW indicator
should light, the FLOW OK indicator should go out, the ALERT
indicator should flash on and off, and the audible alarm will toggle.

g) Level Switch Actuation

To test the actuation of the level switch, perform the following:
1. Fill machine with distilled water until green band on float stem is
fully visible. The ADD WATER indicator should be off.
2. Connect a DBK9 hose to a supply fitting on the machine and direct
the other end to a drain or gallon (4 liter) container.
3. Turn machine on. Set machine in MANUAL mode. Adjust the
temperature set point to 4°C (39.2°F) (COOLING status light on).
4. Allow water to drain until bobber has bottomed out on the drain
screen (about 3 quarts or 3 liters). The ADD WATER indicator should
be lit.
5. Refill machine until the green band is fully visible and verify that the
ADD WATER indicator goes out.

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SERVICE MANUAL FUNCTIONAL CHECK AND
Medi-Therm® III SAFETY INSPECTION

7.3 FUNCTIONAL CHECK h) Cold Water Reservoir Controller

AND SAFETY To check the cold water reservoir controller, perform the following:
INSPECTION 1. Fill machine with distilled water until green band on float stem is
(continued) fully visible.
2. Connect the test setup shown in figure 13, p. 74.
NOTE: To minimize the test time for this test only, do not
connect a blanket as shown in figure 13. Connect the return line
of connector hose to the TPT9 tester.
3. Turn machine on and push the MANUAL mode button.
4. Set the Temperature Setpoint to 4°C (39.2°F).
5. Verify that the machine can supply water anywhere within the 3°C
(37.4°F) to 6°C (42.8°F) range as measured by the thermometer
and that the compressor turns off one time. (This will take 15-30
minutes, depending upon room temperature and other conditions.
The use of a blanket for this test can extend this time up to 60
minutes.)

i) Water Temperature Controller and Display Test

To check the temperature controller, perform the following:
1. Fill machine with distilled water until green band on float stem is
fully visible.
2. Connect the test setup shown in figure 13, p. 74.
3. Turn machine on. Set in MANUAL mode.
4. Set the Temperature Setpoint to the various settings specified on the
INSPECTION FORM (section 7.4, p. 33), wait until both the COOLING
and WARMING indicators turn off and the water temperature
stabilizes, then record the temperature of the thermometer and that
shown on the display. Verify that the recorded values are within
limits outlined on INSPECTION FORM, item i.

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FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK j) High Temperature Backup Thermostat Trip Temperatures

AND SAFETY The following procedure describes two different approaches for
INSPECTION measuring the trip points (actuation temperatures) of the machine’s
high temperature backup thermostats. Steps 1-15, pp. 24-26, should be
(continued) followed when a Gaymar MT590 Test Tool is available. For those facilities
not having access to an MT590, follow steps 1A-20A, pp. 27-28.

FROM MT590 TEST TOOL

TO J1 ON POWER SUPPLY
BOARD IN HEAD

®
J1

C OMPRESSOR
P/N 07713-000
HIG H TE MPERATURE
BAC KUP TH ERMOSTATS
TO J1 ON
C OLD SOL.
MT590 TEST TOOL
S2
HOT S OL. NORMAL BYPASS

S3
PUMP

37°C A
HEATER
32°C B
PATI ENT
PROBE
TE ST
PATIENT PROBE
R.F.U. C IRCUIT S ELECT
SIMULATOR

Figure 4—MT590 Test Tool

j) High Temperature Backup Thermostat Trip

Temperatures [MT590 Test Tool Procedure]

WARNING

• Changes to the wiring of the high temperature backup

thermostats can defeat their operation. To verify thermostat
operation, perform the Thermostat Verification Test described in
section 7.3, item k, p. 29 after performing the following test
procedure.
• After performing the following test procedure, verify that the
MT590 Test Tool or any installed shorting jumpers have been
removed before returning the machine to patient use.
Failure to do the above may result in death or serious
injury.

To measure trip points of the high temperature backup thermostats with an

MT590 Test Tool, perform the following steps 1-15:
1. Fill machine with distilled water until green band on float stem is fully
visible.

24
SERVICE MANUAL FUNCTIONAL CHECK AND
Medi-Therm® III SAFETY INSPECTION

7.3 FUNCTIONAL CHECK 2. Unplug the power cord.

AND SAFETY 3. Connect the test setup as shown in figure 13, p. 74.
INSPECTION 4. Connect MT590 Test Tool as shown in figure 4. Connect P7 (base) to
(continued) J1 (MT590). Connect 12 pin cable (MT590) to J1 (head, power supply
board). Plug machine in. Insure the S2 and S3 toggle switches are in the
NORMAL position.
5. Place the machine in service mode 3. Refer to section 8.1, SERVICE
MODES (pp. 34-35) for instructions on how to access service modes.
6. To insure the correct measurement of thermostat trip points, run
machine for 5 minutes in service mode 3 (see Table 3, service mode 3,
p. 37) after the blanket water temperature has reached 42°C (107.6°F).
This allows the inside of the machine to achieve normal operating
temperature. (Bottom wraparound cover must be on machine during this
test.)
7. Enter service mode 4 (see section 8.1, p. 34) from service mode 3. Mode
4 will cause the machine to heat up until one of the safety thermostats
trip.
8. Monitor the water temperature. When the ALERT and REMOVE FROM
USE NOW / MACHINE SHUTDOWN LED’s light and the audible alarm
sounds, the temperature on the thermometer should be within the high
temperature limits range. (See Table 1 below for high temperature limits.)
When the thermostat trips, record the thermometer temperature on
the INSPECTION FORM (p. 33).
(If this is the second thermostat tested, proceed to step 12. Otherwise,
proceed with step 9.)

High Temperature Limits Fixed 44°C (111.2°F) to

(S2) & (S3) 49°C (120.2°F)

Table 1—High Temperature Limits

9. An LED should be lit on the face of the MT590 Test Tool to indicate
an open S2 or S3 thermostat. If both LED’s are lit, proceed to step
12. (Both thermostats have tripped at the same temperature. This
is allowable so long as the water at the TPT9 was within the high
temperature limits range. See Table 1 for high temperature limits.
Otherwise, toggle the corresponding switch S2 or S3 to the bypass
position for whichever LED was lit.
10. Turn machine off.
11. Place machine in service mode 3. If machine still indicates REMOVE
FROM USE NOW / MACHINE SHUTDOWN, then the other
thermostat has tripped at the same temperature. This is allowable
so long as the water temperature at the TPT9 was within the high
temperature limits range. See Table 1 for high temperature limits.
Verify the non-bypassed LED is lit. Record the temperature. Proceed
to step 12.
If the unit enters service mode 3 with no REMOVE FROM USE NOW
/ MACHINE SHUTDOWN alarm, then repeat steps 6 through 8 to
check the other thermostat

25
FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK j) High Temperature Backup Thermostat Trip Temperatures

AND SAFETY [MT590 Test Tool Procedure, cont'd.]
INSPECTION 12. Place both switches S2 and S3 in the bypass position. Turn the machine
(continued) off, then turn the machine on and select MANUAL mode. Allow machine
to run for approximately 1 minute. This will circulate cold water from
the reservoir past the thermostats, causing them to reset.
13. Return switches S2 and S3 to the normal position. If unit continues to
be in alarm condition, repeat step 12.
14. While the machine is running in MANUAL mode, place the RFU
CIRCUIT SELECT A-B switch in the “A” position and toggle the TEST
switch. The machine should shut down, blank the displays, light the
REMOVE FROM USE NOW / MACHINE SHUTDOWN LED, flash the
ALERT LED and toggle the audible alarm. Turn the machine off, then
restart the machine in the MANUAL mode.
Repeat the above procedure with the RFU CIRCUIT SELECT switch in
the “B” position.
This step will verify that both (redundant) RFU circuits are functioning.
15. Turn machine off and unplug the power cord. Disconnect MT590
Test Tool from wire harness and reassemble machine.

WARNING
Verify that the MT590 Test Tool or any installed shorting jumpers
have been removed before returning the machine to patient use.
Failure to do so may result in death or serious injury.

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SERVICE MANUAL FUNCTIONAL CHECK AND
Medi-Therm® III SAFETY INSPECTION

7.3 FUNCTIONAL CHECK j) High Temperature Backup Thermostat Trip Temperatures

AND SAFETY [Alternate Shorting Jumper Procedure]
INSPECTION To measure trip points of the high temperature backup thermostats if you
(continued) do not have access to an MT590 Test Tool, perform the following steps 1A-
20A. (If you have access to an MT590, follow steps 1-15 on the preceding
pages.)

WARNING
• Changes to the wiring of the high temperature backup thermostats
can defeat their operation. To verify thermostat operation, perform
the Thermostat Verification Test described in section 7.3, item k, p. 29
after performing the following test procedure.
• After performing the following test procedure, verify that the MT590
Test Tool or any installed shorting jumpers have been removed
before returning the machine to patient use.
Failure to do the above may result in death or serious
injury.

1A. Fill machine with distilled water until green band on float stem is fully
visible.
2A. Unplug the power cord.
3A. Remove wraparound (see figure 14, p. 75).
4A. Remove plastic cover from wiring terminal block TB1.
(See figure 14 for TB1 location.)
5A. Replace wraparound cover. Do not reinstall screws at this time.
6A. Connect test setup as shown in figure 13, p. 74.
7A. Plug the machine in.
8A. Place the machine in service mode 3. Refer to section 8.1, SERVICE
MODES (pp. 34-35) for instructions on how to access service modes.
9A. To insure the correct measurement of thermostat trip point (because
the wraparound was removed), run machine for 15 minutes after the
water temperature has reached 42°C (107.6°F). This allows the inside of
the machine to achieve normal operating temperature.
10A. Enter service mode 4 (see section 8.1, p. 34) from service mode 3.
Mode 4 will cause the machine to heat up until one of the safety
thermostats trip.
11A. Monitor the water temperature. When the ALERT and REMOVE FROM
USE NOW / MACHINE SHUTDOWN LED’s light and the audible alarm
sounds, the temperature on the thermometer should be within the
high temperature limits range. (See Table 1, p. 25, for high temperature
limits.) This indicates that one of the safety thermostats has tripped.
Record the thermometer temperature at which the thermostat tripped
on the INSPECTION FORM.

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FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK j) High Temperature Backup Thermostat Trip Temperatures

AND SAFETY [Alternate Shorting Jumper Procedure, cont'd.]
INSPECTION NOTE: If this is the second time the thermostat has tripped
(continued) (i.e., if you have previously completed steps 12A to 18A),
proceed to step 19A. Otherwise, proceed to step 12A.
12A. Turn the machine off and unplug the power cord.
Disconnect hoses.
13A. Remove wraparound cover from machine.
14A. Place a shorting jumper across terminals 7 and 9 of TB1. Reconnect
the machine to the wall outlet, turn it on, and press the MANUAL
mode button. If the unit indicates REMOVE FROM USE NOW /
MACHINE SHUTDOWN proceed to step 15A. If the unit enters
MANUAL mode with no REMOVE FROM USE NOW / MACHINE
SHUTDOWN alarm, then proceed to step 17A.
15A. Turn the machine off and unplug the power cord. Remove
shorting jumper from terminals 7 and 9 of TB1 and reconnect across
terminals 7 and 10.
16A. Plug machine in and turn it on. Press the MANUAL mode button. If
the machine still indicates a REMOVE FROM USE NOW / MACHINE
SHUTDOWN alarm, then both thermostats have tripped at the same
temperature. This is allowable so long as the water temperature
at the TPT9 was within the high temperature limits range. (See
Table 1, p. 25 for high temperature limits.) If both thermostats have
tripped, proceed to step 19A. If the unit enters MANUAL mode with
no REMOVE FROM USE NOW / MACHINE SHUTDOWN alarm, then
proceed to step 17A.
17A. Turn the machine off and unplug the power cord. Replace
wraparound cover. Reconnect hoses from test setup to machine (see
figure 13, p. 74).
18A. Repeat steps 7A through 11A.
19A. Turn the machine off and unplug the power cord. Disconnect
supply hose from TPT9 and allow water to gravity drain into a
container for approximately one minute. This will circulate cold
water from the reservoir past the thermostats, causing them to
reset. Do not install a second shorting jumper. Reconnect supply
hose to TPT9 and return drained water to machine reservoir.
20A. Remove wraparound cover from machine. Remove shorting jumper.
Replace plastic terminal block cover. Replace wraparound cover and
reinstall screws.

WARNING

Verify that the MT590 Test Tool or any installed shorting jumpers
have been removed before returning the machine to patient use.

Failure to do so may result in death or serious injury.

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SERVICE MANUAL FUNCTIONAL CHECK AND
Medi-Therm® III SAFETY INSPECTION

7.3 FUNCTIONAL CHECK k) Thermostat Verification Test

AND SAFETY
INSPECTION WARNING
(continued)
Verify that the high temperature backup thermostats
independently shut down the machine.
Incorrect operation of these thermostats may result in
death or serious injury.

1. Fill machine with distilled water until green band on float stem is
fully visible.
2. Unplug the power cord.
3. Remove wraparound (see figure 14, p. 75).
4. Carefully disconnect the yellow wire from the top thermostat (S3)
by pulling the connector off the terminal along the same angle as the
terminal (see figure 17, p. 79).
5. Plug in the machine and turn it on.
6. Select MANUAL mode.
7. Observe that the machine indicates REMOVE FROM USE NOW /
MACHINE SHUTDOWN.
8. Turn the machine off and unplug the power cord.
9. Reconnect the yellow wire to S3.
10. Carefully disconnect the yellow wire from the lower thermostat (S2)
by pulling the connector off the terminal along the same angle as the
terminal.
11. Plug the machine in and turn it on.
12. Select MANUAL mode.
13. Observe that the machine indicates REMOVE FROM USE NOW /
MACHINE SHUTDOWN.
14. Turn the machine off and unplug the power cord.
15. Reconnect the yellow wire to S2.
16. Replace wraparound and reinstall screws.

29
FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK l) Patient Temperature Display Test

AND SAFETY To check the patient temperature display, perform the following:
INSPECTION 1. Fill machine with distilled water until green band on float stem is
(continued) fully visible.
2. Connect a resistance of 1355 ohms to the patient probe jack, to
simulate a 37°C (98.6°F) patient temperature.
3. Turn machine on and set it in the MANUAL mode.
4. PATIENT Temperature Display should indicate 37°C (98.6°F)
± 0.3°C (0.5°F). Record appropriate value on INSPECTION FORM.
5. Connect a resistance of 1667 ohms to the patient probe jack to
simulate an 32°C (89.6°F) patient temperature.
6. PATIENT temperature display should indicate 32°C (89.6°F)
± 0.3°C (0.5°F). Record appropriate value on INSPECTION FORM.
NOTE: The CHECK PATIENT PROBE alarm may flash on
during step 6 if the display indicates less than 32.0°C
(89.6°F). This condition is considered normal and
allowable.

m) Low Temperature Backup Thermostat (S1) (Optional)

The low temperature backup thermostat is a fixed trip point thermostat
to limit low temperatures between -3.0°C (26.6°F) and +2.5°C (36.5°F).
It is not necessary to test the trip point as part of this
functional test.The function of the thermostat is to protect
the machinery from freezing. It is not a patient safety-related
device.
If there is reason to test this thermostat, perform the following:
1. Drain machine of water as follows:
a. Connect a DBK9 connector hose to the SUPPLY fitting on
machine.
b. Turn machine on and select MANUAL mode. Allow machine to
pump water out until ADD WATER light comes on. Turn machine
off and allow unit to gravity drain until empty.
c. Disconnect DBK9.
2. Unplug the power cord.
3. Add eight (8) quarts (7.6 liters) of water and two (2) quarts (1.9
liters) of alcohol to reservoir.
4. Connect the test setup shown in figure 13, p. 74.
5. Plug machine in and place it in service mode 2. Refer to section
8.1, SERVICE MODES (pp. 34-35) for instructions on how to access
service modes.
NOTE: In service mode 2, the compressor, pump, and cold
solenoid are activated. No temperature measurement
or other control is performed by the machine in this
mode.

30
SERVICE MANUAL FUNCTIONAL CHECK AND
Medi-Therm® III SAFETY INSPECTION

7.3 FUNCTIONAL CHECK m) Low Temperature Backup Thermostat (S1) (cont’d.)

AND SAFETY 6. When the contacts of S1 open up, the audible alarm, the REMOVE
INSPECTION FROM USE NOW / MACHINE SHUTDOWN LED, and the ALERT
(continued) LED will come on. The thermometer should read between -3.0°C
(26.6°F) and +2.5°C (36.5°F) at this point.
7. Turn machine off. Allow it to warm up to reset thermostat.
8. Drain machine of water and alcohol mixture as in step 1 above.
9. Refill with distilled water until the green band on the float stem is
fully visible.

n) Grounding Resistance
Use an ohmmeter to measure the resistance between the grounding
pin on the line cord attachment plug and an exposed metal point on the
chassis. The value should be less than 0.5 ohms.

o) Current Leakage, CHASSIS

Measure the maximum current leakage between the chassis and the
ground in all operating configurations (heating, cooling, compressor ON,
compressor OFF, normal and reverse polarity with the machine grounded
and ungrounded). The current leakage should not exceed the following:
Condition Current Leakage
Machine grounded 10 microamps
Machine ungrounded 100 microamps

Current Leakage, PATIENT PROBE

It is first necessary to prepare a patient probe by wrapping it tightly
along its entire length with metal foil. Then measure current leakage at
the foil for all combinations: grounded, ungrounded, normal polarity, and
reversed polarity. The current leakage should not exceed 50 microamps.
NOTE: If additional information is required, refer to AAMI American National
Standard, Safe Current Limits for Electromedical Apparatus or contact
Gaymar's Technical Service Department.

p) Reset the RFU Code

The Medi-Therm III machine will retain the previously stored code.
Before returning a machine to service, reset the RFU code to zero so
that a previous code is not held in memory.
To reset the RFU code to zero:
1. Place the machine in service mode 1 (see section 8.1, p. 34).
2. Press the TEST LIGHTS button on the control panel.
The RFU code is reset when the number on the blanket display shows “0”.

31
FUNCTIONAL CHECK AND SERVICE MANUAL
SAFETY INSPECTION Medi-Therm® III

7.3 FUNCTIONAL CHECK This completes the recommended functional test and preventive maintenance
AND SAFETY procedures for the Gaymar Medi-Therm III.
INSPECTION If a machine passes all the requirements of paragraphs “a” through “p”, the
(continued) machine should be considered operational and suitable for return to service.

WARNING

Verify that the MT590 Test Tool or any installed shorting jumpers have
been removed before returning the Medi-Therm III to service.
Failure to do so may result in death or serious injury.

32
SERVICE MANUAL INSPECTION FORM
Medi-Therm® III

7.4 INSPECTION FORM

M edi-Therm III Hyper/Hypothermia
Functional Check / Inspection Form *

Location ____________________________________________________ Serial number ___________________________________

Action Taken
Item OK? (Y/N) Action needed
(Date / Initials)

a. Condition of chassis

b. Condition of attachment plug

c. Line cord and strain reliefs

d. Circuit breaker

e. Condition of lights and alarm

f. Flow 1. Greater than . . . 16 GPH (60.6 l/hr)

[ WARMING]

2. Greater than . . . 16 GPH (60.6 l/hr)

[COOLING]

3. Flow switch activation

g. Level switch activation

h. Cold water reservoir controller: 3°C (37.4°F ) to 6°C (42.8°F )

i. Water temperature controller and display test:

Temperature Display Thermometer

Control Setpoint Reading Reading

10°C (50°F)

25°C (77°F)

41°C (105.8°F)

Display readings within 1°C (1.8°F) of temperature setpoint

thermometer readin g within 1°C (1.8°F) of temperature setpoint

j. S2: High temperature backu p thermostat: 44°C (111.2°F) to

49°C (120.2°F)

S3: High temperature backu p thermostat: 44°C (111.2°F) to

49°C (120.2°F)

k. Thermostat verification test: S2/S3

l. Patient temperature display test:

Probe Resistance Patient Temperature Display

(ohms)

1355 37°C ± 0.3°C (98.6°F ± 0.5°F)

1667 32°C ± 0.3°C (89.6°F ± 0.5°F)

m. Low temperature backup thermostat (S1): -3°C (26.6°F) to +2.5°C (36.5°F)

n. Ground resistance less than 0.5 ohms

o. Current leakage:

Chassis (grounded) . . . . . . . . . . . . 10 microamps max.

Chassis (ungrounded) . . . . . . . . . . 100 microamps

max.

Patient Probe . . . . . . . . . . . . . . . . . 50 microamps max.

p. Reset of RFU code

* Complete entire Functional Check / Inspection Form prior to troubleshooting unit.

33
TROUBLESHOOTING SERVICE MANUAL
SERVICE MODES Medi-Therm® III

8.0 TROUBLESHOOTING Some troubleshooting and functional checks may be aided by using the
AND SERVICE MODES Medi-Therm III machine’s service modes of operation.

8.1 SERVICE MODES All service modes are entered from service mode I by pressing the appropriate
digital control panel button within 10 seconds of entry into service mode 1. If no
button is pressed after service mode I is entered, the machine will reset itself to
standby mode after 10 seconds. See table 3 for a description of each mode.

To initiate service mode 1:

1. Turn machine off.
2. Remove the 6 screws holding the head to the base.

CAUTION

Wear a static control device connected to the chassis ground to

prevent electrostatic discharge. (See figure 5, p. 35.)
Electrostatic discharge can damage the control/display
board.

3. Lift the head, press and hold service button S3 on the low voltage
control/display board (figure 5), then turn the machine on.
In service mode 1, the machine will display the last RFU* code
(on the WATER temperature display) and the software version
(on the PATIENT display). An RFU code may help to debug a
machine which has shut down due to a REMOVE FROM USE
condition (table 2).
Pressing the TEST LIGHTS button while in service mode I will
reset the RFU code to zero. Whenever returning a machine
to service, reset the RFU code to zero to avoid basing future
troubleshooting decisions on an old code.

* RFU = REMOVE FROM USE NOW / MACHINE SHUTDOWN

34
SERVICE MANUAL SERVICE MODES
Medi-Therm® III

8.1 SERVICE MODES (continued)

SERVICE BUTTON S3
ON CONTROL/DISPLAY BOARD

Figure 5—Initiating service mode 1

RFU Code Description Troubleshooting Chart

0 Reset code — indicates no RFU† condition recorded. None

1 Measured water or reservoir probe value is out of the range 0°C to 50°C (32°F to 122°F) Figure 6B

2, 3 Microcontroller system failure Figure 6C

4 Compensation resistor 1 (R12) is out of spec–too high or open-circuited. Figure 6D

5 Compensation resistor 1 (R12) is out of spec–too low or short-circuited. Figure 6D

6 Compensation resistor 2 (R13) is out of spec–too high or open-circuited. Figure 6E

7 Compensation resistor 2 (R13) is out of spec–too low or short-circuited. Figure 6E

8 Water temperature probe measurement is out of spec–possibly open or short-circuited. Figure 6F

9 Reservoir probe measurement is out of spec–possibly open or short-circuited. Figure 6G

— Microcontroller system failure–CHECKSUM. Figure 6C

E Microcontroller system failure–RAMTEST. Figure 6C

H Microcontroller received RFU† signal from the power supply board. Figure 6H

L Microcontroller system failure Figure 6C

† RFU = REMOVE FROM USE NOW / MACHINE SHUTDOWN

Table 2 - RFU† Error Codes

35
SERVICE MODES SERVICE MANUAL
Medi-Therm® III

Table 3 - Service Modes

Service Mode 1:
To access Press and hold S3 (see figure 5, p. 35) on the control/display board, then turn machine on.
Uses • Verification of software version level.
• Last RFU code indication and RFU code reset.
• Verification of proper watchdog functioning (U34).
• Entrance to other modes.
Description • Required for entrance to other modes.
• Patient display shows software version level.
• Water temperature display shows RFU code.
• Pressing the TEST LIGHTS button will reset RFU code to zero.
• ALERT LED flashes.
• Leader lights flash.
• Setpoint display flashes “1”.
• 10 second duration. Machine resets to standby mode after 10 seconds if no buttons are pressed.
To exit Pressing the MANUAL, AUTO, or MONITOR buttons will cause entrance into other modes. If no further
action is taken by the user, the machine will reset itself to standby mode after approximately 10 seconds.

Service Mode 2:
To access Press MANUAL button while in service mode 1.
Uses To assist in testing trip point of S1 thermostat.
Description • Patient and water temperature displays are blank.
• ALERT LED flashes.
• Leader lights flash.
• Setpoint display flashes “2”.
• Pump and compressor are turned on, and cold solenoid valve is opened.
• No temperature measurement is performed by the machine.
To exit Pressing any button except the MANUAL button will reset the machine to standby mode.
(Pressing the MANUAL button again will do nothing.)

(continued on next page)

RFU = REMOVE FROM USE NOW / MACHINE SHUTDOWN

36
SERVICE MANUAL SERVICE MODES
Medi-Therm® III

Table 3 - Service Modes (continued)

Service Mode 3:
To access Press AUTO button while in service mode 1.
Uses To prewarm the machine for testing of high temperature thermostat S2 and S3 trip points.
Description • Patient display is blank.
• ALERT LED flashes.
• Leader lights flash.
• Setpoint display flashes “3”.
• The water temperature display shows the water temperature in degrees Celsius or Fahrenheit
depending on choice made in last normal operating mode.
• The output water temperature is controlled to 42°C (107.6°F).
To exit Pressing any button except the AUTO button or the °C/°F button will reset machine to standby
mode. (Pressing AUTO button again will do nothing.) Pressing the °C/°F button will put the
machine into mode 4 from mode 3.

Service Mode 4:
To access Press °C/°F button while in service mode 3.
Uses To test the trip points of the high temperature thermostats S2 and S3.
Description • Patient display is blank.
• ALERT LED flashes.
• Leader lights flash.
• Setpoint display flashes “4”.
• The water temperature display shows the water temperature in degrees Celsius or Fahrenheit,
depending on choice made in last normal operating mode.
• The output water temperature is controlled to 49°C (120.2°F) .
To exit Pressing any button except the °C/°F button will reset the machine to standby mode.
(Pressing the °C/°F button again will do nothing.)

Service Mode 5:
To access Press MONITOR button while in service mode 1.
Uses • To verify reservoir probe reading.
• To assist troubleshooting cooling problems.
Description • Patient display shows the cold water reservoir temperature in degrees Celsius or Fahrenheit,
depending on what was selected during the last normal operating mode.
• ALERT LED flashes.
• Leader lights flash.
• Setpoint display flashes “5”.
• The water temperature display is blank.
• The pump is on and cold solenoid valve is opened.
• The compressor is controlled using normal control algorithms.
To exit Pressing any button except the MONITOR button will reset the machine to standby mode.
(Pressing the MONITOR button again will do nothing.)

37
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

8.2 TROUBLESHOOTING CHARTS

IMPORTANT
Whenever possible, perform the
FUNCTIONAL CHECK AND SAFETY
INSPECTION (see section 7.3) prior
to troubleshooting machine.

Figure 6A—Accessing RFU codes

38
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

RFU CODE 1 Run machine. If RFU condition (RFU

Measured values Insure integrity of the control/display code 1) reappears, unplug machine
from RT1 or RT2 board to power supply board
are not within and measure resistance between pins
connections. Insure integrity of base 10 and 11 of J1 on back of
0°C and 50°C to power supply board connections. control/display board.
(32°F and 122°F)

Yes Is it
Yes Is it Measure resistance between
Suspect temperature between
measurement between pins 23 and 11 811 and 7355
811 and 7355 of J1 on back of ohms
circuitry. ohms control/display board. ?
?

No No

Disconnect connector Disconnect connector P6

P6 from J2 on the from J2 on the power
Repair/replace power supply board and supply board and
the measure resistance measure resistance
control/display board. between pins 2 and 9 of between pins 3 and 5 of
connector P6. connector P6 at base.

Faulty signal lines Yes Is it Is it Faulty signal lines

between between Yes
between between
control/display board 811 and 7355 811 and 7355 control/display board
and RT1. ohms ohms and RT2.
? ?

No No

Is RT1 Is RT2
Yes actual actual Yes
Suspect RT1. temperature between temperature between Suspect RT2.
Repair/replace. 0°C and 50°C 0°C and 50°C Repair/replace.
(32°F and 122°F) (32°F and 122°F)
? ?

No No

Suspect controller failure

caused RT1 or RT2 to read
an actual temperature outside
0°C to 50°C (32°F to 122°F)
range.

Repair/replace
the
control/display board.

Figure 6B—RFU Code 1

39
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

Figure 6C—RFU Codes 2, 3, – , E, and L

40
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

RFU CODE 4 RFU CODE 5

Compensation resistor 1 Compensation resistor 1
(R12 on (R12 on
control/display board) control/display board)
reading is too high reading is too low

Measure R12
resistance.

Is it No
816 ohms Replace R12.
±0.1%
?

Yes

Suspect
temperature
measurement
circuitry.

Repair/replace
the
control/display board.

Figure 6D—RFU Codes 4, 5

41
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

RFU CODE 6 RFU CODE 7

Compensation resistor 2 Compensation resistor 2
(R13 on (R13 on control/display
control/display board) board) reading is too low.
reading is too high.

Measure R13
resistance.

Is it No
7320 ohms Replace R13.
±0.1%
?

Yes

Suspect
temperature
measurement
circuitry.

Repair/replace
the
control/display board.

Figure 6E—RFU Codes 6, 7

42
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

RFU CODE 8
Blanket probe
reading faulty

Insure integrity of control/display Is it

board to power supply board Yes Suspect
between temperature
connections. Insure integrity of 811 and 7355
base to power supply board measurement
ohms circuitry.
connections. ?

No

Run machine. If RFU condition Disconnect

(RFU Code 8) reappears, unplug Repair/replace
connector P6 from the
machine and measure resistance J2 on power supply
between pins 10 and 11 of J1 on control/display board.
board.
back of control/display board.

Measure
resistance between
pins 3 and 5 of
connector P6.

Is it Faulty signal lines

between Yes
between
811 and 7355 control/display
ohms board and RT2.
?

No

Is RT2
temperature Yes
between 0°C and 50°C Suspect RT2.
(32°F and 122°F) Repair/replace.

No

Suspect controller failure

caused RT2 to actually
read outside
0°C to 50°C
(32°F and 122°F) range
(811 to 7355 ohms).

Repair/replace
the
control/display board.

Figure 6F—RFU Code 8

43
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

RFU CODE 9
Reservoir probe
reading faulty

Insure integrity of control/display

Is it Suspect
board to power supply board between Yes
connections. Insure integrity of temperature
811 and 7355 measurement
base to power supply board ohms
connections. circuitry.
?

No

Run machine. If RFU condition Disconnect Repair/replace

(RFU Code 9) reappears, unplug connector P6 from the
machine and measure resistance J2 on power supply control/display
between pins 23 and 11 of J1 on board. board.
back of control/display board.

Measure
resistance between
pins 2 and 9 of
connector P6.

Is it Faulty signal lines

between Yes
between
811 and 7355 control/display
ohms board and RT1.
?

No

Is RT1
temperature Yes
between Suspect RT1.
0°C and 50°C to Repair/replace.
(32°F and 122°F)
?

No

Suspect controller failure

caused RT1 to actually
read outside
0°C to 50°C to
(32°F to 122°F) range
(811 to 7355 ohms).

Repair/replace
the
control/display board.

Figure 6G—RFU Code 9

44
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

[This page has been intentionally left blank.]

45
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

Figure 6H—RFU Code H, Page 1 of 2

46
 model MTA5942.

Does Operate unit in

No No
S1 is open Is it S2 or S3? RFU condition MANUAL mode
reappear? with setpoint
temperature equal
to 4°C (39.2°F).
Yes Yes

Allow unit to warm Allow unit to cool

to room Does
to room No
Medi-Therm® III

temperature or temperature or RFU condition

until reappear?
SERVICE MANUAL

until thermostat
closes. thermostat closes.
Yes

Does
Operate unit in Test S2, S3 as Yes TPT9 read
MANUAL mode indicated in High less than 3°C
with setpoint Temperature (37.4°F)
temperature equal Thermostat
to 4°C (39.2°F). Function Test. No

Test S1
as indicated in
Is Low Temperature
Does No S2 or S3 No
RFU condition Thermostat
thermostat out Function Test.
reappear? of spec
?
Yes Yes

No Is S1
thermostat
Does out of spec
TPT9 read Yes Replace ?
less than 3°C thermostat.
(37.4°F) Yes

No

Replace S1

Possible faulty control system

or temperature measurement
circuitry. Call Gaymar
Technical Services.

47
Figure 6H—RFU Code H, Page 2 of 2
TROUBLESHOOTING CHARTS
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

Figure 6I—Check Water Flow Alert is On, Page 1 of 2

48
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

Figure 6I—Check Water Flow Alert is On, Page 2 of 2

49
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

PUMP MOTOR
NOT RUNNING

Verify unit is in
AUTO or MANUAL
modes.

Line Yes
voltage at Repair/
terminals 6 replace
and 8 of pump.
TB1?

No

Yes Suspect
Line base-to-power
voltage at supply board
output of connection.
Q4? Repair.

No

Disconnect pump and Is Suspect Q4 or U2.

Is Yes
measure resistance for pump No
optocoupler U2 Repair/replace
short. (It should be winding power supply
input pulled approximately 10 shorted
low? board.
ohms.) ?
Yes
No

Is pin Yes Suspect

8 ref to pin board-to-board Replace
10 of U51 connection. pump.
0 VDC? Repair.

No

Suspect Assume Q4 triac is

control/display also damaged.
board. Repair/replace
power supply
Repair/replace.
board.

Figure 6J—Pump Motor Not Running

50
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

[This page has been intentionally left blank.]

51
TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

Figure 6K - Water Won't Heat in Auto or Manual Mode, Page 1 of 2

52
SERVICE MANUAL TROUBLESHOOTING CHARTS
Medi-Therm® III

Figure 6K - Water Won't Heat in Auto or Manual Mode, Page 2 of 2

53
54
Select MANUAL mode.
Connect test setup Adjust setpoint to Is
WATER WILL as shown in figure 4°C (39.2°F). water display No Is Yes Will reservoir Yes
within 1°C (1.8°F)) compressor temperature reach
NOT COOL 13 (but don’t use Allow machine time
of setpoint on? 6°C (42.8°F) or
the blanket). to cool. below?
(30 min. max.) ?
Yes No
No

If thermometer
in TPT9
contradicts this, Refrigeration unit Dirty or restricted
suspect RT2. may have lost refrigeration
its charge condenser

Figure 6L - Water Will Not Cool, Page 1 of 3

TROUBLESHOOTING CHARTS

Yes Is reservoir
temperature
6°C (42.8°F) or
below? Refrigeration
system
No
faulty

See
"WATER WILL
NOT COOL"
(figure 6L,
page 3 of 3)
Check pump
(it should be
running)

Is a steel object
**
attracted to center top of
the valve?

Is See
No "PUMP MOTOR Repair/replace
pump Is SV1 coil No
running NOT RUNNING" cold solenoid
energized?
? (figure 6J) SV1.

Yes
Yes

Is See Line *
there No "CHECK WATER Check voltage at No Check heater
adequate FLOW alert is on" hot solenoid SV2. terminals 2
flow (figure 6I) and 3 of (it should be off)
(it should be off).
? TB1?
SERVICE MANUAL
Medi-Therm® III

Yes
Yes
 Yes
Yes

Check cold * Line * Hot solenoid SV2

Suspect Line
solenoid SV1 base-to-power No voltage at No may be stuck
(it should voltage at
supply board terminals 11 open or cold
be on). output of and 8 of
connection. solenoid SV1
Repair. Q8? TB1? stuck closed.
Yes
Yes
Medi-Therm® III

Line *
voltage at Yes Suspect Suspect * Disassemble
Is Line solenoids.
SERVICE MANUAL

terminals 1 and 3 Q8 or U7. No base-to-power No

of TB1? Repair/replace optocoupler U7 supply board voltage at Clean,
power supply input pulled connection. output of inspect seats,
board. low? Repair. Q3? repair/replace.
No
Yes
Yes

* Suspect
Line
Yes base-to-power
voltage at supply board
output of Suspect Is pin 9 Suspect
connection. No Q3 or U1. No Is
Q9? board-to-board ref to pin 10 optocoupler U1
Repair. of U51 Repair/replace
connection. power supply input pulled
No Repair. 0 VDC? low?
board.

Yes Yes
Is Is pin 11
No ref to pin 10 Yes
optocoupler U8
input pulled of U51
low? 0 VDC? Suspect Suspect Is pin Suspect
control/display board-to-board No 7 ref to pin Yes control/display
Yes No board. connection. 10 of U51 board.
Suspect Repair. 0 VDC? Repair/replace.
Repair/replace.
board-to-board
connection.
Disconnect Suspect Repair.
cold solenoid SV1. control/display
Measure board.
coil resistance
Repair/replace.
for short.

Is Suspect NOTES:
cold solenoid No Q9 or U8.
SV1 coil Repair/replace * The line voltage measured should be the same as that measured across terminals 5
shorted power supply
? board. and 3 of TB1. (There may be residual voltage between terminals 2 and 3 or terminals
Yes 1 and 3 of TB1 when the circuitry is in the OFF state because of the solenoid valve
construction and circuit configuration. These are not considered line voltage.
Assume Q8 is
Repair/replace also damaged.
cold solenoid
** The solenoid coil can be tested with a multimeter set to the diode check function.
Repair/replace
SV1. power supply With the power off, measure the diode drop across the terminals of the solenoid coil
board.
in both directions. There should be an open circuit in one direction and approximately
0.8V in the other. If not, the solenoid valve is bad and should be replaced.

55
TROUBLESHOOTING CHARTS

Figure 6L - Water Will Not Cool, Page 2 of 3

TROUBLESHOOTING CHARTS SERVICE MANUAL
Medi-Therm® III

Figure 6L - Water Will Not Cool, Page 3 of 3

56
SERVICE MANUAL
Medi-Therm® III

9.0 REPAIR PROCEDURES WARNING

Always perform the FUNCTIONAL CHECK AND SAFETY INSPECTION

(section 7.3) after making repairs and before returning the Medi-Therm
III machine to patient use.
Improper repair may result in death or serious injury,
equipment damage, or malfunction.

In addition to the following repair procedures, refer to the troubleshooting charts

in section 8.0, page 34, TROUBLESHOOTING AND SERVICE MODES.

9.1 REFRIGERATION WARNING

SYSTEM
• Equipment contains refrigerant under high pressure. Refer servicing
to a certified refrigeration service technician.
Improper repair procedures can result in serious injury
or damage the compressor unit.

• The refrigeration system contains rotating fan blades. Do not

operate with fan shroud removed.
Injury could result.

NOTE: Servicing and/or repair of the refrigeration system should be

performed in compliance with applicable federal, state, and local
regulations.

9.1.1 R-134a SYSTEMS Do not attempt servicing the R-134a refrigeration system unless you are certified
in R-134a refrigeration maintenance, repair, and reclaiming procedures. Supply the
following information to the refrigeration service technician:

CAUTION

• Use only R-134a refrigerant and polyol ester oil when charging a
Medi-Therm III R-134a system.
Using other refrigerants or oils will damage the compressor.

• The Medi-Therm III R-134a system uses a polyol ester oil for
lubrication because conventional mineral oils do not provide sufficient
lubricity and miscibility. R-134a refrigerant and polyol ester oil are
highly susceptible to moisture absorption (more so than mineral oil).
It is important that proper system evacuation, charging, and leak
detection procedures be employed. Do not leave the refrigeration
system open to ambient air when servicing. Moisture absorption will
result in reduced compressor life.

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 SERVICE MANUAL
Medi-Therm® III

9.1.1 R-134a SYSTEMS • The smaller molecular size of R-134a refrigerant allows it to leak from
(continued) smaller openings.

• Prior to charging the system, Gaymar recommends evacuating the system

to below 500 microns. Then, perform a vacuum decay test to assure there
is not a large differential between the system and the vacuum pump. After 5
minutes, the system should still be at 500 microns or below.

• For optimum performance, charge the R-134a system with 8.5

ounces of R-134a refrigerant. Make sure that the entire 8.5 ounce
charge is pulled from the gauge manifold and hoses into the system before
disconnecting.

• If it is necessary to check a unit’s charge, purge the refrigerant gauge manifold

and hoses with R-134a refrigerant from an external source before opening
the service valves to prevent affecting the unit’s charge.

In a properly charged unit, the low side refrigerant gauge pressure

should be approximately 14 to 23 psi; the high side pressure should be
approximately 123 to 137 psi, under the following conditions:
1. the unit’s wraparound is removed;
2. the ambient temperature is 22.2°C (72°F);
3. the unit is connected to a blanket/body wrap, and the Medi-Therm
III has been set to 4°C (39.2°F) in manual mode;
4. the reservoir water temperature is 4.4°C (40°F); and,
5. the pressure check is performed with a gauge manifold connected to
the system with flexible hoses.
Upon completion of the pressure check, turn the unit off and allow
refrigerant in the manifold and hoses (especially the high side) to migrate
back into the unit before closing the service valves and disconnecting the
hoses. Warming the hose near the service valve with your hands for 2-3
minutes will ensure this.

• If recharging is required, most likely there is a leak in the system. Locate and
repair any leaks before recharging the unit.

• Replace the two service valve caps and two gage port caps after servicing the
refrigeration system.

After servicing the refrigeration unit, make sure to perform the FUNCTIONAL
CHECK AND SAFETY INSPECTION (see section 7.3).

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SERVICE MANUAL
Medi-Therm® III

9.2 REPLACING THE CAUTION

POWER SUPPLY
BOARD Wear a static control device connected to the chassis ground to prevent
electrostatic discharge. (See figure 5, p. 35.)
Electrostatic discharge can damage circuitry on PC boards.

The following procedures describe replacement of the power supply board. A

digital voltmeter is required.

POWER SUPPLY BOARD REMOVAL

(refer to figure 8, p. 67):
1. Unplug the power cord.

2. Disconnect the 26-conductor cable harness assembly from the power supply
board at J4.

3. Disconnect the three cable harness connectors P5, P6, and P7.

4. Remove the seven (7) board mounting screws.

5. Lift board out of head.

POWER SUPPLY BOARD INSTALLATION

(refer to figure 8, p. 67):
1. Unplug the power cord.
2. Place the new power supply board in head.
3. Install seven (7) board mounting screws.
4. Connect the three cable harness connectors P5, P6, and P7 to J3, J2, and J1 on
the power supply board.
5. Perform a voltage check of the power supply board. Do not use the board or
connect it to the control/display board if the voltages are incorrect.

NOTE: To prevent an accidental short circuit, connect voltmeter

leads while the machine is off.
With the 26-conductor cable harness assembly disconnected from the
power supply board and the machine on, measure for the following
voltages at the following board locations (see figure 23, p. 86):
DVM DVM
Common + Lead Voltage
to Pin to Pin Reading
Q7 1 3 -12 ± 0.5V
Q6 2 3 +12 ± 0.5V
C16 – + +5.3 ± 0.3V

6. Turn machine off.

7. Connect the 26-conductor cable assembly.
8. Perform the FUNCTIONAL CHECK AND SAFETY INSPECTION (section 7.3)

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 SERVICE MANUAL
Medi-Therm® III

9.3 REPLACING THE CAUTION

CONTROL/DISPLAY
BOARD Wear a static control device connected to the chassis ground to prevent
electrostatic discharge. (See figure 5, p. 35.)
Electrostatic discharge can damage circuitry on PC boards.

Control/Display Board Removal (refer to figure 8, p. 67):

1. Unplug the power cord.
2. Disconnect the 26 conductor cable harness assembly from the control/
display board at J1.
3. Unfasten the patient probe assembly J1 from the head by removing the hex
nut and pull the assembly from its mounting hole.
4. Remove the six (6) board mounting screws and three (3) lockwashers. Push
aside the 26-conductor cable harness and EMI filter assembly. Remove the
three standoffs from the PC board.
5. Push aside the ground harness and transformer cable and lift board enough
to gain access to the PC board.
6. Disconnect the digital control panel from the board at J4 and the patient
probe assembly from the board at J2.
NOTE: These connectors have locking tabs that must be pressed in order
to disengage them from the board.

CAUTION

Use care when disconnecting the digital control panel ribbon

from the control board.
Folding the ribbon cable may cause failure of the
control panel.

7. Lift board out of cover.

Control/Display Board Installation (refer to figure 8, p. 67):

1. Unplug the power cord.

2. Place the new control/display board in the head.

3. Install the six (6) board mounting screws and three (3) standoffs as follows:

a. Insert one standoff through the middle mounting hole along the
board's longer edge (toward front of machine). This will be used to
hold the transformer cable off the board.
b. Install the other two standoffs in the two mounting holes closest to
the J1 connector for the 26-conductor cable harness. Theses will be
used to hold the 26-conductor cable harness and EMI assembly off
the board.

60
SERVICE MANUAL
Medi-Therm® III

c. Move the 26-conductor cable harness and EMI filter assembly over
the standoffs.
d. Insert two board screws through the transformer cable retaining
clips on the transformer cable and mount one through the corner
EMI filter assembly hole and into the standoff. Mount the other to
the standoff along the board's longer edge.
e. Install three board screws and three lockwashers through the
ground harness:
(1.) Install the corner board screw through the ground wire of
the patient probe assembly, then into the board.
(2.) Install the second screw and washer through the ground
harness into the board.
(3.) Install the third screw and washer through the EMI filter
assembly and into the installed standoff.
f. Install the remaining board screw.
4. Insert patient probe assembly into mounting hole and fasten with hex nut.
Insure patient probe assembly is oriented so that the bevelled corner of the
probe assembly is positioned as shown in figure 16, p. 78.
5. Connect the digital control panel plug P4 to the board at J4.
6. Connect the patient probe assembly plug P2 to the board at J2.
7. Perform a voltage check of the power supply board (see section 9.2,
p. 59).
8. Connect the 26 conductor cable assembly from the power supply board.

9. Perform the FUNCTIONAL CHECK AND SAFETY INSPECTION (section 7.3).

9.4 REPLACING THE To install a complete new cover:

TOP COVER 1. Unplug the power cord.
2. Remove old top cover from machine by removing 6 screws underneath top
cover and disconnecting cables. See figure 14, p. 75.
3. Install new top cover.
4. Perform the FUNCTIONAL CHECK AND SAFETY INSPECTION (section 7.3).

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 SERVICE MANUAL
Medi-Therm® III

9.5 REPLACING To replace thermostat (see figures 15, 17, and 18; pp. 76-77, 79, 81):
THERMOSTATS 1. Unplug the power cord.
2. Remove wraparound from chassis.
3. Disconnect spade lugs from thermostat terminals.
4. Carefully peel back insulating material.
5. Remove the two screws holding the thermostat. Remove the thermostat.
6. Apply thermal grease to the underside of the replacement thermostat to
ensure proper operating temperature ranges.
* Recommended thermal greases:
• Silicone Heat Sink Compound
(Dow Corning; Midland, Michigan)
• Thermal Joint Compound Type 120-5
(Wakefield Engineering; Wakefield, Massachusetts)

CAUTION

Always use thermal grease on thermostats for Medi-Therm III

units.
Failure to use thermal grease could raise trip points
above the acceptable range.

7. Reconnect spade lugs to terminals. Refer to figures 17, p. 79 to ensure

thermostat is connected correctly.

CAUTION

Do not bend or alter terminals.

Terminals may break. Also, bending may alter the trip
point range.

8. Mount thermostat, using existing screws.

9. Reapply insulating material.
10. Perform the FUNCTIONAL CHECK AND SAFETY INSPECTION (section 7.3).

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SERVICE MANUAL
Medi-Therm® III

9.6 CLEANING THE To clean the flow switch (see figure 7 below and figure 15, pp. 76-77):
FLOW SWITCH
1. Remove nuts (item A) and remove assembly.
2. Loosen hose clamps (items B and C) and remove hoses.
3. Remove barbed adapters (item D). Remove piston.
4. Clean all parts with alcohol and remove any foreign matter.
5. To reassemble, reverse steps 1 through 3 above. Ensure that the piston is
replaced into the flow switch housing with its round "disk" side oriented
down.

Figure 7 - Flow Switch

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 SERVICE MANUAL
Medi-Therm® III

9.7 REPLACEMENT For base replacement parts information, refer to figure 15, table 7, pp. 76-77.
PARTS For head replacement parts information, refer to figure 16, table 8, p. 78.

Repairs should only be performed by qualified personnel familiar with repair

practices for servicing medical devices.

9.8 SHIPPING / CAUTION

REPACKAGING
INSTRUCTIONS Failure to install compressor shipping braces before shipment
can result in extensive damage to the refrigeration section. (See
p. 88, figure B.)

See figure 25, p. 88 for complete repackaging instructions to ship the

Medi-Therm III machine back to Gaymar or to a qualified Service Center.
If you do not have the original packing materials, please contact Gaymar's Technical
Service Department and a complete Customer Return Kit will be sent to you.

Be sure to obtain return authorization from our Technical Service Department

before shipping the machine.

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SERVICE MANUAL
Medi-Therm® III

10.0 REFERENCE TABLES

10.1 CELSIUS-FAHRENHEIT
CONVERSION

°C °F °C °F °C °F °C °F
0.0 32.0 11.5 52.7 23.0 73.4 34.5 94.1
0.5 32.9 12.0 53.6 23.5 74.3 35.0 95.0
1.0 33.8 12.5 54.5 24.0 75.2 35.5 95.9
1.5 34.7 13.0 55.4 24.5 76.1 36.0 96.8
2.0 35.6 13.5 56.3 25.0 77.0 36.5 97.7
2.5 36.5 14.0 57.2 25.5 77.9 37.0 98.6
3.0 37.4 14.5 58.1 26.0 78.8 37.5 99.5
3.5 38.3 15.0 59.0 26.5 79.7 38.0 100.4
4.0 39.2 15.5 59.9 27.0 80.6 38.5 101.3
4.5 40.1 16.0 60.8 27.5 81.5 39.0 102.2
5.0 41.0 16.5 61.7 28.0 82.4 39.5 103.1
5.5 41.9 17.0 62.6 28.5 83.3 40.0 104.0
6.0 42.8 17.5 63.5 29.0 84.2 40.5 104.9
6.5 43.7 18.0 64.4 29.5 85.1 41.0 105.8
7.0 44.6 18.5 65.3 30.0 86.0 41.5 106.7
7.5 45.5 19.0 66.2 30.5 86.9 42.0 107.6
8.0 46.4 19.5 67.1 31.0 87.8 42.5 108.5
8.5 47.3 20.0 68.0 31.5 88.7 43.0 109.4
9.0 48.2 20.5 68.9 32.0 89.6 43.5 110.3
9.5 49.1 21.0 69.8 32.5 90.5 44.0 111.2
10.0 50.0 21.5 70.7 33.0 91.4 44.5 112.1
10.5 50.9 22.0 71.6 33.5 92.3 45.0 113.0
11.0 51.8 22.5 72.5 34.0 93.2

Table 4—Celsius-Fahrenheit Conversion

65
 SERVICE MANUAL
Medi-Therm® III

10.2 TEMPERATURE vs. RESISTANCE

PATIENT PROBE, BLANKET WATER PROBE (RT2),

AND RESERVOIR PROBE (RT1) TEMPERATURE RESISTANCE

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

°C °F (OHMS) °C °F (OHMS)
0 32.0 7355 26 78.8 2156
1 33.8 6989 27 80.6 2064
2 35.6 6644 28 82.4 1977
3 37.4 6319 29 84.2 1894
4 39.2 6011 30 86.0 1815
5 41.0 5719 31 87.8 1739
6 42.8 5444 32 89.6 1667
7 44.6 5183 33 91.4 1599
8 46.4 4937 34 93.2 1533
9 48.2 4703 35 95.0 1471
10 50.0 4482 36 96.8 1412
11 51.8 4273 37 98.6 1355
12 53.6 4074 38 100.4 1301
13 55.4 3886 39 102.2 1249
14 57.2 3708 40 104.0 1200
15 59.0 3539 41 105.8 1152
16 60.8 3378 42 107.6 1107
17 62.6 3226 43 109.4 1064
18 64.4 3081 44 111.2 1023
19 66.2 2944 45 113.0 983.8
20 68.0 2814 46 114.8 946.2
21 69.8 2690 47 116.6 910.2
22 71.6 2572 48 118.4 875.8
23 73.4 2460 49 120.2 842.8
24 75.2 2354 50 122.0 811.3
25 77.0 2252

Table 5—Temperature vs. Resistance

66
SERVICE MANUAL SERVICE INFORMATION
Medi-Therm® III

11.0 SERVICE INFORMATION

GROUND
HARNESS

P4 at J4 P5 at J3

PATIENT PROBE
ASSEMBLY

P2 at J2

P3 at J4

CONTROL DISPLAY
BOARD POWER SUPPLY
BOARD

CABLE ASSEMBLY
26 CONDUCTOR

P6 at J2

P1 at J1

GROUND CHASSIS P7 at J1
HARNESS GROUND

Figure 8—Circuit Boards and Connectors (Head)

67
SERVICE INFORMATION SERVICE MANUAL
Medi-Therm® III
2 3 15 16

® ®

1 Flow-OK Warming Cooling

ALERT SELECT MODE TEMPERATURE

5
6 CHECK WATER FLOW. To control WATER temperature:
• Connect blanket(s).
• Press MANUAL button.
7 CHECK PATIENT PROBE. 17
MANUAL
• Set desired water Water Patient
temperature.
8 ADD WATER.
To control PATIENT temperature:
• Connect blanket(s).
°C/°F 18
9 REMOVE FROM USE NOW. • Insert patient probe.
• Press AUTO button.
19
MACHINE SHUT DOWN.
Press again to select Set Point
CONTROL OPTION.
• Set desired patient
AUTO
temperature.
20

To monitor PATIENT temperature:

(NO THERAPY)
21
10 • Insert patient probe.
• Press MONITOR button.
TEST LIGHTS SILENCE MONITOR
AND ALARM ALARM
11

13c

12 13 14 13b
13a

Figure 9A—Operator Controls/Indicators

Item Name Function

1 FLOW-OK Indicates water is flowing adequately.

2 WARMING Indicates water or patient is being heated. Refer to section 4.2 THERMAL SPECIFICATIONS, p.5.

3 COOLING Indicates water or patient is being cooled. Refer to section 4.2 THERMAL SPECIFICATIONS, p.5.

4 ALERT Indicates an alert condition exists.

5 SELECT Indicates a mode must be selected. Flashes if set point buttons are pressed before selecting mode.

Indicates the flow of water to the blanket/body wrap has been restricted. An audible alarm accompanies
6 CHECK WATER FLOW
this alert.

Indicates the patient probe is sensing an abnormal patient temperature (below 29C° [84.2°F] or above
7 CHECK PATIENT PROBE
45°C [113°F]). An audible alarm accompanies this alert.

8 ADD WATER Indicates the water reservoir is below the recommended level.
REMOVE FROM USE May indicate the Medi-Therm III has shut down due to water temperature exceeding either the high or
9 NOW / MACHINE SHUT- low limit. It may also indicate an error in one of the circuit boards of the machine. Remove the Medi-
DOWN Therm III machine from use immediately.
Enables the operator to confirm that all indicator lights and digital displays are working, and that the
10 TEST LIGHTS audible alarm is functioning. The displays flash and the audible alarm sounds as long as the TEST
LIGHTS button is pressed.

68
SERVICE MANUAL SERVICE INFORMATION
Medi-Therm® III

Temporarily silences the audible alarm. The alarm will reactivate in approximately 5 minutes if the
11 SILENCE ALARMS condition persists. The SILENCE ALARM button will not function if the REMOVE FROM US NOW /
MACHINE SHUTDOWN indicator is lit.

Selects the manual mode of operation. In MANUAL mode, the operator must observe the patient tem-
12 MANUAL
perature and adjust the water set point temperature to obtain the desired results.

Selects the automatic mode of operation. In AUTO mode, the operator sets the desired temperature
and the patient temperature is automatically regulated to the operator-specified set point.
13 AUTO
The rate of cooling or warming is user adjustable through the use of the CONTROL OPTION.

COOLING: the coldest water is used for cooling, the temperature can be as low as 4°C (39°F).
13a Rapid
WARMING: the hottest water is used for warming, the temperature can be as high as 42°C (107.6°F).

COOLING: the cooling water temperature is limited to 15°C (27°F) below the PATIENT TEMPERATURE.
13b Moderate WARMING: the PATIENT TEMPERATURE will increase at a rate of 1°C (1.8°F) in a period of 3 hours
(0.33°C/Hr [0.6°F/Hr]).
COOLING: the cooling water temperature is limited to 10°C (18°F) below the PATIENT TEMPERATURE.
13c Gradual WARMING: the PATIENT TEMPERATURE will increase at a rate of 1°C (1.8°F) in a period of 6
hours(0.17°C/Hr [0.3°F/Hr]).

Selects the monitor mode of operation. In MONITOR mode, the operator may monitor the patient tem-
14 MONITOR
perature without providing therapy.

Indicates the temperature of the water being delivered to the blanket/body wrap. This display is only
15 WATER
illuminated when the MODE is set to MANUAL.

Indicates the actual patient temperature as sensed by the probe connected to the patient probe jack.
16 PATIENT This display is illuminated when MODE is set to MANUAL, AUTO, or MONITOR and a patient probe is
plugged into the PATIENT PROBE jack.

17 °C/°F INDICATOR Displays the temperature and set point in either degrees Celsius (°C) or Fahrenheit (°F). Pressing the
18 °C/°F BUTTON °C/°F button will display the appropriate scale and light the corresponding indicator.

19 LEADER LIGHTS Emphasizes whether water temperature or patient temperature is being set.
20 SET POINT Indicates the desired SET POINT temperature. When operating in MANUAL mode, pressing the SET
POINT button (up or down) sets the desired WATER temperature. When in AUTO mode, pressing the
21 SET POINT BUTTONS SET POINT button sets the desired patient temperature.

Table 6A - Operator Controls/Indicators

69
 SERVICE MANUAL
Medi-Therm® III

23

24

25

26
27
28

29

Figure 9B—Operator Controls/Indicators

70
SERVICE MANUAL
Medi-Therm® III

Item Name Function

23 OPERATING Condensed operating instructions are mounted on the machine head and on top of the water fill
INSTRUCTIONS opening cover.

24 WATER FILL Used to fill water reservoir to proper level. To fill, lift cover on the water fill opening and fill with distilled
OPENING water until the green band on the float stem is fully visible.

CAUT ION: Add distilled water only. Failure to use distilled water may result in poor machine
performance. � o not use alcohol. � o not operate without water. � o not overfill.

25 PATIENT PROBE Accepts patient probe plug connecting patient probe to machine.
JACK
Use only Gaymar probes or equivalent YSI 400 series probes approved for use with
medical devices.

26 BLANKET/BODY WRAP Connects machine to � uic� � disconnects on the connector hose.

CONNECTIONS

2� PROBE C� ECK Used to perform probe chec� � refer to Operating � anual for procedure� .
WELL
WARNING: When performing the probe check, use a protective sheath (Becton-Dickinson
catalog � � � � oral sheath or e� uivalent� on probe to prevent cross-contamination.

28 ON / OFF SWITCH (Circuit breaker) Controls power to the unit.

29 AIR VENTS Permits adequate air circulation. Keep louvered openings clear on all three sides of the cabinet.

Table 6B—Operator Controls/Indicators

71
SERVICE INFORMATION SERVICE MANUAL
Medi-Therm® III

When the Medi-Therm III machine is heating, water flows in the path shown below.

Figure 10—Heating flow diagram

When the Medi-Therm III machine is cooling, water flows in the path shown below.

Figure 11—Cooling flow diagram

72
SERVICE MANUAL SERVICE INFORMATION
Medi-Therm® III

Figure 12—Refrigeration flow diagram

73
SERVICE INFORMATION SERVICE MANUAL
Medi-Therm® III

Figure 13—Test setup

74
SERVICE MANUAL SERVICE INFORMATION
Medi-Therm® III

Figure 14—Machine disassembly

75
SERVICE INFORMATION SERVICE MANUAL
Medi-Therm® III

Figure 15—Parts Diagram (Base)

76
SERVICE MANUAL SERVICE INFORMATION
Medi-Therm® III

Table 7—Parts List (Base)

77
SERVICE INFORMATION SERVICE MANUAL
Medi-Therm® III

Figure 16—Parts Diagram (Head)

PART NUMBER

MTA7900

78259-002

77760-000
(ALL PARTS)

100393-000

100310-000

100392-000

07311-000

10852-006

10528-000

07481-000

100386-000

90410-075

Table 8—Parts List (Head)

78
SERVICE MANUAL SERVICE INFORMATION
Medi-Therm® III

NOTE:
Positions 8 and 9 of TB1
are connected together.

Figure 17—Thermostat Wiring Diagram

79
 SERVICE MANUAL
Medi-Therm® III

[This page has been intentionally left blank.]

80
 Gaymar Industries, Inc.
10 Centre Dr.
Orchard Park, New York 14127-2295
Phone: 1-800-828-7341
Fax: 1-800-993-7890

In Canada Contact:
Waterloo Bedding Company, Ltd.
825 Trillium Dr.
Kitchner, Ontario N2R 1J9
MEDI-THERM® III IS Phone: 1-800-203-4293
MADE IN THE USA Fax: 1-591-742-3699
G Medi-Therm® III SERVICE MANUAL

P8 CB1
POWER E1 CIRCUIT
INLET FILTER BREAKER

BLK P P'
LINE LOAD BLK

LINE LOAD WHT RT1

N N' S4 T1
WHT RESERVOIR PROBE TRANSFORMER
2.252 K @25°C LEVEL
WHT BLK SWITCH J1
-T° PATIENT
PROBE JACK
R1 WHT BLK
S5 E5 WHT
F LINE LOAD 47K-1/2W RT2 FILTER
WATER PROBE FLOW C1 RED
BLU BLU RED SWITCH
2.252 K @25°C 2200 pF
-T° YEL
RED YEL PC BOARD GROUND HARNESS GRN RED
DIGITAL CONTROL PANEL
YEL/
BLK BLK WHT
TB1 E3 E6
TERMINAL E2 MAN
BLOCK FILTER FILTER FILTER

AUTO
A B C E4 P6 P5 P2
1 BLU FILTER
C/F
SV1 SV2 2 RED
P7 2
1 2 3 4 5 6 P4
COLD SOLENOID HOT SOLENOID
4 5 3 9 2 8 1 6 4 7 2 3 4 1
UP
VALVE VALVE 3 WHT
1 J2 J3 J2 1
Y1
SENSOR INTERFACE TRANSFORMER TO PATIENT
4 WHT 3 2
Y2
TEST
12
CONTROL/DISPLAY PROBE JACK
3 NC
POWER SCHEMATIC
BLK 5
11 SCHEMATIC 4 NC SIL
B1 BLK J4 X1
E PUMP BLK 6 GRY 8
J1 TO DIGITAL 5
2 POWER INTERFACE CONTROL PANEL 6
X2
MON
YEL/BLK 7 YEL/BLK 6 7
X3
X4 DOWN
9 8
WHT 8 VIO J4 SHIELD
10
TO CONTROL/DISPLAY BOARD J1 9

WHT 9 VIO 7 TO POWER BOARD

HR1 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
YEL 10 YEL
HEATER
E6
WHT 11 ORN FILTER
P3 P1

CABLE ASSY 26 CONDUCTOR -12V

+12V
NC
RESER
RFU IN
S1 LEVEL
D T° YEL PUMP
HEATER
K1 BRN
RELAY
DGND DIGITAL CONTROL
S2 DGND PANEL MATRIX
2 4
T° BLK 0 +5V
+5V
X1 X2 X3 X4
-12V
WHT
1 +12V
Y1 MAN AUTO C/F UP
S3 6 8
PROBE RETURN
T° BLANK
Y2 TEST SIL MON DOWN
BRN RFU OUT
BLK
FLOW
Y3
WHT COLD SOL
HOT SOL
Y4
COMPRESSOR
DGND
DGND
C +5V
RC1 +5V
47 - 0.5uF

REFRIGERATION UNIT

NOTES:

FAN 1. REFERENCE: THIS DRAWING CORRELATES TO DRAWING (E) 100586 REV A.

2. CAUTION: THIS PRODUCT IS SUSCEPTIBLE TO DAMAGE FROM ELECTROSTATIC DISCHARGE. ASSEMBLING, HANDLING AND
START PACKAGING OF THIS ASSEMBLY SHALL BE ACCOMPLISHED ONLY WITH ADEQUATE GROUNDING PROVISIONS TO
THERMAL CAPACITOR ATTENTION
OVERLOAD Static-Sensitive Devices PREVENT ELECTROSTATIC DISCHARGE DAMAGE.
PROTECT

START
3 2
COMMON S
RUN M 1
START/RUN
RELAY
RC2
100 - 0.1uF 100586000 WIRING DIAGRAM, MTA7900
UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES AFTER FINISHING
TOLERANCES:
FRACTIONS: 1/8
.XX .010 10 CENTRE DRIVE, ORCHARD PARK, N.Y
WIRING DIAGRAM
.XXX .005
ANGULAR 1
Figure 18—System wiring diagram
A PART SHALL BE CLEAN AND FREE
OF BURRS AND SHARP EDGES
MTA7900
DIMENSIONS AND TOLERANCES IN
ACCORDANCE WITH ASME Y14.5M-1994
DWN:
C. HABERMEHL 81 E 1005
DATE:
9/12/07
SIZE DRAWING

THIRD ANGLE PROJECTION AP P D: DATE:

SCALE 1:1 S
 Medi-Therm® III SERVICE MANUAL

Figure 19—Power supply board schematic (sheet 1 of 3)

82
 Medi-Therm® III SERVICE MANUAL

Figure 20—Control/display board schematic (sheet 2 of 3)

83
 Medi-Therm® III SERVICE MANUAL

Figure 21—Control/display board schematic (sheet 3 of 3)

84
 Medi-Therm® III SERVICE MANUAL

The control/display board

may not be fully populated.

Figure 22—Control/display board

Designator Description GAYMAR P/N Designator Description GAYMAR P/N Designator Description GAYMAR P/N

U1, U3 LED Lt. Bar, HLMP-2885 90761-026 U53, U54, U64 IC, 74HC377 90886-088 R4 Resistor,750 ohms, 5%, 1/4W 90092-046

U2, U4, U8 LED Lt. Bar, HLMP-2785 90761-003 U55 IC, 74HC541 90886-089 R6 Resistor, 12.4K, 1%, 1/8W 90092-343

U7, U33, U35 LED Lt. Bar, HLMP-2685 90761-002 U58 IC, 74HC32 90886-039 R7 Resistor, 22.6K, 1%, 1/8W 90092-344

U9, U20, U23 LED Lt. Bar, HLMP-2755 90761-005 U60-U62 IC, ULN2003A 90886-054 R8 Resistor, 10.0K, 1%, 1/8W 90092-368

U10, U29, U47 LED Lt. Bar, HLMP-2450 90761-027 ALARM Alarm, MCP320B2 90919-001 R9 Resistor, 2K, 5%, 1/4W 90092-056

U12-U14, U16-U19 LED Digit, HDSP-5551 90761-000 C2, C4, C6, C9-C14,C18, C23- Capacitor, 0.1 µF 90701-169 R10 Resistor, 66.5K, 1%, 1/8W 90092-345
C25, C27, C28, C30, C31, C33,
C34, C36, C38, C39, C42-C54,
U15, U21, U28 LED Lt. Bar, HLMP-2655 90761-001 R11 Resistor, 2.00K, 1%, 1/8W 90092-364
C57-C61

U41-U44 LED Digit, HDSP-7511 90761-006 C5 Capacitor, 330 pF 90701-167 R12 Resistor, 816 ohms, 0.1%, 1/8W 90092-421

U5, U6, U48 IC, ICM7212 90886-072 C19 Capacitor, 1000 pF 90701-166 R13 Resistor, 7.32K, 0.1%, 1/8W 90092-422

U24 IC, VFC32 90886-037 C22, C29, C41, C56 Capacitor, 10 µf-100V 90701-071 R14 Resistor, 47K, 5%, 1/4W 90092-089

U27 IC, CAT93C57P 90886-021 C26, C32, C35 Capacitor, 100 pF 90701-111 R15 Resistor, 33K, 5%, 1/4W 90092-085

U30 IC, 74HC373 90886-086 C37, C40 Capacitor, 22 pF 90701-168 R16, R17, R22, R23, R24 Resistor, 100K, 5%, 1/4W 90092-097

U31 EPROM PROGRAMMED * D1 Diode, LM-385Z-1.2 90717-058 R18 Resistor, 4.7K, 5%, 1/4W 90092-065

U32 IC, 74HC244 90886-085 D2 Diode, 1N914 90717-002 R19, R20, R21 Resistor, 2.7K, 5%, 1/4W 90092-059

U34 IC, MAX691 90886-052 D3, D4, D6-D27 Diode, 1N5282 90717-006 RN1-RN3, RN5 Resistor Net., 27 ohm bussed 91248-001

U37 IC, 80C32 90886-071 D5 TransZorb, Transient Suppressor 91269-001 RN4 Resistor Net., 47K isolated 91248-018

U38, U39 IC, LM308AN 90886-016 DS1-DS3 LED, Lamp Green 90761-017 RN6, RN7 Resistor Net., 10K isolated 91248-017

U40 IC, 74HC02 90886-036 JP1 Jumper 90879-007 RN8-RN11 Resistor Net., 4.7K isolated 91248-016

U45 IC, 74C922 90886-058 Q1-Q6 Transistor, 2N3904 90868-015 RN12-RN13 Resistor Net., 10K bussed 91248-002

U49, U50 IC, 74HC4351 90886-087 R2 Resistor, 27K, 5%, 1/4W 90092-083 SW3 Switch, Push Button 91247-027

U51 IC, DP8310 90886-090 R3 Resistor, 249K, 1%, 1/8W 90092-346 X1 Crystal, 12MHz 91226-001
Table 9—Control/display board parts list
* Not a service part. Call Gaymar's Technical Service Department.

85
 Medi-Therm® III SERVICE MANUAL

Figure 23—Power supply board

Designator Description GAYMAR P/N Designator Description GAYMAR P/N Designator Description GAYMAR P/N

C1, C2 Capacitor, 1000µF-35V, low ESR 90701-080 F1, F2 Fuse 90695-041 R11, R12 Resistor, 4.7K, 5%, 1/2W 90092-225

C3, C12, C16 Capacitor, 0.1µF 90701-169 JP1-JP3 Jumper 90878-002 R13, R14, R19, Resistor, 200 ohm, 5%, 1/4W 90092-032
R24, R27, R28
C4 Capacitor, 390µF-40V, low ESR 90701-079 L1 Inductor, 55µH 91265-001

C5, C7, C8, C10, C15 Capacitor, 0.01µF-400V 90701-096 Q1, Q2, Q3, Q4 Triac, 2N6347A, 2N6348A, 90709-000 R17, R21, R30 Resistor, 1K, 5%, 1/4W 90092-049
2N6349A

C6 Capacitor, 0.001µF-600V 90701-097 Q5 Voltage Regulator, LT1074 90712-043 R18, R23 Resistor, 5.6K, 5%, 1/2W 90092-227

C9, C11, C20 Capacitor, 330µF-35V 90701-064 Q6 Voltage Regulator, LM340T-12 90712-015 R20, R26 Resistor, 5.1M, 5%, 1/4W 90092-138

C13, C14 Capacitor, 1000µF-35V 90701-081 Q7 Voltage Regulator, LM320LZ-12 90712-001 R22, R29 Resistor, 1.3K, 5%, 1/4W 90092-052

C17, C18, C19 Capacitor, 10µF-100V 90701-071 Q8, Q9 Triac, Z0103MA 77894-000 R25 Resistor, 3K, 5%, 1/4W 90092-060

C21 Capacitor, 0.47µF-400V 90701-180 Q10, Q11 Transistor, 2N3904 90868-015 R31 Resistor, 680 ohm, 5%, 1/2W 90092-205

D1 Diode, MBR745 90717-098 Q12 Transistor, 2N6727 90868-030 RC1 RC Network, 47ohm, 0.5 µF 91069-001

D2, D3 Diode, Bridge, W04G 90717-042 R1, R3 Resistor, 2.00K, 1%, 1/8W 90092-364 U1, U7, U8 Integrated Circuit, MOC3010 90886-001

* D4, D5 Diode 90717-028 R2 Resistor, 2.80K, 1%, 1/8W 90092-348 U2 Integrated Circuit, MOC3021 90886-000

D6, D7, D8, D11 Diode, MR501 90717-084 R4, R5, R6, R7 Resistor, 8.2K, 5%, 5W 90092-440 U3, U4, U5, U6 Integrated Circuit, MOC3063 90886-003

D9, D10 Diode, Zener, 1N749A 90717-014 R8, R10, R15, R16 Resistor, 390 ohm, 5%, 1/4W 90092-039 U9, U10 Integrated Circuit, H11A1 90886-002

D12 Diode, 1N4004 90717-001 R9 Resistor, 100 ohm, 5%, 1/4W 0092-025 R1, VR2 Varistor, V130LA 91266-000

*Critical part. Purchase only from Gaymar Industries, Inc. ESR = equivalent series resistance Table 10—Power supply board parts list

86
 Medi-Therm® III SERVICE MANUAL
8 7 6 5 4 3
DRAWING NO.
100585 REV
A
SHT
1 METHOD # : 1
REV DCR # REV DATE REV BY

A 2290 9/13/07 CEH

DESCRIPTION OF CHANGE:
INITIAL RELEASE

VFC AMP

D U24 U39 MUX

U50
D
POWER
PC BOARD

A8

COMP RESER WATER

RESISTOR PROBE PROBE LOW VOLT
SUPPLY
CURRENT
SOURCE DEMUX COMP PATIENT
U38 U49 RESISTOR PROBE

CONTROL
DEVICES

A7 COMPRESSOR
HEATER
PUMP LOW VOLT
LATCH/ HOT SOLENOID INTERFACE OVERTEMP
DRIVER COLD SOLENOID
THERMOSTATS
U51 AUDIO
AUTO LEADER LED ALARM
DRIVERS/
MANUAL LEADER LED DISPLAYS

ADDRESS BUS TO MICROCONTROLLER Q2 RFU_IN

AC
INTO

A6 ALERT
ADD WATER
LOW VOLT LOW VOLT
C
C CHECK PROBE
INTERFACE LATCH LATCH INTERFACE

CHECK FLOW DRIVERS/

EPROM LATCH DISPLAYS
DIGITAL KEYBOARD P1.0- P3.5 U31 U53 REMOVE FROM USE NOW ...
CONTROL ENCODER P1.3 SELECT
PANEL U45 P3.3 P2 LOW VOLT LOW VOLT
F
INTERFACE INTERFACE
ADDRESS
C
P3.0 P0 LATCH
U30

EEPROM B_TxD BUFFER RFU_OUT RFU_OUT

U27 U32 P3.1 P3.4

MICRO- DATA BUS

A5
CONTROLLER LATCH
U37 COOLING
U54
WARMING
EEPROM_CE INTO DRIVERS/
P1.4 P3.2 FLOW_OK
DISPLAYS
RESET AUTO
MANUAL
MONITOR
WDTRIG
WATCHDOG
U34 INPUT
BUFFER TO
PROBE_IN U55 A0
WATCHDOG
LEVEL
FLOW
S3 A9 RAPID
LATCH GRADUAL
U64
MODERATE
DRIVERS/
DISPLAYS

B B

A4 WATER
A1 DISPLAY
DISPLAY U12-U14
A0
DRIVER
U5

A3 PATIENT
A1 DISPLAY
DISPLAY U16-U19
A0
DRIVER
U6

A2 SETPOINT

NOTES: A1
DISPLAY 123456000 DESCRIPTION
DISPLAY U41-U44
A0
1. REFERENCE: THIS DRAWING CORRELATES TO DRAWING (D) 100585 REVISION A. DRIVER UNLESS OTHERWISE SPECIFIED
U48
A 2. CAUTION: THIS DRAWING REPRESENTS AN ASSEMBLY WHICH IS SUSCEPTIBLE TO
DIMENSIONS ARE IN INCHES AFTER FINISHING
A
TOLERANCES:
DAMAGE FROM ELECTROSTATIC DISCHARGE. HANDLING OF THIS PRODUCT FRACTIONS: 1/64
SHALL BE ACCOMPLISHED WITH ADEQUATE GROUNDING PROVISIONS TO .XX .010 10 CENTRE DRIVE, ORCHARD PARK, N.Y. 14127
PREVENT ELECTROSTATIC DISCHARGE DAMAGE.

ATTENTION
.XXX
ANGULAR
.005
1 BLOCK DIAGRAM
Static-Sensitive Devices
CONTROL/DISPLAY
PC BOARD PART SHALL BE CLEAN AND FREE
OF BURRS AND SHARP EDGES
MTA7900
DIMENSIONS AND TOLERANCES IN DWN: DATE: SIZE DRAWING NO. REV
ACCORDANCE WITH ASME Y14.5M-1994

THIRD ANGLE PROJECTION

C. HABERMEHL
A PPD : Figure9/13/07 D 100585
24—System
DATE:
A
block diagram
SCALE: NTS SHEET 1 OF 1
8 7 6 5 4 3 2 1
87
SERVICE INFORMATION Medi-Therm® III SERVICE MANUAL

INSTRUCTIONS
Before physically repacking the Medi-Therm III machine, ten (10) screws.
perform Steps 1 & 2: Step 6. Refer to figure E. Place bottom cap (item 7) on
Step 1. Fill unit with distilled water to proper fill floor.
line. Close the DBK hose assembly clamps (refer to NOTE: Steps 7 through 15 will require two (2) people.
manual) and attach hose connectors to the supply quick Step 7. Refer to figure D. Tape up carton support (item
disconnect fittings on the unit. Direct the DBK hose 5) as shown using nylon tape (item 4) and place on top
assembly Clik-Tite connectors to a drain or container of bottom cap.
having a minimum capacity of three (3) gallons, open the
DBK hose assembly clamps. Plug unit into proper voltage Step 8. Refer to figure C. Place the unit on top of
receptacle, turn unit on, select MANUAL MODE and carton support with the wheels oriented as shown.
set temperature to 30ºC. Drain approximately one (1) Step 9. Refer to figure D. The Return Carton Kit
gallon of water from unit. Turn unit off, close the DBK provides six (6) corner supports (item 3). For units
hose assembly clamps, fasten the Clik-Tite connectors with a rear baffle panel, only four (4) corner supports
together and reopen the clamps. Add eight (8) ounces of are used. Position the four (4) corner supports
isopropyl alcohol to unit. Turn unit on, select MANUAL (item 3) on the corners of the unit as shown in the
MODE, set temperature to 30ºC and run unit for exploded view. Ensure ADP10CE cable is unplugged
approximately three (3) minutes. Turn power off. from patient probe jack.
CAUTION NOTE: The hole in the left rear corner support must
Step 2. Direct the DBK hose assembly Clik-Tite
connectors to a drain or container. Unfasten the be positioned directly over the power cord bushing
Failure to install the connectors. Turn unit on, select MANUAL MODE, set in unit base. No special positioning is required on the
compressor shipping temperature to 4ºC, drain unit until no water comes out. other three corner posts.
braces (see Figure B) Continue draining by tilting the unit forward and keep it Step 10. Position power cord plug so it lays in the
before shipment can in that position until the unit is completely empty. Turn space between the chassis bottom and the bottom of
result in extensive unit off and unplug the power cord. Connect Clik-Tite carton.
connectors together and disconnect the DBK assembly
damage to the from unit.
Step 11. Refer to figure E. Push handle protector (item
refrigeration section. 2) down behind the two (2) front corner supports so
Step 3. Refer to figure A. Coil power cord and place it rests on top of the handle. Slide master carton (item
on strap assembly located on back of rear baffle panel. 1) over corner supports.
Hang plug below chassis. Remove lower wraparound by
Step 12. Refer to figure F. Tape the top of the box
removing ten (10) screws.
closed using nylon filament tape (item 4) supplied with
Step 4. Refer to figure B. Insert three (3) shipping braces. kit.
Use a screw and washer through the housing frame and
Step 13. Refer to figures F & G for folding bottom cap
into shipping brace as shown.
and securing plastic strap and clip (item 6).
Step 5. Refer to figure A. Replace lower wraparound and

CONTENTS OF RETURN KIT (P/N 78261-000)

ITEM DESCRIPTION QTY

1 CARTON 1

2 HANDLE PROTECTOR 1

3 CARDBOARD CORNER SUPPORT 6

4 NY LON FILAMENT TAPE (3/4" WIDE) 1

5 CARDBOARD CARTON SUPPORT 1

6 PLASTIC STRAP w/ ATTACHMENT CLIP 1

7 CARDBOARD BOTTOM CAP 1

8 WOOD SHIPPING BRACE 2

9 WOOD SHIPPING BRACE 1

10 SCREW 3

11 WASHER 3

12 RETURN KIT INSTRUCTIONS 1

Figure 25—Shipping/Repackaging Instructions

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