Technology to the next degree™

ELECTRI-COOL II ®
OPERATION AND TECHNICAL MANUAL
Model 767 Localized Cooling System

Gentherm Medical, LLC • 12011 Mosteller Road Cincinnati, Ohio 45241, U.S.A. www.gentherm.com
Gentherm Customer Relations
Gentherm Medical, LLC

Telephone 1-513-772-8810
Toll-Free 1-800-989-7373
Fax 1-513-772-9119
24-Hour Clinical Support 1-513-460-2038
Medical Technical Support 1-888-437-5608
Email [email protected]
Website: https://www.gentherm.com
Mailing Address: 12011 Mosteller Road
Cincinnati OH 45241
USA

Electri-Cool® II is a registered trademark of Gentherm Medical, LLC, Cincinnati, Ohio, USA.

© 2021, Gentherm Medical, LLC All rights reserved.

All other trademarks are the property of their respective owners.

Part No. 56269 Rev. W

SECTION TITLE Electri-Cool II Model 767

Contents
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1  Receiving and Inspection/ Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2  General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3  General Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4  Indications for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5  Contraindications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6  Transporting and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.0 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.0 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.0 Symbols on the Device and in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.0 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7.0 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
7.1  Receiving Inspection and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.0 Technical Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9.0 Authorized European Representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10.1  Before you call for service.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11.0 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.1  Equipment Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.2  Mounting the unit to a bed bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11.3  Reservoir Filling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11.4  Startup Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11.5  Setting Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11.6  Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
11.7  Pad Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.8  Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.9  Cleaning (External) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.10  Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12.0 Electromagnetic Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13.1  Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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13.2  Inspection Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

13.3  Exterior Physical Inspection & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13.4  Draining the Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14.0 Air Filter Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
14.1  Remove the Filter Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
15.0 Draining the Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
16.0 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
16.1  General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
16.2  Indicator Specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
17.0 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
18.0 ECII Interior Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
18.1  Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
18.2  Water Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
18.3  Temperature Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
18.4  Low Water Switch/Indicator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
18.5  Leakage Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
18.6  Ground Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
18.7  Water Temperature Low-Limit Thermistor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
18.8  Internal Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
19.0 Preventive Maintenance for Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
20.0 Rear Enclosure and Reservoir Lid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
20.1  Rear Enclosure and Reservoir Lid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
20.2  Rear Enclosure and Reservoir Lid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
21.0 Front Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
21.1  Front Enclosure Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
21.2  Front Enclosure Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
22.0 Bottom Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
22.1  Bottom Enclosure Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
22.2  Bottom Enclosure Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
23.0 Equipotential Grounding Stud Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
23.1  Grounding Stud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
23.2  Grounding Stud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24.0 Membrane Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
24.1  Membrane Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
24.2  Membrane Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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25.0 Float Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

25.1  Float Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
25.2  Float Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
26.0 Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
26.1  Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
26.2  Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
27.0 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
27.1  Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
27.2  Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
28.0 Quick Disconnect Panel Mount Couplings Replacement . . . . . . . . . . . . . . . . . . . . . . . 71
28.1  Quick Disconnect Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
28.2  Quick Disconnect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
29.0 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
29.1  Fuse Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
29.2  Fuse Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
30.0 Power Inlet and Wire Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
30.1  Power Inlet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
30.2  Power inlet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
31.0 Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
31.1  Control Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
31.2  Control Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
32.0 Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
32.1  Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
32.2  Power Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
33.0 Thermoelectric (TE) Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
33.1  TE Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
33.2  TE Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
34.0 Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
34.1  Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
34.2  Fan Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
35.0 Fan Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
35.1  Fan Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
35.2  Fan Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
36.0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
36.1  Expected Service LIfe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
36.2  Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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37.0 Fluid Circuit Disinfection/Dry Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

37.1  Draining the Electri-Cool II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
37.2  Chemical Cleaning Circulation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
37.2.1 Disinfection/Dry Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
38.0 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
38.1  General Safety and Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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List of Figures
Figure 1 Mounting the unit to a bed bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2 Mounting the bed bracket to rear enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 3 Electri-Cool II Membrane Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 4 Step 1 Unplug power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 5 Step 2 Pry off retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 6 Step 3 Discard used filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 7 Step 4 Place filter in retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 8 Step 5 Align tabs to slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 9 Step 6 Press retainer into place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 10 Step 1 Unplug power from mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 11 Step 3 Open reservoir lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 12 Step 4 Tip unit forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 13 Control board diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 14 Detail A Operate Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 15 Detail A Test Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 16 Exploded view with callouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 17 Step 1 Unplug power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 18 Step 3 Remove two handle screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 19 Step 4 Remove two base screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 20 Step 5 Remove collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 21 Step 6 Lift rear enclosure with lid up and away . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 22 Step 1 Install enclosure and lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 23 Step 2 Install reservoir collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 24 Step 3 Install two base enclosure screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 25 Step 4 Install two handle screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 26 Step 2 Remove four screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 27 Step 4 Remove front enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 28 Step 5 Disconnect ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 29 Step 3 Install front enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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Figure 30 Step 5 Reconnect ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 31 Step 5 Install front enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 32 Step 5 Remove rubber feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 33 Step 1 Install feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 34 Step 2 Apply the BF label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 35 Step 3 Apply the GTIN label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 36 Step 1 Remove 1st Keps nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 37 Step 2 Remove ground wire and second Keps nut . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 38 Step 1 Insert stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 39 Step 2 Add the green and gold ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 40 Step 3 Install Keps nuts 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 41 Step 5 Attach ground wire and second Keps nut . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 42 Step 3 Unplug ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 43 Step 4 Push flat screwdriver through cable slot from the inside . . . . . . . . . . . 54
Figure 44 Step 1 Thread cable through slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 45 Step 4 Connect ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 46 Step 3 Disconnect J7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 47 Step 4 Loosen reservoir insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 48 Step 5 Unscrew float switch mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 49 Step 1 GEMS orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 50 Step 2 Thread wires through gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 51 Thread connector and wires through reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 52 Step 4 Secure float switch mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 53 Step 5 Loosen reservoir insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 54 Step 6 Route wiring behind bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 55 Step 7 Attach connector to J7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 56 Step 5 Loosen two hose clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 57 Step 6 Remove tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 58 Step 1 connect tubing to reservoir with clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 59 Step 3 Float switch wires position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 60 Step 4 Connect float switch to J7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Figure 61 Step 3 Unplug pump wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Figure 62 Step 4 Remove the wire tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 63 Step 5 Remove EMI suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 64 Step 7 Remove discharge tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 65 Step 5 Loosen two hose clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 66 Step 6 Unscrew pump bracket from base enclosure . . . . . . . . . . . . . . . . . . . . . . 66
Figure 67 Step 8 Remove inlet tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 68 Step 1 Remove pump from bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 69 Step 1 Mount pump to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 70 Step 2 Mount bracket to base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 71 Step 3 slide tubing onto new pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 72 Step 4 Tighten the hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 73 Step 5 Install EMI suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 74 Step 6 Wire tie below EMI suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 75 Step 7 Secure wires to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 76 Step 8 Route wires behind bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 77 Step 9 Connect power wire connector to J5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 78 Step 4 Tubing at 90 degree elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 79 Step 5 Remove tubing from pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 80 Step 6 Slide retainer nuts up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 81 Step 7 Pull couplings out of enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 82 Slide retainer nuts onto tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 83 Step 6 Extend tubing through enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 84 Step 7 Insert couplings into hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 85 Step 8 Turn and align couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 86 Step 9 Tighten retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 87 Step 11 Tape the exposed clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 88 Step 12 Apply electrical tape around insulation . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 89 Step 1 Unplug power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 90 Step 2 Open fuse door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 91 Step 3 Note direction arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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Figure 92 Step 1 Place fuses into holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Figure 93 Step 2 Match arrow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 94 Step 3 Locking tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 95 Step 3 Plastic power inlet shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 96 Step 4 Remove retaining Keps nut and ground wires . . . . . . . . . . . . . . . . . . . . . . 81
Figure 97 Step 5 Disconnect harness from the power supply . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 98 Step 6 Remove suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 99 Step 7 Remove retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 100 Step 8 Power inlet removal 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 101 Step 2 Install power inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 102 Step 3 Connect control board wires to J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 103 Step 4 Install EMI suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 104 Step 5 Route wire harness connector behind bracket . . . . . . . . . . . . . . . . . . . . 85
Figure 105 Step 6 Connect power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 106 Step 7 Attach all grounding wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 107 Step 8 Reinstall plastic power inlet shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 108 Step 3 Disconnect all 5 connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 109 Step 4 Remove three plastic screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 110 Step 5 Remove three plastic washers (one shown) . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 111 Step 1 Remove three plastic washers (one shown) . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 112 Step 2 Reinstall three plastic screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 113 Step 3 Connect all 5 connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 114 Step 4 Unscrew power supply from front bracket . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 115 Step 5 Control board power wire harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 116 Step 6 Remove Phillips screws from rear braket. . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 117 Step 7 Disconnect power supply wires to power inlet . . . . . . . . . . . . . . . . . . . . . . 92
Figure 118 Step 8 Remove wire tie on power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 119 Step 1 Connect power supply wires from power inlet . . . . . . . . . . . . . . . . . . . . . . 93
Figure 120 Step 2 Install two truss-head screws on rear bracket . . . . . . . . . . . . . . . . . . . . . . 93
Figure 121 Step 3 Connect fan wires to the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 122 Step 4 Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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Figure 123 Step 5 Power supply wires placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Figure 124 Step 6 Secure power supply wires to front bracket . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 125 Step 7 Wire tie the harness to the third slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 126 Step 5 Remove screws and plastic spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 127 Step 6 Remove two screws attaching the TE module to the back bracket . . . . 97
Figure 128 Step 7 Remove tubing from TE module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 129 Step 1 Reconnect TE tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 130 Step 2 Install 2 screws attaching TE module to the front bracket . . . . . . . . . . . 99
Figure 131 Step 3 Install 2 screws and spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 132 Step 7 Remove the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 133 Step 8 Remove brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 134 Step 1 Install four screws into fan guard holes . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 135 Step 2 Place filter into retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 136 Step 3 Re-attach filter retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 137 Step 4 Raise up off table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 138 Step 5 Install brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 139 Step 6 Place fan over TE brackets on fan guard screws . . . . . . . . . . . . . . . . . . . 104
Figure 140 Step 7 Wire position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 141 Step 3 Pry filter cover off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 142 Step 4 Remove shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 143 Step 5 Unscrew four screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 144 Step 6 Remove Keps nut #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 145 Step 7 Remove Keps nut #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 146 Step 8 Remove Keps nut #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 147 Step 9 Remove Keps nut #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 148 Step 1 Insert screws in order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 149 Step 3 Hold Keps nut #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 150 Step 4 Insert screw #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 151 Step 5 Hold Keps nut #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 152 Step 6 Place plastic shield in position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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Figure 153 Step 2 Place filter into retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Figure 154 Step 8 Re-attach filter retianer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 155 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 156 Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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List of Tables
Table 1 Device and Manual Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 Presented in Fulfillment of IEC 60601-1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 3 Electromagnetic Immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 5 Preventive Maintenance Inspection Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 6 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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SECTION TITLE Electri-Cool II Model 767

1.0 Introduction
Use this manual for service and repair information. Read and understand all
precautions before servicing the device.

1.1  Receiving and Inspection/ Important Safety Information

After unpacking the Electri-Cool® II, inspect the system for concealed damage. Retain all
packing material and carefully record or photograph any 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 equipment to Gentherm. Call our Medical Technical Service department for
further instruction.

1.2  General Safety Precautions

To provide the patient with maximum safety during the use of the Electri-Cool® II Cold Therapy
system, a thorough knowledge and understanding of the system, and its correct application and
operating use are required. Each person who is responsible for use or direction of use of the
system, such as physicians, nurses, technicians and operators, must read and understand this
operation and technical manual as well as all precautions and warnings prior to use.

Gentherm recommends reading this manual at least semi-annually for safe operation and
application. In-service training is available upon request.

This manual may not be reproduced in whole or in part without written permission from
Gentherm Medical, LLC.

Gentherm Medical, LLC reserves the right to make changes to the Electri-Cool II that might
not be reflected in this manual. Current manuals are available on the website: https://www.
gentherm.com

1.3  General Product Description

The Electri-Cool® II system has been designed to provide maximum thermal transfer efficiency
at optimum safety. The Electri-Cool® II consists of a plastic reservoir for holding sterile water
or water that has been passed through a filter less than or equal to 0.22 microns; a float switch
to sense water level; a pump for circulating water through an external pad; a thermoelectric
(TE) module to cool the water; a microprocessor-based electronic control to regulate water
temperature; and a fan to transfer absorbed heat to the ambient air. The user can select among
three pre-set temperature ranges: 51°F - 55°F (11°C - 13°C); 46°F - 50°F (8°C - 10°C); and 40°F
- 45°F (5°C - 7°C). In addition to the aforementioned features, this model includes audible and
visual indicators for low temperature and low water levels. The unit also shuts down entirely in
the event of an internal component over-temperature condition.

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1.4  Indications for Use

The Electri-Cool® II, Model 767 Portable Cold Therapy Unit is used to provide cold therapy
immediately following the surgical procedure at the wound site. The system is composed of a
water reservoir, a thermoelectric sub-assembly, a circulating pump, a micro-processor control
board, a fan and a local therapy pad.

1.5  Contraindications
There are currently no known contraindications.

1.6  Transporting and Shipping

Drain all water from the reservoir before shipment or storage. The Electri-Cool® II can be
transported through normal shipping methods via ground, air, or water when packaged in its
approved packaging material. During transportation and storage, packaging should not be
exposed to conditions that fall out of the ranges below:

Temperature: -40°C to 70°C (–40°F to 158°F)

Humidity: 10% to 100%

Atmospheric Pressure: 500 to 1060hPa (7.25 to 15.37 PSIA)

Receiving Inspection
After unpacking the ELECTRI-COOL II System, be sure to inspect the components for concealed
damage. Retain all packing material and carefully describe or photograph any 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 equipment to Gentherm. Call our Medical Technical
Service department for further instructions.

2.0 General Safety Precautions

To provide the patient with maximum safety during the use of the Electri-Cool® II Cold Therapy
system, a thorough knowledge and understanding of the system, and its correct application and
operating use are required. Each person who is responsible for use or direction of use of the
system, such as physicians, nurses, technicians and operators, must read and understand this
operation and technical manual as well as all precautions and warnings prior to use.

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3.0 Warnings
Gentherm Medical, LLC, reserves the right to make equipment changes and
improvements, which may not be reflected in this manual.

• A physician’s order is required for setting temperature and use of equipment. At

least every 20 minutes, or as directed by a physician, check the patient’s temperature and
skin condition of areas in contact with the pad. Also check pad water temperature. Pediatric,
temperature-sensitive patients with vascular disease, surgical patients, diabetics and patients
with Raynaud’s Disease should be checked more frequently. Notify the physician promptly
of any change, in order to avoid serious injury.

• Observe patient’s skin condition frequently due to individual differences in sensitivity

and susceptibility to injury from cold and/or externally applied chemicals or pressure.
Patients at greatest risk are those unconscious, on prolonged therapy, diabetics, children
and persons incapacitated or with insensitive skin areas or poor circulation.

• Prevent excessive and/or prolonged tissue pressure and shearing forces, especially over bony
prominences to prevent skin damage which may result.

• Do not place additional heat or cold sources between the patient and pad. Skin damage may
occur.

• The area between the patient and the pad should be kept dry to avoid injury to the patient.

• Do not use pins to secure pad or hoses. Do not allow pad or hoses to come in contact with any
sharp object. A water leak could cause a slip hazard.

• Do not use the Electri-Cool II system in the presence of flammable anesthetics. Risk of
explosion can result.

• Power interruption will cause the Electri-Cool II system to revert to the default range of 40°F
- 45°F (5°C - 7°C). Follow instructions for section 11.4 Startup Instructions, on page 10 to
resume operation. Failure to resume the desired therapy could result in injury.

• In order to avoid the risk of electric shock, this equipment must only be connected to a
supply main with protective earth.

• Electric shock hazard may be present. Do not remove cover. Service is to be performed
by qualified personnel only.

4.0 Cautions
• US Federal Law restricts this device to sale by or on the order of a physician.

• Use sterile water or water that has been passed through a filter less than or equal
to 0.22 microns only. Do not use De-Ionized water. De-ionized water may cause
corrosion to plumbing system components. Do not use tap water or distilled water.

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• Do not use alcohol. Alcohol may cause pad and unit deterioration.

• Do not overfill. Overfilling may result in overflow when the water in the pad drains back into
the system when it is turned off.

• Use only hospital grade power plug, or electrical shock may result.

• Check hose couplings to be certain that they are properly locked together.

• Make sure hose and pads are free of kinks which might restrict flow.

• Complete folding of pad may restrict flow and reduce therapy to patient.

• The pad surface should be checked for damage prior to each application.

• To ensure maximum therapy is delivered, it may be necessary to retain the pad on the patient
with straps for adequate contact with the patient.

• Follow pad instructions as well as hospital/physician instructions for applying, storing and
disposal of product.

• Special precautions regarding electromagnetic compatibility are required and the Electri-
Cool II needs to be installed and put into service according to the electromagnetic
compatibility information provided. Electromagnetic compatibility refers to electronic devices
unintentionally affecting the operation of each other by emitting electromagnetic energy.

• Due to electromagnetic compatibility, other equipment can affect the Electri-Cool II system.
The Electri-Cool II should not be used adjacent to or stacked with other equipment. Other
equipment includes ventilators, patient monitors, anesthesia delivery equipment, etc. If
adjacent placement or stacking is necessary, the Electri-Cool II and the other equipment
should be observed to verify that it is operating normally in the mode that is set.

• If the Electri-Cool II system or other equipment is not operating normally, remove the device
from service and have a biomedical or service technician observe the device in operation.
Refer to the specifications section for recommended separation distances between other
equipment and the Electri-Cool II system.

• For safe handling and use of chemicals, follow manufacturer guidelines for cleaning.

• Always drain the Electri-Cool II to a sanitary drain because bio-contaminants may be present
in the unit’s water supply.

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5.0 Symbols on the Device and in the Manual

Table 1. Device and Manual Symbols

Symbol Definition

I/O On / Off

Read and Understand the Manual

Warning

Inspect and Change Filter Regularly

Low Water Level

Caution

2°C/36°F Low Water Temperature

Type B Applied Part

Temperature Settings

Alternating Current

Externally Accessible Fuse

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Table 1. Device and Manual Symbols

Symbol Definition

Potential Equalization Connection (Grounding)

AP Risk of Explosion: Do not use in the presence of flammable anesthetics

G

Power On (Located on Switch)

Power Off (Located on Switch)

Separate Disposal for Electrical Equipment

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6.0 Serial Number

The serial number is located on the specifications label on the side of the device. The serial
number encodes information about the manufacture of your system. For example, the serial
number 201-767-6123 indicates the following:

20 Year of Manufacture

1 Quarter of the Manufacture year, in this case, first quarter

767 Model number; for this example, it is 767

6123 Manufactured device number

Record the serial number of your system and have it ready if you call for service.

7.0 Warranty
All parts are covered by a one (1) year warranty. Additional warranties are available at time of
purchase or during the warranty period. If a part requires replacement while under warranty,
return the original part to Gentherm. Labor is covered under the warranty only if the device is
returned to Gentherm. If the part is no longer under warranty, dispose of the part as required by
site or local regulations.

7.1  Receiving Inspection and Setup

After unpacking the Electri-Cool II system, be sure to inspect the system for concealed damage.
Retain all packing material and carefully describe or photograph any 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 equipment to Gentherm. Call our Medical Technical Service department
for further instructions.

8.0 Technical Help

24-Hour Clinical Support 1-513-460-2038

Medical Technical Support 1-888-437-5608

Report any serious incident in relation to the device to the manufacturer and to the competent
authority of the Member State in which the user or patient is established.

9.0 Authorized European Representative

CEpartner4U BV
Esdoornlaan 13
3951 DB Maarn
The Netherlands
www.CEpartner4u.com
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10.0 Introduction
10.1  Before you call for service....
To help us better serve you, please have the serial number of your Electri-Cool® II unit ready
when you call for parts or service. The serial number is located on the unit’s rear panel.

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11.0 Setup
11.1  Equipment Set-Up
1. Before use, check the air filter for accumulated dust. If filter is dirty, replace it with a new
one. Refer to section 14.0 Air Filter Inspection and Replacement, on page 19.

2. Check to ensure that the water level in the reservoir is at its maximum level. The
maximum level is at the lowest level of the fill spout (or threaded neck). Refer to section
11.3 Reservoir Filling Instructions, on page 10.

Caution: This product uses sterile water or water that has been passed through a
filter less than or equal to 0.22 microns only. Do not use de-ionized water or
distilled water. De-ionized water may cause corrosion to plumbing system
components. Do not use tap water. Minerals and deposits can clog plumbing
system components. All references throughout this document to water or sterile
water are restricted to this definition.

3. The Electri-Cool II should be placed on a secure, flat surface at least 61cm (2 feet) from
any wall or object that may restrict airflow to the unit. A bed bracket or universal stand as
listed in “Accessories” section can also be used within proximity of the patient so that the
attached hoses will reach the desired therapy site.

11.2  Mounting the unit to a bed

A
bracket
Note: (Bed bracket accessories are sold
separately.)

1. Position the bed bracket so that the two

holes (A) align with the holes in the back
of the unit (B) (Figure 1) and (Figure 2).

2. Insert the thumbscrews and hand- Figure 1 - Mounting the unit to a bed bracket
tighten.

Figure 2 - Mounting the bed bracket to rear

enclosure
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11.3  Reservoir Filling Instructions

CAUTION: This product uses sterile water or water that has been passed through a
filter less than or equal to 0.22 microns only. Do not use de-ionized water or
distilled water. De-ionized water may cause corrosion to plumbing system
components. Do not use tap water. Minerals and deposits can clog plumbing
system components. All references throughout this document to water or sterile
water are restricted to this definition.

1. Lift the reservoir lid and fill the reservoir with sterile water or water that has been passed
through a filter less than or equal to 0.22 microns to its maximum level. The maximum
level is at the lowest level of the fill spout (or threaded neck). Close the lid.

Note: Optimum operation is obtained when water level is well above the low water level
marked “MIN”. The low water cut-off switch will activate before the water level reaches
the bottom of the window.

11.4  Startup Instructions

1. Plug the power cord into a grounded receptacle providing the proper voltage and
frequency.

2. Press the power switch to the “ON” position. Electri-Cool II will then begin a startup
sequence for approximately one (1) minute. During this sequence, check to make sure
that all audible and all five (5) visual indicators are working. Check that there is water flow
through the pad. Check water level and refill with cool sterile water or water that has been
passed through a filter less than or equal to 0.22 microns if necessary.

3. The Electri-Cool II is now ready for use.

11.5  Setting Temperature

1. The Electri-Cool II must be filled with sterile water or water that has been passed through
a filter less than or equal to 0.22 microns and connected to a pad before attempting to
set temperature.

2. Select a temperature range among the three possible settings:

• 11°C - 13°C (51°F - 55°F)

• 8°C - 10°C (46°F - 50°F)

• 5°C - 7°C (40°F - 45°F)

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3. A visual light (green temperature

indicating LED) located near the upper-
left area of the selected button will
indicate the selected range. Allow
fifteen to twenty minutes for the water
to reach selected temperature. The time
required for the unit to reach the set
point depends on the pad used and the
ambient temperature. The time may also
vary from patient to patient.

Green
Temperature
Indicating LEDs
Blue Water Low-
Temperature LED

Blue Low-
Water LED

Figure 3 - Electri-Cool II Membrane Control Panel

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11.6  Accessories
Thermal Pads consist of two layers of plastic sealed together to provide multiple passageways
for water flow in a random-flow pattern designed to prevent occlusion.

The essential accessories for the Electri-Cool® II are listed below:

Localized Cold Therapy Pads

Description Non-Sterile
8” x 12” (20.3cm x 30.5cm) 812-NS
8" x 14" (20.3cm x 35.6cm) 814-NS
11" x 12" (27.9cm x 30.5cm) 1112-NS
Universal (Knee / Shoulder) CT-99-NS

Maxi-Therm® Lite Pads

Description Category Number
12.5” x 18” (31.8cm x 45.7cm) 873
25” x 19” (63.5cm x 31.8cm) 872
22” x 17.25” (55.9cm x 43.8cm) 871
25” x 4” (63.5cm x 10.2cm) 870

Other Accessories
Description Category Number
6’ (1.83m) Connecting Hose, Insulated 757-HIE
12” (1 ft.)(30.5cm) Dual Pad Connecting Hose 757-H1D
Bed Bracket 767-BBK
Universal Stand (must purchase EC-080) UNV LPS
Adapter Plate for Universal Stand EC-080
Dual-Matic (Temp Tester, Flow Meter) TF-100

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11.7  Pad Instructions

The Electri-Cool® II has been designed and tested to be used with GENTHERM thermal pads.
Use of unapproved pads is not recommended. GENTHERM pads allow maximum flow while
resisting restriction or kinks.

1. Read and understand operation manual before connecting pad to Electri-Cool® II.

2. Read and understand pad application instructions accompanying GENTHERM pad.

3. Connect hose to unit by inserting connectors on hose into connectors on unit. Connectors
should “click” as they lock together.

4. Apply pad to patient and attach pad to hose by inserting connectors on pad into hose
connectors. Normal use of the pad is to be applied in direct contact with the patient. Pad
may be used over or under a patient, in the flat state or wrapped around patient.

5. Turn unit “ON” and set to temperature.

6. After pad has filled, check water level in unit. Add sterile water or water that has been
passed through a filter less than or equal to 0.22 microns, only if necessary.

7. When therapy needs to be paused, disconnect the pad from the Electri-Cool II and allow
the unit to continue to run.

NOTE: Reconnect the pad when ready to resume therapy.

8. When therapy is no longer needed disconnect pad from hose by pressing metal clips.
Dispose of pad.

9. Turn unit “OFF” at the power switch and unplug the power cord from the outlet.

11.8  Disposal
Medical Devices that come in contact with patients present the risk of bio-contamination.
This device generates no waste products or residues under normal use and normal cleaning
routines. Follow local State and Hospital guidelines regarding disposal of medical devices at the
end of their useful lives.

11.9  Cleaning (External)

The Electri-Cool® II case is constructed of plastic. For cleaning and disinfecting, always use
conventional hospital-approved topical equipment cleaners and disinfectants that do not contain
alcohol. Avoid alcohol and other strong, undiluted disinfectants. These may cause staining of the
device’s outer skin. Thoroughly wipe down device with a damp cloth to remove any residue from
cleaning solutions. For internal cleaning, please see procedure in section 37.0 on page 122.

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11.10  Storage
CAUTION: Always drain the Electri-Cool® II to a sanitary drain because bio-
contaminants may be present in the unit’s water supply.

Drain the reservoir completely and clean thoroughly prior to storage of the Electri-Cool II.
Contact the Gentherm Technical Service Department for the reservoir disinfection procedure.

12.0 Electromagnetic Emissions

Table 2. Presented in Fulfillment of IEC 60601-1-2
Guidance and manufacturer’s declaration – electromagnetic emissions
The Electri-Cool II system is intended for use in the electromagnetic environment specified
below. The customer or the user of the Electri-Cool II system should assure that it is used in
such an environment.

Emissions tests Compliance Electromagnetic environment – guidance

RF emissions Group 1 The Electri-Cool II system uses RF energy

only for its internal function. Therefore, its
CISPR 11 RF emissions are very low and are not likely
to cause any interference in nearby electronic
equipment.

RF emissions Class A The Electri-Cool II system is suitable for use

in all establishments other than domestic
CISPR 11 and those directly connected to the public
low-voltage power supply network that
Harmonic Class A supplies buildings used for domestic
emissions purposes.

IEC 61000-3-2

Voltage Complies
fluctuations/
flicker emissions

IEC 61000-3-3

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Table 3. Electromagnetic Immunity

Guidance and manufacturer’s declaration – electromagnetic immunity
The Electri-Cool II system is intended for use in the electromagnetic environment specified
below. The customer or the user of the Electri-Cool® II system should assure that it is used in
such an environment.

IEC 60601 test Compliance Electromagnetic environment -

Immunity test
level level guidance

Electrostatic ±6 kV contact ±6 kV contact Floors should be wood, concrete or

discharge ceramic tile. If floors are covered
(ESD) ±8 kV air ±8 kV air with synthetic material, the relative
humidity should be at least 30%.
IEC 61000-4-2

Electrical fast ±2 kV for power ±2 kV for power Mains power quality should be that
transient/ supply lines supply lines of a typical commercial or hospital
burst environment.
±1 kV for input/ ±1 kV for input/
IEC 61000- output lines output lines
4-4

Surge ±1 kV ±1 kV Mains power quality should be that

differential differential of a typical commercial or hospital
IEC 61000- mode mode environment.
4-5
±2 kV common ±2 kV common
mode mode

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Table 3. Electromagnetic Immunity

Guidance and manufacturer’s declaration – electromagnetic immunity
Voltage <5% UT <5% UT Mains power quality should be
dips, short (>95% dip in (>95% dip in that of a typical commercial or
interruptions UT) UT) hospital environment. If the user
and voltage for 0,5 cycle for 0.5 cycle of the Electri-Cool® II system
variations on requires continued operation
power supply 40% UT 40% UT during power mains interruptions,
input lines (60% dip in UT) (60% dip in it is recommended that the Electri-
for 5 cycles UT) Cool® II system be powered from
IEC 61000- for 5 cycles an uninterruptible power supply or a
4-11 70% UT battery.
(30% dip in UT) 70% UT
for 25 cycles (30% dip in
UT)
<5% UT for 25 cycles
(>95% dip in
UT) <5% UT
for 5 s (>95% dip in
UT)
for 5 s

Power 3 A/m 3 A/m Power frequency magnetic fields

frequency should be at levels characteristic
(50/60 Hz) of a typical location in a typical
magnetic field commercial or hospital environment.

IEC 61000-
4-8

Note: UT is the a.c. mains voltage prior to application of the test level.

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Maintenance Electri-Cool II Model 767
Maintenence Electri-Cool II Model 767

Maintenance Section
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13.0 Maintenance
13.1  Overview
Maintenance and service activities will sometimes overlap. In general, maintenance refers to any
activity that does not require a certified technician. Maintenance may be performed by healthcare
personnel or by other trained persons.

The following actions are considered maintenance:

• Exterior inspection, cleaning, and disinfection

• Replacing hoses

• Cleaning hoses, pads

• Draining reservoirs

Service refers to any activity that requires a Medical Equipment Service Technician, Certified
Biomedical Electronics Technician, or a Certified Clinical Engineer. See section 16.0 on page
32. The following actions are considered service:

• Equipment or parts replacement

• Repairs

• Cleaning/disinfecting water reservoirs

13.2  Inspection Frequency

• Gentherm suggests performing maintenance procedures every quarter. Document the results
on the “Preventive Maintenance Inspection Sheet” on page 33.

13.3  Exterior Physical Inspection & Cleaning

• Look for cracked, bent, missing, or otherwise damaged parts. Carefully inspect the power
cord for cuts or exposed wire. Check the plug for missing or bent pins. Check the hoses and
pads for leaks or kinks.

• See section 10.9 Cleaning (External), on page 14.

13.4  Draining the Reservoir

• See section 37.1 Draining the Electri-Cool II, on page 122.

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Filter
14.0 Air Filter Inspection and
Replacement
Inspect filter before each use of unit. Remove
air filter retainer to access the air filter on
the bottom of the unit. Inspect the filter for Tools
accumulated dust. If the filter is 30% clogged
with dust, replace filter with a new one and
reattach the air filter retainer.

Tools:

• Slotted screwdriver

Parts provided:

• Filter

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14.1  Remove the Filter Retainer

1. Unplug the unit from any power source.

Figure 4 - Step 1 Unplug power cord

2. Use a slotted screwdriver to pry where
the filter retainer meets with the filter
housing. Take care to not damage the
fan guard beneath.

Figure 5 - Step 2 Pry off retainer

3. Discard the used filter.

Figure 6 - Step 3 Discard used filter

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4. Place a new filter in the filter retainer

recess.

Figure 7 - Step 4 Place filter in retainer

5. Align the four tabs to the slots of the

filter housing.

Figure 8 - Step 5 Align tabs to slots

6. Press firmly until the retainer snaps into

place.

Figure 9 - Step 6 Press retainer into place

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15.0 Draining the Reservoir

The Electri-Cool II must be drained at least
every 30 days. The unit must also be drained
prior to storage, and prior to transportation.

1. Unplug the unit from any power

source.

2. Place the unit over a sanitary drain.

Figure 10 - Step 1 Unplug power from mains

3. Open the reservoir lid.

Figure 11 - Step 3 Open reservoir lid

4. Tip the unit forward to drain the water

from the reservoir.

Figure 12 - Step 4 Tip unit forward

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Operation & Service Manual

Service Section
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16.0 Troubleshooting Guide

16.1  General
This section provides information to aid the service technician in diagnosing problems with the
Electri-Cool® II system. The left column lists problems which may occur; the right column lists
the most probable causes of the problem.

Table 4. Troubleshooting
Problem Probable Cause
Unit not plugged into proper voltage supply

Unit will not turn on Blown fuse

Loose connector

Kinks in pad/hose

Improper connections to pad/hose

Unit turns on, but will not pump
Improper connections to PC board

Defective PC board

Air filter clogged

Unit will not cool Air intake blocked

Air outlet vents restricted

Reservoir water level too low

Low water warning light/audible
Unit tilted
on
Defective PC board(s)

Water used to fill pump too cold

Low temp warning light/audible
No water flow
on
Defective PC board(s)

Defective membrane control panel

LEDs will not illuminate
Defective PC board

Defective membrane control panel

Desired setting cannot be set
Defective PC board

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Table 4. Troubleshooting
Problem Probable Cause
Loose or disconnected ground (green) wire(s)
Ground continuity exceeds 0.2
Defective connector on ground wire
Ohms.
Defective power cord

Leackage current exceeds 300 Defective power supply

microamperes

16.2  Indicator Specifics

Indicator Condition Indicator

Water Low Temp Limit Constant blue LED & audible indicator

Low Water Constant blue LED & audible indicator

Internal Heatsink High Temp Limit Unit completely shuts down

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17.0 Service
Maintenance and service activities will sometimes overlap. In general, maintenance refers to any
activity that does not require a certified technician. Maintenance may be performed by healthcare
personnel or by other trained persons.

The following actions are considered maintenance:

• Inspecting, cleaning, and disinfecting the exterior

• Replacing hoses

• Cleaning hoses, pads

• Draining reservoirs

Service refers to any activity that requires a Medical Equipment Service Technician, Certified
Biomedical Electronics Technician, or a Certified Clinical Engineer. The following actions are
considered service:

• Equipment or parts replacement

• Repairs

• Cleaning/disinfecting water reservoirs

• Replacing hoses, cords, and other accessories

WARNING: Always unplug the unit before accessing internal components during
service. Failure to unplug the unit could result in electric shock.

WARNING: ALL ground wires must be connected. Improper grounding may result in
electric shock.

WARNING: Working with electronic boards, plugs, and cables requires delicate
handling. Proper Electrostatic Discharge (ESD) procedures should be followed
during replacement of any electronic board. Failure to do so may result in damage
to the board.

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18.0 ECII Interior Access

WARNING: ALL ground wires must be connected. Improper grounding may result in
electric shock.

CAUTION: Working with electronic boards, plugs, and cables requires delicate
handling. Proper Electrostatic Discharge (ESD) procedures should be followed
during replacement of any electronic board. Failure to do so may result in damage
to the board.

NOTE: Drain the reservoir before removing any part from the unit.

All internal operating components are accessible by separating the front and rear enclosure.
Refer to Figure 16 to see the parts locations and general construction. Place the Electri-Cool unit
on a stable work surface before beginning any service.

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18.1  Flow Test

Maximum flow rate is obtained with the water temperature at room temperature and the pad
lying flat on a smooth surface.

1. Plug the device into a power source and turn it on. If no flow rate is observed, check the
pad and hose for kinks, or reversed connections to the pump.

2. Allow water temperature to reach room temperature and check flow rate with a flow
meter. If the flow rate is substantially less than 68 LPH (18 GPH), check the pump
for restrictions. Visually check the hose and pad to see water flow thru the pad.
To check the actual flow rate use the Dualmatic only.

18.2  Water Leak Test

Tools needed: none.

Parts provided: none.

Parts needed: Bypass hose with

male quick disconnects. Sold
separately.

Quick disconnects will fit 1/4 in. ID hose (x2)

Hose is 1/4 in. ID (x1)

1. When removing covers to check for internal water leaks, the assembly person or service
technician must be grounded with an ESD mat and wristband or equivalent.

2. Fill reservoir with sterile water or water that has been passed through a filter less than or
equal to 0.22 microns.

3. Connect bypass hose to both quick-disconnect connectors.

4. Turn unit on.

5. Check Electri-Cool II for any water leaks.

18.3  Temperature Test

Tools needed:

• In-line temperature probe

• Six-foot insulated connecting hose

• Timer

• Pad

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1. Remove the device from any power source.

2. When removing covers to check for internal water leaks, the service technician must be
grounded with an ESD mat and wristband or equivalent.

3. Attach an in-line temperature probe to the device’s outlet and a six foot insulated
connecting hose with a pad to the return port of the machine.

4. Plug the device into a power source, turn the unit on, and set the temperature to 5°C - 7°C
(40°F - 45°F). When the temperature probe reads between 3.9°C – 8.1°C (31°F - 47°F),
start the timer. After at least five (5) minutes, record the temperature probe reading. The
reading must be within 3.9°C – 8.1°C (31°F - 47°F).

5. Set the temperature on the device to 8°C - 10°C (46°F - 50°F). When the temperature
probe reads between 6.9°C – 11.1°C (44°F - 52°F), start the timer. After at least five (5)
minutes record the temperature probe reading. The reading must be within 6.9°C – 11.1°C
(44°F - 52°F).

6. Set the temperature on the device to 11°C - 13°C (51°F - 55°F). When the temperature
probe reads between 9.9°C – 14.1°C (50°F - 57°F), start the timer. After at least five (5)
minutes record the temperature probe reading. The reading must be within 9.9°C – 14.1°C
(50°F - 57°F).

7. Turn the device OFF.

18.4  Low Water Switch/Indicator Test

To perform this test:

1. Unit must be plugged into a power source and running.

2. Open the reservoir access lid.

3. Reach into the reservoir to the float switch and push the float all the way down to its
lowest possible position. The low water indicator should sound and the low water level
LED on the membrane control panel should light. The unit will stop pumping water and
stop cooling immediately.

4. Release the float and let it rise to its highest position. The unit should now resume
normal operation, and the alarms should stop.

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18.5  Leakage Current Test

1. Unit must be plugged into a power source and running.

2. Connect the leakage current tester ground lead clamp to the equipotential ground on the
back of the unit.

3. Test unit in all combinations of power switch off and on, normal and reverse polarity, and
normal and open ground. Record the highest reading. If the readings indicate more than
300 microamperes (for 100V/115V) or more than 500 microamperes (for 230V/240V),
refer to the Service Checklist 19.0 Preventive Maintenance for Service Personnel, on page
33.

18.6  Ground Continuity Test

Using an ohmmeter, measure the resistance between the ground lug and the ground pin of
the power plug. This value shall not exceed 0.2 ohm. If higher than 0.2 ohm, see section 19.0
Preventive Maintenance for Service Personnel, on page 33.

18.7  Water Temperature Low-Limit Thermistor Test

WARNING: Electric shock hazard may be present.

Control Board P/N: 39990

This test is for devices with a control board labeled “P/N: 39990. This includes most devices with
serial number 043-76700185 and later. The last 5 digits are sequential.

1. Unplug the unit from any power source.

2. Disconnect any hoses or pads from the device.

3. Follow instructions for section 20.1 Rear Enclosure and Reservoir Lid Removal, on page
39.

4. Move the jumper at J9 on the control board from the OPERATE to the TEST position.

5. Plug in the unit and turn it on. Wait for it to go through self-calibration, approximately 5
seconds.

6. Locate the 8-position Molex plug (J4) on the control board. When the indicator sounds,
turn the device OFF, remove the 8-position Molex plug (J4) and quickly measure the
resistance at the control thermistor (white wires).

7. Determine and record the equivalent temperature of the control thermistor in Table 5 of
section 19.0 Preventive Maintenance for Service Personnel, on page 33.
The equivalent temperature must be 2.2°C ± 1.1°C.

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8. Confirm that the indicator sounds and verify the low temperature LED lights up.

9. Move the jumper at J9 on the control board from the TEST to the OPERATE position and
reconnect the 8-position connector from the TE subassembly to the control board.

10. Record N/A for the low temp thermistor in Table 5. Preventive Maintenance Inspection
Sheet, on page 33.

11. Follow instructions for section 20.2 Rear Enclosure and Reservoir Lid Installation, on
page 41.

18.8  Internal Physical Inspection

1. Follow instructions for 20.1 Rear Enclosure and Reservoir Lid Removal, on page 39.
Carefully inspect the unit for any signs of leaks, loose components, or damage. Check
wiring for breaks in insulation, exposed wires, loose connections, etc. Repair or replace
components as necessary and retest unit before placing back into service.

2. Once inspection is complete, follow instructions for section 20.2 Rear Enclosure and
Reservoir Lid Installation, on page 41.

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Figure 13 - Control board diagram

Figure 14 - Detail A Operate Position Figure 15 - Detail A Test Position

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19.0 Preventive Maintenance for Service Personnel

Table 5. Preventive Maintenance Inspection Sheet

Daily Preventive Maintenance Inspection Sheet

Date
Section Procedures
12.3 Exterior Physical Inspection Value Pass/Fail
External enclosure in good condition, No cracks,
bent, missing, or damaged parts
Control panel is free of damage and legible
All labels legible and secure
Power cord and strain relief is free of cuts, damage or
exposed wire
Power plug has no bent or missing ground prongs
Quick disconnect couplings are tight, straight, and
not leaking.
Rubber feet are free of damage and secure
14.0 Air Filter Inspection Value Pass/Fail
Air filter is not 30% or more clogged with dust
Air filter is free of cuts, tears, or holes
Air filter extends across all filter retainer openings
when installed
11.4 Functional Verification Value Pass/Fail
Startup sequence completes properly
Check audible and visual indicators
Check water flow through the pad (check water level
and refil if needed)

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Monthly Preventive Maintenance Checklist

18.1 Flow Test Value Pass/Fail
Check flow rate is minimum 68 LPH (18 GPH)
18.7 Water Temperature Low-Limit Thermistor Test Value Pass/Fail
Temperature reading when set at 5-7 °C (40-45 °F).
Reading within 3.9-8.1 °C (31-47 °F)
Temperature reading when set at 8-10 °C (46-50 °F)
Reading within 6.9-11.1 °C (44-52 °F)
Temperature reading when set to 11-13 °C (51-55 °F)
Reading within 9.9-14.1 °C (50-57 °F)
Low Water Switch / Indicator Test
18.5 Leakage Current Test Value Pass/Fail
Power switch off, reverse polarity, ground
disconnected
Power switch off, reverse polarity, ground connected
Power switch off, normal polarity, ground
disconnected
Power switch off, normal polarity, ground connected
Power switch on, reverse polarity, ground
disconnected
Power switch on, reverse polarity, ground connected
Power switch on, normal polarity, ground
disconnected
Power switch on, normal polarity, ground connected

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Figure 16 - Exploded view with callouts

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Table 6. Parts List

Item # Name Qty.

1 Brackets 3
2 Lug Ground, Euro 1
3 Ground Lug Washer, Green/Yellow 1
4 Fuse 2
5 Power Supply 1
6 Control Board 1
7 Float Switch 1
8 TE Module 1
9 Fan Guard 1
10 Fan Motor 1
11 Pump 1
12 Insulation Tubing, 3/8” ID x 1/8 W 1
13 Reservoir 1
14 Reservoir Lid 1
15 Bottom Enclosure 1
16 Front Enclosure 1
17 Back Enclosure 1
18 Panel Mount Coupling 2
19 Reservoir Collar 1
20 PVC Tubing, 12 mm ID x 16 mm OD 1
21 Rubber Feet 4
22 Air Filter 1
23 Reservoir Insulation 1
24 Membrane Control Panel 1
25 Exterior Spec Label 1
26 Plastic Spacer, #8 x 3/8 2
27 Flat Head SS M/S, #8-32 x 1/2” 2
28 Phillips Oval Head SS M/S, #8-32 x 1” 4
29 Keps nut, #8-32 Zinc 4
30 Keps nut, Plated M6 2
31 Filister Head Screw, #10-24 x 3/4” 8
32 Plastic Pan Head Phillips Screw, #8-32 x 3
1/4”
33 Plastic Washer, #8 3
34 Wire Harness Assembly 1

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Item # Name Qty.

35 Insulation Tubing, 1/2” 1
36 Clear PVC Tubing, 1/4” ID x 3/8” OD 1
37 Barbed Elbow, 25 x 25 1
38 Fuse Holder 2
39 Exterior Logo Label 1
40 Power Entry Shroud 1
41 Phillips Screw, #8-32 x 5/16" 2
42 Phillips Truss Head Screw, #8-32 x 3/4 2
43 Head Screw, #8-32 x 3/8" 4
44 Phillips Screw, #8-32 x 1/2" 2
45 Nylon Spacer, Black 2
46 Keps nut, #4-40 SS 2
47 Phillips Pan Head SS M/S, #4-40 x 3/4" 2

Not Shown
1 Power Cord, 2.5 meters, 115V 1
2 18” Velcro Strap 1
3 Carton 1
4 Operation Manual 1
5 #8 internal tooth L/W 410 SS 1
6 6-foot Insulated hose 1
7 EMI Suppressor Core .680 1
8 EMI Suppressor Core .993 1

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20.0 Rear Enclosure and Reser-

voir Lid Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed during
replacement of any electronic board. Failure to
do so may result in damage to the board.

Note: If the rear enclosure replacement must be

replaced for any reason, the specifications label
on the back must also be replaced.

Tools Required: #2 Phillips screwdriver

Parts provided:

• Rear enclosure

• Reservoir lid Tools and parts

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20.1  Rear Enclosure and Reservoir

Lid Removal
1. Disconnect the device from mains power
(Figure 17).

2. Drain the device. See section 15.0

Draining the Reservoir, on page 22.

Figure 17 - Step 1 Unplug power cord

3. Remove the two handle screws. Do not

discard the screws (Figure 18).

Figure 18 - Step 3 Remove two handle

screws

4. Remove the two screws in the base that

hold the base and rear enclosures
together. Do not discard the screws
(Figure 19).

Figure 19 - Step 4 Remove two base screws

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5. Remove the reservoir collar (Figure 20).

Figure 20 - Step 5 Remove collar

6. Lift rear enclosure with lid up and away

(Figure 21).

Figure 21 - Step 6 Lift rear enclosure with lid

up and away

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20.2  Rear Enclosure and Reservoir

Lid Installation
1. Install enclosure and lid (Figure 22).

Figure 22 - Step 1 Install enclosure and lid

2. Screw on the reservoir collar (Figure 23).

Figure 23 - Step 2 Install reservoir collar

3. Secure the rear enclosure to the bottom
enclosure using two #10-24 x 3/4”
Phillips, fillister head screws (Figure 24).

Figure 24 - Step 3 Install two base enclosure

screws.

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4. Secure the rear enclosure handle to the

front enclosure handle with two #10-24
x 3/4” phillips, fillister-head screws
(Figure 25).

5. Tighten all screws to 10 in-lbs.

Figure 25 - Step 4 Install two handle screws

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21.0 Front Enclosure

Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed during
replacement of any electronic board. Failure to
do so may result in damage to the board.
Note: If the front enclosure must be replaced Tools
for any reason, the logo label and the
membrane panel must also be replaced (Step
#2).

Tools:

• #2 Phillips screwdriver

Parts Provided:

• Front enclosure

• Logo label

• Membrane control panel with ribbon cable.

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21.1  Front Enclosure Removal

1. Follow instructions for section 20.0 Rear
Enclosure and Reservoir Lid
Replacement, on page 38.

2. Place the unit on its back. Remove the

four screws in the base (Figure 26). Do
not discard the screws.

Figure 26 - Step 2 Remove four screws

3. Lift the front enclosure up and away

from the base. Note: Be careful to not
apply tension to the membrane ribbon
cable.

Figure 27 - Step 4 Remove front enclosure

4. Disconnect the membrane ribbon cable

from the control board (Figure 28).

Figure 28 - Step 5 Disconnect ribbon cable

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21.2  Front Enclosure Installation

1. Follow instructions for section 24.0
Membrane Panel Replacement, on page
53.

2. Install a new exterior logo label if

required. Remove the adhesive backing
from a corner of the label. Align it with
the recessed area on the front enclosure
and press the corner in place. Remove
the remaining adhesive backer and roll
the rest of the label in place.

3. Place the front enclosure into the

bottom enclosure. Check to make sure
that all wires are properly located within
the enclosure (Figure 29). Ensure wires
do not fall between the plastic divider
and the reservoir.

Figure 29 - Step 3 Install front enclosure.

4. Reconnect the membrane ribbon cable

to connector J1 on the control board
(Figure 30).

Figure 30 - Step 5 Reconnect ribbon cable

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5. Install the front enclosure to the base

enclosure with four #10-24 x 3/4”
Phillips fillister head screws (Figure 31).

6. Perform the maintenance as defined in

the “Preventive Maintenance for Service
Personnel” on page 33.

7. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41.
Figure 31 - Step 5 Install front enclosure

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22.0 Bottom Enclosure

Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed during
replacement of any electronic board. Failure to
do so may result in damage to the board.

NOTE: Do not bend any of the terminals

Tools:

• #2 Phillips screwdriver

• 11/32” wrench or socket

• (2) 10 mm open end wrenches Tools

Parts Provided:

• Bottom enclosure

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22.1  Bottom Enclosure Removal

1. Follow the instructions for section
20.0 Rear Enclosure and Reservoir Lid
Replacement, on page 38.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Follow the instructions for section 35.1

Fan Guard Removal, on page 107.

4. Follow the instructions for section 30.1

Power Inlet Removal, on page 81.

5. Remove the rubber feet and set them

aside.

6. Follow the instructions for section 28.1

Quick Disconnect Removal, on page
72.

Figure 32 - Step 5 Remove rubber feet

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22.2  Bottom Enclosure Installation

1. Install the feet by pushing them into
place and pull and turn them from the
inside to lock them in place.

Figure 33 - Step 1 Install feet

2. Install BF applied part label next to the

quick disconnect couplings (Figure 34).

Figure 34 - Step 2 Apply the BF label

3. Adhere GTIN label (Figure 35).

4. Follow instructions for section 28.2

Quick Disconnect Installation, on page
74.

5. Follow instructions for section 35.2 Fan

Guard Installation, on page 110.

6. Follow instructions for section 30.2

Power inlet Installation, on page 84.
Figure 35 - Step 3 Apply the GTIN label
7. Follow instructions for section 23.2
Grounding Stud Installation, on page
51.

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23.0 Equipotential Grounding

Stud Replacement
Tools:

• 10mm open end wrench (2)

Parts provided:

• Stud replacement kit

23.1  Grounding Stud Removal

1. Use a 10mm open end wrench to remove
the first Keps nut that holds the ground
stud in place. Set the nuts aside.

Figure 36 - Step 1 Remove 1st Keps nut

2. Remove the grounding wires and then

remove the second Keps nut.

3. Remove the ground stud. Set it and the

gold/white ring aside for reuse.

Figure 37 - Step 2 Remove ground wire and

second Keps nut

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23.2  Grounding Stud Installation

1. Insert the stud in the hole in the side of
the bottom enclosure.

Figure 38 - Step 1 Insert stud

2. Slide the green and white ring over it so

that the colors show to the outside of the
enclosure.

Figure 39 - Step 2 Add the green and gold

ring

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3. Install Keps nut #1 on the outside of the

base enclosure, and #2 Keps nut on the
inside. Tighten both nuts with two open
end wrenches.

Figure 40 - Step 3 Install Keps nuts 1 & 2

4. Attach the ground wire and place Keps

nut #3 on the end. Tighten Keps nut #3
with an open end wrench.

Figure 41 - Step 5 Attach ground wire and

second Keps nut

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Membrane Panel
24.0 Membrane Panel
Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed during
replacement of any electronic board. Failure to
do so may result in damage to the board.

Tools required:

• #2 Phillips screwdriver Tools

• 3/16 inch flat screwdriver

Parts provided:

• Membrane panel

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24.1  Membrane Panel Removal

1. Follow instructions for section 20.0
Rear Enclosure and Reservoir Lid
Replacement, on page 38.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Grasp the ribbon cable plug by the

edges. Carefully unplug the ribbon cable
from J1 on the circuit board (Figure 42).

Figure 42 - Step 3 Unplug ribbon cable

4. Remove the old membrane panel by

pushing a flat screw driver against the
membrane through the ribbon cable slot
from the inside of the front enclosure
(Figure 43). Take care to avoid damaging
the front enclosure surface when
removing the membrane.

Figure 43 - Step 4 Push flat screwdriver

through cable slot from the inside

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24.2  Membrane Panel Installation

1. Thread the ribbon cable through the
square cutout on the surface of the front
enclosure (Figure 44).

2. Peel the adhesive backing off the new

membrane panel.

3. Begin applying the membrane from

the narrow end to the wide end. Align
membrane with the edges of the recess
and press membrane panel to the front
enclosure. Figure 44 - Step 1 Thread cable through slot

4. Attach the ribbon cable plug to J1 of the

control board (Figure 45).

5. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

6. Follow instructions for section 20.0

Rear Enclosure and Reservoir Lid
Replacement, on page 38.

7. Perform the maintenance as defined in

19.0 Preventive Maintenance for Service Figure 45 - Step 4 Connect ribbon cable
Personnel, on page 33.

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25.0 Float Switch Replacement Float Switch

Tools required:

• 9/16” open end wrench

Parts provided:

• Float switch with gasket and mounting nut.

Tools

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25.1  Float Switch Removal

1. Follow instructions for section 20.0
Rear Enclosure and Reservoir Lid
Replacement, on page 38.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Disconnect the float switch cable from J7

on the control board (Figure 46).

Figure 46 - Step 3 Disconnect J7

4. Loosen the reservoir insulation
sufficiently enough to remove the float
switch cable (Figure 47).

Figure 47 - Step 4 Loosen reservoir

insulation
5. Unscrew the float switch mounting nut
from the bottom of the reservoir (Figure
48).

6. Remove the float switch, the float switch

wiring and gasket from the reservoir.

Figure 48 - Step 5 Unscrew float switch

mounting nut

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25.2  Float Switch Installation

1. Make sure the words “GEMS Sensors”
on the float are facing up as the switch is
installed. If the words will not face up,
remove the float retainer clip and flip the
float over. Then reinstall the float
retainer clip.

Figure 49 - Step 1 GEMS orientation

2. Thread the float switch connector and

wires through the accompaning gasket.

Figure 50 - Step 2 Thread wires through

gasket

3. Insert the float switch connector and

wires through the hole in the bottom of
the reservoir.

Figure 51 - Thread connector and wires

through reservoir

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4. Secure the float switch in place beneath

the reservoir with the accompanying nut
(Figure 52).

Figure 52 - Step 4 Secure float switch

mounting nut

5. Fasten the float switch cable under the

reservoir insulation. Ensure the float
switch wires extend towards the front left
corner of the reservoir (Figure 53).

Figure 53 - Step 5 Loosen reservoir

insulation

6. Route the float switch cable between the

front thermoelectric subassembly
bracket and the power supply (Figure
54).

Figure 54 - Step 6 Route wiring behind

bracket

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7. Connect the float switch cable to J7 on

the control board (Figure 55).

8. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

9. Perform a leak test with the unit running

(section 18.2 on page 28).

10. Follow instructions for section 18.4 Low

Water Switch/Indicator Test, on page
29. Figure 55 - Step 7 Attach connector to J7

11. Perform the maintenance as required in

19.0 Preventive Maintenance for Service
Personnel, on page 33.

12. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41).

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Reservoir
26.0 Reservoir Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic board. Failure to do so
may result in damage to the board.

Tools required:
Reservoir Kit
• 1/4” nut driver

• Slotted screwdriver

Parts provided:

• Reservoir

• Reservoir insulation kit

Parts not provided:

• Black electrical tape

Tools

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26.1  Reservoir Removal

1. Follow instructions for section 20.0
Rear Enclosure and Reservoir Lid
Replacement, on page 38.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Follow instructions for section 25.0

Float Switch Replacement, on page
56.

4. Remove the electrical tape and

insulation wrapped around the hose
clamps.

5. Use the slotted screwdriver to loosen the

two hose clamps at the tubing
connection to the reservoir (Figure 56).

Figure 56 - Step 5 Loosen two hose clamps

6. Remove the tubing at each of the two

connections from the reservoir.

Figure 57 - Step 6 Remove tubing

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26.2  Reservoir Installation

1. Install tubing onto new reservoir and
secure with hose clamps.

2. Follow instructions for securing the float

switch into the new reservoir, section
25.0 Float Switch Replacement, on page
56.

Figure 58 - Step 1 connect tubing to reservoir

with clamps

3. Position the float switch cable under the

reservoir. Then wrap the primary and
secondary reservoirs with 1/8” thick
insulation. Ensure the float switch wires
come out towards the front left corner of
the reservoir.

Figure 59 - Step 3 Float switch wires

position
4. Connect the float switch connector to J7
on the control board.

5. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45).

6. Perform a leak test with the unit running

(section 18.2 on page 28).

7. Check for kinks in the water tubing.

8. Perform the maintenance as required Figure 60 - Step 4 Connect float switch to J7

in Table 5. Preventive Maintenance
Inspection Sheet, on page 33.

9. Refer to installation of rear enclosure

(section 20.2 Rear Enclosure and
Reservoir Lid Installation, on page
41).

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Pump kit
27.0 Pump Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed during
replacement of any electronic board. Failure to
do so may result in damage to the board.

Tools required

• # 2 Phillips screwdriver

• Slotted screwdriver

• Wire cutter

Parts supplied

• Pump Kit

Tools

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27.1  Pump Removal

1. Refer to section 20.0 Rear Enclosure
and Reservoir Lid Replacement, on page
38.

2. Refer to section 21.0 Front Enclosure

Replacement, on page 43.

3. Disconnect the pump connector from J5

on the control board (Figure 61).

Figure 61 - Step 3 Unplug pump wiring

4. Remove the wire tie holding the fan and

pump wires to the thermoelectric
subassembly bracket (Figure 62).

Figure 62 - Step 4 Remove the wire tie

5. Remove the Electro-magnetic

interferrance (EMI) suppressor that is
around the fan and pump wires (Figure
63).

Figure 63 - Step 5 Remove EMI suppressor

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6. Remove discharge tubing from the

pump.

Figure 64 - Step 7 Remove discharge tubing

7. Use the slotted screwdriver to loosen the

two hose clamps at the tubing
connection to the reservoir

Figure 65 - Step 5 Loosen two hose clamps

8. Remove pump mount bracket from the

base by removing two Phillips screws
(Figure 66). Do not discard the screws.

Figure 66 - Step 6 Unscrew pump bracket

from base enclosure

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9. Remove inlet tubing from the pump.

Figure 67 - Step 8 Remove inlet tubing

10. Use a #2 Phillips screwdriver to remove

pump from the bracket (Figure 68).

Figure 68 - Step 1 Remove pump from

bracket

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27.2  Pump Installation

1. Mount new pump to the new pump
bracket using two #8-32 x 5/16” Phillips
screws (Figure 69).

Figure 69 - Step 1 Mount pump to bracket

2. Mount pump bracket to the base

enclosure using two #8-32 x 1/2” flat-
head screws (Figure 70).

Figure 70 - Step 2 Mount bracket to base

3. Slide the discharge and inlet tubing all

the way onto the new pump (Figure 71).

Figure 71 - Step 3 slide tubing onto new

pump

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4. Use the slotted screwdriver to tighten

the two hose clamps at the tubing
connection to the reservoir.

Figure 72 - Step 4 Tighten the hose clamps.

5. Install the EMI suppressor around the

fan and pump wires (Figure 73).

Figure 73 - Step 5 Install EMI suppressor

6. Slide the EMI suppressor up on the
wires, and fasten the fan and pump wires
together with a wire tie as close to the
pump as possible but below the EMI
suppressor (Figure 74). Use the wire
cutters to remove the excess wire tie.

Figure 74 - Step 6 Wire tie below EMI

suppressor

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7. Secure the fan and pump wires to the

front thermoelectric subassembly
bracket with a wire tie (Figure 75). Use
the wire cutters to remove the excess
wire tie. Slide the EMI suppressor down
to the wire tie.

Figure 75 - Step 7 Secure wires to bracket

8. Route the pump and fan wires between

the power supply and the thermoelectric
subassembly bracket (Figure 76). Make
sure the fan wires are tucked into the
same location with the pump wiring.

Figure 76 - Step 8 Route wires behind

bracket

9. Connect the pump power wire connector

to J5 on the control board.

10. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

11. Perform a leak test with the unit running

(section 18.2 on page 28).

12. Follow instructions for section 20.0

Rear Enclosure and Reservoir Lid
Replacement, on page 38. Figure 77 - Step 9 Connect power wire
connector to J5
13. Perform the maintenance as defined in
19.0 Preventive Maintenance for Service
Personnel, on page 33).

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Quick disconnect panel mount couplings

28.0 Quick Disconnect Panel
Mount Couplings
Replacement
Tools:

• 3/4” open end wrench

• 13/16” open end wrench

• Heat gun

• Tubing cutter

Parts supplied:

• One foot of clear PVC Tubing 1/4” ID x 3/8”

OD from Gentherm

• One foot of Insulation Tubing, 3/8” ID x 1/8

W from Gentherm
Tools

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28.1  Quick Disconnect Removal

1. Follow instructions for section 20.1 Rear
Enclosure and Reservoir Lid Removal,
on page 39.

2. Follow instructions for section 21.1 Front

Enclosure Removal, on page 44.

3. Use the heat gun to soften the tubing at

the couplings. With your fingers, remove
the tubing from the couplings.

4. Use the heat gun to soften the tubing at

the pump 90 degree elbow.

Figure 78 - Step 4 Tubing at 90 degree

elbow

5. Use the heat gun to soften the tubing at

the pump. With your fingers, remove the
tubing from the pump and reservoir
locations.

Figure 79 - Step 5 Remove tubing from

pump

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6. Use the 3/4” wrench to unscrew the

retainer nuts on the back of the quick
disconnect couplings (Figure 80). Slide
the nuts up onto the tubing.

Figure 80 - Step 6 Slide retainer nuts up

7. Pull the quick disconnect couplings out

of the bottom enclosure.

8. Cut or remove the PVC tubing behind

each of the quick disconnect couplings.

9. Discard the old PVC tubing and

Insulation tubing.

Figure 81 - Step 7 Pull couplings out of

enclosure

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28.2  Quick Disconnect Installation

1. Cut a 2 inch length of PVC tubing and
install it on the 90 degree hose barb.

2. Cut a 2-1/2 inch length of Insulation

tubing and slide it over the 2 inch PVC
tube.

3. Cut a 6-1/2 inch length of PVC tubing

and install it on the reservoir barbed
connector

4. Cut a 6-1/2 inch length of Insulation

tubing and slide it over the 6-1/2 inch
PVC tube.

5. Slip the quick disconnect retaining nuts

onto the ends of the tubing just installed
(Figure 82).

Figure 82 - Slide retainer nuts onto tubing

6. Extend the two lengths of tubing

through the appropriate openings in the
base enclosure (Figure 83).

Figure 83 - Step 6 Extend tubing through

enclosure

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7. Heat the PVC tubing ends and push

them onto the quick disconnects (Figure
84).

Figure 84 - Step 7 Insert couplings into hose

8. Push the quick disconnect couplings

through the openings in the base
enclosure. Turn them so the release
button is facing up. Check for kinks in
the tubing.

Figure 85 - Step 8 Turn and align couplings

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9. Thread the retaining nuts onto the

threads and tighten with the open end
wrench.

10. Perform a leak test of the tubing

connections (section 18.2 on page
28).

Figure 86 - Step 9 Tighten retaining nuts

11. Tape up the exposed clamps with

insulation tape.

Figure 87 - Step 11 Tape the exposed clamps

12. Apply electrical tape around insulation
tape (Figure 88).

13. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

14. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41.

Figure 88 - Step 12 Apply electrical tape

around insulation

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Fuses
29.0 Fuse Replacement
Tools:

• 1/8 inch slotted screwdriver

Parts provided: Tools

• Fuses (requires two)

CAUTION: Working with electronic

boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic component.

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29.1  Fuse Removal

1. Disconnect the device from any power
source (Figure 89).

Figure 89 - Step 1 Unplug power

2. Locate the slot at the top of the power

inlet and use a screw driver to pry the
fuse door open (Figure 90).

Figure 90 - Step 2 Open fuse door

3. Note that the direction arrows on the
access door match the arrows on the
slide out fuse holders (Figure 91).

4. One fuse is in each of the two slide out

fuse holders. Pull the fuse holders out to
access the fuse.

Figure 91 - Step 3 Note direction arrows

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29.2  Fuse Installation

1. Replace the fuse with the replacement
fuse from Gentherm. Place each fuse
into a fuse holder.

Figure 92 - Step 1 Place fuses into holders

2. Match the fuse holder arrow direction to
the arrows on the access door. Push the
fuse holder back into its original position
(Figure 93).

Figure 93 - Step 2 Match arrow direction

3. Push the fuse door closed until it snaps
in place. Make sure the lock tabs are
inside the enclosure (Figure 94).

4. Attach a pad to the device.

5. Turn on the Electri-Cool II.

6. Check that the device will sustain power

when it is in 5-7 °C cooling mode.

Figure 94 - Step 3 Locking tabs

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Power inlet and wire harness

30.0 Power Inlet and Wire
Harness Replacement
CAUTION: Working with electronic 10mm x2
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic board. Failure to do so
may result in damage to the board.

Tools:

• #2 Phillips screwdriver

• 11/32” open end wrench

• 10 mm open end x 2

Parts provided:
Tools
• Wire harness with power inlet

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30.1  Power Inlet Removal

1. Follow instructions for section 20.1 Rear
Enclosure and Reservoir Lid Removal,
on page 39.

2. Follow instructions for section 21.1 Front

Enclosure Removal, on page 44.

3. Remove the power inlet plastic shroud

(Figure 95).

Figure 95 - Step 3 Plastic power inlet

shroud

4. Remove the retaining Keps nut and

remove all ground wires from the
grounding post to free the power inlet
wire harness (Figure 96).

Figure 96 - Step 4 Remove retaining Keps

nut and ground wires

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5. Disconnect the power inlet wire harness

from the power supply (Figure 97).

Figure 97 - Step 5 Disconnect harness from

the power supply

6. Remove the EMI suppressor from the

control board power wire.

Figure 98 - Step 6 Remove suppressor

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7. Remove the two retaining screws and

small Keps nuts that mount the power
inlet to the bottom enclosure (Figure
99). Do not discard the screws and nuts.

Figure 99 - Step 7 Remove retaining screws

8. Pull the power inlet out from the bottom

enclosure (Figure 100).

Figure 100 - Step 8 Power inlet removal 2

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30.2  Power inlet Installation

1. Follow instructions for section 29.2 Fuse
Installation, on page 79.

2. Install new power inlet using two (2) #4-

40 x 3/4” screws and two (2) #4-40
Keps nuts (Figure 101).

Figure 101 - Step 2 Install power inlet

3. Connect the control board power wires to

connector J2.

Figure 102 - Step 3 Connect control board

wires to J2
4. Install the EMI suppressor on the control
board power wire that goes to J2 (Figure
103).

Figure 103 - Step 4 Install EMI suppressor

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5. Route the new wire harness connector

behind the thermoelectric subassembly
bracket (Figure 104).

Figure 104 - Step 5 Route wire harness

connector behind bracket

6. Connect the power supply to the three

wires that come from the power inlet
(Figure 105).

• Pin three to green wire

• Pin two to brown wire
• Pin one to blue wire

Figure 105 - Step 6 Connect power supply

7. Connect all ground wires to the

grounding post (Figure 106).

Figure 106 - Step 7 Attach all grounding

wires

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8. Reinstall the power inlet plastic shroud.

9. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

10. Perform the maintenance as defined in

the “Preventive Maintenance for Service
Personnel” on page 33.

11. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41. Figure 107 - Step 8 Reinstall plastic
power inlet shroud

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Control Board
31.0 Control Board Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic board. Failure to do so Tools
may result in damage to the board.

Tools:

• #2 Phillips screwdriver

Parts provided:

• Control board

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31.1  Control Board Removal

1. Refer to section 20.0 Rear Enclosure
and Reservoir Lid Replacement, on page
38.

2. Refer to section 21.0 Front Enclosure

Replacement, on page 43.

3. Disconnect all five (5) electrical

connectors from the control board
(Figure 108).

Figure 108 - Step 3 Disconnect all 5

connectors

4. Remove three plastic screws (Figure

109).

Figure 109 - Step 4 Remove three plastic

screws
5. Remove the three (3) plastic washers
located between the control board and
the thermoelectric bracket assembly at
the same locations as the plastic screws
(Figure 110). Do not discard. Set them
aside for reuse.

6. Remove the control board.

Figure 110 - Step 5 Remove three plastic

washers (one shown)
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31.2  Control Board Installation

1. Reinstall the three #8 plastic washers
onto the thermoelectric bracket
assembly (Figure 112).

Figure 111 - Step 1 Remove three plastic

washers (one shown)

2. Place the new control board in place and

install the three #8-32 x 1/4 “ plastic
Phillips screws to hold the board in place
(Figure 112).

Figure 112 - Step 2 Reinstall three plastic

screws

3. Connect all five (5) electrical connectors

to the control board (Figure 113).

4. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

5. Perform the maintenance as defined in

the “Preventive Maintenance for Service
Personnel” on page 33.

6. Refer to section 20.2 Rear Enclosure

and Reservoir Lid Installation, on page Figure 113 - Step 3 Connect all 5 connectors
41.

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Power Supply
32.0 Power Supply Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic board. Failure to do so
may result in damage to the board.
Tools
Tools:

• #2 Phillips screwdriver

Parts provided:

• Power supply

• Wire ties

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32.1  Power Supply Removal

1. Refer to section “Rear Enclosure and
Reservoir Lid Replacement” on page
38.

2. Refer to section “Front Enclosure

Replacement” on page 43.

3. Follow instructions for section 31.1

Control Board Removal, on page 88.

4. Remove the two Phillips, truss-head

screws and two spacers holding the
power supply to the thermoelectric
subassembly front bracket. Set them
aside for re-use.

5. Remove the 2 Phillips screws holding

the power supply to the TE rear bracket.
Set them aside for re-use.

Figure 114 - Step 4 Unscrew power supply

from front bracket

6. Disconnect the control board power wire

harness and fan wires from the power
supply.

Figure 115 - Step 5 Control board power

wire harness

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7. Remove the two Phillips, truss-head

screws and two spacers (if present)
holding the power supply to the
thermoelectric subassembly rear
bracket.

Figure 116 - Step 6 Remove Phillips screws

from rear braket.

8. Use the Phillips screwdriver to

disconnect the power supply from the
three wires that come from the power
inlet.

Figure 117 - Step 7 Disconnect power supply

wires to power inlet

9. Remove the wire tie holding the wires to

the power supply.

Figure 118 - Step 8 Remove wire tie on

power supply

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32.2  Power Supply Installation

1. Connect the power supply to the three
wires that come from the power inlet
(Figure 119). 1 2 3

• Connect the blue wire to pin one

• Connect the brown wire to pin two
• Connect the green wire to pin three

Figure 119 - Step 1 Connect power supply

wires from power inlet

2. Secure the power supply by installing

with two #8-32 x 3/8” truss-head screws
on the thermoelectric subassembly rear
bracket. Note: Inspect all wire positions
to ensure they are not pinched when
tightening screws.

Figure 120 - Step 2 Install two truss-head

screws on rear bracket

3. Connect the fan wires to the power

supply (Figure 121).

• Red wire to pin two

• Black wire to pin four

Figure 121 - Step 3 Connect fan wires to the

power supply

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4. Connect the control board power wire

harness to the power supply (Figure 4 3 2 1
122).

• Red wire to pin one

• Black wire to pin three

Figure 122 - Step 4 Detail

5. Make sure the power supply wires are

placed between the power supply and
the thermoelectric subassembly bracket
(Figure 123).

Figure 123 - Step 5 Power supply wires

placement

6. Secure the power supply to the

thermoelectric subassembly front
bracket using two #8 x 3/8” spacers and
two #8-32 x 3/4” Phillips truss-head
screws (Figure 124).

Figure 124 - Step 6 Secure power supply

wires to front bracket

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7. Wire tie the power supply wiring harness

to the third slot on the side of the power
supply (Figure 125).

8. Follow instructions for section 31.2

Control Board Installation, on page
89.

9. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

10. Perform the maintenance as defined in Figure 125 - Step 7 Wire tie the harness to
the “Preventive Maintenance for Service the third slot
Personnel” on page 33.

11. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41.

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Thermoelectric Module
33.0 Thermoelectric (TE)
Module Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic components.

Tools: Tools
• #2 Phillips screwdriver

Parts provided:

• Thermoelectric module

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33.1  TE Module Removal

1. Follow instructions for section 20.0
Rear Enclosure and Reservoir Lid
Replacement, on page 38.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Follow instructions for section 31.1

Control Board Removal, on page 88.

4. Follow instructions for section 32.1

Power Supply Removal, on page 91.

5. Remove two Phillips screws and the

plastic spacers that attach the TE
module on the front bracket (Figure
126). Note: Some ECII units do not have
the plastic spacers.

Figure 126 - Step 5 Remove screws and

plastic spacers

6. Remove the two Phillips screws that

attach the TE module on the back
bracket.

Figure 127 - Step 6 Remove two screws

attaching the TE module to the back bracket

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7. Remove the tubing from the TE module.

8. Lift the TE module out of the enclosure.

Figure 128 - Step 7 Remove tubing from TE

module

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33.2  TE Module Installation

1. Reconnect the tubing that goes from the
TE module to the pump and quick
disconnect (Figure 129).

Figure 129 - Step 1 Reconnect TE tubing

2. Install the TE Module onto the front

bracket with two #8-32 x 3/8” truss-
head screws (Figure 130).

Figure 130 - Step 2 Install 2 screws attaching

TE module to the front bracket

3. Install the TE Module with two #8-32 x

1/2” phillips screws and plastic spacers
onto the back bracket. Spacers are
installed between the TE module and
the back thermoelectric subassembly
bracket.

Figure 131 - Step 3 Install 2 screws and

spacers

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4. Follow instructions for section 32.2

Power Supply Installation, on page
93.

5. Follow instructions for section 31.2

Control Board Installation, on page
89.

6. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

7. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41.

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Fan Motor
34.0 Fan Motor Replacement
CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic board. Failure to do so
may result in damage to the board.

Tools:
Tools
• #2 Phillips screwdriver

• 11/32” open end wrench

Parts provided:

• fan motor

• filter (optional)

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34.1  Fan Motor Removal

1. Follow instructions for section 20.0
Rear Enclosure and Reservoir Lid
Replacement, on page 38.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Follow instructions for section 31.1

Control Board Removal, on page 88.

4. Follow instructions for section 32.1

Power Supply Removal, on page 91.

5. Follow instructions for section 33.1 TE

Module Removal, on page 97.

6. Follow instructions for section 35.1 Fan

Guard Removal, on page 107. Remove
the filter and filter retainer.

7. Remove the fan.

Figure 132 - Step 7 Remove the fan

8. The thermoelectric module (TE)

brackets will be loose when the screws
are removed. Set the brackets aside.

Figure 133 - Step 8 Remove brackets

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34.2  Fan Motor Installation

1. Place four #8-32 x 1” phillips, oval-head
screws into the fan guard screw holes.

Figure 134 - Step 1 Install four screws into

fan guard holes
2. Install the Gentherm air filter into the
filter retainer.

Figure 135 - Step 2 Place filter into retainer

3. Re-attach filter retainer to fan guard to

hold screws in place when you put the
fan motor on top of them.

Figure 136 - Step 3 Re-attach filter retainer

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4. Raise the bottom enclosure off of the

table. Place a support under the fan
guard so that the unit is suspended
(Figure 137).

Figure 137 - Step 4 Raise up off table

5. Place the TE brackets over the fan guard

screws.

Figure 138 - Step 5 Install brackets

6. Place the fan motor over the TE

brackets. The arrow showing air flow
direction must point toward the interior
of the device.

Figure 139 - Step 6 Place fan over TE

brackets on fan guard screws

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7. Position the fan wires (Figure 140).

8. Follow instructions for section 35.2 Fan

Guard Installation, on page 110.

9. Follow instructions for section 33.2 TE

Module Installation, on page 99.

10. Follow instructions for section 32.2

Power Supply Installation, on page
93.
Figure 140 - Step 7 Wire position
11. Follow instructions for section 31.2
Control Board Installation, on page
89.

12. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

13. Power on the unit and perform a leak

test (section 18.2 on page 28).

14. Remove any kinks in the water tubing.

15. Determine if the fan is blowing correctly

to the inside of the device by placing a
piece of paper below the filter inlet.

16. Perform the maintenance as required by

the Preventive Maintenance Inspection
Sheet in Table 5.

17. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41.

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Fan Guard & Filter

35.0 Fan Guard Replacement

CAUTION: Working with electronic
boards, plugs, and cables requires
delicate handling. Proper
Electrostatic Discharge (ESD)
procedures should be followed
during replacement of any
electronic board. Failure to do so
may result in damage to the board.

Tools:

• #2 Phillips screwdriver
Tools
• Long small tip slotted screwdriver

• Needle-nose pliers

Parts provided:

• Fan guard with Manufacturer Filter*

*A Gentherm filter is not supplied and must be

ordered separately.

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35.1  Fan Guard Removal

1. Follow instructions for section 20.1 Rear
Enclosure and Reservoir Lid Removal,
on page 39.

2. Follow instructions for section 21.0 Front

Enclosure Replacement, on page 43.

3. Use the slotted tip screwdriver to pry the

filter retainer from the base of the unit.
(Figure 141).

Figure 141 - Step 3 Pry filter cover off

4. Remove the plastic shield and set it

aside (Figure 142).

Figure 142 - Step 4 Remove shield

5. Set the unit on its feet with one corner

hanging over the edge of a secure work
surface. Use the #2 Phillips screwdriver
from beneath the unit to remove the four
screws and Keps nuts that secure the fan
motor and thermoelectric subassembly
to the fan guard. Use the slotted
screwdriver against a flat side of the
Keps nut to hold it stationary while
unscrewing the screw (Figure 143).
Figure 143 - Step 5 Unscrew four screws

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6. Remove screw and nut #1.

Figure 144 - Step 6 Remove Keps nut #1

7. Remove screw and nut #2.

Figure 145 - Step 7 Remove Keps nut #2

8. Remove screw and nut #3.

Figure 146 - Step 8 Remove Keps nut #3

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9. Remove screw and nut #4.

10. Dispose of the used fan guard, the

filter and the filter retainer according to
facility protocols.

Figure 147 - Step 9 Remove Keps nut #4

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35.2  Fan Guard Installation

Screws should be inserted and tightened in the
order shown.

1. Insert the first #8-32 x 1” oval-head

screw into the fan guard screw holes.
The screw should point in the opposite 4
direction from the filter. Insert them in
the order shown for best results (Figure 1
148). Use the Phillips screwdriver to
tighten the screw while holding the Keps 3
nut with the slotted screwdriver. Screw
#3 shown. 2

2. Insert screw #2, place a Keps nut on top,

and tighten. Figure 148 - Step 1 Insert screws in order.

3. Insert screw #3 through the fan guard

and mounting holes on the base
enclosure. Use the slotted screwdriver to
hold the nut in position, then place the
Keps nut over the top and slowly thread
the screw into the nut (Figure 149).

Figure 149 - Step 3 Hold Keps nut #3

4. Insert screw #4 through the fan guard

mounting holes (“Figure 150 - Step 4
Insert screw #4”).

Figure 150 - Step 4 Insert screw #4

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5. Hold it in place in the same manner as

screw #3, and thread the screw into the
nut (Figure 151).

Figure 151 - Step 5 Hold Keps nut #4

6. Place the plastic shield in position

(Figure 152).

Figure 152 - Step 6 Place plastic shield in

position

7. Place the Gentherm air filter inside the

filter retainer recess.

Figure 153 - Step 2 Place filter into retainer

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8. Place the filter retainer with filter into

position against the fan guard. Press
firmly on all four sides until it snaps into
place (Figure 154).

9. Follow instructions for section 21.2 Front

Enclosure Installation, on page 45.

10. Check for leaks with power on. See

section 18.2 on page 28.

11. Check for kinks in the water tubing. Figure 154 - Step 8 Re-attach filter retianer

12. Determine if the fan is blowing correctly

to the inside of the device by placing a
piece of paper below the filter inlet.

13. Perform the maintenance as defined in

the “Preventive Maintenance Inspection
Sheet” on page 117.

14. Follow instructions for section 20.2 Rear

Enclosure and Reservoir Lid Installation,
on page 41.

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36.0 Specifications
Physical
Approximate Dimensions: 30.5 cm (12 in.) Width
15.2 cm (6 in.) Depth
30.5 cm (12 in.) Height
Approximate Weight: 5.9 kg (13 lb.)
Approximate Hose Length: 1.83 m (6 ft.)
Filtration:
Outer Construction: Case material: G.E Cycoloy 6600 Plastic, Grey
Portability: Molded carrying handle
Connectors: Quick-Connect, Self
Sealing
Electrical System
Maximum Current: 3.5 Amps
Heating power: 650 W
115V Cord: 100 – 240 VAC, 50 -60Hz
Fuse: 5 Amp, Rated at 250Vm 5mm x 20mm, Time
Delay. 2x Line and Neutral
Power Cord: 115V & 100V – 3 Conductor, 16/18 AWG, 10’ Molded
Hospital Grade Plug. 230V – 3 x 1mm, 10A
Leakage Current: Under 300 Microamps
Shock Protection Type: Class 1
Degree of Shock Protection: Type B Applied Part
Circulating System
Reservoir Capacity 400ml (11.84 fl. oz.)
Reservoir Fluid Sterile water or water that has been passed through
a filter less than or equal to 0.22 microns
Fill Cap: Vented
Flow Rate (through pad): 68 LPH (18 GPH)
Water level indicator: Yes
Low Water Cut-off Switch: Yes
Storage: Dry
Degree of Protection: IPX0 Rated Equipment

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Safety System
Low Water 200ml (6.76 fl. oz.)
Low Temperature 2.2°C (36.0°F)
Warning Lights Low Temp and Low Water
Audible Indicators: Low Temp and Low Water
Classified to UL 60601-1: Yes
Classified to IEC 60601-1-2: Yes

36.1  Expected Service LIfe

The Electri-Cool II has a maximum lifetime of 5 years, when used with sterile water or water that
has been passed through a filter less than or equal to 0.22 microns.

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Guidance and manufacturer’s declaration – electromagnetic immunity

The Electri-Cool® II system is intended for use in the electromagnetic environment specified
below. The customer or the user of the Electri-Cool® II system should assure that it is used in
such an environment.

Immunity test IEC 60601 test Compliance Electromagnetic environment -

level level guidance

Portable and mobile RF

communications equipment should
be used no closer to any part of the
Electri-Cool® II system, including
cables, than the recommended
separation distance calculated
from the equation applicable to the
frequency of the transmitter.
Conducted RF 3 Vrms 3 Vrms
Recommended separation distance
IEC 61000- 150 kHz to 80
4-6 MHz d = 1,2√P

3 V/m
Radiated RF 3 V/m

IEC 61000-4-3 80 MHz to 2,5 d = 1,2√P 80 MHz to 800 MHz

GHz
d = 2,3√P 800 MHz to 2,5 GHz

Where P is the maximum output

power rating of the transmitter
in watts (W) according to the
transmitter manufacturer and d is the
recommended separation distance in
meters (m).

Field strengths from fixed RF

transmitters, as determined by an
electromagnetic site survey,a should
be less than the compliance level in
each frequency range.b

Interference may occur in the vicinity

of equipment marked with the
following symbol:

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Guidance and manufacturer’s declaration – electromagnetic immunity

Note 1: At 80 MHz and 800 MHz, the higher frequency range applies.

Note 2: These guidelines may not apply in all situations. Electromagnetic propagation is
affected by absorption and reflection from structures, objects and people.

a Field strengths from fixed transmitters, such as base stations for radio (cellular/cordless)
telephones and land mobile radios, amateur radio, AM and FM radio broadcast and TV
broadcast cannot be predicated theoretically with accuracy. To assess the electromagnetic
environment due to fixed RF transmitters, an electromagnetic site survey should be
considered. If the measure field strength in the location in which the Electri-Cool® II system
is used exceeds the applicable RF compliance level above, the Electri-Cool® II system should
be observed to verify normal operation. If abnormal performance is observed, additional
measures may be necessary, such as re-orienting or relocating the Electri-Cool® II system.

b Over the frequency range 150 kHz to 80 MHz, field strengths should be less than 3
V/m.

Recommended separation distances between portable and mobile RF communications

equipment and the Electri-Cool® II system

The Electri-Cool® II system is intended for use in an electromagnetic environment in which

radiated RF disturbances are controlled. The customer or the user of the Electri-Cool® II
system can help prevent electromagnetic interference by maintaining a minimum distance
between portable and mobile RF communications equipment (transmitters) and the Electri-
Cool® II system as recommended below, according to the maximum output power of the
communications equipment.

Rated maximum Separation distance according to frequency of transmitter

output power of m
transmitter
150 kHz to 80 MHz 80 MHz to 800 MHz 800 MHz to 2,5
W GHz
d = 1,2√P d = 1,2√P
d = 2,3√P

0,01 0,12 0,12 0,23

0,1 0,38 0,38 0,73

1 1,2 1,2 2,3

10 3,8 3,8 7,3

100 12 12 23

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For transmitters rated at a maximum output power not listed above, the recommended
separation distance (d) in meters (m) can be estimated using the equation applicable to the
frequency of the transmitter, where (P) is the maximum output power rating of the transmitter
in watts (W) according to the transmitter manufacturer.

Note 1: At 80 MHz and 800 MHz, the separation distance for the higher frequency range
applies.

Note 2: These guidelines may not apply in all situations. Electromagnetic propagation is
affected by absorption and reflection from structures, objects and people.

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36.2  Replacement Parts

All replacement parts for the Electri-Cool® II can be found below and must be purchased from
Gentherm.

Service is intended to be performed by a biomedical technician.

The Electri-Cool® II must be turned OFF and the power cord must be unplugged before
replacing any parts. The Electri-Cool® II system is isolated from the mains power supply by
unplugging the power cord at the Electri-Cool® II or at the outlet.

The exploded view of the Electri-Cool® II (Figure 6) below can be used to replace parts.
Replacement parts should be installed in the reverse order of removal unless instructions specify
otherwise.

Item No. Description Illustration

1 Bracket, Pump Shown in Figure 6
2 Lug Ground, Euro Shown in Figure 6
3 Ground Lug Washer, Green/Yellow Shown in Figure 6
Power Cord, 2.5 meters, 115V Not shown
4
Power Cord, 2.5 meters, 230/240V
5 Fuse Shown in Figure 6
6 Power Supply Shown in Figure 6
7 Control Board Shown in Figure 6
8 Float Switch Shown in Figure 6
9 TE Module Shown in Figure 6
10 Fan Guard Shown in Figure 6
11 Fan Motor Shown in Figure 6
12 Pump Shown in Figure 6
13 Insulation Tubing, 3/8” ID x 1/8 W Shown in Figure 6
14 Reservoir Shown in Figure 6
15 Reservoir Lid Shown in Figure 6
16 Enclosure Bottom Shown in Figure 6
17 Side Enclosure Front Shown in Figure 6
18 Side Enclosure Back Shown in Figure 6
19 Panel Mount Coupling Shown in Figure 6
20 Reservoir Collar Shown in Figure 6
21 18” Velcro Strap Not shown
22 PVC Tubing, 12 mm ID x 16 mm OD Shown in Figure 6
23 Rubber Feet Shown in Figure 6
24 Carton Not shown
25 Air Filter Shown in Figure 6

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Item No. Description Illustration

26 Reservoir Insulation Shown in Figure 6
27 Operation Manual Not shown
28 Membrane Control Panel Shown in Figure 6
29 Exterior Spec Label Not shown
30 Plastic Spacer Shown in Figure 6
31 Screw, 8-32 x ½” flat head SS Shown in Figure 6
32 8-32 x 1” Phillips Pan M/S 300 SS Shown in Figure 6
33 Kepnut, 8-32 Zinc Shown in Figure 6
34 Kepnut, Plated M6 Shown in Figure 6
35 #8 internal tooth L/W 410 SS Not shown
36 Screw, Filister Head, 10-24 x 3/4” Shown in Figure 6
37 Screw, Plastic 8-32 x1/4”, pan head Phillips Shown in Figure 6
38 Washer, Plastic #8 Shown in Figure 6
39 Wire Harness Assembly Shown in Figure 6
40 ½” Insulation Tubing Shown in Figure 6
41 PVC Tubing ¼” ID x 3/8” OD Clear Shown in Figure 6
42 Not Used
43 6 foot Insulated hose Not shown
44 Barbed Elbow, 25 x 25 Shown in Figure 6
45 Fuse Holder Shown in Figure 6
46 EMI Suppressor Core, .680 Not shown
47 EMI Suppressor Core, .993 Not shown
48 Exterior Logo Label Shown in Figure 6
49 Power Entry Shroud Shown in Figure 6

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Figure 156 - Exploded view

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Figure 157 - Wiring Schematic

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37.0 Fluid Circuit Disinfection/Dry Storage Procedure

Quarterly, at a minimum, the FLUID CIRCUIT DISINFECTION/DRY STORAGE PROCEDURE,
listed below, should be conducted.

CAUTION: For safe handling and use of chemicals, follow manufacturer guidelines for cleaning.

37.1  Draining the Electri-Cool II

See section 15.0 Draining the Reservoir, on page 22.

Always drain the Electri-Cool® II to a sanitary drain because bio-contaminants may be present in
the unit’s water supply.

37.2  Chemical Cleaning Circulation Chart

UNIT MODE TEMPERATURE CLEANING AGENT DURATION
Bleach 5 Minutes
11°C - 13°C
Electri-Cool® II Cooling Maranon H 5 Minutes
(51°F - 55°F)
Gigasept FF 15 Minutes

37.2.1 Disinfection/Dry Storage Procedure

The following procedure disinfects the fluid circuit in the Electri-Cool II.

Required tools and supplies:

• Household bleach

• Sterile water or water that has been passed through a filter less than or equal to 0.22 microns

• Appropriate AC electrical power.

Procedure:

1. Turn the unit off (“O” position).

2. Drain the water from the reservoir by tipping the unit forward over a sanitary drain.

3. Fill the reservoir with the appropriate amount of solution shown in the chart below.

Household Bleach (United States only) Water

29 Milliliters 321 Milliliters

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Gigasept FF (not available in the US) Water

35 Milliliters 315 Milliliters

(Product of Schulke & Mayr)
29 Milliliters of Maranon H 321 Milliliters
(Product of Ecolab)

4. Turn the unit on and circulate for 5 minutes.

5. Drain the unit as instructed in Step #1.

6. Rinse the unit three (3) times with sterile water or water that has been passed through a
filter less than or equal to 0.22 microns and circulate for 5 minutes.

7. After the third rinse, drain the unit and fill the reservoir with sterile water or water that has
been passed through a filter less than or equal to 0.22 microns and circulate.

8. Check the water at the hose with pH strips or other appropriate test method for detecting
bleach. If bleach is detected, repeat Steps 4-6.

9. Continue to fill the water reservoir with sterile water or water that has been passed
through a filter less than or equal to 0.22 microns.

10. If unit is being placed in dry storage, continue with procedure.

11. When all fluid has been removed from the unit, wipe unit clean.

12. Document unit maintenance.

When returning the unit to service:

• Verify the reservoir is properly filled with sterile water or water that has been passed through
a filter less than or equal to 0.22 microns.

• Perform all the checks as described in the respective manual, section 18.1 Flow Test, on page
28, through section 18.7 Water Temperature Low-Limit Thermistor Test, on page 30.

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38.0 Approvals
38.1  General Safety and Electrical Safety
• Electromagnetic Compatibility (EMC)

• Tested and passed in accordance with IEC 60601-1-2 EMC requirements

Classified by Underwriters Laboratory Inc.
® with respect to Electric Shock, Fire and
Mechanical Hazards only in accordance with
UL 60601-1, CAN/GENTHERM-C22.2 No.
601-1, 5R37

European

In compliance with the Medical Device Directive 93/42/EEC

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 Technology to the Next DegreeTM

Gentherm Medical LLC

12011 Mosteller Road
Cincinnati OH 45241 USA
www.gentherm.com

1-800-989-7373 Fax: 1-513-772-9119