Mini pump and Check Valve Solenoid
Upgrade your Dock Pro's existing Check Valve to the latest revision or replace your faulty Check Valve Solenoid
Table of Contents
Use Caution
Before beginning any repairs, please ensure you follow general electrostatic discharge (ESD) safety procedures to protect your device from damage.
Use Only Genuine Repair Parts
Overview
The mini pump moves water from the Dock Pro's removeable reservoir to the internal water loop. If the pump is not working properly the control unit will not fill.
Note that the mini pump and solenoid work together to allow the unit to fill properly. For this reason these instructions cover how to replace both the mini pump and the check valve (solenoid). The repair kit includes all of the components needed to update or replace both the pump and the earlier revision check valves.
The Check Valve Solenoid is a critical component in preventing the control unit from backflowing (and leaking via the reservoir socket). The Chilipad Pro contains a lot of water and when the the Chilipad is off the water (thanks to gravity) moves back into the control unit.
The first three revisions of the Chilipad Dock Pro contained mechanical check valves. Over time we have continued to improve this design in order to further improve reliability. The latest revision moves from a mechanical check valve to an electric Check Valve Solenoid. The solenoid is connected in parallel to the mini pump. When the minipump is powered on, the solenoid opens. When the mini pump is off, the solenoid is closed.
Regardless of check valve design it is critical that you follow proper maintenance procedures to prevent leaks and to keep the unit filling properly.
This repair kit also comes with a replacement mini pump. If you mini pump is working properly then you do not need to replace it. We include it as one kit because these parts are all interconnected and need to be disconnected as part of the repair process.
What you'll need
Parts
Tools
| Tool 1 | Phillips screwdriver |
| Tool 2 | Wire cutters |
| Supplies | System Cleaner Packet |
| Supplies | Bucket, Distilled Water, Clean Damp Cloth |
Ready the Dock Pro for Disassembly
Click to expand instructions
Unplug the Power Cord: Disconnect the power cord from the Dock Pro.
Unplug the Water Feed Hose: Disconnect the water feed hose from the Dock Pro. *Note: Keep a rag handy for any spilled water.
Remove the Water Reservoir: Take the water reservoir out of its housing.
Dump the Water: Remove the reservoir, then detach the lid and transfer the water into a bucket..
Attach the Drain Key: Secure the Drain Key to the Dock Pro.
Drain Water: Position the Dock Pro over a bucket, holding it at an angle with the drain key pointed downward to drain water from the unit.
Drain remaining water: Align the Dock Pro reservoir opening over the bucket to pour out any remaining water from the unit.
Flip the Dock Pro: Turn the Dock Pro on its side to access the screws.
Remove the Screws: Using a screwdriver, take out the 8 screws.
Reposition the Dock Pro: Once the screws are removed, set the Dock Pro back upright.
Lift the Cover: Lift the cover partially away from the Dock Pro to Identify the display cable connected to the control board, identify the display cable connected to the control board.
Disconnect the Display Cable: Carefully detach it, and then set the Dock Pro housing aside.
Mini Pump Replacement
Cut Zip Ties: Cut the zip ties that are bundling the cables.
Unplug Power Cables: Unplug the Air Solenoid power cables from the control board.
Unplug Water Level Sensor: Unplug the Reservoir Water Level Sensor cables from the control board.
Disconnect Air Line: Unplug the air line from the Air Solenoid by cutting the zip.
Remove Reservoir Housing: Unscrew the 3 screws holding the Reservoir Housing to the base to remove it.
Remove Water Line from Reservoir Outlet: Cut the zip tie holding the water line connected to the Reservoir Outlet and remove the hose.
Set Reservoir Water Aside: Set the Reservoir Water aside for later use.
Please note there are several check valve BOM revisions.
Revision A
Revision B
Revision C
Revision D
Remove Water Line from Accumulator: Cut the zip tie holding the water line connected to the Accumulator and remove the hose.
Remove Mini Pump: Unscrew the 2 screws holding the mini pump to the base and remove the pump.
Unplug Mini Pump Cables: Unplug the Reservoir mini pump cable from the control board.
Connect Water Hose to New Mini Pump (accumulator side): Attach the water hose to the new mini pump connected to the accumulator. Secure the connection with a zip tie.
Connect Water Hose to Mini Pump (solenoid): Install the water hose to the mini pump that connects to the solenoid. Secure the connection with a zip tie.
Mount the Mini Pump: Use two screws to secure the mini pump to the base.
Connect Water Hose from Mini Pump to accumulator: Attach the water hose from the mini pump to the accumulator. Secure the connection with a zip tie.
Ready zip tie : Position the zip tie for tightening.
*If you are only replacing the mini pump, please scroll to the “Connect Power Cables:” step below.
Foam block: Remove the tape backing from the foam block and place the block in front of the mini pump.
Check Valve Solenoid Replacement
Ready Check Valve Solenoid: Locate the preinstalled water hose and connect it to the water reservoir side.
Attach Water Hose from Solenoid to Reservoir Outlet: Connect the water hose from the solenoid to the reservoir outlet. Secure the connection with a zip tie.
Check Valve Solenoid to Mini Pump: Connect the Check Valve Solenoid to the Mini Pump.
Secure water hose: : Secure water hose connection with a zip tie.
Secure Mount Reservoir Housing: Screw the 3 screws holding the Reservoir Housing to the base.
Connect Power Cables: Plug both the mini pump and solenoid power cables into the Y power splitter.
Connect Y Power Splitter to Control Board: Plug the Y power splitter into the control board.
Connect Air Line: Connect air line from the air solenoid to reservoir housing. Secure the connection with a zip tie.
Plug Power Cables: Plug the Air Solenoid power cables to the control board.
Plug Water Level Sensor: Pug the Reservoir Water Level Sensor cables to the control board.
Secure the cable bundle: Combine cables by using the provided zip ties.
Reassembling the Dock Pro
Click to expand instructions
Retrieve the Dock Pro Housing: Take the Dock Pro housing that was previously set aside.
Reconnect the Display Cable: Carefully attach the display cable back to the control board.
Lower the Cover: Gently lower the cover back into place on the Dock Pro.
Reposition the Dock Pro: Set the Dock Pro upright.
Reinsert the Screws: Using a screwdriver, insert and tighten the 8 screws securely.
Flip the Dock Pro: Turn the Dock Pro back to its original upright position.
Reattach the Water Reservoir: Place the water reservoir back into its housing.
Reconnect the Water Feed Hose: Attach the water feed hose back to the Dock Pro.
Plug in the Power Cord: Reconnect the power cord to the Dock Pro.
Instructions for Refilling Your Dock Pro
- Open the reservoir and add one packet of System Cleaner.
- Fill the reservoir with distilled water.
- Using a clean damp cloth, wipe down the control unit to keep it clean and functioning properly.
- Power up the Dock Pro and check for leaks.
- Refill the reservoir as necessary until the system is completely filled.
- Reattach the cap to seal the reservoir.
If you have any questions or concerns, don't hesitate to get in touch with our Customer Experience Team.