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HUNTLEIGH Mini Infusion Pump Service Manual

1. Figure 23 Snap lock Connectors Table 27 Snap lock Connectors Part Number Description Qty 10 500350 Connector Panel Female 1 4 Flow 20 504316 Connector Panel Male 1 4 Flow 500361 Tube Sil Blue ID 6 OD 10 24 LG 1 500360 Tube Sil Blue ID 6 OD 10 15LG 1 Chap 3 Issue 2 Page 44 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 41 Replacing the Snap lock Connectors Note Older versions have a pump connectors moulded within the side panel and are not replaceable 41 1 Remove pressure control module vvith side panel Refer to Section 29 1 to 29 7 41 2 Refer to Fig 15 disconnect the three signal connectors Fig 15 Item 30 and the power wires from the PCB 41 3 Remove screw Fig 15 Item 10 and remove the PCB 41 4 Undo locknut and withdraw connector through side panel with tube 41 5 Remove tube from connector 41 6 Replace with the same type Replacement is the reverse of the above procedure Ensure that the snap lock release clip on the female lower connector is pointing toward the rear of the case Make sure the locknut is on the pressure module before the connector and tube is inserted Issue 2 Chap 3 Nov 2001 SER0004 Page 45 Pump Repair Mini Pump Service Manual 42 Removing the Front Case 42 1 Remove the pressure control knob Page 3 Section 2 42 2 Disassemble the rear case Page 5 Sect
2. Figure 3 Removing and Replacing the Pump Filter Table 7 Pump Filter Part List 500340 Felt Filter FAS223 Pan Head Screw PT 3 Dia x 10 Pozi FAS225 Pan Head Screw PT 3 Dia x 16 Pozi Chap 3 Issue 2 Page 4 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 4 Disassembling the Pump Filter 4 1 Remove the centre screw Fig 3 Item 40 retaining the filter plate Fig 3 Item 20 in the rear case Fig 3 Item 30 4 2 Carefully remove the filter plate and felt filter Fig 3 Item 10 from the rear case Discard the old filter 5 Assembling the Pump Filter 5 1 Install a new filter Fig 3 Item 10 in the filter plate Fig 3 Item 20 ensuring that the curved edge is at the top 5 2 Ensure that the filter is correctly positioned over the boss in the filter plate then fit the filter plate to the rear case Fig 3 Item 30 and secure with the screw Fig 3 Item 40 6 Disassembling the Rear Case Note It is necessary to remove the rear case from the front case to allow access to all internal pump connections 6 1 Remove the front panel control knob Refer to Page 3 Section 2 6 2 Place the pump on a flat clean surface with the case front face down 6 3 Unscrew and remove the four corner screws Fig 3 Item 50 6 4 Carefully remove the rear case assembly Fig 3 Item 30 from the case front 7 Assembling the Rear Case 7 1 Assembly of the rear case is in the reverse order of disassembly Issue 2 Chap 3 Nov 2
3. This manual contains information on maintenance servicing repair troubleshooting and testing for the range of pressure regulated pump units pump models within the range are as follows e AlphaXcell Electronic AlphaXcell Mechanical e AlphaRelief Electronic e Aura Electronic e AlphaTrancell Mechanical e AlphaBed Mechanical e AlphaCare Mechanical Pump models are available for use world wide model codes are shown in Table 1 while for country codes and power supply details refer to Table 2 Table 1 Product Range Distribution Model Z Code CountryCode AlphaXcell Mechanical ALX Aura ALS AlphaTrancell ALT AlphaCare ALC AlphaBed ALB Issue 2 Chap 1 Nov 2001 SER0004 Page 1 Introduction Mini Pump Service Manual Table 2 Country Codes Power Supplies Country Code Voltage Volts AC Freguency Hz o o s rosa ao IEA o reso ao s m reso o oo Warnings Cautions and Notes WARNINGS given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in death injury or other serious adverse reactions Cautions given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in eguipment failure or damage Notes given in this manual are used to explain or amplify a procedure or condition WARNINGS BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES ENSURE THAT THE
4. Mini Pump Service Manual Pump Repair 2 Removing the Pressure Control Knob Note Removing the control knob avoids possible damage and allows the pump to sit on a flat surface without rocking 2 1 Locate the slot at the rear of knob Fig 2 Item 10 and insert a 3 mm flatpoint screwdriver 2 2 Lever the screwdriver upward to lift the knob off the three retaining prongs 3 Installing the Pressure Control Knob Note When installing the pressure control knob ensure that the small prong sits in its own housing Then the two larger prongs will line up correctly Aura Pin fitted Turn knob arbour clockwise to it s full extent Fit control knob in the position shown below oO ENSURE 90 MOVEMENT SMALL PRONG AlphaRelief AlphaBed AlphaCare AlphaTrancell ALT10 No pin fitted Turn knob arbour counter clockwise to it s full extent Fit control knob in the position shown below Z ENSURE SMALL PRONG 4 270 MOVEMENT AlphaXcell AlphaTrancell ALT01 09 Pin fitted Turn knob arbour counter clockwise to it s full extent Fit control knob in the position shown below Z ENSURE SMALL PRONG RO 1800 MOVEMENT 3 1 Carefully position the knob Fig 2 Item 10 so that the prongs are correctly aligned with the recesses in the knob arbour Fig 2 Item 20 3 2 Press the knob into place on the arbour and ensure that it is correctly seated Issue 2 Chap 3 Nov 2001 SER0004 Page 3 Pump Repair Mini Pump Service Manual
5. 165310 165310 FAS160 FASO51 FAS095 FAS054 500347 Chap 7 Page 2 Mini Pump Service Manual Description e Screw Hex Head 4BA x 3 4 e 4BA Full Nut e e Valve Body Washer e e Valve Flap Valve Flap Securing Pad e E Stack e Pan Head Screw M3 x 25 mm Pozi e Washer 6BA Anti Vib e Coil Assembly 230V 50Hz black white leads Coil Assembly 110V 60Hz grey leads Coil Assembly 100V 50 60Hz blue leads e Grommet e Compressor Case e Compressor Lid e Compressor Gasket e Silencer Bag F Tube Connector Filter Retaining Clip Inlet Filter Compressor Mounting Bracket New style AV Mount New style AV Mount Old style Upper Bump Stop Lower Bump Stop Washer M4 Plain Screw Pan Head Pozi M4 x 6 mm Screw Pan Head Pozi M4 x 10 mm Screw Countersunk Pozi M4 x 12 mm Pressure Control Module Terminal Block 5 way SER0004 Fig ltem 12 30 12 40 12 50 12 60 12 70 13 10 13 20 13 30 13 40 13 50 13 60 10 20 10 40 10 50 6 20 10 60 6 30 6 40 7 10 7 20 8 20 9 10 9 20 9 40 9 50 9 60 10 30 14 10 18 30 Qty 2 PD N N N N Issue 2 Nov 2001 Part Number BP196 500362 FAS145 FAS223 500315 500328 151309 500338 FAS224 500347 FAS225 500304 500312 500318 550303 500341 151339 PRE022 500103 500355 403306 FAS225 500305 500411 500339 500349 FAS223 500097 500098 500099 151409 Issue 2 Nov 2001 Mini
6. EGUIPMENT HAS BEEN ADEQUATELY DECONTAMINA TED VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC CAN IN CERTAIN CIRCUMSTANCES BE LETHAL WHEN WORKING ON EGUIPMENT REGUIRING EXPOSURE TO LIVE UNPROTECTED CONDUCTORS WHERE SUCH VOLTAGES ARE PRESENT EXTREME CARE MUST BE EXERCISED WHEN AN UNSERVICEABLE MAINS LEAD POWER CORD FITTED WITHA NON REWIREABLE PLUG IS REMOVED FROM THIS EGUIPMENT THE LEAD CORD AND THE PLUG MUST BE DESTROYED AND DISPOSED OF SAFELY TO AVOID THE DANGER OF ELECTRIC SHOCK THE PLUG MUST NEVER BE INSERTED IN ANY POWER OUTLET Chap 1 Issue 2 Page 2 SER0004 Nov 2001 Mini Pump Service Manual Introduction 2 Technical Description The pressure regulated pump units listed in section 1 provide pressurised air for alternating pressure mattress systems which are used in aiding the prevention treatment and management of pressure ulcers Pressurised air is fed to a range of support systems mattresses seat cushions etc which support patients at risk of developing pressure ulcers All pumps are self contained units powered by the single phase mains power supply Low air pressure and power failure alarm functions are included in some models and pump output pressure is adjustable by means of a rotary control mounted on the unit front panel Operating Principle Refer to Figure 1 for details of the pneumatic circuit All pumps have two pressurised air outlets air from the outlets is fed to separate cells or groups of cells
7. Gearbox Rotor Stator Assembly Part List continued Part Number Description 500319 Stator Gasket 1 500418 Stator Gasket Restricted 1 500356 Rotor Drive Cup 1 500322 Pin Rotor Drive 500354 Washer Starlock O D 21 mm 500358 Spring Comp 1 6 Diameter FL 22 36 TIMO17 Oil Seal Cap 37 Replacing the Synchronous Motor Gearbox Rotor Stator Assembly Note It is not necessary to remove the side panel assembly from the pressure control module 37 1 Remove the pressure control module from the pump case as described in Section 29 37 2 Remove any relevant cable ties 37 3 Identify the synchronous motor electrical lead from the terminal block terminals 1 and 2 Fig 18 Item 30 remove the relevant cable ties and release the synchronous motor electrical lead 37 4 Remove the two screws securing the gearbox motor Fig 21 Item 10 37 5 Carefully remove the synchronous motor rotor and stator Fig 21 Items 20 30 and 40 from the pressure control module Remove the felt rotor silencer Fig 21 Item 50 from the rotor Remove the stator gasket Fig 21 Item 60 from the pressure assembly module 37 6 Depress the motor drive cup Fig 21 Item 70 toward the motor and remove the drive shaft pin Fig 21 Item 80 37 7 Carefully remove the rotor drive cup star washer Fig 21 Item 90 spring Fig 21 Item 100 and oil seal cap Fig 21 Item 110 from the motor 37 8 Replace any faulty parts with same type 37 9 Discard the s
8. Pump Service Manual Description Cable Tie Tube Sil ID 3 16 135 mm 5 mm LG Screw 3 Dia x 8 mm Pozi Pan Head PT Screw 3 Dia x 10 mm Pozi Pan Head PT Panel Side Colder Panel Side Push On Fixing Cap Micro switch Sub Min 230 V 0 1A Screw 2 2 Dia x 14 mm Pozi Pan Head PT Terminal Block 5 Way Screw 3 Dia x 16 mm Pozi Pan Head PT Knob Control Arbour Upper Pressure Control Flap Pivot Pin Pressure Control Lower Pressure Control Flap Spring 0 024 Diameter Pressure Control Disc Rubber Valve Disc Bag Pressure with Restrictor Assembly Screw M3 x16 mm Socket Cap Hd Black Restrictor Aura Pumps Only Control Adjustment Screw 3 Dia x 16 mm Pozi Pan Head PT Knob Control Cam Cup Arbour Drive Spring Spring Comp 1 07 Diameter Pressure Assembly Module Screw 3 Dia x 10 mm Pozi Pan Head Gearbox 240V and Ferrule Assembly Gearbox 120V and Ferrule Assembly Gearbox 100V and Ferrule Assembly Motor Gearbox 100V 50 Hz 1 10 RPM SER0004 Fig ltem 14 20 14 30 14 40 14 50 14 60 14 70 14 80 18 10 18 20 18 30 18 40 19 10 20 60 19 20 19 30 19 40 19 50 19 60 19 70 19 80 19 90 19 100 20 10 20 20 20 30 20 40 20 50 21 10 21 20 Parts list Qty Chap 7 Page 3 Parts list Part Number 500308 500307 500332 500319 500418 500356 500322 500354 500358 TIMO17 500346 500345 151457 FAS083 500324 500373 500371 FAS083 500351 500343 5
9. Replacement is the reverse procedure of the above Ensure the correct orientation of components Connect the wires to the terminal block and the Micro switch in accordance with the wiring diagram for the mechanical version of the pump unit Chap 4 Fig 25 Issue 2 Chap 3 Nov 2001 SER0004 Page 33 Pump Repair Mini Pump Service Manual Ik Z obo O Figure 18 Replacing the Micro switch and Terminal Block Table 22 Micro switch and Terminal Block Part List Part Number Description 500338 Micro switch Sub Min 230 V 0 1A 500347 Terminal Block 5 Way ESE FAS225 Screw 3 Dia x 16 mm Pozi Pan Head PT Chap 3 Issue 2 Page 34 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 33 Replacing the Microswitch Note It is not necessary to remove the pressure control module from the pump case 33 1 Pull off connectors from the Micro switch terminals 1 and 3 Fig 18 Item 10 33 2 Release two screws Fig 18 Item 20 and remove the Micro switch from the pressure control module 33 3 Replacement is the reverse of the above procedure 34 Replacing the Terminal Block Note It is not necessary to remove the pressure control module from the pump case 34 1 Disconnect all wires from the terminal block Fig 18 Item 30 34 2 Release t
10. all pumps Wait indicator does not go out not allowing the system to pressurize Applicable to ALR 01 10 ALX 01 10 Mains Power Fail indicators audible and visual are active Applicable to ALR 01 10 ALX 01 10 ALS 01 10 Issue 2 Nov 2001 CPR not inserted mattress only Tubes kinked Pump not switched on No pump output Tubes not correctly fitted CPR not inserted mattress only Tubes not correctly fitted Leakage CPR not inserted mattress only Tubes not correctly fitted Leakage Mains power failure has occurred The mains power lead has been removed from the wall socket SER0004 Check CPR See Mattress Service Manual SER0005 Check Check Check See Pump not operating below Check Check CPR See Mattress Service Manual SER0005 Check Check See Mattress Service Manual SER0005 Check CPR See Mattress Service Manual SER0005 Check Check CPR See Mattress Service Manual SER0005 Chap 4 Page 1 Troubleshooting Mini Pump Service Manual Table 29 Troubleshooting continued Mains Power Fail indicator There has been a mains power Check if electrical plug is remains illuminated but failure but power has been restored correctly fitted and if pump is there is no audible alarm running correctly Applicable to ALR 01 10 ALX 01 10 ALS 01 10 Pump is very noisy and or is System is damaged or dirty Check compressor causing exc
11. checks by dismantling the pump 3 Low Pressure Alarm Fault sao ss i poda wee do don po a ae a Ed a de Mi 4 Air Not Alternating continuous pressurefaut 4 Loss of Electrical Power 4 Contents Issue 2 Page ii SER0004 Nov 2001 Mini Pump Service Manual Contents Circuit Diagrams see a e e e pe e ha ed A qua Red Cu bab ea oe A 5 CHAPTER 5 TESUNO i ae EE eee See OR eo we ee El des 1 Pump Flow Pressure and FunctionTest 1 Electrical Testing crab ee Ee Se qm ER we ate de ges ee 5 PCB Functional Tests Electrical UnitsOnI 6 Functional Tests MechanicalUnitsOnly 7 CHAPTER 6 Technical specification LL 1 CHAPTER 7 Parts Sts cas 6 8 66 oe Oa be A A AAN AAA 1 CHAPTER 8 Service Contact Details 1 Issue 2 Contents Nov 2001 SER0004 Page iii Contents Mini Pump Service Manual Contents Issue 2 Page iv SER0004 Nov 2001 Mini Pump Service Manual Introduction CHAPTER 1 INTRODUCTION 1 About This Manual Huntleigh Healthcare strongly recommend that their eguipment is only serviced by trained personnel and provide courses for customers who wish to become licensed to service their own eguipment In no event will Huntleigh Healthcare be responsible for any service performed by customers or third parties
12. described in Section 26 2 and 26 3 27 3 Disconnect the compressor electrical wires from the terminal block Carefully cut the cable ties from the pneumatic tubing cable loom as required 27 4 Feed the compressor electrical wires through the compressor case cable grommet Fig 13 Item 50 27 5 Remove the E stack coil assembly from the compressor case Fig 13 Item 60 and carefully separate the coil from the E stack 27 6 Replace the coil assembly by reversing the operations carried out in Section 27 5 27 4 27 3 and 27 2 fit new cable ties where required 27 7 Fit a new silencer bag and gasket then replace the compressor lid Refer to Page 19 and reverse the operations carried out in Section 22 4 22 3 and 22 2 27 8 Refit the compressor AV bracket assembly to the pump case Refer to Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts 28 Replacing the Compressor Assembly 28 1 Disconnect the compressor electrical wires as described in Section 27 3 Issue 2 Chap 3 Nov 2001 SER0004 Page 25 Pump Repair Mini Pump Service Manual 28 2 Remove the compressor air inlet filter and clip from the F tube connector then disconnect the F tube connector from the silencer bag outlet tubes Refer to Page 11 Section 12 1 12 2 12 3 and 12 4 28 3 Remove the compressor AV bracket assembly from the pump case Refer to Page 13 Section 14 1 14 2 and 14 3 ne
13. in the mattress or cushion via a rotary valve The support cells are continuously inflated and deflated utilising a ten minute cycle During the cycle air is pumped from one outlet for 4 minutes 10 seconds there is then a period of 50 seconds where air is pumped from both outlets Air is then pumped from the other outlet for 4 minutes 10 seconds followed by a 50 second period where air is supplied from both outlets During the period when air is suppled from a single outlet to one group of cells the opposing outlet is vented to atmosphere deflating the corresponding cells Issue 2 Chap 1 Nov 2001 SER0004 Page 3 Introduction Mini Pump Service Manual COMPRESSOR PRESSURE CONTROL rd mno iu 5 iz zun 4 I OUTLET ROTOR STATOR l PORTS I PRESSURE CONTROL MODULE J MICROSWITCH HEAD SECTION STATIC ALTERNATING CELLS Va O 1 AXB AKB B B BMG B INFLATED RO808809008888988 mar RR RR RR ERC GE CC CORS CC OR CCOO EXCEPTION Aura has 9 alternating cells but no static cells N A Figure 1 Pneumatic Diagram and Pressure Variations For the Aura mini pump small adjustments can be made to cell pressure using the comfort control knob on the pump unit This is a patient comfort feature to make small adjustments to the softness or firmness of the support cells All other mini pumps have a pressure adjustment control that must be set to the patient weight in accordance with the instructions g
14. the pump Refer to Page 5 Section 7 17 5 Install the pressure control knob Refer to Page 3 Section 3 Issue 2 Chap 3 Nov 2001 SER0004 Page 15 Mini Pump Service Manual Pump Repair Figure 9 Replacing Mounting Brackets and Bump Stops Issue 2 Nov 2001 SER0004 Mini Pump Service Manual Pump Repair Table 13 Compressor Mounting Brackets and Bump Stops Part List 10 165310 Upper Bump Stop 1 20 165310 Lower Bump Stop 1 500124 Compressor Mounting Bracket New Style 1 30 O na cen uring Brat sme Teo rasos sown Pan Head Pod MAJ tom 18 Removing the Compressor Mounting Bracket 18 1 Remove the compressor AV bracket assembly from the pump case and disassemble AV mounts as described on Page 13 Section 14 new style AV mounts or Page 15 Section 16 old style AV mounts Section 16 4 should be omitted if old style AV mounts are not to be replaced Note Figure 7 Illustrates the new style AV mount system Compressor mounting bracket to compressor assembly methods are the same for both old and new style AV mount systems 18 2 Remove screw washer and lower bump stop Fig 9 Items 50 40 20 from the compressor mounting bracket Fig 9 Item 30 18 3 Remove three screws Fig 9 Item 60 and detach the mounting bracket from the compressor 19 Installing the Compressor Mounting Bracket 19 1 Fit replacement mounting bracket Fig 9 Item 30 same type if required to the compressor Ens
15. the pump case as described in Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts Figure 10 Compressor Silencer Bag Chap 3 Issue 2 Page 18 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair Table 14 Compressor Silencer Bag Part List 502003 Compressor Assy 230V 50Hz 11K T o 502002 Compressor Assy 110V 60Hz 5K T USA 502007 Compressor Assy 100V 50 60Hz 4 5K T Japan N 502301 Compressor Lid FAS054 Screw Countersunk Pozi M4 x 12 mm BP032 Compressor Gasket 502055 Silencer Bag 500320 F Tube Connector o m N A Silencer Bag Outlet Tubes JU m mn N A Silencer Bag Inlet Tubes 22 Replacing the Compressor Silencer Bag 22 1 Remove the compressor AV bracket assembly from the pump case Refer to Page 13 Section 14 1 14 2 and 14 3 new style AV mounts or Page 15 Section 16 1 16 2 and 16 3 old style AV mounts 22 2 Remove four screws Fig 10 Item 30 and carefully lift off the compressor lid Fig 10 Item 20 and gasket Fig 10 Item 40 from the compressor assembly Fig 10 Item 10 Discard the gasket 22 3 Disconnect the outlet tubes Fig 10 Item 70 of the silencer bag Fig 10 Item 50 from the F tube connector Fig 10 Item 60 22 4 Disconnect the inlet tubes Fig 10 Item 80 of the silencer bag from the valve bodies 22 5 Fit a new silencer bag and gasket then replace the compres
16. 001 SER0004 Page 5 Pump Repair Mini Pump Service Manual Figure 4 Replacing the New Style Bed Hook Table 8 New Style Bed Hook Part List item Part Number 500495 Bed Hook New Style 20 500496 Hook Plate Left Hand ME 30 500497 Hook Plate Right Hand ME ao FAS223 Pan Head screw PT 3 Dia x 10 MES 500381 Rubber foot MES Chap 3 Issue 2 Page 6 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 8 Disassembling the New Style Bed Hook 8 1 Remove the pressure control knob from the pump Refer to Page 3 Section 2 8 2 Remove the pump rear case Refer to Page 5 Section 6 Note The bed hook brackets are right and left handed 8 3 Holda hook plate Fig 4 Item 20 or 30 in position and remove the four securing screws Fig 4 Item 40 from the inside of the pump rear case Release the hook plate from the rear case and lift clear 8 4 If necessary repeat Section 8 3 to remove the other hook plate and bed hook Fig 4 Item 10 9 Installing the New Style Bed Hook Note Replacement Old Style Bed Hooks are no longer available The Old Style Rear Case assembly will not accommodate the New Style Bed Hook so where Old Style Bed Hooks must be replaced it will be necessary to obtain all the parts listed in Table 8 plus the rear case Item 30 in Table 6 Note For step 9 2 remember to place the left hand bracket on the right and the right ha
17. 00359 198315 BP532 CAS041 BP087 CAS020 Chap 7 Page 4 Mini Pump Service Manual Description Rotor Module Stator Module Felt Rotor Silencer Stator Gasket Stator Gasket Restricted Rotor Drive Cup Pin Rotor Drive Washer Starlock O D 21 mm Spring Comp 1 6 Diameter FL 22 36 Oil Seal Cap PCB Electronic versions only PCB Alarm Monitoring 230 V PCB Alarm Monitoring 100 120 V e Battery Screw No 6 x 5 16 Pozi Pan Head PT Neon Indicator Mechanical versions only Plate Neon Mounting Neon Assembly Red 230 V Neon Assembly Red 110 V Screw No 6 x 5 16 Pozi Pan Head PT Mains Power Switch and Supply Switch Mains Power Rocker 230 V Black All electronic pumps Switch Mains Power Rocker 230 V Green Illuminated Switch Mains Power Rocker 110 V Green Illuminated Grommet Cordset Standard Moulded UK Cable Mains Power Cable European Shuko Socket Mains Power Cable USA 2 pin Mains Power Cable Japan 2 pin SER0004 Fig ltem 21 30 21 40 21 50 21 60 21 70 21 80 21 90 21 100 21 110 15 20 16 10 15 10 17 20 17 30 17 10 22 10 22 20 22 30 Qty Issue 2 Nov 2001 Part Number BP171 500344 CAS011 500350 504316 500361 500360 500135 BP043 502055 502053 502054 500340 500417 Issue 2 Nov 2001 Mini Pump Service Manual Description Mains Power Cable Australia Fuse Holder Fuselink 20 x 5 mm 500 mA OB Snap lock Co
18. 0316 500318 500484 500304 500317 500340 500327 FAS223 FAS225 500495 500496 500497 FAS223 500381 502003 502002 502007 502054 BP215 502053 BP214 BP043 BP554 BP351 Issue 2 Nov 2001 Mini Pump Service Manual CHAPTER 7 PARTS LIST Description Front and Rear Case Front Case Pin if fitted Control Rnob MR2 Rnob Arbour Rear Case Felt Filter Filter Plate Pan Head Screw PT 3 Dia x 10 Pozi Pan Head Screw PT 3 Dia x 16 Pozi Bed Hook New Style Hook Plate Left Hand Hook Plate Right Hand Pan Head screw PT 3 Dia x 10 Rubber foot Label Sets See Chap 3 Page 47 Table 28 Compressor Assembly Compressor Assy 230V 50Hz 11K T Compressor Assy 110V 60Hz 5K T USA Compressor Assy 100V 50 60Hz 4 5K T Japan e Bellows Armature Assembly Left Hand 230V 50Hz Bellows Armature Assembly Left Hand 110V 60Hz e Bellows Armature Assembly Right Hand 230V 50Hz Bellows Armature Assembly Right Hand 110V 60Hz e Armature Pivot e Valve Body Assy Blue e e Valve Body SER0004 Fig ltem 2 40 2 30 2 10 2 20 3 30 3 10 3 20 3 40 3 50 4 10 4 20 4 30 4 40 4 50 6 10 10 10 6 10 10 10 6 10 10 10 11 10 11 20 11 30 11 40 12 10 12 20 Parts list Qty Chap 7 Page 1 Parts list Part Number FAS027 FAS013 BP039 BP037 BP038 BP028 FAS048 FAS002 502050 502062 BP275 165303 502304 502301 BP032 502055 500320 500410 500417 500124 500416 198375
19. 3 Disassembling the Pump Filter gt s eso L L L 5 Assembling the Pump Filer rew aa oe ed eo ee es 5 Disassembling the Rear Case 5 Assembling the Rear Case 2 LL Le 5 Disassembling the New Style Bed Hook 7 Installing the New Style Bed Hook 7 Removing the Old Style Bed Hook 2 2 k k a 9 Installing the Old Style Bed Hook x sei a Bowe ee a da a ew a ae ca A AA 9 Removing the Compressor Inlet Filter 2 ee 11 Installing the Compressor InletFiler 11 Removing the New Style AVMounts 13 Replacing the New Style AV Mounts 13 Removing the Old Style AV Mounts 15 Issue 2 Contents Nov 2001 SER0004 Page i Contents Mini Pump Service Manual Installing the Old Style AV Mounts 15 Removing the Compressor Mounting Bracket 17 Installing the Compressor Mounting Bracket 17 Removing the Compressor Bump Stops 17 Installing the Compressor BUMPStops 18 Replacing the Compressor SilencerBag 19 Replacing the Bellows Armature Assemblies and Pivots 21 Replacing the Compressor Armature Pivots 21 Replacing the
20. 4 10 Figure 8 Replacing the Old Style AV Mounts Table 12 Old Style AV Mounts Part List Chap 3 Issue 2 Page 14 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 16 Removing the Old Style AV Mounts Note Replacements are not available for the old style AV mounts 16 1 Remove the pressure control knob from the pump Refer to Page 3 Section 2 16 2 Remove the rear case assembly Refer to Page 5 Section 6 16 3 Remove the securing spacers Fig 8 Item 70 and carefully lift the compressor Fig 8 Item 50 and AV bracket assembly Fig 8 Items 10 20 30 40 60 from the mountings 16 4 Release the to AV mount nuts Fig 8 Item 30 and washers Fig 8 Item 40 and remove the two AV mounting brackets Fig 8 Item 10 from the AV mounts Fig 8 Item 20 16 5 Release the bottom AV mount nuts and washers and remove the four AV mounts from the compressor mounting bracket Fig 8 Item 60 17 Installing the Old Style AV Mounts 17 1 Fit four replacement AV mounts Fig 8 Item 20 to the compressor mounting bracket Fig 8 Item 60 and secure with washers Fig 8 Item 40 and nuts Fig 8 Item 30 17 2 Fit the two AV mounting brackets Fig 8 Item 10 to the AV mounts and secure with washers and nuts 17 3 Carefully fit the compressor Fig 8 Item 50 and AV bracket assembly Fig 8 Items 10 20 30 40 60 to the mountings in the pump case and fit securing spacers Fig 8 Item 70 17 4 Assemble the rear case to
21. 7 11 80 Holland Huntleigh Healthcare BV Flevolaan 8 1382 JZ Weesp Holland T 31 294 415001 F 31 294 430475 India Indian Liaison Office 61 Goldmist Gulmohar Road Juha Scheme Mumbai 400 049 India Middle East Huntleigh Technology PLC 307 Sh Zayed Road Dubai United Arab Emirates New Zealand Huntleigh Healthcare Ltd Unit 6 38 Eaglehurst Road Ellerslie Auckland NZ T 464 9 525 2488 F 64 9 525 2433 Singapore Huntleigh Healthcare Singapore 6 Temasek Boulevard Fourth Floor Sunlee Tower Four Singapore T 461 8 9 309 3083 F 60 8 9 309 4582 Sweden Huntleigh Liljenberg AB Limhammsg rdens alle 15 21610 Limhamm Malmo Sweden T 446 40 49 57 80 F 46 40 49 43 75 UK Huntleigh Healthcare Limited 310 312 Dallow Road Luton Bedfordshire LU1 1TD T 44 0 1582 413104 F 44 0 1582 459100 United States of America Huntleigh Healthcare Inc 40 Christopher Way Eatontown NJ 07724 USA T 1 732 578 9898 F 1 732 578 9889 Huntleigh Latin America Inc 2602 North West 97th Avenue Miami Florida 33172 USA T 1 305 463 0526 F 1 305 463 0216 Issue 2 Nov 2001 Chap 8 SER0004 Page 1 Service Contact Details Mini Pump Service Manual Chap 8 Issue 2 Page 2 SER0004 Nov 2001
22. Compressor Valve Bodies 23 Replacing the E Stack Assembly 25 Replacing the Coil Assemby 25 Replacing the Compressor Assembly 2 2 2 a 25 Replacing the Pressure Control Module 27 Replacing the Alarm Monitoring POB 29 Changing the Battery occ 24 Es Boe oe ake SE a ee a 31 Replacing the Neon Indicatorlight 33 Replacing the Microswitch 35 Replacing the Terminal Block 2 LL 35 Replacing the Pressure Control FlapsandAirBag 37 Replacing the Pressure Control Assembly 39 Replacing the Synchronous Motor Gearbox Rotor Stator Assembly 41 Replacing the Side Panel Mains Power ON OffSwiteh 43 Replacing the Side Panel Mains PowerLead 43 Replacing the Fuses 2 so Qua a ee k iN 43 Replacing the Snap lock Connectors 45 Removing the FrontCase 46 Installing the Front Case 46 Pump kabel Sets s 6 6 4 4 6 gb ah Sete Bo eR ee a dd ek int 47 CHAPTER 4 Troubleshooting desa des iniciara 1 Gomera a NE ae a ke ee DL BS et es ee ee a 1 Low Pressure fault indicated checks without dismantling the pump 2 Loss of Output Pressure
23. Huntleigh HEALTHCARE SER0004 Mi EF Mini Pump Service Manual Issue 2 Nov 2001 Mini Pump Service Manual Contents AMENDMENT RECORD Issue 2 Contents Nov 2001 SER0004 Page i Contents Mini Pump Service Manual Contents Issue 2 Page ii SER0004 Nov 2001 Mini Pump Service Manual Contents Contents CHAPTER 1 INWOdUCHON esse na need SE ae e See eae ee EE GL si Ge amp 1 About This Manual s x s g aoe Ga eG aa A ae a LG A a Ger Re a El ad Gea he 1 Warnings Cautions and Notes 2 Technical Description LL 3 Operating Principle eis ae bee be Gog a da a ae ee es 8 3 System Start Up Sequence 5 Low Pressure Alarm Electronic UnitsOnly 6 Low Pressure Alarm All Units 6 Low Pressure Alarm Protocol Electronic Units Only 6 Power Failure Alarm Electronic UnitsOnNly 6 Battery Management Electronic Units Only 7 CHAPTER 2 Maintenance see x oles Bowe bei bm pe de ESE EE da Gus s 1 Pump Maintenance Checks oaaao LL LL 1 Pump Soak Break in Times ooa a a 2 Pump SENICE o a adieu Ge ac a da AR A 2 CHAPTER 3 Pump Repair ia aaao e 1 Eer PE Ne de E ode Bp ks ee A oy es te E ees 1 Removing the Pressure Control Knob 3 Installing the Pressure Control Knob
24. M M M E E M E or Electrical E fw rar Pe x pe Pe Px pe porra O Taja Do System Start Up Seguence All pump types must be connected to the appropriate mains power supply via a suitable plug After a mechanical pump is switched on the start up seguence is as follows e The ON OFF switch lever will be illuminated green Issue 2 Chap 1 Nov 2001 SER0004 Page 5 Introduction Mini Pump Service Manual e The red low pressure indicator will be illuminated When operating pressure is achieved the low pressure indicator will be extinguished automatically After an electronic pump is switched to Run the start up seguence is as follows The unit performs a diagnostic self test illuminating all LED indicators and sounding the audible alarm If an internal fault is sensed or a problem with the wiring of the mains power sense switch the pump will remain in this state If the self test is successful then the start up seguence will proceed e On start up the low pressure alarm will be inhibited until one minute after the low pressure signal is deactivated The amber WAIT indicator will be illuminated while the low pressure alarm is inhibited See Low pressure Protocol Other functions will work as normal Note Aura ALS model has no WAIT indicator apart from this one difference however the Aura pump performs the same as the other electronic pump units Low Pressure Alarm Electronic Units Only When the alarm is acti
25. Section 23 2 24 6 Fit a new silencer bag and gasket then replace the compressor lid Refer to Page 19 and reverse the operations carried out in Section 22 4 22 3 and 22 2 24 7 Refit the compressor AV bracket assembly to the pump case Refer to Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts Issue 2 Chap 3 Nov 2001 SER0004 Page 21 Pump Repair Mini Pump Service Manual Figure 12 Compressor Valve Bodies Table 16 Compressor Valve Bodies Part List Part Number Description BP554 Valve Body Assy Blue Each valve body contains items 20 to 70 BP351 Valve Body FASO27 Screw Hex Head 4BA x 3 4 FAS013 4BA Full Nut BP039 Valve Body VVasher BP037 Valve Flap BP038 Valve Flap Securing Pad Chap 3 Issue 2 Page 22 SER0004 Nov 2001 25 25 1 25 2 25 3 25 4 25 5 25 6 25 7 25 8 25 9 Mini Pump Service Manual Pump Repair Replacing the Compressor Valve Bodies Remove disassemble the compressor AV bracket assembly and remove the silencer bag Refer to Page 19 Section 22 1 22 2 22 3 and 22 4 Unclip the bellows part of bellows armature assembly from the valve body Refer to Page 20 Fig 11 Items 10 or 20 and 40 Unscrew and remove the securing nut Fig12 Item 40 on the side of the compressor housing Remove the valve body Fig 12 Item 20 and Valve body washers Fig 12 Item 50 Remove the valve flap securing p
26. ads and the valve flaps Fig 12 Items 70 and 60 Discard the old valve body and replace with the same type Repeat Sections 25 3 to 25 6 as necessary to replace the other valve body When replacing the valve flaps and valve flap securing pads make sure that the valve flap sits flat over the hole in the valve body and the valve securing pad is pushed fully on to the lug Position the replacement valve body and secure with screw Fig 12 Item 20 and nut Fit the bellows to the valve body 25 10 Fit a new silencer bag and gasket then replace the compressor lid Refer to Page 19 and reverse the operations carried out in Section 22 4 22 3 and 22 2 25 11 Refit the compressor AV bracket assembly to the pump case Refer to Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts Issue 2 Chap 3 Nov 2001 SER0004 Page 23 Pump Repair Mini Pump Service Manual Figure 13 E Stack and Coil Assembly Table 17 E STACK and Coil Assembly Part List Part Number Description E Stack FAS048 Pan Head Screw M3 x 25 mm Pozi FAS002 Washer 6BA Anti Vib 502050 Coil Assembly 230V 50Hz black white leads 1 502062 Coil Assembly 110V 60Hz grey leads Coil Assembly 100V 50 60Hz blue leads 50 165303 Grommet 502304 Compressor Case Chap 3 Issue 2 Page 24 SER0004 Nov 2001 26 Mini Pump Service Manual Pump Repair Replacing
27. bellows need to warm up to reach normal output 2 3 If any of the following major critical components have been replaced or repaired then it is recommended that the pump be soaked broken in for 12 hours prior to being tested Valve body Silencer Bag e Printed Circuit Boards PCB if applicable e Compressor e Rotary Valve Assembly 3 Pump Service A pump should be serviced every 12 months To carry out a service on the pump do the following 3 1 Carry out the Pump Maintenance Checks Section 1 3 2 Replace the following components 3 2 1 Silencer bag Refer to Chapter 3 Section 22 3 2 2 Pivot points Refer to Chapter 3 Section 24 3 2 3 Bellow assemblies Refer to Chapter 3 Section 23 3 2 4 Valve bodies Refer to Chapter 3 Section 25 3 2 5 Compressor filter Refer to Chapter 3 Section 12 3 2 6 Compressor gasket Refer to Chapter 3 Section 22 3 2 7 Pump case filter Refer to Chapter 3 Section 4 3 2 8 AV mounts Refer to Chapter 3 Section 14 new style Section16 old style 3 2 9 Internal rechargeable battery Refer to Chapter 3 Section 31 Chap 2 Issue 2 Page 2 SER0004 Nov 2001 Mini Pump Service Manual Maintenance 3 3 Reassemble the pump and soak break in for the recommended time Refer to Section 2 3 4 Carry out a flow pressure and function test on the pump in accordance with Chapter 5 3 5 Carry out electrical tests on the pump in accordance with Chapter 5 Issue 2 Chap 2 No
28. ck that switch is operating and n o terminals 1 3 are in use 4 3 Check free movement of lower flap 4 4 Check low pressure switching point with an external pressure meter 4 5 Check the pressure control module for leaks 4 6 Check the location and orientation of low pressure spring and disc by removing upper and lower flaps 5 Air Not Alternating continuous pressure fault Should the cells of the mattress not inflate and deflate during a 10 minute cycle then the timer motor may be defective not rotating 5 1 Check the timer motor electrical connections for security and integrity If all are sound and the timer motor still does not rotate then the timer motor must be replaced Notes The timer motor is a sealed unit and cannot be repaired When replacing the timer motor it is advisable to replace the stator gasket at the same time Refer to Chap 3 Pump Repair 6 Loss of Electrical Power Power loss can be due to any of the following 6 1 No electricity supply at wall socket 6 2 Faulty wall socket 6 3 Damaged plug or mains power cable 6 4 Defective fuse link in pump or plug 6 5 Damaged internal wiring 6 6 Loose connections at the terminal block micro switch or PCB 6 7 Faulty PCB component Chap 4 Issue 2 Page 4 SER0004 Nov 2001 Mini Pump Service Manual Troubleshooting 7 Circuit Diagrams The circuit diagram for the electronic models is given in Fig 24 The circuit diagram for mechanical models is give
29. ctivate at or before the pressure reaches 5 mmHg descending and deactivate at or before the pressure reaches 20 mmHg ascending Low Pressure Indicator Test Electronic units only WARNING DANGER OF ELECTRIC SHOCK DURING THE FOLLOWING TESTS LIVE TERMINALS AND CONDUCTORS MAY BE EXPOSED EXERCISE EXTREME CAUTION Note Pump units fitted with an alarm monitoring PCB should have the low pressure alarm settings tested within 60 seconds of switching the pump on 1 8 Remove the rear case assembly Refer to Chap 3 Section 6 1 8 1 Fit snap lock connectors to both outlet ports Connect the pressure gauge and a bleed valve to the duty port 1 8 2 Connect a buzzer or LED to the microswitch terminals to indicate microswitch operation see Chap 4 Fig 24 for microswitch terminal connections 1 8 3 Ensure that the bleed valve is fully closed Ensure that the low pressure adjustment screw on the upper flap is fully disengaged Turn the arbour clockwise and counter clockwise over the full range three or four times Leave it in the fully counter clockwise position 1 8 4 Turn the pressure control knob until the indicated pressure is 50 mmHg maximum setting for Aura models only 1 8 5 Open the bleed valve to induce a leak until the pressure is 10 mmHg 60 mmHg for Aura models only 1 8 6 The microswitch should activate before the pressure reaches X mmHg descending and deactivate before the pressure reaches Y mmHg ascending as specified
30. ctor if fitted 1 1 9 Check labels are present located correctly and legible 1 1 10 Ensure LED s are not cracked 1 2 Remove the compressor lid Refer to Chap 3 Section 22 and visually inspect the following for damage wear and potential faults Note If any parts require repairing or replacing then refer to Chap 3 Pump Repair 1 2 1 Coil E stack assembly 1 2 2 Elbows and connectors 1 2 3 Bellows 1 2 4 Security of compressor 1 2 5 Integrity of filters and gaskets 1 2 6 Valve body assembly 1 2 7 Armature blades 1 2 8 Pivot points 1 2 9 Silencer bags 1 2 10 Valve shuttle assembly Issue 2 Chap 2 Nov 2001 SERO004 Page 1 Maintenance Mini Pump Service Manual Once the compressor has been visually inspected connect to a power supply and run this is to ensure the compressor is working and that there is flow pressure at the outlet port of the pump Check for any excessive noise and vibration 2 Pump Soak Break in Times 2 1 A pump must be soaked broken in for the following reasons Note Soaking breaking in consists of running the pump with the outlet ports blocked e To ensure that the pump is at normal running temperature prior to pneumatic performance tests being carried out To stress test major critical parts which have been replaced or repaired 2 2 All pumps should be soaked broken in for a period of 30 to 60 minutes prior to any pneumatic performance test being carried out This is because the compressor
31. ded screwdriver carefully remove the pressure control knob Be careful not to move the arbour 1 4 3 Rotate the screw in the centre of the pressure control arbour counter clockwise to increase until the indicated pressure is as specified in Table 33 Note Ensure that the pressure control arbour does not move Table 33 Indicated Pressure sI indicated Pressure AlphaBed Set at dead AlphaCare centre value Alpha Trancell Alpha Relief Aura AlphaXcell 1 4 4 Carefully replace the pressure control knob ensuring that the control knob rotation is limited between the minimum setting and the stop pin if fitted 14 5 Check the indicated pressure at minimum and maximum settings Refer to Table 32 and readjust if necessary 1 4 6 Variation between the ports is to be no greater than 4 mmHg 1 4 7 Attach the flow meter tube to whichever outlet is the duty port and check the free flow again The flow readings should be as specified in Table 31 Variation between the ports is to be no greater than 1 litre minute Issue 2 Chap 5 Nov 2001 SER0004 Page 3 Testing Mini Pump Service Manual Low Pressure Indicator Test Mechanical Units Only 1 5 With the test equipment set up as in Section 1 1 set the pressure control knob in the mid position and use the flowmeter valve to adjust the pressure slowly up and down 1 6 Observe the LOW PRESSURE warning light to indicate the operation of the Micro switch 1 7 The micro switch should a
32. dule as described in Page 27 Section 29 1 to 29 7 30 2 Disconnect PCB power wires Fig 15 Item 60 from PCB 30 3 Disconnect the three signal connectors from the PCB Fig 15 Item 30 30 4 Remove the PCB securing screw Fig 15 Item 10 and withdraw the PCB Fig 15 Item 20 30 5 Replacement is the reverse procedure to removal Ensure that the PCB is seated in the two slotted mounts of the side panel Fig 15 Item 40 and the lug Fig 15 Item 50 on the pressure control module Issue 2 Chap 3 Nov 2001 SER0004 Page 29 Pump Repair Mini Pump Service Manual Figure 16 Replacing the Power Failure Alarm Battery Table 20 Battery Power Failure Alarm Part List Part Number Description Qty 10 151457 Battery 20 N A Cable Tie 30 N A Battery Plug to PCB Chap 3 Issue 2 Page 30 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 31 Changing the Battery Caution Electrostatic discharge can seriously damage the alarm monitoring PCB Prior to replacing or handling adequate earth grounding precautions must be taken Notes 1 It is not necessary to remove the side panel in order to change the battery 2 The battery power failure alarm is only applicable to electronic versions of the mini pump 31 1 Remove the PCB Refer to Page 29 Section 30 31 2 Remove the battery plug Fig 16 Item 30 from the PCB 31 3 Cut and remove the cable tie Fig 16 Item 20 and remove the battery Fig 16 Item 10 31 4 Replacem
33. e Connector Female Connector Note All test equipment must be calibrated to national or international standards Flow and Pressure Checks 1 1 Connect the flowmeter via a valve to whichever outlet is working Connect the pressure gauge to measure the pressure at the outlet 1 2 Open the valve fully The free flow rate should not be less than specified in Table 31 Table 31 Minimum Flow Rates Airflow at Airflow at 20 mmHg Itr min 50 mmHg Itr min AlphaBed AlphaCare Alpha Trancell Alpha Relief Aura AlphaXcell 1 3 Close the valve and operate the pressure control knob on the pump from minimum to maximum setting The pressure indicated on the gauge in mmHg should be as specified in Table 31 Issue 2 Chap 5 Nov 2001 SER0004 Page 1 Testing Mini Pump Service Manual PRESSURE ADJUSTMENT SCREW MANOMETER mmHg DAMPER FOR EVEN FLOW 9V BATTERY Figure 26 Typical Test Rig setup for Mini Pumps Chap 5 Issue 2 Page 2 SER0004 Nov 2001 Mini Pump Service Manual Testing Table 32 Pressure Range AlphaBed AlphaCare Alpha Trancell ALT01 09 ALT10 Alpha Relief Aura AlphaXcell If the pressure readings are incorrect then calibrate the pressure control as described below Calibration 1 4 If the pressure readings are incorrect then calibrate the pressure control as follows 1 4 1 Turn the pressure control knob to the minimum setting 1 4 2 Using a small flat bla
34. ent is the reverse procedure to removal Note The cable tie must be renewed replaced when changing the battery Issue 2 Chap 3 Nov 2001 SER0004 Page 31 Pump Repair Mini Pump Service Manual 30 Figure 17 Replacing the Neon Indicator Light Table 21 Neon Indicator Part List Part Number Description FAS083 Screw No 6 x 5 16 Pozi Pan Head PT 500373 Neon Assembly Red 230 V 500371 Neon Assembly Red 110 V item 500324 Plate Neon Mounting m A Chap 3 Issue 2 Page 32 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 32 Replacing the Neon Indicator Light Note The neon indicator light is only applicable to the mechanical versions of the pump The 32 1 32 2 32 3 32 4 32 5 electronic version of the pump has two red indicators a green indicator and a yellow indicator These are wired directly into the PCB and are replaced only by exchanging the complete PCB Disconnect the indicator lead from the terminal block terminal 2 Fig 14 Item 10 Disconnect the indicator lead from the Micro switch Fig 18 Item 10 Release the screw Fig 17 Item 20 attaching the neon mounting plate Fig 17 Item 10 and remove the neon Fig 17 Item 30 and mounting plate assembly Note the orientation of the components unclip the neon Fig 17 Item 30 from the lens and push the lens out of the mounting plate
35. essive vibration mounts for wear Applicable to all pumps Refer to Ch 3 Pg 13 Check compressor is not loose on its mounting plate Refer to Ch 3 Pg 17 Check the compressor bellows are not split Refer to Ch 3 Pg 21 Pump not operating Pump run switch not on Switch on Applicable 10 all pumps Plug not inserted correctly Check Fuse blown Replace the fuse Refer to Ch 3 Pg 43 Loss of output pressure Refer to Section 2 and 3 below All indicators lights remain Internal fault Test the pump Refer to illuminated on initial Ch 5 switch on Check PCB Applicable to ALR 01 10 ALX 01 10 ALS 01 10 2 Low Pressure fault indicated checks without dismantling the pump Check the following before dismantling the pump unit Perform the pressure flow and low pressure alarm tests as specified in Chap 5 Testing If the results are satisfactory the mattress is at fault Note All testing must be done when pumps are warm ie they have been running with closed ports for at least 1 hour Check 2 1 All tubing connections on pump and mattress are securely fastened and snap locked into place 2 2 Check that the rapid deflate stopper or CPR is fitted correctly Refer to Mattress Service Manual SER0005 Chap 4 Issue 2 Page 2 SER0004 Nov 2001 2 3 3 Mini Pump Service Manual Troubleshooting If the alarm still indicates visually inspect tubing and mattress cells for punctures or tears and chec
36. h closures as well as between second and third switch closures The lockout period is to allow temporary disconnection of tubing In addition to the above a wait period of 25 minutes is allowed on start up During this time the low pressure alarm is inhibited to allow inflation of the mattress to operating pressure If during this wait period the low pressure switch is activated i e the system is up to pressure the wait period will be terminated 1 minute later and normal protocol is obeyed thereafter Power Failure Alarm Electronic Units Only In the event of a power failure the red POWER FAIL indicator will flash in combination with an audible warning which increases with time If the power supply is restored the audible alarm will stop but the indicator will remain illuminated continuously until the system is reset Resetting by switching the pump to Stand by and then back to Run will clear all alarm indications Chap 1 Issue 2 Page 6 SER0004 Nov 2001 Mini Pump Service Manual Introduction The power failure alarm is initiated by the removal of the mains power supply from the unit for a period of more than 5 seconds by a means other than operation of the Run Standby switch A drop in the supply voltage below the minimum supply specification will be interpreted as a supply failure If power is restored within 5 seconds no alarm is given and normal operation is resumed A battery backup supply provides power to ope
37. hanical hazards only in accordance with UL 2601 1 Canada CSA C22 2 No 601 1 Classified by Underwriters Laboratories Inc with respect to electric shock fire and mechanical and other hazards only in accordance with CAN CSA C22 2 No 601 1 For the AlphaBed AlphaCare and Alpha Trancell pumps standards BS 5724 part 1 1989 and VDE 0750 Teill also apply Protection Class The protection class for all pump models is Class Il type BF The pumps are not protected against the ingress of water Indicator Lights The Alpha Relief Aura and AlphaXcell electronic have four indicator lights Power On Wait except Aura Low Pressure Power Fail The AlphaXcell mechanical AlphaBed AlphaCare and Alpha Trancell have one indicator light Low Pressure Chap 6 Issue 2 Page 2 SER0004 Nov 2001 Mini Pump Service Manual Environmental Conditions Operating conditions for all models Temperature range 410 C to 40 C Relative humidity 30 to 75 Atmospheric pressure 700 hPa to 1060 hPa Storage conditions for all pump models Temperature range 40 Cto 70 C Relative humidity 10 to 100 non condensing Atmospheric pressure 500 hPa to 1060 hPa Technical specification Disposal All units must be disposed of in accordance with local environmental regulations Issue 2 Nov 2001 SER0004 Chap 6 Page 3 Technical specification Mini Pump Service Manual Chap 6 Issue 2 Page 4 SER0004 Nov 2001 Part Number 50
38. he insulation and the measured resistance must be greater than 2 MQ This test can be conducted by using a Portable Appliance Tester Also check the continuity of the mains cable Dielectric Strength Test Flash Test This test shows the response of the insulation to high ac voltage stress to the effects of the capacitive current and gives an early warning of any electrical problems developing in the appliance Leakage Circuit Test USA Measure the risk currents in accordance with the ANSI AAMI ESI 1993 Standard American National Standard Safe Current Limits for Electromedical Apparatus or as specified in UL 2601 1 Issue 2 Chap 5 Nov 2001 SER0004 Page 5 Testing Mini Pump Service Manual WARNINGS DANGER OF ELECTRIC SHOCK DO NOT TOUCH ANY EXPOSED PARTS WHILE CONDUCTING THIS TEST DO NOT TOUCH ANY PART OF YOUR BODY WITH THE CONTACTS OF THE PROBES THIS EGUIPMENT SHOULD NOT BE USED IF YOU HAVE A HEARING AID OR PACEMAKER FITTED DUE TO THE POSSIBILITY OF ELECTROMAGNETIC DISTURBANCE Specification 3 0 kVac is applied between the connected Live and Neutral wires and the appliance s metal compressor assembly box No breakdown should occur Note The voltage levels used for this test may stress and weaken the insulation This test is therefore not recommended as a routine test It should only be used after a major assembly disassembly has been completed 3 PCB Functional Tests Electrical Units Only Tests must be carried
39. in Table 34 1 8 7 Set the low pressure adjustment screw so that the microswitch activates at this set level Do this very slowly Adjust the pressure up and down by means of the bleed valve and verify that the microswitch goes on and off accordingly 1 8 8 Replace the rear cover Refer to Chap 3 Section 7 Chap 5 Issue 2 Page 4 SER0004 Nov 2001 Mini Pump Service Manual Testing Table 34 Descending and Ascending Pressures AlphaBed AlphaCare Alpha Trancell Alpha Relief Aura AlphaXcell 2 Electrical Testing To test and calibrate the pump unit correctly the following equipment is required Table 35 Electrical Test Equipment Insulation resistance tester Megger 500 Vdc Portable appliance tester Multimeter Continuity tester Dielectric strength tester Flash tester 3 0 RVac with current limit Electrical Safety Checks Class Il There are several electrical safety checks that must be carried out after breakdown repairs rental re checks and servicing Where alternatives are given the test will depend upon the available equipment The tests are as follows e Insulation Resistance Test Megger Test or e Dielectric Strength Flash Test Insulation Resistance Test This test checks the integrity of the appliance s insulation For all appliances this test is applied between the connected Live and Neutral wires and the appliance s metal compressor assembly box Specification 500 Vdc is applied to t
40. ing the electrical wires for the mechanical version of the pump Replacing the Side Panel Mains Power Lead Remove the pressure control module and remove the side panel as described in Section 29 Carefully withdraw the mains power lead Fig 22 Item 30 through the mains lead power cord grommet Carefully withdraw the mains power lead grommet Fig 22 Item 20 through the side panel Replace the lead with the same part number Replacement is the reverse of the above procedure Ensure adequate cable length so that wires are not strained WARNING WHEN AN UNSERVICEABLE MAINS POWER LEAD FITTED WITH A NON REWIREABLE PLUG IS REMOVED FROM THIS EQUIPMENT THE LEAD CORD AND THE PLUG MUST BE DESTROYED AND DISPOSED OF SAFELY TO AVOID THE DANGER OF ELECTRIC SHOCK THE PLUG MUST NEVER BE INSERTED IN ANY POWER OUTLET Replacing the Fuses Note The side panel assembly is supplied complete with fuse holder fitted The fuse holder is not a 40 1 40 2 replaceable item To replace the pump fuse undo the fuse holder Fig 22 Item 40 and remove the fuse Fig 22 Item 50 Replace with fuse of same type To replace the mains power lead plug fuse in moulded plugs use a small bladed electrical screwdriver and carefully lever off the fuse cover on the pin side of the plug Replace with fuse of same type Issue 2 Chap 3 Nov 2001 SER0004 Page 43 Pump Repair Mini Pump Service Manual
41. ion 6 42 3 Remove the screw and the fixing cap Refer to Fig 14 Items 40 and 80 from the pressure control module 42 4 Remove the pressure control module together with the side panel and the compressor from the front case Fig 2 Item 40 43 Installing the Front Case 43 1 For Aura AlphaXcell AlphaTrancell ALTO1 09 fit the pin Fig 2 Item 30 to the new front case Note For Alpharelief Alphabed Alphacare and Alpha Trancell ALT10 pumps the pin is not needed This allows 270 movement of the Pressure Control Knob 43 2 Fit a front label to the front case Refer to Table 28 for the correct label set 43 3 Install the pressure control module together with the side panel and the compressor in the front case 43 4 Install the fixing cap and the screw Refer to Fig 14 Items 80 and 40 to the pressure control module 43 5 Assemble the rear case Page 5 Section 7 43 6 Install the pressure control knob Page 3 Section 3 43 7 Fit rubber feet to the base of the front case Fig 4 Item 50 Chap 3 Issue 2 Page 46 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 44 Pump Label Sets The following table gives the part numbers for the pump label sets Table 28 Pump Label Sets Part Number ay Series 500390 Label set France AlphaXcell ALX05 1 500391 Label set Japan AlphaXcell ALX06 1 500392 Label set Italy AlphaXcell ALX017 500393 Label set Australia AlphaXcell ALX08 500394 Label se
42. itable sealing caps to close the ports Operate the run standby switch to run Verify that after 1 minute the WAIT indicator is extinguished 3 7 Open both ports to atmosphere Verify that after 4 minutes and 45 seconds the red LOW PRESSURE indicator flashes in conjunction with the audible alarm 3 8 Operate the run standby switch to standby and back to run Verify that all alarm indications are cleared and normal operation is resumed Chap 5 Issue 2 Page 6 SER0004 Nov 2001 Mini Pump Service Manual Testing 4 Functional Tests Mechanical Units Only Tests must be carried out using a 220 240 V 50 Hz power supply Test Setup and Initial Switch On 4 1 Set the pressure control knob fully counter clockwise and ensure that both outlet ports are open to atmosphere 4 2 Connect the mains power cable to a suitable power socket outlet and then set the on off switch to on Verify that the green indicator in the switch is illuminated Verify that the red LOW PRESSURE indicator is illuminated Use the fingers to close both outlet ports and verify that the LOW PRESSURE indicator goes off Issue 2 Chap 5 Nov 2001 SER0004 Page 7 Testing Mini Pump Service Manual Chap 5 Issue 2 Page 8 SER0004 Nov 2001 Mini Pump Service Manual Technical specification CHAPTER 6 TECHNICAL SPECIFICATION Pump Models The pump models covered in this series are Alpha Relief Aura AlphaXcell Electronic AlphaXcell Mecha
43. iven in the relevant user manual and or the pump labels The range of air pressure delivered by the series of pumps varies as does the achievable flow rate One extreme of pressure range can be adjusted by obtaining access to a screw under the pressure control knob see Table 3 for details of pressure variations The range achievable is fixed by the pressure control spring only the set pressure can be reset Chap 1 Issue 2 Page 4 SER0004 Nov 2001 Mini Pump Service Manual Introduction Table 3 Air Pressure Flow Rates Minimum Flow Minimum Flow Rate at 20 mmHg Rate at 50 back pressure mmHg litres minute litres minute Minimum Maximum Adjustable Pressure Pressure Pressure mmHg mmHg 83 87 Less than 110 Comfort control only Holland pumps ALT10 only max pressure is 80 100 mmHg Pump units may be divided into two types Mechanical and Electronic Major differences between the two types of pump unit are as follows e Alarm indicators mechanical type has a neon indicating low air pressure also an illuminated mains power on off switch The electronic type incorporates an alarm monitoring PCB driving a number of LED indicators and audible warning sounder See Table 4 for visual indicator details e Air outlets mechanical type has simple push on connectors except ALX11 which has snap lock type connectors The electronic type utilises snap lock type connectors Table 4 Product Visual Indicators Mechanical
44. k they are fitted to the manifold correctly Refer to the mattress service manual SER0005 for full details WARNING DANGER OF ELECTRIC SHOCK DURING THE FOLLOWING TESTS LIVE TERMINALS AND CONDUCTORS MAY BE EXPOSED EXERCISE EXTREME CAUTION Loss of Output Pressure checks by dismantling the pump If the low pressure alarm operates when both pump outlets are blocked or the pump does not pass the flow test in Chapter 5 Testing the pump unit internal compressor should be tested as follows 3 1 3 2 3 3 3 4 3 5 Remove the rear case Refer to Chap 3 Page 5 Disconnect the white pneumatic tube from the compressor F Tube connector Connect the pressure gauge to the compressor F Tube connector and switch the pump unit on The pressure reading should be at least 100 mmHg If the pressure does not reach 100 mmHg the compressor is at fault Either replace the compressor or remove the compressor lid remove the silencer bag from the valve bodies and connect the pressure gauge to each valve body in turn The pressure should be approximately 100 mmHg in each case Refer to Chap 3 Section 22 If the required pressure cannot be reached then the bellows armature assemblies and valve bodies must be replaced Refer to Chap 3 Section 23 If the reguired pressure is obtained then the silencer bag must be replaced Refer to Chap 3 Section 22 Note The flow pressure performance of a compressor may be altered by heating the new bel
45. lace with new item Remove and discard the air bag assembly Fig 19 Item 80 Replace with a new item Ensure the air bag is secure by pushing in the centre and rotate it slightly to ensure it is seated Ensure that the low pressure adjustment screw Fig 19 Item 90 is fully disengaged Carefully locate the brass disc Fig 19 Item 60 boss uppermost in the rebate in the upper flap Locate the spring Fig 19 Item 50 on the disc and position the lower flap Fig 19 Item 40 against the spring Refitting is the reverse of the above procedure When refitting hold the group of components together and position them on the pressure control module Insert the pivot pin Fig 19 Item 30 to retain the flaps Issue 2 Chap 3 Nov 2001 SER0004 Page 37 Pump Repair Mini Pump Service Manual ie NEW VOY 44 Figure 20 Control Knob Cam and Arbour Table 24 Control Knob Cam and Arbour Part List Part Number Description 10 FAS225 Control Adjustment Screw 3 Dia x 16 mm Pozi Pan Head PT 20 500305 Knob Control Cam 50 500349 Pressure Assembly Module 500304 Knob Control Arbour 500411 Cup Arbour Drive Spring 1 500339 Spring Comp 1 07 Diameter 1 Chap 3 Issue 2 Page 38 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 36 Replacing the Pressure Control Assembly Note It is not necessary to remove the side panel assembly from the pressure control module 36 1 Remove the pressure control modu
46. le from the pump case as described in Section 29 36 2 Remove the pressure control flaps as described in Section 35 36 3 Release the control adjustment screw on the control knob arbour Fig 20 Item 10 36 4 Carefully remove the arbour cam spring cup and spring Fig 20 Items 20 30 and 40 36 5 Renew replace components with the same type Note Early versions may have a nylon washer in lieu of the spring cup Discard the washer and replace with the cup 36 6 Replacement is the reverse of the above procedure Refit the pressure control flaps as described in Section 35 Note The new control knob arbour will NOT fit the old pressure assembly module because of the moulded wall on the old pressure assembly module The old control knob abour will fit both Issue 2 Chap 3 Nov 2001 SER0004 Page 39 Pump Repair Mini Pump Service Manual Figure 21 Synchronous Motor Gearbox Rotor Stator Assembly Table 25 Synchronous Motor Gearbox Rotor Stator Assembly Part List Part Number Description Qty FAS223 Screw 3 Dia x 10 mm Pozi Pan Head 20 500097 Gearbox 240V and Ferrule Assembly 500098 Gearbox 120V and Ferrule Assembly 500099 Gearbox 100V and Ferrule Assembly 151409 Motor Gearbox 100V 50 Hz 1 10 RPM 500308 Rotor Module 500307 Stator Module 500332 Felt Rotor Silencer Chap 3 Issue 2 Page 40 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair Table 25 Synchronous Motor
47. lows and adjusting the E stack gap 3 6 If the compressor is operating correctly but the correct pressure cannot be obtained at the pump outlet then the rotor stator pressure control module and snap lock connectors must be checked Reassemble the compressor and attach pressure rig to pump outlet again 3 7 Remove the gearbox and rotor stator clean all dust off rotor stator and reassemble with new gasket If rotor stator is chipped or damaged replace components Refer to Chap 3 Section 37 If this does not correct the problem check the pressure control 3 8 Push on the pressure control flap Fig 19 Item 20 to press the seal Fig 19 Item 70 against the valve seat Check the pressure control bag inflates fully and pushes on the flap if not the bag could be split check and replace as necessary 3 9 If the snap lock connectors or tubing show signs of damage replace If there is still a problem re check in the following order compressor e rotor stator assembly pressure control assembly e connections If pressure flow still cannot be achieved return pump to Service department Issue 2 Chap 4 Nov 2001 SER0004 Page 3 Troubleshooting Mini Pump Service Manual 4 Low Pressure Alarm Fault If the low pressure alarm does not function correctly after recalibration as described in Chap 5 Testing check 4 1 The electrical connections and leads between the low pressure micro switch and the printed circuit board 4 2 Che
48. n in Fig 25 Check for the above faults against the relevant circuit and repair as appropriate I Terminal Block Fuse Mains Power Mains Power Live O O Switch Lead Neutral ZA Ja 2A 4Bi Me sli C O n IL N 1 3 Sounder la 12 al Microswitch Gearbox Compressor PCB LIIN Figure 24 Circuit diagram for Alpha Relief Aura and AlphaXcell Electronic Mini Pumps Chap 4 Issue 2 Nov 2001 SER0004 Page 5 Troubleshooting Mini Pump Service Manual Terminal Block Mains Power Live a Mains Power Switch Lead Neutral N L N Microswitch Gearbox T 10 Z 30 Compressor 3 Figure 25 Circuit diagram for AlphaXcell AlphaBed AlphaCare and Alpha TranCell Mechanical Mini Pumps Chap 4 Page 6 SER0004 Issue 2 Nov 2001 Mini Pump Service Manual Testing CHAPTER 5 TESTING 1 Pump Flow Pressure and Function Test This procedure must be carried out after a service or major repair of a pump To test calibrate the pump unit correctly the following equipment or equivalent is required Table 30 Pump Flow Pressure and Function Test Equipment Typical Test Kit including PRE 060 Digital Manometer pressure gauge 0 199 mmHg resolution 0 1 accuracy 0 2 of range Flowmeter 0 10 litre minute resolution 0 2 accuracy 2 of measured value Mal
49. nd bracket on the left since their relative positions will be reversed when they are presented to the rear case assembly 9 1 Assembly of the new Pump Filter is in the reverse order of disassembly Make sure the slots in the Filter Housing Plates Fig 4 Item 20 are uppermost in the positions shown in Fig 4 9 2 Lay the left hand Fig 4 Item 20 and the right hand Fig 4 Item 30 brackets on a hard flat surface with their rubber pads face down and their shaped heads pointing inward 9 3 Ensure the bed hook Fig 4 Item 10 is correctly placed to the left hand and right hand slots where the coating has been removed Firmly press home the bed hook until it clicks into place 9 4 Lay the rear case assembly on a hard flat surface with its back uppermost Turn over the bed hook subassembly and place into the rear case assembly 9 5 Position one bracket and press it firmly until it clicks into place Repeat this process for the other bracket 9 6 Turn over the rear case assembly and fit four securing screws to each bracket 9 7 Assemble the rear case to the pump Refer to Page 5 Section 7 9 8 Install the pressure control knob Refer to Page 3 Section 3 Issue 2 Chap 3 Nov 2001 SER0004 Page 7 Pump Repair Mini Pump Service Manual a 40 e 40 Figure 5 Replacing the Old Style Bed Hooks Chap 3 Issue 2 Page 8 SER0004 No
50. nical AlphaBed AlphaCare Alpha Trancell Notes Each model has a three letter code For example the Alpha Relief pump has the code ALR Size Following the three letter code is a two digit code representing customer country s power supply system For example the Alpha Relief pump is available to countries 01 02 03 and 04 UK Germany USA and Europe general respectively A complete breakdown of the pump model three letter codes and two digit codes is given in Chap 1 Tables 1 and 2 All pumps are 248 x 160 x 116 mm 9 8 x 6 3 x 4 6 inches Weight All pump models are 2 75 kg 6 Ib Pressure Ranges a ms E Alpha Relief Aura AlphaXcell AlphaBed AlphaCare Alpha Trancell ALTO1 09 Alpha Trancell ALT10 Issue 2 Chap 6 Nov 2001 SER0004 Page 1 Technical specification Mini Pump Service Manual Cycle Time The cycle time for all pump models is 10 minutes Rated Voltages The voltage ratings for each of the customer two digit codes is given in Chap 1 Table 2 Rated Freguency The mains power freguency ratings for each of the customer two digit codes is given in Chap 1 Table 2 Rated Input Power The rated input power for all pump models is 14 VA Running Time All pump models are designed for continuous consumption Test Standards All pumps are tested to Europe En 60601 1 USA UL 2601 1 Classified by Underwriters Laboratories Inc with respect to electric shock fire and mec
51. nnectors Connector Panel Female 1 4 Flow Connector Panel Male 1 4 Flow Tube Sil Blue ID 6 OD 10 24 LG 1 Tube Sil Blue ID 6 OD 10 15 LG 1 Service Rit Service Kit 240v only Armature Pivot Silencer Bag Bellows Armature Assembly Right Hand 230v 50Hz Bellows Armature Assembly Left Hand 230v 50Hz Felt Filter Case Inlet Filter Compressor SER0004 Fig ltem 22 40 22 50 23 10 23 20 23 30 23 40 Parts list Qty Chap 7 Page 5 Parts list Mini Pump Service Manual Chap 7 Issue 2 Page 6 SER0004 Nov 2001 Mini Pump Service Manual Service Contact Details CHAPTER 8 SERVICE CONTACT DETAILS Africa Huntleigh Africa Pty Limited 126 B Sarel Baard Crescent Rooishuiskraal Pretoria South Africa T 27 1266 10368 F 27 1266 10380 Australia Huntleigh Healthcare Pty Limited 63 Buckingham Drive Wangara Western Australia 6065 T 61 8 9 309 3083 F 61 8 9 309 4582 Belgium Huntleigh Healthcare NV SA Stapelplein 70 9000 Gent Belgium T 32 9 265 8770 F 1329 265 8771 Denmark Huntleigh Healthcare Denmark Hejreskovvej 18A DK 3490 Kvistgard Denmark T 45 4 913 8486 F 45 4 913 8487 France HNE Medical SA Parc d affaires Silic 6 1 Rue des Vergers 69760 Limonest France T 33 0 4 78 66 62 66 F 33 0 4 78 66 62 67 Germany HNE Huntleigh Nesbit Evans Healthcare GmbH Im H lsenfeld 19 40721 Hilden Germany T 49 0 2103 97 110 F 49 0 2103 9
52. out using a 220 240 V 50 Hz power supply Test Setup and Initial Switch On 3 1 Install the mating parts of the snap lock connectors on the pump outlets so that both outlets are open to atmosphere Set the pressure control knob fully counterclockwise 3 2 Connect the mains power cable to a suitable power socket outlet and then set the run standby switch to run All four indicator lights should illuminate and the audible alarm should sound for about 3 seconds The green ON indicator the amber WAIT indicator and the LOW PRESSURE indicator will remain on The POWER FAIL indicator light should extinguish Power Fail Alarm Check 3 3 With the pump operating disconnect the power supply at the power socket outlet then reconnect it after 4 seconds Verify that no alarms are given and normal operation is resumed 3 4 Again disconnect the power supply at the power socket outlet Verify that after 5 seconds the red POWER FAIL indicator flashes in conjunction with the audible alarm The WAIT indicator should go off when the POWER FAIL alarm indicator flashes Reconnect the power supply Verify that the POWER FAIL indicator is extinguished 3 5 Operate the run standby switch to standby and verify that all indicators are off After 5 seconds operate the switch back to run Verify that all alarm indications are cleared and normal operation is resumed Operate the run standby switch to standby Low Pressure Alarm Check 3 6 Use su
53. rate the visual and audible alarm Battery Management Electronic Units Only On switching the pump to Run the processor automatically initiates a standard charge seguence 3 mA for a predetermined period On completion of the standard charge period a trickle charge 0 9 mA will be applied to the battery for the remainder of the operating period When discharging during a power failure alarm the battery supply will be shut down in a controlled manner if the terminal voltage falls below 4 6 V before the alarm duration has expired Issue 2 Chap 1 Nov 2001 SER0004 Page 7 Introduction Mini Pump Service Manual Chap 1 Issue 2 Page 8 SER0004 Nov 2001 Mini Pump Service Manual Maintenance CHAPTER 2 MAINTENANCE 1 Pump Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with Chapter 3 Pump Repair 1 1 Visually inspect the following for damage wear and potential faults Note If any parts require repairing or replacing then refer to the Huntleigh Healthcare service manual 1 1 1 Check outer casings for damage 1 1 2 Functionally check switches and control knobs 1 13 Ensure hanging brackets are secure and located 1 1 4 Check outlet ports and connecting points for damage 1 1 5 Ensure feet are secure and present 1 16 Check fuses are satisfactory 1 1 7 If a gauge is fitted ensure the glass is not cracked or damaged 1 1 8 Check that there is no damage to the mains power conne
54. re assembly Discard the old bellows armature assembly and fit a replacement of the same type by reversing the actions carried out in Section 23 3 and 23 2 Fit a new silencer bag and gasket then replace the compressor lid Refer to Page 19 and reverse the operations carried out in Section 22 4 22 3 and 22 2 Refit the compressor AV bracket assembly to the pump case Refer to Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts Test the assembly Note in order to achieve flow pressure performance the new bellows may have to be heated with a hot air gun whilst operating This anneals the bellows permanenily and alters the pressure flow characteristics Caution The bellows will be damaged if overheated 24 Replacing the Compressor Armature Pivots 24 1 Remove disassemble the compressor AV bracket assembly and remove the silencer bag Refer to Page 19 Section 22 1 22 2 22 3 and 22 4 24 2 Extract the armature blade from the pivot Refer to Section 23 2 24 3 Use a sharp pointed tool and carefully extract the pivot Fig 11 Item 30 from the hole in the compressor casing 24 4 Discard old armature pivots and replace with same type Carefully insert the new pivot into the compressor casing using a small screwdriver to ensure the slot in the pivot is aligned to accept the armature blade 24 5 Fit the armature blade to the pivot reversing the actions carried out in
55. side panel attached from the pump case 29 8 Disconnect the fuse wire from the terminal block terminal 6 and disconnect the adjacent switch wire terminal 5 Fig 14 Item 10 29 9 Disconnect the mains power lead wires from the terminal block terminals L and N Fig 14 Item 10 29 10 Remove three screws Fig 14 Item 50 and detach pull off the pressure control module from the side panel assembly Fig 14 Item 70 29 11 Replacement is the reversal of the above procedures Refer to the wiring diagram Chap 4 Fig 23 electronic or 24 mechanical when reconnecting the wires to the terminal block Issue 2 Chap 3 Nov 2001 SER0004 Page 27 Pump Repair Mini Pump Service Manual 50 40 20 AD 30 Figure 15 Removing the Alarm Monitoring PCB Table 19 Removing the Alarm Monitoring PCB Part List t Chap 3 Issue 2 Page 28 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 30 Replacing the Alarm Monitoring PCB CAUTION Electrostatic discharge can seriously damage the alarm monitoring PCB Prior to replacing or handling adeguate earth grounding precautions must be taken Notes 1 It is not necessary to remove the side panel in order to replace the alarm monitoring PCB 2 The alarm monitoring PCB is only applicable to electronic versions of the mini pump 30 1 Remove the pressure control mo
56. sor lid by reversing operations detailed in Section 22 4 22 3 and 22 2 22 6 Refit the compressor AV bracket assembly to the pump case Refer to Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts Issue 2 Chap 3 Nov 2001 SER0004 Page 19 Pump Repair Mini Pump Service Manual Figure 11 Bellows Armature Assembly and Pivots Table 15 Bellows Armature Assembly Part List Part Number Description 502054 Bellows Armature Assembly Left Hand 230V 50Hz BP215 Bellows Armature Assembly Left Hand 110V 60Hz 502053 Bellows Armature Assembly Right Hand 230V 50Hz Bellows Armature Assembly Right Hand 110V 60Hz 2 2 Armature Pivot Valve Body Chap 3 Issue 2 Page 20 SER0004 Nov 2001 23 23 1 23 2 23 3 23 4 23 5 23 6 23 7 23 8 Mini Pump Service Manual Pump Repair Replacing the Bellows Armature Assemblies and Pivots Remove disassemble the compressor AV bracket assembly and remove the silencer bag Refer to Page 19 Section 22 1 22 2 22 3 and 22 4 Using long nosed pliers extract the armature blade part of bellows armature assembly Fig 11 Item 10 or 20 from the armature pivot Fig 11 Item 30 Unclip the bellows part of bellows armature assembly from the valve body Fig 11 Item 40 and lift the bellows armature assembly clear of the compressor Repeat 23 2 and 23 3 as reguired to remove the other bellows armatu
57. t Rest of the World AlphaXcell ALX09 1 Series 500399 Label set Australia AlphaBed ALB08 1 500400 Label set Rest of the World AlphaBed ALB09 1 Series Issue 2 Chap 3 Nov 2001 SER0004 Page 47 Pump Repair Mini Pump Service Manual Table 28 Pump Label Sets continued Series i 500470 Label set USA Alpha Relief ALRO3 500476 Label set Euro Alpha Relief ALRO4 AlphaCare Series Q ty 1 1 1 1 500401 Label set USA AlphaCare ALC03 Chap 3 Page 48 SER0004 1 1 1 1 1 Issue 2 Nov 2001 Mini Pump Service Manual Troubleshooting CHAPTER 4 TROUBLESHOOTING 1 General This section details some problems which may occur after a long period of use and the appropriate procedures to correct them The Alpha Relief Aura and AlphaXcell electronic pump units are fitted with a visual and audible alarm for LOW PRESSURE and POWERFAIL alarm conditions The alarm for the AlphaBed Care and Trancell mechanical pump units are limited to a visual red LOW PRESSURE I lamp indicator The alarm automatically resets when the operating pressure is regained See Table 4 for details of the each product s visual indicators Table 29 gives a guick reference to common problems possible causes and actions Refer to the table first when carrying out troubleshooting on a pump Table 29 Troubleshooting Mattress Seat not Inflating Applicable to all pumps Low pressure alarm Applicable to
58. tator gasket and replace with a new one before reassembly 37 10 Replacement is the reverse of the above procedure Ensure that the stator is correctly located in the key and cables are secured with relevant cable ties Issue 2 Chap 3 Nov 2001 SER0004 Page 41 Pump Repair Mini Pump Service Manual Figure 22 Replacement of the Side Panel On Off Switch Table 26 Side Panel On Off Switch Mains Power Lead and Fuses Part List ay 500351 Switch Mains Power Rocker 230 V Black All electronic pumps 1 30 BP532 Cordset Standard Moulded UK Cable CAS041 Mains Power Cable European Shuko Socket Chap 3 Issue 2 Page 42 SER0004 Nov 2001 38 38 1 38 2 38 3 38 4 39 39 1 39 2 39 3 39 4 40 Mini Pump Service Manual Pump Repair Replacing the Side Panel Mains Power On Off Switch Remove the pressure control module and remove the side panel as described in Section 29 Pull off the electrical connections from the On Off switch Fig 22 Item 10 Sgueeze together the retaining flanges located on either side of the switch body and push the switch through the side panel Replace the switch with same type Ensure correct orientation of the switch symbol nearest the fuse Ensure that the retaining flanges snap into position Refer to the wiring diagram Chap 4 Fig 23 when reconnecting the electrical wires for the electronic version of the pump and Chap 4 Fig 24 when connect
59. the E Stack Assembly Note After doing work in either Section 26 or 27 the pressure flow characteristics can be altered by moving the coil assembly E stack nearer or further from the armature magnets This can be done by adjusting screws Fig 13 Item 20 Ensure the screws are tightened afterwards 26 1 Remove disassemble the compressor AV bracket assembly and remove the silencer bag Refer to Page 19 Section 22 1 22 2 22 3 and 22 4 26 2 Unscrew and remove the two screws and anti vibration washers Fig 13 Items 20 and 30 which secure the E stack coil assembly Fig 13 Items 10 and 40 26 3 Withdraw the E stack coil assembly from the compressor case as far as the electrical wires will allow 26 4 Carefully remove the E stack from the coil assembly 26 5 Replace the E stack by reversing the operations carried out in Section 26 4 26 3 and 26 2 26 6 Fit a new silencer bag and gasket then replace the compressor lid Refer to Page 19 and reverse the operations carried out in Section 22 4 22 3 and 22 2 26 7 Refit the compressor AV bracket assembly to the pump case Refer to Page 13 Section 15 2 15 3 and 15 4 new style AV mounts or Page 15 Section 17 3 17 4 and 17 5 old style AV mounts 27 Replacing the Coil Assembly 27 1 Remove disassemble the compressor AV bracket assembly and remove the silencer bag Refer to Page 19 Section 22 1 22 2 22 3 and 22 4 27 2 Remove the E stack coil assembly as
60. to Page 3 Section 3 Issue 2 Chap 3 Nov 2001 SER0004 Page 9 Pump Repair Mini Pump Service Manual Figure 6 Replacing the Compressor Filter Assembly Table 10 Compressor Filter Assembly Part List tem Part Number Description 502003 Compressor Assy 230V 50Hz 11K T UH 502002 Compressor Assy 110V 60Hz 5K T USA O seo opresor se 100v soon aria Chap 3 Issue 2 Page 10 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair 12 Removing the Compressor Inlet Filter 12 1 Remove the pressure control knob from the pump Refer to Page 3 Section 2 12 2 Remove the rear case assembly Refer to Page 5 Section 6 12 3 Carefully pull the filter retaining clip Fig 6 Item 30 from the F tube connector Fig 6 Item 20 12 4 Remove and discard the old inlet filter Fig 6 Item 40 13 Installing the Compressor Inlet Filter 13 1 Locate a new inlet filter Fig 6 Item 40 over the air intake hole in the case of the compressor assembly Fig 6 Item 10 13 2 Carefully reposition the filter retaining Clip Fig 6 Item 30 on the F tube connector Fig 6 Item 20 to retain the inlet filter Fig 6 Item 40 Make sure the clip is fitted with the longer arm downward if appropriate 13 3 Assemble the rear case to the pump Refer to Page 5 Section 7 13 4 Install the pressure control knob from the pump Refer to Page 3 Section 3 Issue 2 Chap 3 Nov 2001 SER0004 Page 11 Pump Repair Mini Pump Service Man
61. ual 0000 ro 30 Figure 7 Replacing the New Style AV Mounts Table 11 New Style AV Mounts Part List tem Part Number ay 500124 Compressor Mounting Bracket N A Mounting Pins Chap 3 Issue 2 Page 12 SER0004 Nov 2001 14 14 1 14 2 14 3 14 4 15 15 1 15 2 15 3 15 4 Mini Pump Service Manual Pump Repair Removing the New Style AV Mounts Remove the pressure control knob from the pump Refer to Page 3 Section 2 Remove the rear case assembly Refer to Page 5 Section 6 Carefully lift the compressor mounting bracket Fig 7 Item 10 and AV mounts Fig 7 Item 20 from the mounting pins Fig 7 Item 30 Remove the AV mounts from the mounting bracket and discard them Replacing the New Style AV Mounts Fit new AV mounts Fig 7 Item 20 of the same type to the mounting bracket Fig 7 Item 10 Carefully fit the compressor mounting bracket and AV mounts to the mounting pins Fig 7 Item 30 in the pump case Ensure that all four AV mounts are correctly located on the mounting pins Assemble the rear case to the pump Refer to Page 5 Section 7 Assemble the pressure control knob to the pump Refer to Page 3 Section 3 Issue 2 Chap 3 Nov 2001 SER0004 Page 13 Pump Repair Mini Pump Service Manual 10 4 20 4 30 440 40 X30 420 1 10 40 X30 420
62. ure that the four pegs are correctly located and secure the mounting bracket to the compressor with three screws Fig 9 Item 60 19 2 Fit the screw washer and lower bump stop Fig 9 Items 50 40 20 to the mounting bracket 19 3 Assemble AV mounts and fit the compressor AV bracket assembly into the pump case as described in Section 15 new style AV mounts or Section 17 old style AV mounts Section 17 2 may be omitted 20 Removing the Compressor Bump Stops 20 1 Remove the compressor AV bracket assembly from the pump case as described in Section 14 1 14 2 and 14 3 new style AV mounts or Section 16 1 16 2 and 16 3 old style AV mounts Note Figure 7 illustrates the new style AV mount system Bump stop to compressor and bump stop to compressor mounting bracket assembly methods are the same for both old and new style AV mount systems 20 2 Remove screw washer and upper bump stop Fig 9 Items 50 40 10 from the compressor lid Issue 2 Chap 3 Nov 2001 SER0004 Page 17 Pump Repair Mini Pump Service Manual 20 3 Remove screw washer and lower bump stop Fig 9 Items 50 40 20 from the compressor mounting bracket 21 Installing the Compressor Bump Stops 21 1 Fit screw washer and replacement upper bump stop Fig 9 Items 50 40 10 to the compressor lid 21 2 Fit screw washer and replacement lower bump stop Fig 9 Items 50 40 10 to the compressor mounting bracket 21 3 Refit the compressor AV bracket assembly to
63. v 2001 Mini Pump Service Manual Pump Repair Table 9 Old Style Bed Hook Part List 10 Bed Hook Left Hand Bed Hook Right Hand Hook Plate Note The old bed hook bracket assemblies are left and right handed Replacements are no longer available 10 Removing the Old Style Bed Hook 10 1 Remove the pressure control knob from the pump Refer to Page 3 Section 2 10 2 Remove the pump rear case Refer to Page 5 Section 6 10 3 Hold a hook plate Fig 5 Item 30 in position and remove the three securing screws Fig 5 Item 40 from the inside of the rear case 10 4 Carefully remove the hook plate and its bed hook Fig 5 Item 10 or 20 10 5 Repeat Section 10 3 and 10 4 for the other hook plate and bed hook if required Note The above procedure will not be necessary when changing the old bed hooks for the new bed hook which needs the new rear case assembly 11 Installing the Old Style Bed Hook 11 1 When refitting the old bed hook brackets replacement is the reversal of the above procedure 11 2 Ensure correct orientation of the left and right handed assemblies The spring on the right hand assembly is colour coded red 11 3 Position the hook and spring assembly on the rear case install the hook plate and hold it in place while inserting the three securing screws from the inside of the rear case 11 4 Assemble the rear case to the pump Refer to Page 5 Section 7 11 5 Install the pressure control knob Refer
64. v 2001 SER0004 Page 3 Maintenance Mini Pump Service Manual Chap 2 Issue 2 Page 4 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair CHAPTER 3 PUMP REPAIR 1 General This chapter details repair procedures for the range of pump units listed in Chapter 1 Page 1 Table 1 All repairs should be carried out by Huntleigh approved service personnel After carrying out a service or any repairs the pump must be soak tested broken in for the recommended time Refer to Chapter 2 and tested for serviceability The table below defines the test reguirements which must be carried out following certain repairs To carry out a flow pressure and function test on the pump refer to Chapter 5 To carry out the electrical tests on the pump refer to Chapter 5 Table 5 Repair to Testing Reguirements Components Assemblies idi ry Pusction Electrical Safety ee INES O o o pana SS o ra CS SS NE NE cem JJ a Je Eto comes e o rs es e pos JI a Je e ne Fuse No Yes Electrical Connectors No Yes Issue 2 Chap 3 Nov 2001 SER0004 Page 1 Pump Repair Mini Pump Service Manual Figure 2 Removing the Control Knob Table 6 Control Knob Part List NET a a En 500318 Pin if fitted 1 Note The obsolete MR1 control knobs are fully interchangeable with the MK2 control knobs If the MK1 control knob needs replecing replace it with the MK2 version Chap 3 Issue 2 Page 2 SER0004 Nov 2001
65. vated the red LOW PRESSURE indicator will flash in combination with an audible warning which increases in pitch with time The alarm can be reset by momentarily switching the pump to Stand by and then back to Run Alternatively the alarm will automatically reset after 15 minutes provided that the low pressure switch is not activated during this time If however the low pressure switch is activated for more than 15 seconds during this time the timer will reset to zero and the alarm will continue for a further 15 minutes Low Pressure Alarm All Units On all pump units except the ALS model the low air pressure alarm will be activated on or before 5 mmHg and deactivated before the pressure reaches 17 mmHg For the ALS model only the low air pressure alarm will be activated on or before 50 mmHg and deactivated at or before 82 mmHg Low Pressure Alarm Protocol Electronic Units Only The low pressure alarm will be activated only when the reguirements of the low pressure alarm protocol have been met by a seguence of low pressure signals The system is designed to detect low pressure fault conditions without responding to spurious signals due to patient movement mattress cell crossover short term tube disconnection etc In order to generate a low pressure alarm the system must detect three low pressure switch closure of 15 seconds duration each within a 25 minute period There will be a 2 minute lockout between the first and second switc
66. w style AV mounts or Page 15 Section 16 1 16 2 and 16 3 old style AV mounts 28 4 Remove the compressor mounting bracket Refer to Page 17 Section 18 28 5 Fit a replacement compressor assembly by reversing the actions detailed above Figure 14 Pressure Control Module Chap 3 Issue 2 Page 26 SER0004 Nov 2001 Mini Pump Service Manual Pump Repair Table 18 Pressure Control Module Part List tem Part Number Description 10 500347 Terminal Block 5 way 20 BP196 Cable Tie 500362 Tube Sil ID 3 16 135 mm 5 mm LG 1 2 1 30 Om soss panses O Teo so ges JJ 29 Replacing the Pressure Control Module 29 1 Remove the pressure control knob as described in Page 3 Section 2 29 2 Remove the rear case assembly as described in Page 5 Section 6 29 3 Remove the compressor wires Fig 14 Item 10 from the terminal block terminals 3 and 4 This also releases two switch wires 29 4 Carefully cut the cables ties from the wiring loom as required Fig 14 Item 20 29 5 Remove the tube Fig 14 Item 30 between the pressure control module and the F connector 29 6 Remove the module securing screw Fig 14 Item 40 and the fixing cap Fig 14 Item 80 29 7 Carefully lift the module with the
67. wo securing screws Fig 18 Item 40 and remove the terminal block from the pressure control module 34 3 Replacement is the reversal of the above procedure Refer to the wiring diagram Chap 4 Fig 24 when reconnecting the wires for the electronic version of the pump and wiring diagram Chap 4 Fig 25 when reconnecting the wires for the mechanical version of the pump Issue 2 Chap 3 Nov 2001 SER0004 Page 35 Pump Repair Mini Pump Service Manual Figure 19 Pressure Control Flaps Air Bag Control Knob Cam and Arbour Table 23 Pressure Control Flaps Air Bag Control Knob Cam and Arbour Part List 9 Part Number Description 500304 Knob Control Arbour 500312 Upper Pressure Control Flap 500318 Pivot Pin Pressure Control 500303 Lower Pressure Control Flap 500341 Spring 0 024 Diameter 151339 Pressure Control Disc o Chap 3 Issue 2 Page 36 SER0004 Nov 2001 35 35 1 35 2 35 3 35 4 35 5 Mini Pump Service Manual Pump Repair Replacing the Pressure Control Flaps and Air Bag Turn the control knob arbour fully counter clockwise Fig 19 Item 10 Hold the upper pressure control flap Fig 19 Item 20 in position and withdraw the pivot pin Fig 19 Item 30 Carefully remove the upper flap and the lower flap Fig 19 Item 40 together with the low pressure operating spring and brass disc Fig 19 Items 50 and 60 Remove and discard the pressure control disc Fig 19 Item 70 from the upper flap Rep

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