ARJOHUNTLEIGH NIMBUS 4 SYSTEMS Service Manual Issue 1 Aug 2009

Nimbus 4 Systems Service Manual

Service Bulletins Incorporated Bulletin

Issue 1 Aug 2009

Content

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Date incorporated

Ammendment Record Page i

Nimbus 4 Systems Service Manual

Ammendment Record Page ii

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Issue 1 Aug 2009

Nimbus 4 Systems Service Manual

CONTENTS

CONTENTS CHAPTER 1 Introduction... 1 About This Manual... 1 Warnings, Cautions and Notes... 1 About Nimbus 4 and Nimbus Professional... 2 Dynamic Mode... 2 Static Mode... 4 Auto-Matt... 5 System Start Up Sequence... 5

CHAPTER 2 Maintenance... 1 Pump Maintenance Checks... 1 Pump Soak Times... 1 Pump Service... 2 Mattress Maintenance Checks... 2 Mattress Service... 3

CHAPTER 3 Pump Repair... 1 General... 1 Removing the Hanging Bracket... 3 Installing the Hanging Bracket... 3 Disassembling the Rear Case... 5 Assembling the Rear Case... 5 Disassembling the Pump Filter... 7 Assembling the Pump Filter... 7 Removing the Double Compressor Assembly... 9 Installing the Double Compressor Assembly... 9 Removing the AV Mounts... 10 Installing the AV Mounts... 10 Replacing the Compressor Filters... 13 Removing the Compressor Bump Stops... 13 Installing the Compressor Bump Stops... 13 Replacing the Shuttle Assemblies... 16 Replacing the Coil Assemblies... 16 Replacing the Manifold Gasket... 18

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CONTENTS

Nimbus 4 Systems Service Manual

Removing the Rotary Valve Assembly... 21 Installing the Rotary Valve Assembly... 21 Removing the Display PCB... 23 Installing the Display PCB Assembly... 23 Removing the Front Panel... 27 Installing the Front Panel (if required)... 27 Replacing the Mains/Power Inlet Socket and Cordset... 29 Replacing the Mains/Power Fuses... 31 Replacing the Mains/Power Inlet Fuse Holders... 31 Removing the Pressure Control Assembly... 33 Installing the Pressure Control Assembly... 33 Removing the High Pressure Switch... 35 Installing the High Pressure Switch... 35 Replacing the Mains/Power Switch... 37 Replacing the Silencer Bag... 39 Removing the Bio Filter... 41 Installing the Bio Filter... 41 Changing the Battery... 42 Replacing the Pump Case... 43 Pump Label Sets... 44

CHAPTER 4 Mattress Repair... 1 General... 1 Removing the Top Cover... 3 Installing the Top Cover... 3 Removing the Base Cover... 3 Installing the Base Cover... 6 Cell Replacement... 9 Removing a Cell... 9 Installing a Cell... 10 Removing the Manifold Assembly... 11 Installing the Manifold Assembly... 11 Removing the Heel Protector... 12 Installing the Heel Protector... 13 Removing the CPR Assembly... 13 Installing the CPR Assembly... 13 Removing the Partial Non-Return Valve Assemblies... 13 Installing the Partial Non-Return Valve Assemblies... 13

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CONTENTS

Removing the Loop Sheet Assembly... 15 Installing the Loop Sheet Assembly... 15 Replacing the Elastic Loops... 16 Removing the Auto Matt Assembly... 17 Installing the Auto Matt... 17 Tubeset Assembly Components... 18 Repairing the Tubeset Connector Assembly... 19 Service Engineers Tubeset Assembly... 23 Replacing the Tubeset... 23 Replacing the CPR O-Rings... 27 Replacing the Transport Assembly... 27 Repairing the CPR Handle Sub-Assembly... 27 Replacing the CPR Manifold Gasket... 29 Removing the Knob from the Vent Valve... 31 Installing the Knob on a Vent Valve... 32

CHAPTER 5 Troubleshooting... 1 Troubleshooting Table... 1

CHAPTER 6 Testing... 1 Pump Flow, Pressure and Function Test... 1 Test Setup... 1 Power Fail Alarm Check... 2 Alarm Functions... 2 High/Low Pressure Setpoint and Mute Mode Checks... 2 Static and Dynamic Mode Pressure Tests... 2 High/Low Pressure Setpoint Checks and Mute Mode Check using the Psion Organiser... 3 Psion Organiser Setup... 3 High Pressure Switch Setpoint Check... 3 Low Pressure Switch Setpoint Check... 3 Mute Mode Check... 4 High/Low Pressure Setpoint Checks and Mute Mode Check using the IR Interface Module . . 4 IR Interface Setup... 4 High Pressure Switch Setpoint Check... 5 Low Pressure Switch Setpoint Check... 5 Mute Mode Check... 5 Static and Dynamic Mode Pressure Tests using the Psion Organiser... 5

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CONTENTS

Nimbus 4 Systems Service Manual

Static and Dynamic Mode Calibration Readings... 5 Adjusting the Pressure... 5 Psion Organiser Setup... 5 Static Mode Pressure Tests... 6 Dynamic Mode Pressure Tests... 7 Check Pump Serial Number... 8 Static and Dynamic Mode Pressure Tests using the IR Interface... 8 Static and Dynamic Mode Calibration Readings... 8 Adjusting the Pressure... 8 IR Interface Setup... 8 Static Mode Pressure Tests... 9 Dynamic Mode Pressure Tests... 9 Check Pump Serial Number... 10 Psion Organiser Setup... 11 IR Interface Setup and Passwords for ProNimbus... 11 Electrical Testing... 13 Electrical Safety Checks - Class I... 13 Earth Continuity Tests... 13 Mattress Pressure and Function Test... 14 Test Procedure... 14

CHAPTER 7 Technical Specification... 1 Pump... 1 Test standards... 1 Accessories... 2 Mattress... 3 Cover Specification... 4 Cleaning Symbols... 5

CHAPTER 8 Parts List... 1 Pump Assembly Parts List... 1 Mattress Assembly Parts List... 5

CHAPTER 9 Service Contact Details... 1

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Introduction

CHAPTER 1 INTRODUCTION 1

About This Manual

ArjoHuntleigh strongly recommend that their equipment is only serviced by trained personnel and provide courses for customers who wish to become licensed to service their own equipment. In no event will ArjoHuntleigh be responsible for any service performed by customers or third parties. This manual contains information on maintenance, servicing, repair, troubleshooting and testing for the Nimbus® 4 and Nimbus Professional systems which comprise a pump and a mattress. Read and understand this manual before attempting to service or repair the equipment.

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 equipment failure or damage. Notes given in this manual are used to explain or amplify a procedure or condition.

WARNING: BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES, ENSURE THAT THE EQUIPMENT HAS BEEN ADEQUATELY DECONTAMINATED. VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC CAN, IN CERTAIN CIRCUMSTANCES, BE LETHAL. WHEN WORKING ON EQUIPMENT REQUIRING EXPOSURE TO LIVE, UNPROTECTED CONDUCTORS WHERE SUCH VOLTAGES ARE PRESENT, EXTREME CARE MUST BE EXERCISED.

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Introduction

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Nimbus 4 Systems Service Manual

About Nimbus 4 and Nimbus Professional

Nimbus 4 and Nimbus Professional are highly effective Dynamic Flotation Systems providing active therapy for the prevention, treatment and management of pressure ulcers. The systems comprise a pump and mattress replacement which can be used on standard hospital and normal domestic beds. Beds with divided sections for independent elevation of a patient's head and/or knees can be adjusted with these mattresses in position. Both systems use the same Nimbus pump, which has two operating modes: •

Dynamic mode that cycles the support surface beneath the patient every 10 minutes providing periods of pressure relief for the whole body.

•

Static mode where the support surface remains constant (all cells equally inflated).

The Nimbus Professional mattress combines all the qualities of the Nimbus range of mattresses with the added benefit of optional head cell deflate; this will assist the clinician with a range of nursing procedures including prone nursing, intubation, neck cannulation and hygiene, while the body of the mattress continues to provide optimal alternating pressure redistribution. Both mattresses have been designed with specialised Vent Valves, so that some of the cells (including the three head cells on the Nimbus Professional mattress) can be selectively deflated to assist with pressure area care and patient management. The mattresses incorporate an advanced AutoMatt® sensor pad which ensures the patient is automatically supported at optimum pressures regardless of size, height, position or weight distribution. Both mattresses incorporate the five Heelguard® cells at the foot end of the mattress which ensure that the patient’s heels are provided with the maximum pressure relief. If cardiac arrest occurs, the mattresses can be rapidly deflated using the CPR (Cardio-Pulmonary Resuscitation) Control to allow cardiac resuscitation procedures to be performed.

Dynamic Mode In dynamic mode the support surface beneath the patient is cycled every 10 minutes providing periods of pressure relief for the whole body. Figure 1 and Figure 2 show how the system operates in dynamic and static modes. Figure 2 shows the pneumatic circuit in principle. A dual compressor system is used to provide a source of air supply. This is fed to a high pressure switch, the Auto-Matt sensor and a rotary valve. The high pressure switch is used to detect system over-pressures through blockages. The low pressure switch, which is located in the pressure control assembly, is used to detect if the air pressure in the system falls below minimum. The rotary valve channels the air supply as shown below: C to outlet A with B at atmosphere (D)

- A & C Cells Inflated

C to outlet A and B

- All Cells Inflated (A, B & C)

C to outlet B with A at atmosphere (D)

- B & C Cells Inflated

C to outlet A and B

- All Cells Inflated (A, B & C)

This then allows cells A and B in the mattress to be inflated and deflated in a cycle period of ten minutes.

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Introduction

Figure 1 - Mattress Cell Inflation Cycle In the mattress there is a third section of cells labelled as C. These are fed through partial non-return valves from cells A and B and are therefore never at zero pressure. These are positioned as shown in Figure 1 to prevent the torso section from ‘bottoming’ during dynamic mode and when a patient is sitting upright. Semi-dynamic pressure is also applied to the heel protector (above CPR unit) and the head cells (Nimbus 4 only, not Professional) for added patient comfort. On Nimbus 4 and Nimbus Professional, loop sheets, the heel cells have a special powered-down feature to facilitate fast deflation and thereby improve pressure relief under the heels.

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Introduction

Nimbus 4 Systems Service Manual

Static Mode In static mode the support surface is kept constant and provides pressure reduction without cycling. The rotary valve is held in a constant position so that cells A, B, C and the heel protector are equally inflated.

Figure 2 - Pneumatic System Diagram

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Introduction

Auto-Matt The Auto-Matt sensor consists of a flexible air sensor pad which is located underneath the mattress cells. This acts as a pressure regulator and accommodates changes in patient weight and position in the following manner: It is pneumatically connected in parallel to the mattress cells and when it is not occluded, it channels the air supply away from the cells. Occlusion of the Auto-Matt sensor is by patient weight and position. In this manner it allows internal mattress air pressures to be compensated to that required to support the patient. With no patient on the mattress the Auto-Matt sensor is not occluded and pressure in the mattress is governed by the pressure control shown in Figure 2. This is in turn set to a pressure range which can be slightly adjusted to change mattress pressures for patient comfort. With a patient on the mattress, pressure is exerted onto the cells and this can partially or totally occlude the Auto-Matt sensor. This results in more air being supplied to the cells increasing their internal pressure until full patient support is achieved. Should the patient change to a position which necessitates a lower pressure, air is released via the Auto-Matt sensor through the pressure control valve until the correct lower pressure is achieved in the cells.

System Start Up Sequence After the pump is switched on the start up sequence is as follows: •

All display indicators illuminate for a few seconds.

•

Low Pressure and Wait indicators remain illuminated while the mattress inflates (approx 20 Min). All the other indicators go out.

•

The pump runs one compressor until the rotor turns to the cross over position (within 5 Min).

•

The rotor then depresses the microswitch which stops the rotor and activates the second compressor.

•

Both compressors run for 20 minutes or when the mattress reaches the minimum pressure setting.

•

When the minimum pressure setting is reached the Low Pressure and Wait indicators go out.

•

The pump cuts down to one compressor and the rotor starts to rotate.

•

In Dynamic Mode the compressors will alternate every 4 hours.

•

In Static Mode the Coils (4 off) will alternate every 4 hours (one at a time). The compressors alternate depending on which coil is working (there are two coils in each compressor).

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Introduction

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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

1.2

1.3

Visually inspect the following for damage, wear and potential faults: 1.1.1

Outer Casing

Check for damage and security.

1.1.2

Switches, Control Knobs

Check function.

1.1.3

Hanging Bracket

Check for damage and security.

1.1.4

Outlet ports

Check for damage and free from obstructions.

1.1.5

Rubber feet (8 Off)

Check for security.

1.1.6

Fuses

Check condition.

1.1.7

Front panel

Check for damage to LED’s and buttons.

1.1.8

Mains/Power lead

Check for damage and security of plug.

1.1.9

Labels

Check all labels are present and legible.

Disassemble the Rear Case (Chapter 3, Page 5, Section 4) and visually inspect the following for damage, wear, security and potential faults: 1.2.1

Compressor

1.2.2

Rotary Valve Assembly

1.2.3

Printed Circuit Boards (PCB’s)

1.2.4

Pressure Control Assembly

1.2.5

High Pressure Switch

1.2.6

Silencer Bag

1.2.7

Bio Filter

1.2.8

Tubing and Wiring

1.2.9

Screws, Nuts and bolts

Remove the compressor lids and visually inspect the following for damage, wear and potential faults: 1.3.1

Coils

1.3.2

Elbows and connectors

1.3.3

Filters and gaskets

1.3.4

Shuttle Valve Assemblies

2

Pump Soak Times

2.1

A pump must be soaked with its ports occluded for the following reasons:

•

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.

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Maintenance

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2.2

All pumps should be soaked for a period of 30 to 60 minutes prior to any pneumatic performance test being carried out.

2.3

If any of the following major/critical components have been replaced or repaired, then it is recommended that the pump be soaked for 12 hours prior to being tested:

•

Valve Shuttle Assemblies

•

Silencer Bags

•

Printed Circuit Boards (PCB’s)

•

Compressor

•

Rotary Valve Assembly

3

Pump Service

A pump should be serviced every 12 months or when the service on the pump, do the following:

symbol is illuminated. To carry out a

3.1

Carry out the Pump Maintenance Checks (Chapter 2, Page 1, Section 1).

3.2

Replace the following components: 3.2.1

Case Seal (Chapter 3, Page 5, Section 4 and Section 5).

3.2.2

Valve Shuttle Assemblies (Chapter 3, Page 16, Section 15).

3.2.3

Compressor AV Mounts (Chapter 3, Page 10, Section 10 and Section 11).

3.2.4

Compressor Filters (Chapter 3, Page 13, Section 12).

3.2.5

Case Filter (Chapter 3, Page 7, Section 6).

3.2.6

Pump Manifold Gasket (Chapter 3, Page 18, Section 17).

3.3

Reassemble the pump and soak for the recommended time (Refer to Page 1, Section 2).

3.4

Carry out a flow, pressure and function test on the pump in accordance with Chapter 6, Page 1, Section 1.

3.5

Carry out electrical tests on the pump in accordance with Chapter 6, Page 13, Section 8.

4

Mattress Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Chapter 4 “Mattress Repair”. 4.1

Visually inspect the following for damage, wear and potential faults: 4.1.1

Base and Top Cover

Check for tears, staining, clarity of printed labels.

4.1.2

Base/Top Cover Zip

Check the zip runs freely and condition of zip teeth.

4.1.3

Anti-slip pads

Check for damage.

4.1.4

Fixing straps

Check condition and security.

4.1.5

Loop sheet

Check for broken/torn loops.

4.1.6

Auto Matt

Check condition and security of tubes.

4.1.7

Soft/Hard Foam

Check condition.

4.1.8

Connectors

Check for damage and security.

4.1.9

Tubing

Check for security and ensure no kinks or twists.

4.1.10

Cells

Check for damage and security.

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5

Maintenance

4.1.11

Manifold

Check for damage and security.

4.1.12

Partial Non-Return Valves

Check for condition.

4.1.13

Heel Protector

Check for damage and security.

4.1.14

Pop Studs

Check condition.

4.1.15

CPR Unit

Check operation of Fast Deflate mechanism.

4.1.16

CPR Transport Knob

Check operation.

4.1.17

CPR Inlet Manifold

Check for damage and free from obstructions.

4.1.18

Tubeset assembly

Check for damage and security of connection.

4.1.19

Vent Valves

Check operation.

Mattress Service

To carry out a service on the mattress, do the following: 5.1

Carry out the Mattress Maintenance Checks (Refer to Page 2, Section 4).

5.2

Check the following components and replace if necessary:

5.3

5.2.1

CPR ‘O’ rings (Chapter 4, Page 27, Section 26).

5.2.2

CPR Manifold Gasket (Chapter 4, Page 29, Section 29).

Carry out an inflation test on the mattress in accordance with Chapter 6, Page 14, Section 9.

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Maintenance

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Pump Repair

CHAPTER 3 PUMP REPAIR WARNING: BEFORE DISMANTLING THE PUMP, ENSURE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET.

1

General

This chapter details repair procedures for the Nimbus 4 and Nimbus Professional pump. All repairs should be carried out by ArjoHuntleigh approved service personnel. After carrying out a service or any repairs, the pump must be soaked for the recommended time (Refer to Chapter 2, Page 1, Section 2) and tested for serviceability. The table below defines the test requirements which must be carried out following certain repairs: To carry out a flow, pressure and function test on the pump refer to Chapter 6, Page 1, Section 1. To carry out the electrical tests on the pump refer to Chapter 6, Page 13, Section 8. Table 1 - Repair to Testing Requirements Components / Assemblies

Flow/Pressure & Function Test

Electrical Safety

Compressor

Yes

Yes

Pressure Control

Yes

Yes

Gearbox Assembly

Yes

Yes

Silencer Bag

Yes

No

High / Low Pressure Switches

Yes

Yes

Shuttle Assembly

Yes

Yes

Coils

Yes

Yes

Elbows & Connectors

Yes

No

AV Mounts

Yes

Yes

PCB

Yes

Yes

Front Casing

Yes

Yes

Rear Casing

No

No

Battery

No

Yes

Switches

No

Yes

Fuses

No

Yes

Electrical Connectors

No

Yes

Mains/Power Lead

No

Yes

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Pump Repair

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Figure 3 - Removing and installing the Hanging Bracket Table 2 - Hanging Bracket Part List Item

Part Number

10

649123

Hanging Bracket Assembly

1

20

151427

Bracket

1

30

649428

Wire

1

40

FAS046

Screw M3 x 10 CSK

2

50

FAS216

Nut M3 x 0.5 Euro Series

2

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Description

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Pump Repair

2

Removing the Hanging Bracket

2.1

Ease the bottom of the hanging bracket off of the base of the pump.

2.2

Rotate the hanging bracket (Figure 3) and remove it from the handle recess in the back of the pump.

3

Installing the Hanging Bracket

3.1

Lay the pump face down and insert the bridge of the hanging bracket (Figure 3) into the handle recess of the pump.

3.2

Pull the bottom of the hanging bracket over the bottom of the pump and push firmly downwards so that the bracket clips into place around the base of the pump.

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Chap 3 Page 3