Flowtron Plus Service Manual Issue 1 A Sept 1998

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PRELIMINARIES Revision Record All revisions incorporated in this copy of the manual must be recorded below. Section

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Preface Review this manual before attempting to service or repair the equipment. This manual is intended to be used only by qualified Huntleigh Healthcare service technicians. In the event that the manual is provided to a customer in response to customer requirements, the customer is advised not to attempt repairs and to direct any required service to qualified Huntleigh service technicians. In no event will Huntleigh be responsible for any service performed by customers or third parties.

Warnings, Cautions and Notes WARNINGS given in this manual identify possible hazards in procedures or conditions which, if not followed correctly, could result in loss of life or severe personal injury. CAUTIONS given in this manual identify procedures or conditions which, if not followed correctly, could result in equipment damage. NOTES given in this manual are used to explain or amplify a procedure or condition. General Warnings 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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Contents INTRODUCTION... 1-1 How To Use This Manual... 1-1 Technical Description... 1-2 Product Range... 1-2 Servicing Protocol... 1-3 OPERATIONAL MAINTENANCE... 2-1 Routine Checks... 2-1 TROUBLESHOOTING... 3-1 Preliminary Checks... 3-1 Further Checks... 3-1 PREVENTIVE MAINTENANCE... 4-1 Pump Unit... 4-1 SERVICING THE PUMP... 5-1 Dismantling the Pump Unit... 5-1 Replacing the Pressure Gauge... 5-1 Replacing the Alarm Light... 5-2 Replacing the On/Off Switch... 5-2 Replacing the Fuse Holder... 5-2 Replacing the Pressure Control Assembly... 5-3 Replacing the Timer Motor/Gear Box Assembly... 5-4 Replacing the Electric Supply Cord... 5-4 Replacing the Compressor Air Inlet Sponge Filter... 5-5 Replacing the Compressor Assembly... 5-6 Replacing the Compressor Assembly Components... 5-6 Testing... 5-8 TECHNICAL SPECIFICATIONS... 6-1 APPENDIX A... A-1 Wiring Diagram... A-1 Pneumatic Diagram... A-1 APPENDIX B... B-1 Spare Parts List... B-1

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1 1.1

INTRODUCTION How To Use This Manual

This manual contains information for servicing the Flowtron® Plus system which consists of a pump and a selection of compression therapy garments. The manual is partitioned with tabbed dividers for ease of use and consists of the following sections: Section 1 - Introduction: includes a general description of the operation of the system and a servicing protocol. Section 2 - Operational Maintenance: describes both functional and static checks to ensure correct operation during the service life of the system. Section 3 - Troubleshooting: contains details of fault symptoms, their possible causes and suggested steps to rectify the problem. Section 4 - Preventive Maintenance: contains a list of parts which must be replaced periodically to ensure the correct operation of the system. Section 5 - Servicing the Pump: contains illustrated instructions for replacing pump components, together with testing and calibration procedures. Section 6 - Technical Specifications: contains a list of technical data. Section 7 - Spare Parts: contains a recommended list of parts which should be held in stock. Appendix A - Diagrams: contains electrical wiring and pneumatic diagrams. Appendix B - Parts List: a list of currently available spare parts.

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1.2

Technical Description

The Flowtron Plus System has been specifically designed to provide compression therapy to the limbs of patients for the treatment of venous and lymphatic conditions. The system comprises: 1. Pressure regulated pump Model AC200/2 2. Either one or two garments from the Flowtron range Pressure regulated pump unit AC200/2 to be used with Flowtron garments only. The pump supplies cycles of air pressure, inflating and deflating the garments, and uses a three minute cycle (90 seconds inflation / 90 seconds deflation). Each compression garment is inflated alternately. If only one garment is in use, the second pump outlet is sealed. The pump unit is a piece of precision equipment, and provided it is handled and serviced correctly (normally every 12 months), should give long and troublefree service. Controls and indicators on the pump unit comprise: a)

Power switch (green rocker switch) illuminated when in the “ON” position

b)

Pressure control knob. Pressure adjustment between 30 mmHg and 90 mmHg

c)

Red alarm light, indicates low pressure situations

d)

Pressure gauge

Flowtron garments have a single chamber providing uniform pressure. 1.3

Product Range

This manual is applicable to the following pumps :Flowtron Plus AC200-2 STD 220-240V Flowtron Plus AC200-2 EURO 220-240V Flowtron Plus AC200-2 HMT 220-240V Flowtron Plus AC200-2 GYMNA 220-240V

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1.4

Servicing Protocol

1.4.1

General Service - Pump

Initial Assessment (Visual check): a)

Enclosure for integrity and cleanliness of top and base

b)

Fittings for damage and security

c)

Labelling is secure and legible

Open Pump: d)

Wiring security and terminations are secure

e)

Tubing security and integrity

f)

Components fastenings are secure

g)

General condition inside is clean

Open Compressor: h)

Silencer bag weld seams

i)

Bellows/armature blade assembly condition

General: j)

Check main lead assembly for security

k)

Clean condition of pump

If any items in a) - i) appear defective, then replacement from spares stock should be fitted and action recorded on service record sheet. Re-assemble pump unit completely. 1.4.2

Garment Service Protocol Following Laundering/Cleaning

Layout garment and check: a)

General condition of garment

b)

All components are secure and intact

c)

Tube is in good condition

Inflate System: d)

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Garment integrity (i.e., no leaks)

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1.4.3

Testing

The following procedures should be performed following any repair and as part of the routine service. Perform electrical safety checks, pressure, flow and calibration checks and functional checks as given in Section 5. Note:

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It is important to ensure that all tools which are used in servicing are kept in good condition and test rigs for flow and pressure are regularly calibrated to a reference gauge with calibration directly traceable to appropriate National Standards.

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OPERATIONAL MAINTENANCE

2.1

Routine Checks

These procedures should be performed each time the system is used. 2.1.1

Pump Unit

a)

Inspect the pump unit for external damage to case, controls and connections etc.

b)

Inspect the electric mains lead for damage, cuts, abrasion, twisting and replace, if necessary

c)

Test all controls

2.1.2

Garments

Check integrity of garments. Visually inspect for punctures, tears, damage to connections, fasteners and tubes.

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3

TROUBLESHOOTING

This section lists problems which may occur after long periods of time, and outlines the corrective action. The Flowtron Plus System has a visual alarm. When a low pressure fault condition occurs, the red light illuminates. The following checks should be performed by a Huntleigh Healthcare technician. 3.1

Preliminary Checks

Check the following before dismantling the pump unit. 1. Verify that all tubing connections on pump and garment are securely fastened and in place. 2. Visually inspect tubing and garments for punctures or tears. This eliminates possible garment and tubing faults. 3.2

Further Checks

3.2.1

Low pressure fault

If alarm stays on: Set pressure control knob to minimum (completely counter-clockwise). The alarm light should be on if tubes are disconnected from the pump outlets. Close the pump outlets with the fingers. The alarm light should go off. 3.2.2

Continuous (high) pressure fault

If the pressure gauge indicates a pressure higher than the control setting: Switch off pump and remove garments. A continuous pressure fault condition occurs when the timer motor stops rotating (air will not alternate). If this should occur, check integrity of the the electrical connections of the timer motor. If connections are sound and the motor still does not rotate, the timer motor must be replaced.The timer motor is a sealed unit which cannot be repaired. Switch off pump unit and disconnect the mains lead from the power outlet before commencing any repair work.

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3.2.3

Loss of air output pressure

Should the garments not inflate, check them for leaks or kinked tubing. If the garments appear satisfactory, the pump unit internal compressor must be tested. WARNING Danger of electric shock. During the following tests live terminals and conductors will be exposed. 1. Switch off pump unit and disconnect the mains lead from the power outlet. 2. Remove unit lid as described in Section 5. 3. Disconnect the compressor outlet tubes from the 4 way connector and connect a “Y” piece to the two tubes. 4. Connect a pressure gauge to “Y” piece outlet. 5. Reconnect the pump unit to the power supply and switch on the pump. The pressure reading should be at least 100 mmHg. If the pressure does not reach 100 mmHg or drops quickly, this may be due to: a)

Leak in air silencer bag

b)

Tube disconnected between compressor and silencer

c)

Defective compressor

Disconnect the power supply again and 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 reading should once again be approximately 100 mmHg. If this pressure cannot be reached, the bellow/armature assemblies and valve bodies must be replaced. If pressure can be obtained, the silencer bag assembly must be replaced. Switch off pump unit and disconnect the mains lead from the power outlet before commencing any repair work. If the compressor is operating correctly but the correct pressure cannot be obtained at the pump outlets, the rotor/stator assembly and the pressure control assembly must be checked.

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3.2.4

Checking the Pressure Control Assembly

1. Remove the timer motor/gearbox assembly as described in Section 5. 2. Compress the rotary valve assembly and remove the drive pin. 3. Check the bearing surfaces for cracks or bad scores. Also check the security of the elbow connectors. 4. Remove the pressure control assembly as described in Section 5. 5. Inspect the pressure control bags for leaks. Any damaged parts must be replaced. It is recommended,in either case, that the complete assembly is replaced. Switch off pump unit and disconnect the mains lead from the power outlet before commencing any repair work. 3.2.5

Loss of electrical power

Power loss can be due to the following: 1. No electricity supply at wall outlet 2. Faulty wall outlet 3. Damaged plug or electric mains lead 4. Defective fuse link 5. Damaged internal wiring Evaluate each potential fault and correct as necessary. 3.2.6

Technical assistance

Technical assistance, if required, is obtainable from: Service Department Huntleigh Healthcare 310 - 312 Dallow Road Luton, Bedfordshire LU1 1TD UK Telephone : + 44 (0) 1582 413104 Fax : + 44 (0) 1582 459100

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4

PREVENTIVE MAINTENANCE

The following preventive maintenance should be carried out every 12 months. 4.1

Pump Unit

Replace the following components: 1. Silencer bag 2. Pivot points 3. Bellow arms 4. Valve bodies 5. Compressor air inlet sponge filter 6. Compressor gasket Check: a)

Base is free from debris

b)

Filter sponge position correct

c)

Compressor seating

d)

Electrical connections are secure and completely insulated

e)

Pressure control knob is tight

f)

Tubes are fully pushed on and are free from kinks

g)

Tubes and electrical insulation are not damaged

h)

On/off switch illuminates

i)

Wiring is tidy

j)

Air is alternating between each pump outlet

k)

Outlet tubes are secure and fitted correctly

4.1.1

Testing

Test the unit as given in Section 5.

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5

SERVICING THE PUMP Caution

All servicing and repair work must be performed by a Huntleigh Healthcare service technician. 5.1

Dismantling the Pump Unit

Before dismantling the pump unit, ensure that it has been switched off and isolated from the power supply by removing the mains lead plug from the wall outlet. To remove the case lid, place the unit upside down on a flat, clean surface. Remove the rubber feet and unscrew the four fixing screws. Holding the unit in both hands, turn it onto its base. Note:

The pressure gauge is mounted on the lid and is connected by a flexible tube to the main assembly.

Carefully remove the lid and place to one side of the base. 5.2

Replacing the Pressure Gauge

Disconnect the tube from the pressure gauge inlet Remove three self tapping screws and the fixing clamps which attach the gauge to the case lid. Remove the pressure gauge.

Replacement is a reversal of the above procedure.

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5.3

Replacing the Alarm Light

To remove the neon alarm light, disconnect (pull off) the electrical connections, squeeze together the retaining flanges located at the top and bottom of the light body and push the unit through the front panel. To replace the alarm light, push in from the front ensuring the retaining flanges snap into position. Reconnect the electrical connections as per the wiring diagram.

5.4

Replacing the On/Off Switch

To remove the on/off switch, disconnect (pull off) the electrical connections, squeeze together the retaining flanges located at the top and bottom of the switch body and push the switch through the front panel. To replace the switch, push in from the front ensuring the switch retaining flanges snap into position. Reconnect the electrical connections as per the wiring diagram. 5.5

Replacing the Fuse Holder

Disconnect the fuse holder wires from the on/off switch and from the terminal block. Compress the retaining flanges on the fuse holder body and push the fuse holder out of the case. Replacement is a reversal of the above procedure.

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