Huntleigh AlphaXcell Service Manual Issue 2 Mar 1999

Page 2

Issue 2

Mar. 1999

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PRELIMINARIES

Revision Record

All revisions incorporated in this copy of the manual must be recorded below.

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Contents

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Electrical Safety Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Servicing Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

OPERATIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Mattress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Further Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

SERVICING THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Dismantling the Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Replacing the Neon Alarm Light . . . . . . . . . . . . . . . . . . . . . . . 5-1

Replacing the Mains On/Off Switch . . . . . . . . . . . . . . . . . . . . . 5-2

Replacing the Pressure Control Assembly . . . . . . . . . . . . . . . . . 5-2

Replacing the Timer Motor/Gear Box Assembly . . . . . . . . . . . . . . . 5-3

Replacing the Compressor Assembly Components . . . . . . . . . . . . . 5-4

SERVICING THE MATTRESS . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Mattress Service Following Laundering/Cleaning . . . . . . . . . . . . . . 6-1

Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

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1

1.1

INTRODUCTION

About this Manual

Huntleigh Healthcare 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.

This manual contains information on servicing the AlphaXcell® system which

comprises the pump and the mattress. The manual is sectioned with tabbed

dividers for ease of use and consists of the following sections.

Section 1 – Introduction : later on in this section a general description of the

overall operation of the system is given.

Section 2 – Operational Maintenance : describes both functional and static

checks to ensure correct operation during the service life of the system.

Section 3 – Preventative Maintenance : contains a list of parts which are

replaced periodically to ensure the correct operation of the system.

Section 4 – Troubleshooting : contains tables of fault symptoms, their possible

causes and suggested steps to rectify the problem.

Section 5 – Servicing the Pump : contains illustrated procedures for replacing

pump components.

Section 6 – Servicing the Mattress : describes procedures for replacing mattress

components.

Section 7 – Technical Data : contains the technical specification of the product.

Appendix – Parts List : contains a list of currently available spares.

Note:

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This manual will be updated every 6 months if required or sooner if

there is a safety issue. Please replace the appropriate pages and

Revision History Sheet, signing and dating it when it has been done.

Destroy the out of date pages. It is the owner’s responsibility to keep

this manual up-to-date.

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1.2

Technical Description

The AlphaXcell system is an advanced Active Pressure Area Management

System specifically designed to provide prevention as well as treatment and

management of pressure sores up to stage 3.

The System is comprised of a pressure regulated pump unit (ACA 001, ACA

005 or ACA 016) and a mattress overlay (ICT20) with 17 alternating cells and 3

static head section cells.

Pressure regulated pump unit ACA001 to be used with ICT20 mattress overlay

only.

The pump supplies cycles of air pressure inflating and deflating the mattress

overlay continuously, working on a ten minute cycle time. 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, then again a 50 second period where no air is supplied

from both outlets.

The pump unit is a piece of precision equipment, and providing it is handled

and serviced correctly (normally every 12 months) should give long and

trouble-free service.

Controls on the pump unit comprise of :

• Mains power switch (green rocker switch) illuminated when in ‘ON’

position.

• Pressure control knob. Pressure adjustment is between:

26 mmHg (±2) and 77mmHg (±7).

• Red alarm indicator neon indicates LOW pressure faults.

The Alphaxcell pump unit is fitted with a visual alarm, when a fault condition

occurs, the neon light illuminates.

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1.3

1.3.1

Electrical Safety Checks

After Repair/Service

Huntleigh Healthcare recommend that the following electrical safety checks are

conducted after any repair and as part of the routine service .

1.3.2

Insulation Resistance Test

500V DC at 2MW. Pass limit is greater than 2MW.

1.3.3

Earth Continuity Test

In addition, the equipment should undergo the following tests on an annual

basis.

1.3.4

1.3.4.1

Annually

Earth Bond Test.

Tested according to IEC 601 - 1 using a 25 amp 6 volt supply, the pass limit is:

0.1W. between any earthed part and the main earthed terminal or:

0.2W between any earthed part and the earth pin on the power plug.

1.3.4.2

Dielectric Strength (Flash) Test.

To be carried out following any major component replacement.

Dielectric strength test conducted at 1.5kV AC to earthed parts and 3kV to

double insulated enclosures. The pass limit is 5mA max.

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1.4

Servicing Protocol

1.4.1

General Service - Pump

Initial Assessment (Visual)

Check:

a)

Enclosure condition

b)

Fittings for damage and security

c)

Labelling is secure and legible.

Open Pump and check:

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 and check:

h)

Silencer bag weld seams

i)

Shuttle valve assembly condition

General:

j)

Check main lead assembly for security

k)

Clean condition of pump.

If any items in a) - i) appear defective, then a replacement from spares stock

should be fitted and this action recorded on the service record sheet.

Re-assemble pump unit completely, run for a minimum for 1 hour and check

calibration. Adjust if required.

1.4.2

Mattress Service Protocol Following Laundering/Cleaning

Layout mattress and check:

a)

General condition of mattress

b)

All components are secure and intact

c)

Tubeset is in good condition.

Inflate System and check:

d)

Weld integrity (i.e. no leaks)

e)

All fittings i.e. aprons, base sheets connectors are secure, are of

good quality and in good condition

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f)

Printing of instructions is legible

g)

Cover sheet assembly is in good condition

h)

Serial number is secure and legible.

If any item a) - g) appears defective then, where possible, replacements should

be fitted and action recorded on service record sheet.

Note:

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It is important to ensure all tools used in servicing are kept in good

condition and test rigs for measuring flow and pressure are regularly

calibrated to international standards.

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2

2.1

OPERATIONAL MAINTENANCE

Routine Checks

These procedures should be carried out each time the system is used.

2.2

Pump Unit

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

connections etc.

2. Inspect mains cable for damage, twisting and renew if necessary.

3. Test all controls.

2.3

Mattress

Check integrity of Mattress top cover, manifold connections and C.P.R

assembly etc.

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3

PREVENTIVE MAINTENANCE

Preventive maintenance should be carried out every 12 months

3.1

Pump Unit

Replace the following components :

1. Silencer bag

2. Pivot points

3. Bellow arms

4. Valve bodies

5. Compressor sponge filter

6. Compressor gasket

Check :

a)

Base is free from debris.

b)

Filter sponge position.

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)

Mains switch illuminates.

i)

Wiring is tidy.

j)

Air is alternating.

k)

Outlet tubes and Colder connectors are secure and fitted correctly.

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3.1.1

To Check and Calibrate Air Pressure/Flow

To calibrate the pump unit correctly the following equipment is required:

• A Sphygmomanometer or pressure gauge (0–160 mmHg.)

• A Flow meter (0–10 litres/minute).

Attach the pressure gauge/sphygmomanometer tube to whichever outlet is

operating. Pressure range should be:

• 24–28 mmHg on minimum setting

• 70–84 mmHg on maximum setting

Flow of 6 litres/minute freeflow (ACA100 only, flow of 3.5 litres/minute @ 55

mmHg).

If the pressure readings are incorrect then perform the following:

1. Remove the pressure control knob by slackening off the side screw.

Rotate the brass arbor until the pressure reads 24–28mmHg.

2. Carefully replace the pressure control knob, ensuring the pointer

indicates to the minimum setting on the facia label.

3. Press the knob firmly into the recess, compressing the friction spring,

then tighten the side screw.

4. Check the minimum and maximum settings and readjust if necessary.

5. Variation between ports not to be greater than 4 mmHg.

6. Attach the flow meter tube to the port under test and check the flow

measurements. The flow readings should be 6 litres/minute free flow.

3.1.2

Low Pressure Alarm Check

1. With the pump unit running and the outlet ports open, the low pressure

alarm light should be illuminated.

2. Block the duty port; the low pressure alarm light should go out.

3. Allow the duty port to exhaust to atmosphere and the low pressure

alarm light should illuminate again.

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4

TROUBLESHOOTING

Some of the more usual problems which may occur after long periods of time,

and the way in which to correct them are outlined below.

The AlphaXcell pump unit is fitted with a visual alarm and when a ‘LOW

PRESSURE’ fault condition occurs, the red neon illuminates.

4.1

Preliminary Checks

Check the following before dismantling the pump unit.

1. All tubing connections on pump and mattress are securely fastened and

snap locked into place.

2. Check the C.P.R. stopper is fitted correctly.

3. If alarm is still illuminated, visually inspect tubing and mattress cells

for punctures or tears and are fitted to the manifold correctly.

This eliminates possible mattress and tubing faults.

4.2

4.2.1

Further Checks

Loss of Output Pressure

If the alarm stays on, this could be due to loss of output pressure in which case

the pump unit internal compressor must be tested as follows:

1. Remove unit lid as described in Section 5.1.

2. Disconnect compressor outlet tubes from 4-way connector and connect

a ‘Y’ piece to the two tubes.

3. Connect pressure gauge to the ‘Y’ piece outlet, pressure reading should

be at least 100mmHg.

If the pressure does not reach 100 mmHg, then 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 once again be approximately

100mmHg.

If this pressure cannot be reached then the bellow/armature assemblies and

valve bodies must be replaced. If 100mmHg can be obtained then the silencer

bag assembly must be replaced.

4.2.2

Air Not Alternating

Should the cells of the mattress not inflate and deflate alternately during a 10

minute cycle, then the timer motor may be defective. Check the timer motor

electrical connections for security and integrity. If all are sound and the timer

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motor still does not rotate, then the timer motor must be replaced.

The timer motor is a sealed unit and cannot be repaired and must be replaced if

faulty.

When replacing the timer motor it is advisable to replace the rotor/stator

assembly.

Should the compressor be operating correctly and the correct pressure cannot be

obtained at the pump outlets, then the rotor/stator assembly must be checked.

Remove the timer motor/gear box assembly (as previously described), compress

the rotary valve assembly and remove the drive pin. Check the bearing surfaces

for cracks or bad scores.

Also check the security of the elbow connectors.

Any damaged parts must be replaced.

4.2.3

Loss of Electrical Power

Power loss can be due to the following :1. No electricity supply at wall socket.

2. Faulty wall socket.

3. Damaged plug or mains cable.

4. Defective fuse link.

5. Damaged internal wiring.

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5

5.1

SERVICING THE PUMP

Dismantling the Pump Unit

Before dismantling the pump unit ensure it has been isolated from the mains

power supply by removing the mains cable from the wall socket.

To remove the case lid place the unit upside down on a flat, clean surface.

Remove the rubber feet and unscrew the four self tapping screws.

Holding the unit in both hands, turn it onto its base and carefully remove the lid

and place to one side.

Before the removal or replacement of the Pressure Control assembly, the facia

label must be carefully peeled to one side to allow access to the fixing screws.

5.2

Replacing the Neon Alarm Light

To remove the alarm neon disconnect the electrical connections, squeeze

together the retaining flanges located at the top and bottom of the neon body

and carefully push neon through the front panel.

Replacement of the alarm neon is reverse of the above ensuring the retaining

flanges snap into position.

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5.3

Replacing the Mains On/Off Switch

Removal of the mains On/Off switch is similar to that of the neon alarm light

(see previous illustration). Disconnect 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.

5.4

Replacing the Pressure Control Assembly

1. Remove facia label as previously described.

2. Unscrew and remove the three countersunk securing bolts and nuts.

3. Disconnect all tubing attached to the assembly.

4. Disconnect microswitch electrical connections.

5. Replacement is reverse of the above.

6. Ensure that the pressure control spring and rivet are in position before

securing pressure control to front panel.

7. Reconnect the microswitch to the alarm module.

8. Reconnect tubing to the pressure control, ensuring all tubes are pushed

fully onto their mounts.

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5.5

Replacing the Timer Motor/Gear Box Assembly

This is a sealed unit which cannot be repaired and must be replaced if faulty.

When replacing the motor/gear box assembly it is advisable to replace the

rotor/stator assembly.

Unscrew and remove the timer motor securing screws. Disconnect all tubing

attached to the assembly, and disconnect electrical connections from the

terminal block.

Replacement is reverse of above.

Note:

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When reconnecting tubes to the assembly ensure there are no kinks and

tubes are pushed fully onto their mounts.

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5.6

Replacing the Compressor Assembly Components

Unscrew and remove the four M4 countersunk screws, remove the lid and

gasket and place to one side.

5.6.1

Silencer Bag Assembly

Disconnect the silencer bag outlet tubes from the four way connector,

disconnect silencer bag inlet tubes from valve body assemblies.

Replacement is reverse of above.

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5.6.2

Bellows/Armature Blade Assemblies

Unclip bellow from valve body assembly and extract armature blade from pivot

point using long nosed pliers.

Replacement is reverse of above.

5.6.3

Valve Body Assembly

Unscrew and remove securing nuts on side of compressor casing. Remove

valve body from compressor body.

Replacement is reverse of above.

Note that the compressor can be replaced as a complete assembly if required.

Disconnect the silencer bag outlet tubes from the 4-way connector. Disconnect

the compressor electrical leads from the terminal block.

Replacement is reverse of the above.

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6

SERVICING THE MATTRESS

6.1

Mattress Service Following Laundry/Cleaning

Layout mattress and check:

a)

General condition of mattress.

b)

All components are secure and intact.

c)

Tube set/Manifolds are in good condition.

Inflate system and check:

d)

Cell weld integrity (ie. no leaks)

e)

All fittings ie. base sheets, connectors are secure and in good

condition.

f)

Printing of instructions is legible.

g)

Cover sheet is in good condition.

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6.2

6.2.1

Replacing Components

Top Cover

To remove the top cover, unzip at both sides and unfasten velcro strips at each

end.

6.2.2

Replacing Mattress Cells

If for any reason one of the mattress cells is leaking, these can be replaced by

disconnecting the press stud fastener at each end of the cell, and removing the

cell connector from each manifold. Slide the cell from the cell retaining loops.

Replacement of the cell is reverse of the above procedure, ensuring the cell is

fed through all the retaining loops.

6.2.3

Replacing the Manifolds

To replace the manifold, disconnect all the press stud fasteners on the

appropriate side of the mattress.

Remove all the cell connectors from the manifold.

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Replacement of the manifold is reverse of the above.

6.2.4

Non - Return Valves

Each mattress manifold is fitted with two (white) non-return valves situated at

the head section of the mattress.

These can easily be removed and replaced from the manifold.

When replacing the non-return valves always ensure the arrow points towards

the head (top) of the mattress.

6.2.5

C.P.R. Assembly

To replace the C.P.R. assembly, carefully remove from the end of the manifold.

Inspect and renew if necessary.

Disconnect the assembly from the non-return valves.

Replacement is reverse of the above.

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