Huntleigh Nimbus II, Nimbus 3, DFS2 and DFS3 Service Manual Issue 1 June 2001

Nimbus / DFS Service Manual

Amendment Record

AMENDMENT RECORD Amendment

Incorporated by

Date

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Contents

Contents CHAPTER 1 Introduction... 1 About This Manual... 1 Warnings, Cautions and Notes... 1 Technical Description... 1 Operating Principle... 1 Dynamic Mode... 2 Static Mode... 3 Auto-Matt... 4 System Start Up Sequence... 4 Alternating Head Cells Modification... 4

CHAPTER 2 Maintenance... 1 Pump Maintenance Checks... 1 Pump Soak Times... 2 Pump Service... 2 Mattress Maintenance Checks... 3 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... 15

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Nimbus / DFS Service Manual

Replacing the Coil Assemblies... 15 Replacing the Manifold Gasket... 17 Removing the Rotary Valve Assembly... 18 Installing the Rotary Valve Assembly... 19 Circuit Boards... 21 Removing the Old Style Display Panel PCB, the PCB Transformer and Daughter Board (if fitted)... 21 Removing the New Style Display Panel PCB... 25 Installing the New Style Display Panel PCB... 26 Removing the Pressure Control Assembly... 29 Installing the Pressure Control Assembly... 29 Removing the High Pressure Switch... 31 Installing the High Pressure Switch... 31 Replacing the Mains/Power Switch... 33 Replacing the Mains/Power Inlet Socket and Cordset (Moulded Cordset Versions Only) . 35 Replacing the Mains/Power Fuses (All Versions)... 37 Replacing the Mains/Power Inlet Fuse Holders (Moulded Cordset Versions Only)... 37 Removing the Mains/Power Cable (Hard wired versions only)... 39 Installing the Mains/Power Cable (Hard wired versions only)... 39 Removing the Mains/Power Fuseholders (Hard wired versions only)... 41 Installing the Mains/Power Fuseholders (Hard wired versons only)... 42 Removing the Mains/Power Filter (Hard wired versons only)... 42 Installing the Mains/Power Filter (Hard wired versions only)... 43 Removing the 5-Way Connector and Support (Hard wired versions only)... 45 Installing the 5-Way Connector and Support (Hard wired versions only)... 45 Replacing the Silencer Bag... 47 Removing the Bio Filter (Nimbus 3 and DFS 3 Pumps Only)... 49 Installing the Bio Filter (Nimbus 3 and DFS 3 Pumps Only)... 49 Changing the Battery... 51 Replacing the Sounder... 51 Replacing the Pump Case... 52 Pump Label Sets... 53

CHAPTER 4 Mattress repair... 1 General... 1 Removing the Top Cover... 3 Installing the Top Cover... 3

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Removing the Base Cover... 3 Installing the Base Cover... 7 Replacing the Soft Foam Sheet... 9 Cell Replacement... 11 Removing a Cell... 11 Installing a Cell... 11 Removing the Manifold Assembly... 12 Installing the Manifold Assembly... 12 Removing the Partial Non-Return Valve Assemblies... 14 Installing the Partial Non-Return Valve Assemblies... 14 Removing the Loop Sheet Assembly... 15 Installing the Loop Sheet Assembly... 15 Replacing the Elastic Loops (Nimbus 3/DFS 3 Only)... 16 Removing the Sensor Pad Assembly... 17 Installing the Sensor Pad... 17 Removing the CPR Unit... 18 Installing the CPR Unit... 18 Replacing the Release Button... 19 Replacing the Tubeset... 20 Replacing the CPR O-Rings... 23 Replacing the Transport Assembly... 23 Repairing the CPR Handle Sub-Assembly... 24 Replacing the CPR Manifold Gasket... 25 Alternating Head Cells... 27 Modification Kit... 27 Installing the Alternating Head Cell Modification - Configuration 1... 27 Installing the Alternating Head Cell Modification - Configuration 2... 30

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

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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 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... 8 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 Insulation Resistance Tests... 13 Dielectric Strength Test (Flash Test)... 14 Leakage Circuit Test (USA)... 14 Mattress Pressure and Function Test... 15 Test Procedure... 15

CHAPTER 7 Technical specification... 1 CHAPTER 8 Parts List... 1

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Pump Assembly Parts List... 1 Mattress Assembly Parts List... 7

CHAPTER 9 Service Contact Details... 1

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Introduction

CHAPTER 1 INTRODUCTION 1

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. In no event will Huntleigh Healthcare 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® 2, Nimbus 3, DFS 2 and DFS 3 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.

WARNINGS: 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. 2

Technical Description

The Nimbus 2, Nimbus 3, DFS 2 and DFS 3 are Dynamic Flotation Systems for use in aiding the prevention, treatment and management of pressure sores. It is a powered, air-filled mattress replacement system with microprocessor-aided control and alarm functions which have LED indication on the front panel of the pump. Operating Principle The patient is supported by twenty cells which are enclosed by a polyurethane coated fabric cover. This cover has waterproof, vapour permeable, and two-way stretch properties. The system incorporates a sensor that automatically adjusts the support pressure within the system to accommodate different weight patients and their weight density or distribution. This sensor pad, known as the Auto-Matt® sensor, optimises the pressure to which the cells are inflated to be the minimum to support that patient in a given position.

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Introduction

Nimbus / DFS Service Manual

Small adjustments can be made to the mattress pressure, using the comfort control knob on the pump. This is a patient comfort feature to make small adjustments to the softness or firmness of the mattress. The Nimbus 3 and DFS 3 mattress also includes the HeelGuard® special powered-down feature which is designed to maximise pressure relief under the heels. 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. Figures 1 and 2 show how the system operates in dynamic and static modes. Fig 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) • C to outlet A and B • C to outlet B with A at atmosphere (D) • C to outlet A and B

- A & C Cells Inflated - All Cells Inflated (A, B & C) - B & C Cells Inflated - 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.

Alternating 1

A

B

Lower Body Section

Anti-sink Torso Section

Head Section

Upper and lower cells alternate

Upper cells alternate, lower cells semi-dynamic

Semi-dynamic

A

B

A

B

A

B

B

A

A C C

B

B A A C C C C

B

A C C

C C C

B A C C

C C C

Semi-dynamic cells

Static

2

A

B

A

B

A

B

A

B

A

B A C C

B A B A C C C C

All cells constantly inflated

Alternating 3

Static

4

A

A B

A

B

A B

A

B

A B

A

B

A B

A

B

A

B

A

B

A

B

A

B

A

C C

C C

C C

C C

C

C C

B A C C

B A B A C C C C

B A C C

C C C

All cells constantly inflated

Figure 1 - Mattress Cell Inflation Cycle

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Introduction

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 Fig 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 head cells (C) and the heel protector (above CPR unit) for added patient comfort. On Nimbus 3 and DFS 3, loop sheets, the heel cells have a special powered-down feature to facilitate fast deflation and thereby improve pressure relief under the heels. 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.

Compressor 1

High Pressure Switch

Compressor 2

C

Restrictor

B

Rotary Valve

D (Atmosphere) A

Pump

Pressure Control Adjuster Atmosphere

Low Pressure Switch

5

2

3 Not Used

1

4 Tubeset

Cells A Cells B Partial Non Return Valves

Sensor Pad (Auto Matt)

Cells C

Mattress

Figure 2 - Pneumatic System Diagram

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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 Fig 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).

Alternating Head Cells Modification The Nimbus and DFS beds are normally supplied with the top three (head) cells configured so that they are inflated to a specific pressure. Although the pressure in the head cells normally remains constant, the pressure in the rest of the cells slowly alternates. The Alternating Head Cells Modification converts the static head cells into alternating cells. The modification can be applied in two configurations that follow: Configuration 1 converts all three head cells from static pressure to alternating pressure. Configuration 2 converts the second and third cells from static pressure to alternating pressure. The top head cell remains as a static pressure cell.

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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 0ff)

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 (Refer to 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 (Nimbus 3 and DFS 3 Only)

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

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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. 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 a service on the pump, do the following:

symbol is illuminated. To carry out

3.1

Carry out the Pump Maintenance Checks (Refer to Page 1, Section 1).

3.2

Replace the following components: 3.2.1

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

3.2.2

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

3.2.3

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

3.2.4

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

3.2.5

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

3.2.6

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

3.3

Reassemble the pump and soak 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 6, Page 1, Section 1.

3.5

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

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Maintenance

Mattress Maintenance Checks

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

5

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

Sensor Pad

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.

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

Alternating Head Cells

If fitted, Check the security of all the connectors.

Mattress Service

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

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

5.2

Check the following components and replace if necessary:

5.3

5.2.1

CPR ‘O’ rings (Refer to Chapter 4, Page 4, Section 23).

5.2.2

CPR Manifold Gasket (Refer to Chapter 4, Page 25, Section 26).

Carry out an inflation test on the mattress in accordance with Chapter 6, Page 15, Section 9.

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Pump Repair

CHAPTER 3 PUMP REPAIR 1

General

This chapter details repair procedures for the Nimbus 2, Nimbus 3, DFS 2 and DFS 3 pumps. All repairs should be carried out by Huntleigh 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 2, 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 Flow/Pressure & Function Test

Electrical Safety

Compressor

Yes

Yes

Pressure Control

Yes

Yes

Rotors & Stators

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

Components / Assemblies

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20

40

50 30

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

Part Number

10

151123

Hanging Bracket Assembly

1

20

151427

Bracket

1

30

151428

Wire

1

40

FAS046

Screw M3 x 10 CSK

2

50

FAS216

Nut M3 x 0.5 Euro Series

2

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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 (Fig 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 (Fig 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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