Contoura Model 460 Service Manual Issue 60 June 2005

PREFACE Read and understand this manual before attempting to service or repair the equipment. This manual is intended to be used by Huntleigh Healthcare approved service technicians. The manual may be provided to a customer in response to customer requirements, but in no event will Huntleigh Healthcare Ltd be responsible for any service or repair 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 correctly followed, could result in death, injury or other serious adverse reactions. Cautions given in this manual identify procedures or conditions which, if not correctly followed, could result in equipment failure or damage. Notes given in this manual (indicated by +) are used to explain or amplify a procedure or condition. General Warnings WARNINGS Before starting any service or maintenance procedures, ensure that the equipment has been adequately decontaminated. Electrical equipment can be hazardous if misused. Obey safety instructions. Do not use electrically powered beds in the presence of flammable gases such as anaesthetic agents. The bed and its sub-assemblies are very heavy and appropriate precautions must be taken to avoid injury when lifting or moving them. Sections of the bed may move under battery power even if the bed is disconnected from the mains power supply.

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CONTENTS 1 1.1 1.2 1.3

2 2.1 2.2

3 3.1 3.2 3.3 3.4

4 4.1 4.2 4.3 4.4

INTRODUCTION

3

About This Manual Product Description Operation

3 4 5

OPERATIONAL MAINTENANCE General Decontamination

13 13 13

PREVENTIVE MAINTENANCE

14

General CPR Release Cable Castors, Brakes and Steering Batteries

14 14 14 15

TESTING

16

Preliminary Power Operated Functions Battery Operation Manual Functions

16 16 17 17

5

TROUBLESHOOTING

19

6

SERVICING INSTRUCTIONS

20

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23

7 7.1

General Product Assembly Structure Special Tools and Equipment Base Cover - access to components Base Cover - Replacement Brake Adjustment Castors - Replacement Mains cable assembly - Replacement Batteries - Replacement Control Box - Replacement Handsets and ‘T’-piece Cable - Replacement Attendant Control Panel - Replacement Flexible Conduit - Replacement Height Actuators - Replacement Leg Section Actuator - Replacement Backrest Actuator - Replacement CPR Release Cable - Replacement Gas Spring and Release Moulding - Replacement Roller Buffer - Replacement (typical) X-ray Cassette Module - Replacement Dismantling the Bed Assembling the Bed Restoration of Paintwork

CALIBRATION

20 21 23 23 24 24 25 27 28 29 30 31 32 33 34 35 37 38 39 40 42 45 50

51

Calibration of Height/Tilt Actuators

51

8

TECHNICAL DATA

52

9

TRANSPORTATION AND STORAGE

53

APPENDIX A

ASSEMBLY SPARES MANUAL

APPENDIX B

DISPOSAL OF GAS SPRINGS

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1 1.1

INTRODUCTION About This Manual

This manual contains information on servicing and maintenance of the Huntleigh Healthcare Contouraâ 460 series modular beds. The manual comprises the following sections: Section 1 - Introduction (this section): Includes a general description of the equipment with an explanation of the function and operation of the controls. Section 2 - Operational Maintenance: Describes routine procedures and checks to ensure correct operation during the service life of the equipment. Section 3 - Preventive Maintenance: Gives details of regular, periodic maintenance actions to ensure correct operation of the equipment. Section 4 - Testing: Defines a serviceability test to verify correct operation of the equipment if function is suspect or following any maintenance or servicing procedure. Section 5 - Troubleshooting: Contains details of fault symptoms, their possible cause and suggested actions to rectify the problem. Section 6 - Servicing Instructions: Contains illustrated procedures for removal and installation of replaceable parts and sub-assemblies. Section 7 - Calibration: Gives calibration procedures for the electrical controls and actuators. Section 8 - Technical Data: Contains a list of technical data for the equipment and components. Appendix A - Assembly Spares Manual: Contains the Modification Record, together with drawings and detailed parts lists for the identification of replaceable parts. Appendix B - Disposal of Gas Springs: Contains instructions for the safe disposal of unserviceable gas springs.

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1.2

Product Description

The Contouraâ 460 is an acute care bed with multiple patient positioning functions and other features to aid patient therapy. The maximum safe working load is 180kg. The bed has a four-section profiling mattress platform with power driven adjustment of bed height, two-way tilt angle, backrest angle and leg elevation. Kneebreak angle is manually adjustable with power assistance by gas spring. The mattress platform incorporates a built-in bed extension and removable (lift-off) headboard and footboard. Revolving buffers are provided on all four corners. The bed may have built in, single section (¾ length) safety sides. Alternatively, removable safety sides are available as an accessory. The bed is mounted on four castors with braking and steering facility. The complete base of the bed is enclosed by a moulded and sculptured cover.

Figure 1-1

Contouraâ 460 bed with safety sides

On all models the power driven functions of height, backrest angle and leg elevation are operated by push button controls. The Auto Contour button simultaneously operates both backrest and leg elevation. The pendant type push button handset(s) is accessible to either patient or attendant. An additional handset, for use by the attendant only, is stored at the foot of the bed. Tilt angle can be controlled only from the attendant handset. The Attendant Control Panel (ACP), mounted at the foot of the bed, 4

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enables the power driven functions to be individually disabled. Operation of the bed by the patient is thus at the discretion of the attendant. The electrical actuators consist of a screw and nut assembly driven by a 24V d.c. motor and gearbox. Power for the actuators is derived from a mains operated d.c. power supply with emergency battery back up. The bed may be supplied with an x-ray translucent backrest incorporating a cassette carrier to provide the facility for chest x-ray photography. 1.3

Operation

1.3.1 Brakes and Steering

At the foot of the bed is a pair of linked brake pedals that operate on three of the castors. When the pedals are in the middle position, the brakes are free and all four castors are able to rotate and swivel. When the pedal is pushed down, the brakes are applied on both foot end castors and one head end castor. When the pedal is lifted up, one head end castor is engaged so that it cannot swivel. Always engage the castor in line and trailing. The bed can then be steered by pushing from the foot end.

FREE Figure 1-2

BRAKE

STEER

Castors – Brakes and Steering

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1.3.2 Safety Sides

WARNING

Safety side contact points are identified by this symbol. Keep hands and fingers away from these areas to avoid trapping. To lower the safety side: Hold the top rail near the foot end (3). Pull the release knob (1) and lower the side toward the foot of the bed (2). As the side is being lowered, let go of the release knob (1). 2

3

1

Figure 1-3

Safety side operation

To raise the safety side: Lift the top rail up and toward the head until the latch engages at maximum height. The safety side release mechanism has a yellow indicator band (1). When this indicator band is visible, it means that the safety side is not securely locked in the raised position.

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1.3.3 Bed Extension (if fitted)

Before extending or shortening the bed, ensure that the leg sections are lowered to the horizontal position. To extend the bed: Apply the brakes. Squeeze the latch lever (1) and handle (2) together and pull out the foot end of the mattress platform (3). Allow the latch to re-engage when the platform is fully extended. Lift the calf section extension sheet (5), pull the mattress retention rail (4) out toward the foot of the bed and engage the extension sheet (5) in the outer location holes in the calf section deck sheet.

3 2

1

Figure 1-4

Extending or retracting the bed

To retract the bed: Reverse the above procedure.

Figure 1-5

Extending or retracting the mattress platform

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1.3.4 Kneebreak Angle

When the legs are raised, the kneebreak angle can be manually adjusted by lowering or raising the foot end of the calf section. Hold the mattress retention rail (4) on the foot end of the calf section (6), Lift the release lever (7) and push the foot end down against the action of the gas spring. Let go of the lever to lock the calf section at any angle. To raise the foot end, lift the release lever and the gas spring will assist the foot to rise. There is a release lever on both sides of the calf section.

Figure 1-6

Adjusting the kneebreak angle

1.3.5 Power Operation

The bed has power driven adjustment of tilt angle, height, backrest angle and leg elevation. 1.3.5.1

Control Handsets

The patient handset, accessible to either patient or attendant, is connected to the bed by an extendible, flexible cable. An additional handset, for use only by the attendant, is located at the foot of the bed. When a handset push button is pressed the appropriate bed function will operate until the button is released or the limit of travel is reached. The Auto Contour button simultaneously operates both backrest and leg elevation. Tilt angle can be controlled only from the attendant handset. When reverting from a tilt condition, the bed will automatically pause in the horizontal position for two seconds before continuing its movement. 8

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Backrest Leg elevation Bed height Auto Contour

Figure 1-7

Patient handset

Leg elevation

Backrest

Backrest

Leg elevation Bed height Tilt

Battery charge indicator

CPR button

Figure 1-8

Tilt and Height

Attendant handset and ACP

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1.3.5.2

CPR Control Button

There is a CPR button on the attendant handset. Press and hold this button to automatically return the bed to a flat, horizontal, low height condition. Before using the CPR button, ensure that all lock out switches on the ACP are in the vertical, unlocked position. 1.3.5.3

Attendant Control Panel (ACP)

The ACP is located on a bracket at the foot of the bed. To prevent operation by the patient, the individual bed functions can be disabled by turning the appropriate lock-out switch so that the pointer is horizontal. In this condition the selected function is disabled on both the patient handset and the attendant handset. 1.3.5.4

Calibration Error

When operating the function buttons, if a bleeping sound is heard and the function is inoperative this indicates an actuator calibration error. Refer to Section 7, Calibration. 1.3.5.5

Batteries

The emergency back-up battery is automatically switched on if the bed is disconnected from the mains power supply. The batteries will enable emergency power operation for short periods, e.g. when the bed is being moved. To ensure that the batteries are kept fully charged, the bed must be connected to the mains power supply at all times during normal use. If, when the bed is operated using the batteries, a bleeping sound is heard, this indicates a low charge condition. The bed should be re-connected to the mains power supply, for a minimum of 24 hours, in order to recharge the batteries. The battery charge indicator on the ACP illuminates when the batteries are being charged.

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1.3.6 Manually Operated CPR

A CPR emergency release handle is provided on both sides of the bed on the mattress deck. To lower the backrest in emergency, lift the CPR release handle at the side of the bed. At maximum elevation or with no patient weight, it may be necessary to push the backrest down. WARNING The backrest can fall quickly. Keep hands clear to avoid trapping.

Figure 1-9

CPR Emergency release handle

In addition to the CPR handle there is also a CPR button on the attendant handset. Refer to paragraph 1.3.5. Power Operation.

1.3.7 X-ray Facilities (if fitted)

The backrest x-ray cassette carrier provides the facility for chest x-ray photography. For information regarding use refer to the User Manual, publication number 746-260.

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1.3.8 Mains Power Cable

For UK use, the mains supply cable is provided with a BS1363A 13A, 3pin plug. For European use the mains supply cable terminates in an IEC83-C4 (2 pole with dual earth contacts) non-rewireable plug. When the bed is to be moved, disconnect the mains cable from the socket outlet and store the cable on the cable tidy at the head of the bed. Always unwind the cable fully from the cable tidy when it is connected to the power supply. WARNING Do not attempt to insert a two-pin mains connector directly into a UK three-pin 13 amp mains outlet. Make sure that the handset and mains cables cannot become entangled with moving parts of the bed.

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2 2.1

OPERATIONAL MAINTENANCE General

The equipment has been designed to be virtually maintenance-free between service intervals. The degree of periodic cleaning and maintenance necessary will be determined by use and condition. Examine the bed for obvious signs of damage. If found take appropriate remedial action. 2.2

Decontamination WARNING

Disconnect the bed from the mains power supply before carrying out decontamination procedures. Cleaning

Wearing protective clothing, clean all surfaces with a disposable cloth soaked in a neutral detergent and hand hot water. The head and foot end panels can be removed from the bed for cleaning. If the bed has detachable mattress platform sheets, these can also be removed for cleaning. Start by cleaning the upper sections of the bed and work along all horizontal surfaces. Work methodically towards the lower sections of the bed and clean the wheels last. Take extra care to clean areas that may trap dust or dirt. Rinse with clean water and dry with disposable paper towels. Allow the cleaned parts to dry before replacing the mattress.

Disinfecting After cleaning the bed as described above, wipe all surfaces with Sodium Dichloroisocyanurate (NaDCC) at a concentration of 1,000ppm (0.1%) of available chlorine. In the case of pooling body fluids, e.g. blood, the concentration of NaDCC should be increased to 10,000ppm (1%) of available chlorine. Caution Do not use abrasive compounds or pads as these may damage the paint finish. Do not use phenol-based disinfectants. 13

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3

PREVENTIVE MAINTENANCE

The following preventive maintenance checks and procedures should be carried out every 12 months. If the result of any check is unsatisfactory, take the appropriate remedial action. 3.1

General

Examine the bed for obvious signs of damage. Make sure that all nuts, bolts and other fastenings are secure and not missing. Examine the flexible cable for cuts, abrasions, kinking or other deterioration. Check the power connector plug for damage. Check that the (UK) plug fuse is of the correct type and rating (BS 1362, 5A). If either the power connector plug or cable is damaged, they must be replaced as a complete assembly. 3.2

CPR Release Cable

After long use, the CPR release cable may stretch. This could prevent proper operation of the CPR release. To remedy this, adjust the two lock nuts on the outer cable at the release lever end. 3.3

Castors, Brakes and Steering

Check the brakes for efficient operation. Apply the brakes and push the bed. If any of the three braking castors rotate, the brake is not fully effective. Set the brake pedal in the steering position and verify that one head end castor is engaged so that it cannot swivel. Brakes that fail to lock effectively indicate that the castor requires adjustment or replacement. Refer to Section 6. WARNING Before commencing any maintenance activity, disconnect the bed from the electrical power supply. Avoid skin contact with lubricants. Gloves and protective clothing should be worn when carrying out maintenance work.

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3.4

Batteries

If, when the bed is operated using the batteries a “bleeping” sound is heard, this indicates a low charge condition. The bed should be reconnected to the mains power supply, for a minimum of 24 hours, in order to recharge the batteries. Check the condition of the batteries using the following procedure: 1. Ensure that the bed has been connected to the mains power supply for a minimum of 24 hours. 2. Disconnect the bed from the mains power supply. 3. Apply a load of 80kg to the mattress platform. 4. Raise and lower the mattress platform, from minimum to maximum height, three times. 5. If the bed does not operate satisfactorily in step 4, perform steps 1 to 4 again. If the bed again fails to operate satisfactorily, the batteries are not holding sufficient charge and should be replaced. Refer to Section 6.

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4

TESTING

The following serviceability tests should be performed before returning the bed to use after service, or if any function is suspect. These instructions should be read in conjunction with Section 1, Subsection 1.3. If the result of any test is unsatisfactory, investigate and take the appropriate remedial action. Refer to Section 5, Troubleshooting and Section 6, Servicing Instructions.

+

All references to left or right of the bed are when viewed from the head end. WARNING

If any electrical assembly or wiring has been replaced or repaired, the appropriate electrical safety checks must be made before returning the bed to use. Sections of the bed may move under battery power even if the bed is disconnected from the mains power supply. Keep clear of the bed when it is being operated. Severe injury can result from crushing by moving parts. 4.1

Preliminary

a) Verify that no furniture or other obstruction can impede the movements of the bed. b) Connect the bed to the mains power supply. c) Verify that the battery charge indicator on the ACP is illuminated. d) Verify that the rotary switches on the ACP are in the vertical (unlocked) position. e) Using the attendant handset, level the mattress platform (zero tilt). 4.2

Power Operated Functions

a) Using the patient handset, check the functions of bed height, backrest angle and leg elevation. Verify satisfactory operation over the full range of movement as specified in Section 8, Technical Data. Verify that the actuators are de-energised when the push button is released or the limit of travel is reached. 16

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b) Repeat step a) using the attendant handset. Verify that the lock out switches on the ACP disable the push buttons on both the patient and attendant handsets. c) Check the function of the tilt control using the attendant handset. Verify satisfactory operation over the full range of movement as specified in Section 8, Technical Data. Check that, on reaching the horizontal condition, the mechanism will pause for two seconds then continue if the push button is still being pressed. d) Position the bed at near maximum height with both backrest and legs raised and apply foot down tilt. Press and hold the CPR button on the attendant handset Verify that the bed reverts to flat, horizontal, low height condition. 4.3

Battery Operation

a) Disconnect the bed from the mains power supply. b) Check the functions of bed height, backrest angle, leg elevation and two-way tilt using the attendant handset. Verify that the patient handset is inoperative. c) Re-connect the bed to the mains power supply. Verify that the battery charge indicator on the ACP is illuminated. d) Test the batteries as described in sub-section 3.4. 4.4

Manual Functions

4.4.1 Brakes and Steering

a) Refer to paragraph 1.3.1. Check the brakes for efficient operation. Apply the brakes and push the bed. None of the three braking castors should rotate. b) Set the brake pedal in the steering position and verify that one head end castor is engaged so that it cannot swivel. 4.4.2 Safety Sides

a) Refer to paragraph 1.3.2. Check operation of the safety sides (if fitted). Verify that the release button is effective and the sides are firmly locked when raised. 4.4.3 Backrest CPR Release

a) Using either push button handset, raise the backrest to approximately 60°. 17

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b) Refer to paragraph 1.3.6. Lift the release handle and push the backrest down. Verify that the release mechanism is effective and the backrest reclines in a smooth, controlled manner with minimum force applied. 4.4.4 Kneebreak

a) Using either push button handset, raise the leg section to maximum height. b) Refer to Paragraph 1.3.4. Verify that the foot end of the calf section can be raised and lowered over the full range of movement as specified in Section 8. c) Lift the foot end to an intermediate position and check that the gas spring is firmly locked. Lower the foot end again. d) Using either push button handset, lower the legs. Check that the kneebreak angle returns to zero as the leg section is lowered to the horizontal position. 4.4.5 Bed Extension

a) Refer to Paragraph 1.3.3. Check the operation of the bed extension. Verify that the latching mechanism is effective.

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5

TROUBLESHOOTING

The following table identifies some fault symptoms, their possible cause and suggested remedial actions.

Test Step 4.2

Symptom

Possible cause

Action

None of the actuators will work

Power disconnected or batteries discharged

Make sure power supply lead is connected

Fuse blown

Check fuse in (UK) plug

4.2

One actuator does not work

Actuator plug disconnected

Check that actuator plug is fully inserted in control box socket

4.3

“Battery Charge” indicator on ACP not illuminated

Power disconnected or fuse blown

Check and rectify

ACP disconnected

Check that all plugs are fully inserted in control box sockets

Battery charger fault

Check by substitution of control box

4.5.1

Brakes and/or steering lock not effective

Wear or damage

Adjust or replace castor as required

4.5.3

Backrest CPR release not effective

Release mechanism not properly adjusted

Check and adjust as required

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