Autoexcel and DFS Homecare Service Manual Issue 1 Feb 2002

Autoexcel / DFS Homecare Service Manual

Contents

CONTENTS CHAPTER 1 Introduction... 1 About This Manual... 1 Warnings, Cautions and Notes... 1 Technical Description... 1 Operating Principle - Autoexcel System... 2 Operating Principle - DFS Homecare System... 4 Rapid Deflation of the Mattress... 5 Auto-Matt... 5 System Start Up Sequence... 5

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

CHAPTER 3 Pump Repair... 1 General... 1 Mains/Power Cable Check... 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 Lid and Cables from the Compressor Casing... 9 Installing the Lid and Cables to the Compressor Casing... 9 Removing the Compressor Assembly... 11 Installing the Compressor Assembly... 12 Removing the Anti-Vibration (AV) Mounts... 12 Installing the Anti-Vibration (AV) Mounts... 13 Replacing the Compressor Filters... 15 Removing the Compressor Bump Stops... 15

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Autoexcel / DFS Homecare Service Manual

Installing the Compressor Bump Stops... 15 Replacing the Valve/Shuttle Assembly on the Compressor... 17 Replacing the Coil/E-stack Assembly... 17 Removing the Silencer Bag... 19 Installing the Silencer Bag... 19 Removing the Pressure Control Assembly... 21 Installing the Pressure Control Assembly... 21 Adjusting the Pressure Control... 21 Removing the High Pressure Switch... 23 Installing the High Pressure Switch... 23 Removing the Rotary Valve Assembly... 25 Installing the Rotary Valve Assembly... 26 Removing the Display Panel PCB... 29 Installing the Display Panel PCB... 29 Removing the Front Panel... 31 Installing the Front Panel... 31 Replacing the Battery... 32 Removing the Sounder Assembly... 35 Installing the Sounder Assembly... 35 Replacing the Fuse on the Display Panel PCB... 35 Replacing the Mains/Power Fuses... 36 Removing the Mains/Power Switch... 39 Installing the Mains/Power Switch... 39 Removing the Mains/Power Cable... 41 Installing the Mains/Power Cable... 41 Replacing the Manifold Gasket... 43 Repairing the Pneumatic Side Panel Assembly... 45 Removing the Pneumatic Side Panel Assembly... 48 Installing the Pneumatic Side Panel Assembly... 49 Removing the Mains/Power Side Panel Assembly... 50 Installing the Mains/Power Side Panel Assembly... 51 Replacing the Plastic Panel on the Mains/Power Side Panel Assembly... 53 Removing the Pump Case... 56 Installing the Pump Case... 56 Pump Labels... 57

CHAPTER 4 Autoexcel Mattress Repair... 1 General... 1

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Contents

Removing the Top Cover... 3 Installing the Top Cover... 3 Removing a Cell... 3 Installing a Cell... 4 Removing the One-Way Valve Tube Assemblies... 5 Installing the One-Way Valve Tube Assemblies... 5 Replacing the 5-Way Manifold Gasket... 7 Disassembling the 5-way Tubeset Connector Assembly... 7 Assembling the 5-way Tubeset Connector Assembly... 8 Removing the Static Manifold Assembly (opposite side to 5-way tubeset connector)... 11 Installing the Static Manifold Assembly... 11 Removing the Standard Manifold Assembly (same side as 5-way tubeset connector)... 11 Installing the Standard Manifold Assembly... 12 Replacing the CPR Swing Label and Web Assembly... 12 Removing the Base and Sensor Pad Assembly... 13 Installing the Base and Sensor Pad Assembly... 14 Disassembling the Base and Sensor Pad Assembly... 17 Assembling the Base and Sensor Pad Assembly... 18 Replacing the Tubeset Assembly... 21 Replacing the Tubeset Release Button, Springs and Connector Body... 21 Press Stud Replacement... 23

CHAPTER 5 DFS Homecare Mattress Repair... 1 General... 1 Removing the Top Cover... 3 Installing the Top Cover... 3 Removing the Base Cover... 3 Installing the Base Cover... 7 Replacing the Soft Foam Sheet... 8 Cell Replacement... 9 Removing a Cell... 9 Installing a Cell... 10 Removing the Manifold Assembly... 11 Installing the Manifold Assembly... 12 Removing the One-Way Valve Tube Assemblies... 13 Installing the One-Way Valve Tube Assemblies... 13 Removing the Loop Sheet Assembly... 14 Installing the Loop Sheet Assembly... 14

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Autoexcel / DFS Homecare Service Manual

Removing the Sensor Pad Assembly... 15 Installing the Sensor Pad... 15 Replacing the Tubeset Assembly... 17 Replacing the Tubeset Release Button, Springs and Connector Body... 17 Removing the CPR Unit... 18 Installing the CPR Unit... 18 Press Stud Replacement... 21 Replacing the CPR O-Rings... 23 Replacing the Transport Assembly... 23 Repairing the CPR Handle Sub-Assembly... 24 Replacing the CPR Manifold Gasket... 25

CHAPTER 6 Troubleshooting... 1 Troubleshooting Table... 1

CHAPTER 7 Testing... 1 Pump Flow, Pressure and Function Test... 1 General... 1 Test Setup... 1 Power Fail Alarm Check... 2 Low Pressure Alarm Test... 2 High Pressure Alarm Test... 2 High/Low Pressure Setpoint and Mute Mode Checks... 2 Calibration Check... 2 Alarm Reset and Pump Serial Number Check... 3 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 Alarm Reset and Pump Serial Number Check using the Psion Organiser... 5 Psion Organiser Setup... 5

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Contents

Alarm Reset... 5 Pump Serial Number Check... 5 Alarm Reset and Pump Serial Number Check using the IR Interface Module... 6 IR Interface Setup... 6 Alarm Reset... 6 Pump Serial Number Check... 6 Psion Organiser Setup... 8 IR Interface Setup and Passwords for Autoexcel and DFS Homecare... 8 Electrical Testing... 10 Electrical Safety Checks - Class I... 10 Earth Continuity Test... 10 Insulation Resistance Test... 10 Dielectric Strength Test (Flash Test)... 10 Leakage Circuit Test (USA)... 11 Mattress Pressure and Function Test... 12 Test Procedure... 12

CHAPTER 8 Technical Specification... 1 Pump... 1 5-way Tubeset... 2 Autoexcel Mattress Overlay... 2 DFS Homecare Mattress Replacement... 3

CHAPTER 9 Parts List... 1 Pump Assembly Parts List... 1 Autoexcel Mattress Overlay Assembly Parts List... 8 DFS Homecare Mattress Replacement Assembly Parts List... 10

CHAPTER 10 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 Autoexcel® and DFS Homecare™ 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. WARNING: 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 Autoexcel and DFS Homecare are Dynamic Flotation Systems to aid the prevention, treatment and management of pressure ulcers. The Autoexcel is a powered, air-filled mattress overlay system, which is designed to be placed over any standard hospital mattress or bed. The DFS Homecare is a powered, air filled mattress replacement system, which is designed to replace the standard mattress. In the Autoexcel mattress overlay system, the patient is supported by 18 individual cells, 15 of which inflate alternately. In the DFS Homecare mattress replacement system, the patient is supported by 20 individual cells, 17 of which inflate alternately. Both systems have microprocessor-aided control and alarm functions, and have LED indications on the front panel of the pump. The pump on both systems provides a dynamic system of inflating the support surface underneath the patient, cycling every 10 minutes to produce periods of pressure relief for the whole body. The mattress on both systems is enclosed by a polyurethane coated fabric cover. This cover has waterresistant, vapour permeable, and two-way stretch properties to assist with any repositioning requirements and enhance patient comfort, whilst protecting the mattress interior from contamination. It is simple to clean in situ, but can also be quickly unzipped and totally removed for cleaning.

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Introduction

Autoexcel / DFS Homecare Service Manual

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 support pressure (the pressure to which the cells are inflated) to the minimum required to support that patient in a given position. In the event of cardiac arrest, the mattress on both systems can be quickly deflated in less than 10 seconds to allow cardiac resuscitation procedures to be performed.

Operating Principle - Autoexcel System Figures 1 and 2 show how the system operates in dynamic and static modes. Figure 2 shows a simplified pneumatic diagram for the Autoexcel system. A compressor system in the pump provides a source of air supply. This is fed to a high pressure switch and a rotary valve in the pump, and the Auto-Matt sensor in the mattress. The high pressure switch detects system over-pressures through blockages. The low pressure switch, which is located in the pressure control assembly in the pump, detects if the air pressure in the system falls below a minimum value. The rotary valve channels the air supply to the cells labelled “A” and “B” in the mattress, via the tubeset. In the mattress, there is a third set of cells labelled “C”, which are supplied from a static feed. This static feed “C” is generated by two partial non-return valves (in the mattress) from alternating feeds “A” and “B”, and is therefore never at zero pressure. There are three “C” cells in the head section of the mattress, which provide a stable pillow section and prevent the patient’s head from rising and falling. The distribution of air by the rotary valve in the pump is as shown in Table 1. This allows cells “A” and “B” in the mattress to be inflated and deflated in a cycle period of ten minutes. Head Section Static Cells

Alternating Cells Alternating

1

Static

2

Alternating

3

Static

4 Figure 1 - Autoexcel Mattress Cell Inflation Cycle Table 1 - Air Supply Distribution by the Rotary Valve

Part of Cycle

Outlet A

Outlet B

Comment

1

Alternating

Inlet (C)

Atmosphere (D)

“A” and “C” cells inflated

2

Static

Inlet (C)

Inlet (C)

All cells inflated (“A”, “B” and “C”)

3

Alternating

Atmosphere (D)

Inlet (C)

“B” and “C” cells inflated

4

Static

Inlet (C)

Inlet (C)

All cells inflated (“A”, “B” and “C”)

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Introduction

Compressor D (Atmosphere) High Pressure Switch

C Restrictor

B

Pressure Control

A

Rotary Valve

Adjuster Atmosphere

Low Pressure Switch Plug

Pump Tubeset Mattress

Tube from Cells “C” (Autoexcel only) CPR Control (DFS Homecare only) Cells “B” Cells “A” Partial Non-return Valves Auto-Matt Sensor Pad

Cells “C”

Figure 2 - Pneumatic System Diagram

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Autoexcel / DFS Homecare Service Manual

Operating Principle - DFS Homecare System Figures 2 and 3 show how the system operates in dynamic and static modes. Figure 2 shows a simplified pneumatic diagram for the DFS Homecare system. A compressor system in the pump provides a source of air supply. This is fed to a high pressure switch and a rotary valve in the pump, and the Auto-Matt sensor in the mattress. The high pressure switch detects system over-pressures through blockages. The low pressure switch, which is located in the pressure control assembly in the pump, detects if the air pressure in the system falls below a minimum value. The rotary valve channels the air supply to the cells labelled “A” and “B” in the mattress, via the tubeset. In the mattress, there is a third set of cells labelled “C”, which are supplied from a static feed. This static feed “C” is generated by two one-way valves (in the mattress) from alternating feeds “A” and “B”, and is therefore never at zero pressure. The “C” cells are positioned under certain “A” and “B” cells (Refer to Figure 3) to prevent the torso section from ‘bottoming’ during dynamic mode and/or when a patient is sitting upright. This static feed is also applied to the three cells in the head section and the heel protector above the CPR (Cardio-Pulmonary Resuscitation) unit for added patient comfort. The distribution of air by the rotary valve in the pump is as shown in Table 1. This allows cells “A” and “B” in the mattress to be inflated and deflated in a cycle period of ten minutes.

Lower Body Section Upper and lower cells alternate

Anti-sink Torso Section Upper cells alternate, lower cells static

Head Section Static cells

Alternating 1

Static

2

Alternating 3

Static

4

Figure 3 - DFS Homecare Mattress Cell Inflation Cycle

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Introduction

Rapid Deflation of the Mattress Both the DFS Homecare and Autoexcel systems allow the air to be evacuated from the mattress in under 10 seconds, should cardiac arrest occur. On the DFS Homecare system, there is a Cardio-Pulmonary Resuscitation (CPR) unit positioned at the foot end of the mattress. The CPR unit is connected directly to the three feeds “A”, “B” and “C” inside the mattress. The air is evacuated when the CPR control is operated. The Autoexcel system does not have a CPR unit. Instead, the three feeds “A”, “B” and “C” inside the mattress are connected directly to the pump via the tubeset. The air is evacuated when the tubeset is removed from either the mattress or the pump.

Auto-Matt The Auto-Matt sensor consists of a flexible air sensor pad which is located underneath the mattress cells. It acts as a pressure regulator, and accommodates changes in patient weight and position. It is pneumatically connected in parallel to the mattress cells, such that 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 on the pump (refer to Figure 2). This, in turn, is set to a pressure range which can be adjusted slightly to change mattress pressure for patient comfort. With a patient on the mattress, pressure is exerted on 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. The On and Wait indicators remain illuminated while the mattress inflates (approximately 20 minutes). All the other indicators go out. When the minimum pressure setting is reached the Wait indicator goes out.

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Maintenance

CHAPTER 2 MAINTENANCE 1

Pump Service

A pump should be serviced every 12 months or after 8760 hours have been registered. To carry out a service on the pump, do the following: 1.1

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

1.2

Replace the following components: 1.2.1

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

1.2.2

Valve shuttle assembly (Refer to Chapter 3, Page 17, Section 17).

1.2.3

Compressor AV mounts (Refer to Chapter 3, Page 12, Section 12 and Chapter 3, Page 13, Section 13).

1.2.4

Compressor filters (Refer to Chapter 3, Page 15, Section 14).

1.2.5

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

1.2.6

Pump manifold gasket (Refer to Chapter 3, Page 43, Section 41).

1.3

Reassemble the pump and soak for the recommended time (Refer to Page 2, Section 3).

1.4

Carry out a flow, pressure and function test on the pump in accordance with Chapter 7, Page 1, Section 1

1.5

Carry out electrical tests on the pump in accordance with Chapter 7, Page 10, Section 8.

2

Pump Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Chapter 3, Pump Repair. 2.1

2.2

Visually inspect the following for damage, wear and potential faults: • Outer casing:

Check for damage and security

• Switches, control knobs:

Check function

• Hanging bracket:

Check for damage and security

• Outlet ports:

Check for damage and free from obstructions

• Rubber feet (8 0ff):

Check for security

• Fuses:

Check condition

• Front panel:

Check for damage to LEDs and buttons

• Mains lead:

Check for damage and security of plug

• Labels:

Check all labels are present and legible

Disassemble the Rear Case (Refer to Chapter 3, Page 5, Section 4) and visually inspect the following for damage, wear, security and potential faults: • Compressor assembly and bump stops. • Rotary valve assembly.

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Maintenance

Autoexcel / DFS Homecare Service Manual

• Display panel PCB. • Pressure control assembly. • High pressure switch. • Silencer bag. • Wiring, and check connections to the mains/power switch, fuseholders, mains/power filter and connector block. • Tubing. • Screws, nuts and bolts. 2.3

Remove the compressor lid and visually inspect the following for damage, wear and potential faults: • Coils assemblies. • Elbows and connectors. • Gaskets

3

Pump Soak Times

3.1

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.

3.2

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

3.3

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 assembly • Silencer bag • Display panel PCB • Compressor • Rotary valve assembly

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4

Maintenance

Mattress Service

To carry out a service on the mattress, do the following: 4.1

Carry out the Mattress Maintenance Checks (Refer to Page 3, Section 5).

4.2

On DFS Homecare mattresses only, check the following components and replace if necessary: • CPR O-rings (Refer to Chapter 5, Page 23, Section 23). • CPR manifold gasket (Refer to Chapter 5, Page 25, Section 26).

4.3

Carry out an inflation test on the mattress in accordance with Chapter 7, Page 12, Section 9.

5

Mattress Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Chapter 4, Autoexcel Mattress Repair or Chapter 5, DFS Homecare Mattress Repair. 5.1

Visually inspect the following for damage, wear and potential faults: • Base and top cover

Check for tears, staining, clarity of printed labels.

• Base/top cover zip (DFS Homecare)

Check the zip runs freely and condition of zip teeth.

• Anti-slip pads

Check for damage.

• Fixing straps

Check condition and security.

• Loop sheet

Check for broken/torn loops.

• Sensor pad

Check condition and security of tubes.

• Soft/hard foam

Check condition.

• Connectors

Check for damage and security.

• Tubing

Check for security and ensure no kinks or twists.

• Cells

Check for damage and security.

• Manifold

Check for damage and security.

• Partial non-return valves

Check for condition.

• Heel protector (DFS Homecare)

Check for damage and security.

• Pop Studs

Check condition.

• CPR unit (DFS Homecare)

Check operation of Fast Deflate mechanism.

• CPR transport knob (DFS Homecare)

Check operation.

• CPR inlet manifold (DFS Homecare)

Check for damage and free from obstructions.

• Tubeset assembly

Check for damage and security of connection.

• Alternating head cells

Check the security of all the connectors.

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Maintenance

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Pump Repair

CHAPTER 3 PUMP REPAIR 1

General

This chapter details repair procedures for the Autoexcel and DFS Homecare 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 3) and tested for serviceability. Table 2 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 7, Page 1, Section 1. To carry out the electrical tests on the pump refer to Chapter 7, Page 10, Section 8.

Mains/Power Cable Check WARNING: FOR SAFETY, IF THE MAINS/POWER CABLE IS ACCIDENTALLY PULLED OUT OF THE PUMP, THE EARTH WIRE MUST BE THE LAST OF THE THREE WIRES IN THE CABLE TO BE DISCONNECTED FROM THE PUMP. If the rear case is removed for any reason, either to inspect or to repair any sub-assembly, then the mains/power cable must be checked inside the pump where it is connected to the 3-way connector, to make sure that: •

The Live and Neutral wires are as short as possible.

•

The Earth wire is longer than the other two wires, and long enough to have a loop in it.

If the wire lengths are incorrect, particularly if the Earth wire is too short, then the ends of the wires in the mains/power cable must be re-made and re-connected to the 3-way connector. Refer to Page 41, Section 40 (Installing the Mains/Power Cable) for details on how to check the installation of the three wires in the mains/power cable, and how to re-make them if necessary.

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Pump Repair

Autoexcel / DFS Homecare Service Manual Table 2 - Repair to Testing Requirements Flow / Pressure & Function Test

Electrical Safety

Compressor

Yes

Yes

Pressure Control

Yes

Yes

Rotary Valve

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

Pneumatic Side Panel Assembly

Yes

Yes

Mains Inlet Side Panel Assembly

Yes

Yes

Battery

No

Yes

Switches

No

Yes

Fuses

No

Yes

Electrical Connectors

No

Yes

Mains Lead

No

Yes

Components / Assemblies

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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 (Refer to Figure 4).

2.2

Rotate the hanging bracket 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 into the handle recess of the pump (Refer to Figure 4).

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.

10 30

40

20

Figure 4 - Replacing the Hanging Bracket Table 3 - Hanging Basket Parts List Item

Part Number

-

151123

Hanging Bracket Assembly (includes Items 10 to 40)

1

10

151427

Bracket

1

20

151428

Wire

1

30

FAS046

Screw, M3 x 10 Csk Head

2

40

FAS216

Nutsert, M3 x 0.5 Euro Series

2

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