Mattress and Seat Systems Service Manual Various Models Issue 2 Jan 2005

Mattress and Seat Systems Service Manual

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 range of pressure relief mattress and seat systems shown in Table 1. The information in this handbook is limited to the mattresses and seat cushions. The pumps for this range of systems are described in the appropriate service manual. Mattress replacements (MR), are a replacement for the normal bed mattress. Overlays (OL) are placed on top of a normal bed 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. CAUTION: Do not use hypercarbonate and phenolic based cleaning solutions. CAUTION: Ensure the system is clean and dry prior to storage. Note: Store the systems in the protective bags provided.

2

General Description

The mattress replacement, overlays and seat systems identified in Table 1 are designed specifically to aid in the prevention, treatment and management of pressure ulcers. They are air-filled, alternating pressure mattress and seat systems powered by air pumps. Some of the pumps provide an option of microprocessor aided control and sound alarm functions and have LED indications on the front panel. The mattresses can be used on standard hospital and normal domestic beds. The seat cushions can be used on standard hospital and normal domestic chairs.

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Introduction

Mattress and Seat Systems Service Manual Table 1 - Mattresses and Seat Pads included in this service manual Type(a)

Part Number

Figure Number

Alpha Active (Dartex Cover, USA)

MR

400001DAR

Chap 3, Page 2, Fig 6

Alpha Active (Dartex Cover, German)

OL

400002DAR

Chap 3, Page 3, Fig 7

Alpha Active (Advantex Cover, German)

MR

400003ADV

Chap 3, Page 2, Fig 6

Alpha Active (Dartex Cover, German)

MR

400003DAR

Chap 3, Page 2, Fig 6

Alpha Relief (Dartex Cover)

MR

402001DAR

Chap 3, Page 6, Fig 9

Alpha Relief (Hairnet Cover, USA)

MR

402003HN

Chap 3, Page 6, Fig 9

Alpha Trancell II

OL

401001

Chap 3, Page 8, Fig 10

Alpha Trancell II (German)

OL

401002

Chap 3, Page 8, Fig 10

Alpha Trancell II (Ventilated)

OL

401003

Chap 3, Page 8, Fig 10

Alpha Trancell II (Without Cover)

OL

401007

Chap 3, Page 8, Fig 10

Alpha Trancell (ICC13)

Seat

IC004

Chap 3, Page 18, Fig 15

AlphaXcell (Studded Cover, Euro)

OL

IC087

Chap 3, Page 10, Fig 11

AlphaXcell (Zipped Cover, Euro)

OL

IC137

Chap 3, Page 10, Fig 11

AlphaXcell (Studded Cover, USA)

OL

IC076

Chap 3, Page 10, Fig 11

AlphaXcell Double Mattress

OL

632001

Chap 3, Page 12, Fig 12

Aura

Seat

403001

Chap 3, Page 19, Fig 16

Turbo-Puls (Standard Cover)

OL

BB27001

Chap 3, Page 14, Fig 13

Turbo-Puls (Luxury Cover)

OL

BB27004

Chap 3, Page 14, Fig 13

Turbo-Puls (Standard Cover)

MR

BB27002

Chap 3, Page 14, Fig 13

Turbo-Puls

Seat

BB27003

Chap 3, Page 20, Fig 17

ICT/6R Standard

OL

IC001

Chap 3, Page 5, Fig 8

ICT18 (Harada)

OL

IC044

Chap 3, Page 16, Fig 14

ICT18 (Sanse Do)

OL

IC109

Chap 3, Page 16, Fig 14

ICT18 (Taiwan)

OL

IC116

Chap 3, Page 16, Fig 14

ICT18 (Ventilated, Harada)

OL

IC120

Chap 3, Page 16, Fig 14

Product

a. Mattress Type: MR = Mattress Replacement, OL = Mattress Overlay

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Introduction

Mattress Overlay Systems (OL)

A typical mattress overlay (OL) system is shown in Figure 1. It includes a base sheet, alternating and static cells (which are individually replaceable), a cover, air inlet tubes (with connectors where applicable) and a Cardiopulmonary Resuscitation (CPR) pull tag (also referred to as a Rapid Deflate stopper). The cell configurations are detailed in Table 2. The AlphaXcell Double Mattress system is a double inflatable mattress overlay, which provides static pressure to one side and alternating pressure relief to the other side. The static and alternating sides of the mattress can be set up on either side of the bed depending on customer requirements. The Trancell system is an exception. The cells for the Alpha Trancell system are not individual replaceable cells but are a one-piece manufactured item and can only be replaced as a complete item.

Static Cells (Head Section) Cardiopulmonary Resuscitation (CPR) Pull Tag Cover Air Inlet Tubes

Tube Connections

Strap Alternating Cells

Securing Apron

Base Sheet Cell Loops

Strap

Setting-up Instructions

Figure 1 - Typical Mattress Overlay (OL) System

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Mattress and Seat Systems Service Manual

Mattress Replacement Systems (MR)

A typical mattress replacement (MR) system is shown in Figure 2. The MR systems are basically the same configuration as the OL systems with the addition of a foam base which replaces the normal bed mattress. The foam base provides a safety and transport function should the air supply fail or the alternating cells deflate. The cell configurations are detailed in Table 2. Cardiopulmonary Resuscitation (CPR) Pull Tag

Cover

Static Cells (Head Section) Cell Loops Alternating Cells Air Inlet Tubes Base Cover Foam Base

Tube Connections

Figure 2 - Typical Mattress Replacement (MR) System

5

Seating Systems

A typical seating system is shown in Figure 3. The seat includes a base sheet, alternating cells, a cover and air inlet tubes (with connectors where applicable).The cell configurations are detailed in Table 2.

Cover

Cell Loops Alternating Cells

Straps Air Inlet Tubes Base Sheet Tube Connections Figure 3 - Typical Seating System

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Introduction

Table 2 - Static and Alternating Cell Configurations Mattress Type(a)

Total Number of Cells

Alternating Cells

Static Cells

Alpha Active

MR

17(b)

14

3

Alpha Active (German)

OL

17(b)

14

3

Alpha Relief

MR

17

17

0

Alpha Trancell II

OL

16

14

2

Alpha Trancell II (Ventilated)

OL

16

14

2

Alpha Trancell II (Without Cover)

OL

16

14

2

Alpha Trancell (ICC13)

Seat

9

9

0

AlphaXcell (Studded/Zipped Cover)

OL

20

17

3

AlphaXcell Double Mattress

OL

20 + 20(c)

17 + 0(c)

3 + 20(c)

Aura

Seat

9

9

0

Turbo-Puls

OL

20

20

0

Turbo-Puls

MR

20

20

0

Turbo-Puls

Seat

9

9

0

ICT/6R Standard

OL

20

20

0

ICT18

OL

18

15

3

ICT18 (Ventilated, Harada)

OL

18

15

3

Product

a. Mattress Type: MR = Mattress Replacement, OL = Mattress Overlay b. The Alpha Active system has 8 ventilated cells and 9 non-ventilated cells. c. The AlphaXcell Double Mattress has 20 cells on each side. On one side 17 cells are alternating and 3 are static, and on the other side all 20 cells are static.

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Operating Principles

Refer to Figure 4 for a typical pneumatic system diagram and cell inflation cycle, and Table 2 for the actual cell configurations. All pumps have two pressurised air outlets. Air from the outlets is fed to separate cells or groups of cells in the mattress or seat cushion via a rotary valve. The mattress or seat cushion support cells are continuously inflated and deflated during a ten minute cycle. During the cycle, air is pumped from one outlet to cells “A” (or “B”) for 4 minutes and 10 seconds. This is followed by a period of 50 seconds when air is pumped from both outlets to cells “A” and “B”. Subsequently, air is pumped from the other outlet to cells “B” (or “A”) for 4 minutes and 10 seconds, and then a further 50 seconds with air from both outlets to cells “A” and “B”. During the period when air is pumped from an outlet to one group of cells, the second set of cells is slowly vented to atmosphere, causing them to reduce pressure. In some of the mattress replacements or overlays, 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 manifold assembly) from alternating feeds “A” and “B”, and is therefore never at zero pressure. Where fitted, the “C” cells are normally in the head section of the mattress, to provide a stable pillow section and prevent the patient’s head from rising and falling.

Air Inputs Feet End

Head End Alternating Cells

Static (where Cells applicable) Alternating 1

Static 2

Alternating 3

Static 4

Manifold Assembly

Partial Non-return Valves (where applicable)

CPR (where applicable)

Figure 4 - Typical Mattress Pneumatic Diagram and Cell Inflation Cycle

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Rapid Deflation of the Overlay or Mattress Replacement

Most, but not all, mattress replacement and overlay systems have a cardiopulmonary resuscitation (CPR) or Rapid Deflate plug to allow rapid deflation of the mattress replacement or overlay system. None of the seat systems have a CPR (or Rapid Deflate) plug. The CPR (or Rapid Deflate) plug is located at the head end of the overlay or mattress replacement, on the same side as the tubeset (refer to Figure 5). For rapid deflation of the overlay or mattress replacement in an emergency, pull the CPR (or Rapid Deflate) tag to remove the CPR (or Rapid Deflate) plug from the manifold. To re-inflate the overlay or mattress replacement, replace the CPR (or Rapid Deflate) plug securely, reconnect the manifold tubes to the pump, and switch on.

CPR Tag

CPR Plug

Figure 5 - Cardiopulmonary Resuscitation (CPR) or Rapid Deflate Plug

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Maintenance

CHAPTER 2 MAINTENANCE 1

Mattress/Seat System Service

To carry out a service on the mattress or seat system, do the following: 1.1

Carry out the Mattress/Seat System Maintenance Checks (Refer to Page 1, Section 2).

1.2

Carry out the Pressure and Function Test on the mattress or seat system in accordance with Chapter 5, Page 1, Section 1.

2

Mattress/Seat System Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with the procedures detailed in Chapter 3, Repair. Note: Some of the items may not be applicable to a particular model of mattress or seat system. 2.1

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

Check the zip runs freely and condition of zip teeth.

• Anti-slip pads

Check for damage.

• Fixing straps

Check condition and security.

• Loop base sheet

Check for broken/torn loops.

• Foam block

Check condition.

• Connectors

Check for damage and security.

• Cells

Check for damage and security.

• Manifold

Check for damage and security.

• Non-return valves

Check for condition.

• Turn valves

Check operation

• Press studs

Check condition.

• CPR (or Rapid Deflate) plug

Check condition and operation.

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Repair

CHAPTER 3 REPAIR 1

General

This chapter details the repair procedures for the range of mattress and seat systems identified in Chapter 1, Page 2, Table 1. All repairs should be carried out by Huntleigh approved service personnel. The repair procedures in this chapter are general and not unique to a product. Refer to Table 3 first to identify the relevant assembly drawing and parts list for the product being repaired, and then refer to them whilst carrying out the repair procedures detailed in Section 3 onwards of this chapter. It is easier to carry out the repair procedures if the mattress or seat system is fully deflated first. Disconnect the tubeset between the mattress or seat system and the pump to deflate it. After carrying out a service or any repairs on the mattress or seat system, but before installing the top cover, check the following: 1.1

All press studs on the mattress, overlay or seat system are connected.

1.2

All cells are evenly positioned in their loop straps. The repair will normally have disturbed the position of the cells, and they should be re-positioned evenly.

After carrying out a service or any repairs, the mattress or seat system must be tested for serviceability, by carrying out the Pressure and Function Test on the mattress or seat system in accordance with Chapter 5, Page 1, Section 1.

2

Product Assembly Drawings and Parts Lists

Refer to Table 3 for the assembly drawing and parts list for each mattress or seat system. Table 3 - Product Assemblies and Parts Lists Product

Assembly Drawing

Parts List

Alpha Active Mattress Replacement (MR)

Figure 6

Table 4

Alpha Active Mattress Overlay (OL)

Figure 7

Table 4

Alpha Relief Mattress Replacement (MR)

Figure 9

Table 6

Alpha Trancell II Mattress Overlay (OL)

Figure 10

Table 7

Alpha Trancell Seat

Figure 15

Table 12

AlphaXcell Mattress Overlay (OL)

Figure 11

Table 8

AlphaXcell Double Mattress Overlay (OL)

Figure 12

Table 9

Aura Seat

Figure 16

Table 13

Turbo-Puls Mattress Replacement (MR)

Figure 13

Table 10

Turbo-Puls Mattress Overlay (OL)

Figure 13

Table 10

Turbo-Puls Seat

Figure 17

Table 14

ICT/6R Mattress Overlay (OL)

Figure 8

Table 5

ICT18 Mattress Overlay (OL)

Figure 14

Table 11

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100

50

130 120 See Detail A

110

60

90

40

30 80

20 160

See Detail A

70 10 150

160

140 Detail A Note the orientation of the Non-Return Valves (Item 70)

70

Cell Arrangement Head End

Static Non-ventilated Item 170 (2 off)

Feet End

Static Ventilated Item 180 (1 off)

Alternating Ventilated Item 180 (7 off)

Alternating Non-ventilated Item 170 (7 off)

Figure 6 - Alpha Active Mattress Replacement (MR)

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130

100

50 120

110 See Detail A 40

60

90

30 80

160 10

See Detail A 70 160 150 140

Detail A Note the orientation of the Non-Return Valves (Item 70)

70

Cell Arrangement Head End

Static Non-ventilated Item 170 (2 off)

Feet End

Static Ventilated Item 180 (1 off)

Alternating Ventilated Item 180 (7 off)

Alternating Non-ventilated Item 170 (7 off)

Figure 7 - Alpha Active Mattress Overlay (OL)

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Table 4 - Alpha Active Mattress - Replacement (MR) and Overlay (OL) - Parts List Item

Part Number

Description

Qty

REF

400001DAR

Alpha Active Mattress Replacement (Dartex Cover, USA)

-

-

400002DAR

Alpha Active Mattress Overlay (Dartex Cover, German)

-

-

400003ADV

Alpha Active Mattress Replacement (Advantex Cover, German)

-

-

400003DAR

Alpha Active Mattress Replacement (Dartex Cover, German)

-

10

400064

Base Cover Assy (for 400001DAR, 400003ADV & 400003DAR)

1

-

400061

Base Cover Assy (for 400002DAR)

1

20

402302

Foam Base (for 400001DAR, 400003ADV & 400003DAR only)

1

30

400050

Loop Base Sheet Assembly (for 400001DAR & 400002DAR)

1

-

400076

Loop Base Sheet Assembly (for 400003ADV & 400003DAR)

1

40

400062

Top Cover Assembly (for 400001DAR)

1

-

400077

Top Cover Assembly (for 400003ADV)

1

-

400058

Top Cover Assembly (for 400002DAR & 400003DAR)

1

50

400065

Manifold Assembly, Pump End (comprises Items 60 - 100)(a)

1

60

400065UF

Manifold Tube, Twin Bore

1

70

IC036

Non-Return Valve Assembly

4(a)

80

BP432

Connector, Female

2

90

197301

Connector, Straight Male/Male

2

100

IC067

End Plug Assembly (comprises Items 110 - 130)

1

110

IC033

End Plug, 2-way

1

120

FAS167

Clevis Pin, OD 3/16” x 5/8” Long

1

130

IC300

Swing Label and Web Assembly (CPR Pull)

1

140

400057

Manifold Assembly, Short (comprises Items 70, 150 - 160)(a)

1

150

400057UF

Manifold Tube, Twin Bore

1

160

BP418

Stopper

4

170

400053

Cell Assembly, Non-Ventilated

9

180

400055

Cell Assembly, Ventilated

8

a. There are two non-return valve assemblies (Item 70) in each manifold assembly (Items 50 and 140).

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30 20

40

50

10

Figure 8 - ICT/6R Mattress Overlay (OL)

Table 5 - ICT/6R Mattress Overlay (OL) Parts List Item

Part Number

REF

IC001

ICT/6R Standard Mattress Overlay

-

10

IC061

Loop Base Sheet Assembly

1

20

IC095

Cell Assembly

20

30

SP042

Manifold Assembly (comprises Items 40 - 50)

1

40

BP418

Stopper

2

50

SP042UF

Manifold Tube, Twin Bore

1

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Note the orientation of the Non-Return Valves (Item 70)

110

100

70 60

120 130 10

90

50

80

40

30

20

Figure 9 - Alpha Relief Mattress Replacement (MR)

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Table 6 - Alpha Relief Mattress Replacement (MR) Parts List Item

Part Number

REF

402001DAR

Alpha Relief Mattress Replacement (Dartex Cover, UK)

-

-

402003HN

Alpha Relief Mattress Replacement (Hairnet Cover, USA)

-

10

402059

Top Cover Assembly (for 402001DAR)

1

-

402055

Hairnet Cover Assembly (for 402003HN)

1

20

400064

Base Cover Assembly (for 402001DAR)

1

30

402302

Foam Base

1

40

402053

Loop Base Sheet Assembly

1

50

402050

Cell Assembly

17

60

402051

Manifold Assembly (comprises Items 70 - 130)

1

70

IC036

Non-Return Valve Assembly

2

80

BP431

Connector, Male

1

90

BP432

Connector, Female

1

100

IC033

End Plug, 2-way

1

110

FAS167

Clevis Pin, OD 3/16” x 5/8” Long

1

120

401309

Swing Label and Web Assembly (CPR Pull)

1

130

402051UF

Manifold Tube, Twin Bore

1

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10

20

30

60

100

50

70

40

80

90

40

Note the orientation of the Non-Return Valves (Item 40)

Figure 10 - Alpha Trancell II Mattress Overlay (OL)

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Table 7 - Alpha Trancell II Mattress Overlay (OL) Parts List Item

Part Number

REF

401001

Alpha Trancell II Mattress Overlay (Standard)

-

-

401002

Alpha Trancell II Mattress Overlay (German)

-

-

401003

Alpha Trancell II Mattress Overlay (Ventilated)

-

-

401007

Alpha Trancell II Mattress Overlay (Without Cover)

-

10

401068

Top Cover Assembly (for 401001, 401002 & 401003)

1

20

401053

Mattress Overlay Assembly (for 401001, 401002 & 401007)

1

-

401069

Mattress Overlay Assembly, Ventilated (for 401003)

1

30

401065

Manifold Assembly (comprises Items 40 - 100)

1

40

IC036

Non-Return Valve Assembly

2

50

401300

T-Connector

16

60

197301

Connector, Straight Male/Male

2

70

IC033

End Plug, 2-way

1

80

FAS167

Clevis Pin, OD 3/16” x 5/8” Long

1

90

401309

Swing Label and Web Assembly (CPR Pull)

1

100

400065UF

Manifold Tube, Twin Bore

1

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