Hillrom The ZoneAire Sleep Surface System User manual

SERVICE MANUAL
The ZoneAire
Sleep Surface
System
From Hill-Rom
Product No. P993-00
For Parts Or Technical Assistance man121
USA 1-800-445-3720 Canada 1-800-267-2337
errata
man121-e1

ZoneAire ® Sleep Surface System Service Manual Page i
ZoneAire Sleep
Surface System
Service Manual
Revisions
man121
Revision Letter Pages Affected Date
Original Issue May, 1996

Revisions
Page ii ZoneAire ® Sleep Surface System Service Manual
COPYRIGHT1996 HILL-ROM, INC.
All rights reserved. No part of this text shall be reproduced or transmitted in
any form or by any means, electronic or mechanical, including photocopying,
recording, or by any information or retrieval system without written
permission from HILL-ROM COMPANY, INC. (Hill-Rom).
First Edition
First Printing 1996
Printed in the USA
Advance® is a registered trademark of Hill-Rom Company, Inc.
Centra®is a registered trademark of Hill-Rom Company, Inc.
Century CC®is a registered trademark of Hill-Rom Company, Inc.
DynamicAire™is a trademark of Hill-Rom Company, Inc.
EnhanceMate®is a registered trademark of Hill-Rom Company, Inc.
Hill-Rom®is a registered trademark of Hill-Rom Company, Inc.
ZoneAire® is a registered trademark of Hill-Rom Company, Inc.
Staphcheck Comfort®is a registered trademark of Herculite Products, Inc.
The information contained in this manual is subject to change without notice.
Hill-Rom makes no commitment to update or keep current, the information
contained in this manual.
The only product warranty intended by Hill-Rom is the express, written
warranty accompanying the bill of sale to the original purchaser. Hill-Rom
makes no other warranty, express or implied, and in particular, makes no
warranty of merchantability or fitness for any particular purpose.
Additional copies of this manual can be obtained from Hill-Rom.

ZoneAire ® Sleep Surface System Service Manual Page iii
Table of Contents
Chapter 1: Introduction
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Organization of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 2: Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 3: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 4: Removal, Replacement, and Adjustment Procedures. . . . . . . . . . . 1 - 4
Chapter 5: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Chapter 6: General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Chapter 7: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Typographical Conventions Used in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Introduction to the ZoneAire Sleep Surface System . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Mattress Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Caregiver Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Comfort Mode (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Pressure Relief Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Auto Firm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Heel Relief Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Patient Pendant (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Electrical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
CSA/UL Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13

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Page iv ZoneAire ® Sleep Surface System Service Manual
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Caution and Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Chapter 2: Troubleshooting Procedures
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Initial Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 4
Caregiver Pendant Diagnostic Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Valve Driver Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Pneumatic Components Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Final Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
Slow Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
Pneumatic Subsystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
Continuous Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19
Triac Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
Sensor EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 22
Mattress Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 24
Triac Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 31
LON Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 37
Key Stuck Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 39
ZoneAire Sleep Surface System Does Not Work. . . . . . . . . . . . . . . . . . . . . . . . . 2 - 40
Chapter 3: Theory of Operation
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Software Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
Air Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
Off Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
Pressure Relief Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 19
Heel Relief Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 19
Comfort Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20

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ZoneAire ® Sleep Surface System Service Manual Page v
Auto Firm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
Mode Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
Intermode Transitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
Slow Leak Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
Continuous Run Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
Triac Short Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
EEPROM Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
Mattress Connection Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25
Triac Open Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25
LON Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25
Diagnostic Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 26
Hardware Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27
Air Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
Echelon Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
Latches and Buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
Valve/Sensor Module Digital Control Lines . . . . . . . . . . . . . . . . . . . . . . 3 - 29
Other Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
External Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
24V AC Solenoid Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 30
Compressor and Crossover valve drivers . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 30
ESD Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 30
LON Connector (P112, P113) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31
Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31
Sensor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31
Input Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
Output Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32

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Page vi ZoneAire ® Sleep Surface System Service Manual
EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
Digital-to-Analog Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33
Analog Multiplexer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33
Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33
Analog-to-Digital Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 34
Solenoid Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 34
Grounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 34
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
Caregiver Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
Echelon Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
Switch Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 35
Connector P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36
Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36
Mattress Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36
Chapter 4: Removal, Replacement, and Adjustment Procedures
Mattress Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4
Mattress Sensor Control Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
Sensor Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Mattress Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Mattress Air Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13

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ZoneAire ® Sleep Surface System Service Manual Page vii
Power Supply Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Air Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Switching Valve Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
Transformer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
Line Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Power Unit Power Cord Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
Caregiver Pendant PC Board And Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31
Chapter 5: Parts List
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Ordering Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Exchange Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
In-Warranty Exchanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Out-of-Warranty Exchanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Power Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8

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Page viii ZoneAire ® Sleep Surface System Service Manual
Caregiver Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 12
Patient Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
Power Supply Board Assembly—P/N 4471904. . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16
Air Control Board—P/N 4476004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
Sensor Control Board Assembly—P/N 44740 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
Caregiver Pendant Board Assembly—P/N 46943 . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Sleep Surface Mattress Assembly—P1412CA01,02 & P1412EA01,02 . . . . . . . 5 - 28
Sleep Surface Mattress Assembly—P1414CA01,02 & P1414EA01,02 . . . . . . . 5 - 30
Sleep Surface Mattress Assembly—P1416CA01,02 & P1416EA01,02 . . . . . . . 5 - 32
Sleep Surface Control Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34
Trapeze Support Adapter—P844A02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36
Chapter 6: General Procedures
Installing on a Retractable Bed Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Installing on a Non-Retractable Bed Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
Installing on a Critical Care Bed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
Pre-Installation For Beds With Scale Option Only . . . . . . . . . . . . . . . . . . . . 6 - 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 19
Post Installation For Beds With Scale Option Only . . . . . . . . . . . . . . . . . . . . 6 - 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 27
Cleaning and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
Steam Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
Hard to Clean Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
Disinfection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
Lubrication Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30

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Preventive Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31
Tool and Supply Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32
Chapter 7: Accessories
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Trapeze Support Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

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Chapter 1
Introduction
Chapter Contents
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Organization of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 2: Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 3: Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 4: Removal, Replacement, and Adjustment Procedures. . . . . . . . . . . 1 - 4
Chapter 5: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Chapter 6: General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Chapter 7: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Typographical Conventions Used in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Introduction to the ZoneAire Sleep Surface System . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Mattress Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Caregiver Pendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Comfort Mode (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Pressure Relief Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Auto Firm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Heel Relief Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Patient Pendant (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12

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Electrical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
CSA/UL Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Caution and Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16

Purpose of this Manual
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Purpose of this Manual
This manual provides the information required for Hill-Rom ZoneAire Sleep
Surface System normal operation and maintenance. It also includes a complete
parts list for ordering replacement components. The parts list is located in
chapter 5.
Who Should Use this Manual
This manual is intended to be used by facility authorized maintenance
personnel only. Failure to observe this restriction can result in serious damage
to material and/or severe injury to people.
Organization of this Manual
This manual contains seven chapters.
Chapter 1: Introduction
You are currently reading chapter 1. This chapter defines the manual’s purpose
and who should use the information in the manual. It also describes the
manual’s organization and explains the various typographical conventions
used throughout the manual. Also included is an introduction to the product,
specifications, model identification, safety tips, and the ZoneAire Sleep
Surface System caution and warning labels.
Chapter 2: Troubleshooting Procedures
Chapter 2 contains the proper ZoneAire Sleep Surface System troubleshooting
procedures. It also includes a troubleshooting introduction, initial actions,
function checks, final actions, and repair analysis procedures.
Chapter 3: Theory of Operation
Chapter 3 contains the hardware and software theory of operation of the
ZoneAire Sleep Surface System. It also includes the wiring diagrams and a
block diagram for the ZoneAire Sleep Surface System.

Organization of this Manual
Chapter 1: Introduction
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Chapter 4: Removal, Replacement, and Adjustment
Procedures
Chapter 4 includes removal, replacement, and adjustment procedures for the
ZoneAire Sleep Surface System components.
Chapter 5: Parts List
Chapter 5 contains Hill-Rom’s warranty, replacement part ordering procedure,
exchange policy, illustrated parts lists, and general service information.
Chapter 6: General Procedures
Chapter 6 contains cleaning and care, lubrication requirements, preventive
maintenance, ZoneAire Sleep Surface System tool and supply requirements.
Chapter 7: Accessories
Chapter 7 includes available ZoneAire Sleep Surface System accessories,
illustrations, and mounting instructions.

Typographical Conventions Used in this Manual
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Typographical Conventions Used in this Manual
This manual contains different typographical conventions designed to enhance
readability and understanding of its content. Note the following examples:
• Standard text—used for standard text throughout the manual.
•Boldface text—emphasizes a word or phrase.
•NOTE:—sets apart special information or important instruction
clarification.
• The symbol below highlights a CAUTION or WARNING:
Figure 1-1. Caution and Warning Symbol
– A CAUTION points out special procedures or precautions that
service personnel must follow to avoid equipment damage.
– A WARNING identifies situations or actions that may affect
patient or user safety. Disregarding a warning could result in
patient or user injury.
• The symbol below highlights an electrical shock hazard warning:
Figure 1-2. Electrical Shock Hazard Warning

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Introduction to the ZoneAire Sleep Surface System
Overview
The ZoneAire Sleep Surface System is a zoned mattress replacement product
providing for the prevention and treatment of pressure ulcers in acute care. All
necessary electronic and pneumatic components are packaged in a single
control housing. The system is transportable from bed to bed and can be used
on both hard pan and fabric surfaces.
Specifications
Physical Description
The ZoneAire Sleep Surface System consists of the following:
• Sleep surface (mattress)
• Power unit assembly
• Caregiver pendant
• Patient pendant (optional)
Mattress Specifications
Dimensions
35" x 84"
• Advance Series bed (3 motor): 1100, 1110, 1120, 1130, 1140
• Advance Series bed (4 motor): 1105, 1115, 1135, 1145
• 840 and 850 series bed: 840, 842, 850, 852
• Centra bed (4 motor): 1060, 1061, 1062, 1063, 1064
35" x 80"
• Century Series bed: 835, 837
• 425, 426, 715, 720, 723, 820, 822
32" x 79"
• Century CC bed: 892, 894, 895, 896

Specifications
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Mattress Ticking
The zippered clam shell design polyester ticking covers both foam and air
bladder components. The bottom portion of the ticking has six magnets
enclosed in pockets located around the outer edge of the mattress. The magnets
help hold the mattress and sheets in place by adhering to the metal sleep sur-
face. For beds with a spring fabric deck, a buckle located at the footend of the
mattress holds the mattress in place.
Mattress Top and Bottom Foam
The top foam is segmented to provide different densities of support for the
patient. It also provides some protection against punctures to the upper bladder
from needle sticks and other sharp objects.
The bottom foam is shaped like a tub with dense side walls. The foot end is cut
out to allow room for the surface control module and locator plate. This tub
cradles the upper and lower air bladders.
Mattress Main Air Bladders—Upper and Lower
The main air bladders are contained inside the bottom foam section. The upper
and lower main air bladders are identical, only the hose connections from the
surface control module determine the bladder functions. These two air bladders
are segmented into three sections: the head, seat, and thigh sections.
Heel Air Bladder
The heel air bladder is divided into three zones: 1, 2, and 3. These zones are
connected to and controlled by the surface control module.
Air Hoses
The ZoneAire Sleep Surface System has one air hose that connects the air
pump to the surface control module inside the mattress. This air hose both
inflates and deflates the air bladder.
Six air hoses connect the air manifold to the mattress air bladders. These air
hoses are used for both inflate and deflate functions. The air manifold is
located on the surface control module inside the mattress.
Six air hoses connect the mattress air bladders to the pressure sensors. The
pressure sensors are located on the surface control module inside the mattress.

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Multiple Zone Bladders
The sleep surface consists of multiple zone bladders to provide significant
improvement in the reduction of patient interface pressure. Multiple zone
bladders allow greater patient and/or nurse adjustment to particular parts of the
patient’s body. The multiple zones consist of six different zones. The six zones
are the head, seat, thigh, and heel zones 1, 2, and 3.
Power Unit Assembly
The power unit assembly consists of an aluminum housing and a plastic case
cover. These two parts enclose all of the electronic and pneumatic components
not contained within the sleep surface. The power unit assembly attaches to the
mounting posts in place of the headboard. This unit weighs approximately 29
pounds.
Caregiver Pendant
The caregiver pendant contains the following switches and LED’s (see figure
1-3 on page 1-9):
• Sleep surface power switch and green LED
• Pressure relief switch and green LED
• Heel relief 1 switch and green LED
• Heel relief 2 switch and green LED
• Heel relief 3 switch and green LED
• Comfort switch and green LED
• Firmer switch and green LED
• Softer switch and green LED
• Auto firm switch and green LED
• Service required yellow LED
• Mains power green LED

Specifications
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Figure 1-3. Caregiver Pendant
Modes of Operation
The ZoneAire Sleep Surface System has four patient care modes. They are
pressure relief, heel relief, auto firm, and comfort. The choice of mode is best
determined through an assessment of the patient as to his or her risk of pressure
ulceration.
To activate the ZoneAire Sleep Surface System, press the POWER button on
the caregiver pendant. The LED light on the POWER button will illuminate,
indicating the system is on. The pressure relief LED will automatically
illuminate as pressure relief is the default mode. If the comfort mode is desired,
press the COMFORT button.
m121_007