Huntleigh AlphaXcell Electric User manual

Issue 2
SER0004 Nov 2001
Mini Pump
Service Manual
Huntleig
h
HEALTHCARE

AMENDMENT RECORD
Amendment Incorporated by Date
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Issue 2 Contents
Nov 2001 SER0004 Page (i)
Mini Pump Service Manual Contents

Contents Issue 2
Page (ii) SER0004 Nov 2001
Contents Mini Pump Service Manual

Contents
CHAPTER 1
Introduction ....................................1
About This Manual ......................................1
Warnings, Cautions and Notes ............................2
Technical Description .....................................3
Operating Principle...................................3
System Start Up Sequence ..............................5
Low Pressure Alarm (Electronic Units Only) ......................6
Low Pressure Alarm (All Units) ............................6
Low Pressure Alarm Protocol (Electronic Units Only) .................6
Power Failure Alarm (Electronic Units Only)......................6
Battery Management (Electronic Units Only) .....................7
CHAPTER 2
Maintenance ...................................1
Pump Maintenance Checks .................................1
Pump Soak/Break-in Times..................................2
Pump Service .........................................2
CHAPTER 3
Pump Repair ...................................1
General ............................................1
Removing the Pressure Control Knob ............................3
Installing the Pressure Control Knob .............................3
Disassembling the Pump Filter ................................5
Assembling the Pump Filter .................................5
Disassembling the Rear Case ................................5
Assembling the Rear Case ..................................5
Disassembling the New Style Bed Hook ...........................7
Installing the New Style Bed Hook ..............................7
Removing the Old Style Bed Hook ..............................9
Installing the Old Style Bed Hook...............................9
Removing the Compressor Inlet Filter............................11
Installing the Compressor Inlet Filter ............................11
Removing the New Style AV Mounts ............................13
Replacing the New Style AV Mounts ............................13
Removing the Old Style AV Mounts .............................15
Issue 2 Contents
Nov 2001 SER0004 Page (i)
Mini Pump Service Manual Contents

Installing the Old Style AV Mounts .............................15
Removing the Compressor Mounting Bracket........................17
Installing the Compressor Mounting Bracket ........................17
Removing the Compressor Bump Stops ..........................17
Installing the Compressor Bump Stops ...........................18
Replacing the Compressor Silencer Bag ..........................19
Replacing the Bellows Armature Assemblies and Pivots ..................21
Replacing the Compressor Armature Pivots ........................21
Replacing the Compressor Valve Bodies ..........................23
Replacing the ‘E’ Stack Assembly..............................25
Replacing the Coil Assembly ................................25
Replacing the Compressor Assembly ............................25
Replacing the Pressure Control Module...........................27
Replacing the Alarm Monitoring PCB ............................29
Changing the Battery ....................................31
Replacing the Neon Indicator Light .............................33
Replacing the Microswitch..................................35
Replacing the Terminal Block ................................35
Replacing the Pressure Control Flaps and Air Bag .....................37
Replacing the Pressure Control Assembly .........................39
Replacing the Synchronous Motor (Gearbox), Rotor Stator Assembly ...........41
Replacing the Side Panel Mains/Power On/Off Switch ...................43
Replacing the Side Panel Mains/Power Lead ........................43
Replacing the Fuses.....................................43
Replacing the Snap-lock Connectors ............................45
Removing the Front Case ..................................46
Installing the Front Case ..................................46
Pump Label Sets ......................................47
CHAPTER 4
Troubleshooting .................................1
General ............................................1
Low Pressure fault indicated (checks without dismantling the pump) ............2
Loss of Output Pressure (checks by dismantling the pump) .................3
Low Pressure Alarm Fault ..................................4
Air Not Alternating (continuous pressure fault) ........................4
Loss of Electrical Power ...................................4
Contents Issue 2
Page (ii) SER0004 Nov 2001
Contents Mini Pump Service Manual

Circuit Diagrams .......................................5
CHAPTER 5
Testing ......................................1
Pump Flow, Pressure and Function Test ...........................1
Electrical Testing .......................................5
PCB Functional Tests (Electrical Units Only) .........................6
Functional Tests (Mechanical Units Only) ..........................7
CHAPTER 6
Technical specification..............................1
CHAPTER 7
Parts list ......................................1
CHAPTER 8
Service Contact Details .............................1
Issue 2 Contents
Nov 2001 SER0004 Page (iii)
Mini Pump Service Manual Contents

Contents Issue 2
Page (iv) SER0004 Nov 2001
Contents Mini Pump Service Manual

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 regulated pump units; pump models within the range are as follows:
•AlphaXcell (Electronic)AlphaXcell (Mechanical)
•AlphaRelief (Electronic)
•Aura (Electronic)
•AlphaTrancell (Mechanical)
•AlphaBed (Mechanical)
•AlphaCare (Mechanical)
Pump models are available for use world wide – model codes are shown in Table 1, while for country
codes and power supply details refer to Table 2.
Model Code Country Code
AlphaXcell (Electronic) ALX 01 to 10
AlphaXcell (Mechanical) ALX 11
AlphaRelief ALR 01 - 10
Aura ALS 01 - 10
AlphaTrancell ALT 01 - 10
AlphaBed ALB 01 - 10
AlphaCare ALC 01 - 10
Issue 2 Chap 1
Nov 2001 SER0004 Page 1
Mini Pump Service Manual Introduction
Table 1 - Product Range Distribution

Table 2- Country Codes/Power Supplies
Country Code Country
Mains Power
Voltage (Volts AC) Frequency (Hz)
01 UK 220 - 240 50
02 Germany 220 - 240 50
03 USA 110 - 120 60
04 Euro 220 - 240 50
05 France 220 - 240 50
06 Japan 100 50/60
07 Italy 220 - 240 50
08 Australia 220 - 240 50
09 Rest of World 220 - 240 50
10 Holland 220 - 240 50
11 Rest of World 110 - 120 60
Warnings, Cautions and Notes
WARNINGS given in this manual identify possible hazards in procedures or conditions which, if not
correctly followed, could result in death, injury or other serious adverse reactions.
Cautions given in this manual identify possible hazards in procedures or conditions which, if not
correctly followed, could result in equipment failure or damage.
Notes given in this manual are used to explain or amplify a procedure or condition.
WARNINGS:
BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES,
ENSURE THAT THE EQUIPMENT HAS BEEN ADEQUATELY
DECONTAMINATED.
VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC CAN, IN
CERTAIN CIRCUMSTANCES, BE LETHAL. WHEN WORKING ON
EQUIPMENT REQUIRING EXPOSURE TO LIVE, UNPROTECTED
CONDUCTORS WHERE SUCH VOLTAGES ARE PRESENT, EXTREME CARE
MUST BE EXERCISED.
WHEN AN UNSERVICEABLE MAINS LEAD/POWER CORD FITTED WITH A
NON-REWIREABLE PLUG IS REMOVED FROM THIS EQUIPMENT, THE
LEAD/CORD AND THE PLUG MUST BE DESTROYED AND DISPOSED OF
SAFELY. TO AVOID THE DANGER OF ELECTRIC SHOCK THE PLUG MUST
NEVER BE INSERTED IN ANY POWER OUTLET.
Chap 1 Issue 2
Page 2 SER0004 Nov 2001
Introduction Mini Pump Service Manual