Huntleigh AlphaXcell Electric User manual

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

AMENDMENT RECORD
Amendment Incorporated by Date
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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

2 Technical Description
The pressure regulated pump units listed in section 1 provide pressurised air for alternating pressure
mattress systems which are used in aiding the prevention, treatment and management of pressure
ulcers.
Pressurised air is fed to a range of support systems, mattresses, seat cushions etc., which support
patients at risk of developing pressure ulcers.
All pumps are self-contained units powered by the single phase mains/power supply. Low air
pressure and power failure alarm functions are included in some models, and pump output pressure
is adjustable by means of a rotary control mounted on the unit front panel.
Operating Principle
Refer to Figure 1 for details of the pneumatic circuit. All pumps have two pressurised air outlets, air
from the outlets is fed to separate cells or groups of cells in the mattress or cushion via a rotary valve.
The support cells are continuously inflated and deflated utilising a ten minute cycle. During the cycle,
air is pumped from one outlet for 4 minutes 10 seconds, there is then a period of 50 seconds where
air is pumped from both outlets. Air is then pumped from the other outlet for 4 minutes 10 seconds,
followed by a 50 second period where air is supplied from both outlets. During the period when air is
suppled from a single outlet to one group of cells, the opposing outlet is vented to atmosphere,
deflating the corresponding cells.
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Nov 2001 SER0004 Page 3
Mini Pump Service Manual Introduction

For the Aura mini pump small adjustments can be made to cell pressure using the comfort control
knob on the pump unit. This is a patient comfort feature to make small adjustments to the softness or
firmness of the support cells. All other mini pumps have a pressure adjustment control that must be
set to the patient weight in accordance with the instructions given in the relevant user manual and/or
the pump labels.
The range of air pressure delivered by the series of pumps varies, as does the achievable flow rate.
One extreme of pressure range can be adjusted by obtaining access to a screw under the pressure
control knob; see Table 3 for details of pressure variations. The range achievable is fixed by the
pressure control spring, only the set pressure can be reset.
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Introduction Mini Pump Service Manual
COMPRESSOR
PRESSURE
CONTROL
MICROSWITCH
M
ROTOR/
STATOR
OUTLET
PORTS
PRESSURE
CONTROL
MODULE
A3
A4
A2
A
1= INFLATED
KEY
= DEFLATED
A
A
A
A
A
A
A
A
A
A
A
A
ALTERNATING CELLS
EXCEPTION:
Aura has 9 alternating cells but no static cells.
HEAD
SECTION
(STATIC)
A
A
A
A
A
A
A
A
A
A
A
A
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
C
C
C
C
C
C
C
C
C
C
C
C
Figure 1 - Pneumatic Diagram and Pressure Variations

Table 3 - Air Pressure/Flow Rates
Pump
Model
Minimum
Pressure
(mmHg)
Maximum
Pressure
(mmHg)
Adjustable
Pressure
Range
Minimum Flow
Rate at 20 mmHg
back pressure
(litres/minute)
Minimum Flow
Rate at 50
mmHg
(litres/minute)
ALX 20-24 57-73 Yes 6 3
ALR 20-24 72-92 Yes 6 3
ALS 83-87 Less than 110 Comfort
control only
3.25 2.25
ALT 25-35 65-81* Yes 6 3
ALB 25-35 80-100 Yes 6 3
ALC 25-35 80-100 Yes 6 3
* Holland pumps (ALT10) only - max pressure is 80-100 mmHg
Pump units may be divided, into two types, Mechanical and Electronic. Major differences between
the two types of pump unit are as follows:
•Alarm indicators - mechanical type has a neon indicating low air pressure, also an illuminated
mains/power on/off switch. The electronic type incorporates an alarm monitoring PCB driving a
number of LED indicators and audible warning sounder. See Table 4 for visual indicator
details.
•Air outlets - mechanical type has simple push-on connectors (except ALX11 which has
snap-lock type connectors). The electronic type utilises snap-lock type connectors.
Table 4 - Product Visual Indicators
Model Code ALB ALC ALT ALR ALX ALX ALS
Mechanical (M)
or
Electrical (E)
MMME EME
Indicator
Illuminated Mains/Power Switch X X X X
On X X X
Wait X X
Low Pressure X X XXXXX
Power Fail X X X
System Start Up Sequence
All pump types must be connected to the appropriate mains/power supply via a suitable plug.
After a mechanical pump is switched on the start up sequence is as follows:
•The ON/OFF switch lever will be illuminated green.
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Nov 2001 SER0004 Page 5
Mini Pump Service Manual Introduction

•The red ‘low pressure’ indicator will be illuminated. When operating pressure is achieved, the
low pressure indicator will be extinguished automatically.
After an electronic pump is switched to ‘Run’ the start up sequence is as follows:
•The unit performs a diagnostic self test, illuminating all LED indicators and sounding the
audible alarm. If an internal fault is sensed or a problem with the wiring of the mains/power
sense switch, the pump will remain in this state. If the self test is successful then the start up
sequence will proceed.
•On start up, the low pressure alarm will be inhibited until one minute after the low pressure
signal is deactivated. The amber WAIT indicator will be illuminated while the low pressure
alarm is inhibited. (See Low pressure Protocol) Other functions will work as normal.
Note: Aura (ALS) model has no WAIT indicator; apart from this one difference, however, the Aura
pump performs the same as the other electronic pump units.
Low Pressure Alarm (Electronic Units Only)
When the alarm is activated, the red LOW PRESSURE indicator will flash, in combination with an
audible warning which increases in pitch with time. The alarm can be reset by momentarily switching
the pump to ‘Stand by’ and then back to ‘Run’. Alternatively, the alarm will automatically reset after
15 minutes provided that the low pressure switch is not activated during this time. If however the low
pressure switch is activated (for more than 15 seconds) during this time, the timer will reset to zero
and the alarm will continue for a further 15 minutes.
Low Pressure Alarm (All Units)
On all pump units except the ALS model the low air pressure alarm will be activated on or before
5 mmHg and deactivated before the pressure reaches 17 mmHg.
For the ALS model only, the low air pressure alarm will be activated on or before 50 mmHg and
deactivated at or before 82 mmHg.
Low Pressure Alarm Protocol (Electronic Units Only)
The low pressure alarm will be activated only when the requirements of the low pressure alarm
protocol have been met by a sequence of low pressure signals. The system is designed to detect low
pressure fault conditions without responding to spurious signals due to patient movement, mattress
cell crossover, short term tube disconnection etc.
In order to generate a low pressure alarm the system must detect three low pressure switch closure,
of 15 seconds duration each, within a 25 minute period. There will be a 2 minute lockout between the
first and second switch closures as well as between second and third switch closures. The lockout
period is to allow temporary disconnection of tubing.
In addition to the above, a wait period of 25 minutes is allowed on start up. During this time the low
pressure alarm is inhibited to allow inflation of the mattress to operating pressure. If, during this wait
period, the low pressure switch is activated (i.e., the system is up to pressure), the wait period will be
terminated 1 minute later, and normal protocol is obeyed thereafter.
Power Failure Alarm (Electronic Units Only)
In the event of a power failure, the red POWER FAIL indicator will flash in combination with an
audible warning which increases with time.
If the power supply is restored, the audible alarm will stop, but the indicator will remain illuminated
(continuously) until the system is reset. Resetting, by switching the pump to ‘Stand by’ and then back
to ‘Run’, will clear all alarm indications.
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Introduction Mini Pump Service Manual

The power failure alarm is initiated by the removal of the mains/power supply from the unit for a
period of more than 5 seconds, by a means other than operation of the ‘Run/Standby’ switch. A drop
in the supply voltage below the minimum supply specification will be interpreted as a supply failure. If
power is restored within 5 seconds, no alarm is given and normal operation is resumed.
A battery backup supply provides power to operate the visual and audible alarm.
Battery Management (Electronic Units Only)
On switching the pump to ‘Run’, the processor automatically initiates a standard charge sequence
(3 mA) for a predetermined period. On completion of the standard charge period, a trickle charge
(0.9 mA) will be applied to the battery for the remainder of the operating period.
When discharging during a power failure alarm, the battery supply will be shut down in a controlled
manner if the terminal voltage falls below 4.6 V before the alarm duration has expired.
Issue 2 Chap 1
Nov 2001 SER0004 Page 7
Mini Pump Service Manual Introduction

Chap 1 Issue 2
Page 8 SER0004 Nov 2001
Introduction Mini Pump Service Manual

CHAPTER 2
MAINTENANCE
1 Pump Maintenance Checks
If any parts are found to be damaged they must be replaced in accordance with Chapter 3, Pump
Repair.
1.1 Visually inspect the following for damage, wear and potential faults:
Note : If any parts require repairing or replacing then refer to the Huntleigh Healthcare service
manual.
1.1.1 Check outer casings for damage.
1.1.2 Functionally check switches and control knobs.
1.1.3 Ensure hanging brackets are secure and located.
1.1.4 Check outlet ports and connecting points for damage.
1.1.5 Ensure feet are secure and present.
1.1.6 Check fuses are satisfactory.
1.1.7 If a gauge is fitted ensure the glass is not cracked or damaged.
1.1.8 Check that there is no damage to the mains/power connector if fitted.
1.1.9 Check labels are present, located correctly and legible.
1.1.10 Ensure LED’s are not cracked.
1.2 Remove the compressor lid (Refer to Chap. 3, Section 22) and visually inspect the following for
damage, wear, and potential faults:
Note : If any parts require repairing or replacing then refer to Chap 3, Pump Repair.
1.2.1 Coil/’E’ stack assembly.
1.2.2 Elbows and connectors.
1.2.3 Bellows.
1.2.4 Security of compressor.
1.2.5 Integrity of filters and gaskets.
1.2.6 Valve body assembly.
1.2.7 Armature blades.
1.2.8 Pivot points.
1.2.9 Silencer bags.
1.2.10 Valve shuttle assembly.
Issue 2 Chap 2
Nov 2001 SER0004 Page 1
Mini Pump Service Manual Maintenance

Once the compressor has been visually inspected connect to a power supply and run, this is to
ensure the compressor is working and that there is flow/pressure at the outlet port of the pump.
Check for any excessive noise and vibration.
2 Pump Soak/Break-in Times
2.1 A pump must be soaked/broken-in for the following reasons:
Note : Soaking/breaking-in consists of running the pump with the outlet ports blocked.
•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.
2.2 All pumps should be soaked/broken-in for a period of 30 to 60 minutes prior to any pneumatic
performance test being carried out. This is because the compressor bellows need to warm up
to reach normal output.
2.3 If any of the following major/critical components have been replaced or repaired, then it is
recommended that the pump be soaked/broken-in for 12 hours prior to being tested:
•Valve body.
•Silencer Bag.
•Printed Circuit Boards (PCB) if applicable.
•Compressor.
•Rotary Valve Assembly.
3 Pump Service
A pump should be serviced every 12 months. To carry out a service on the pump, do the following:
3.1 Carry out the Pump Maintenance Checks (Section 1).
3.2 Replace the following components:
3.2.1 Silencer bag (Refer to Chapter 3, Section 22).
3.2.2 Pivot points (Refer to Chapter 3, Section 24).
3.2.3 Bellow assemblies (Refer to Chapter 3, Section 23).
3.2.4 Valve bodies (Refer to Chapter 3, Section 25).
3.2.5 Compressor filter (Refer to Chapter 3, Section 12).
3.2.6 Compressor gasket (Refer to Chapter 3, Section 22).
3.2.7 Pump case filter (Refer to Chapter 3, Section 4).
3.2.8 AV mounts (Refer to Chapter 3, Section 14 - new style, Section16 - old style).
3.2.9 Internal rechargeable battery (Refer to Chapter 3, Section 31).
Chap 2 Issue 2
Page 2 SER0004 Nov 2001
Maintenance Mini Pump Service Manual

3.3 Reassemble the pump and soak/break-in for the recommended time (Refer to Section 2).
3.4 Carry out a flow, pressure and function test on the pump in accordance with Chapter 5.
3.5 Carry out electrical tests on the pump in accordance with Chapter 5.
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Nov 2001 SER0004 Page 3
Mini Pump Service Manual Maintenance

Chap 2 Issue 2
Page 4 SER0004 Nov 2001
Maintenance Mini Pump Service Manual