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Chap 3

Issue 2

Page 30

SER0004

Nov 2001

Pump Repair

Mini Pump Service Manual

Figure 16 - Replacing the Power Failure Alarm Battery

Item

Part Number

Description

Qty

151457

Battery

N/A

Cable Tie

N/A

Battery Plug to PCB

Table 20 - Battery (Power Failure Alarm) Part List

Summary of Contents for AlphaBed

Page 1: ...Issue 2 SER0004 Nov 2001 Mini Pump Service Manual Huntleigh HEALTHCARE...

Page 2: ......

Page 3: ...ENDMENT 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 Content...

Page 4: ...Contents Issue 2 Page ii SER0004 Nov 2001 Contents Mini Pump Service Manual...

Page 5: ...p 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...

Page 6: ...ndicator 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...

Page 7: ...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...

Page 8: ...Contents Issue 2 Page iv SER0004 Nov 2001 Contents Mini Pump Service Manual...

Page 9: ...re regulated pump units pump models within the range are as follows AlphaXcell Electronic AlphaXcell Mechanical AlphaRelief Electronic Aura Electronic AlphaTrancell Mechanical AlphaBed Mechanical Alph...

Page 10: ...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...

Page 11: ...perating 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...

Page 12: ...e 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...

Page 13: ...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 ty...

Page 14: ...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 o...

Page 15: ...ower 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 predeterm...

Page 16: ...Chap 1 Issue 2 Page 8 SER0004 Nov 2001 Introduction Mini Pump Service Manual...

Page 17: ...factory 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 correctl...

Page 18: ...ng 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 P...

Page 19: ...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 Issue 2 Chap 2...

Page 20: ...Chap 2 Issue 2 Page 4 SER0004 Nov 2001 Maintenance Mini Pump Service Manual...

Page 21: ...llowing certain repairs To carry out a flow pressure and function test on the pump refer to Chapter 5 To carry out the electrical tests on the pump refer to Chapter 5 Issue 2 Chap 3 Nov 2001 SER0004 P...

Page 22: ...lace it with the MK2 version Chap 3 Issue 2 Page 2 SER0004 Nov 2001 Pump Repair Mini Pump Service Manual 10 20 Pin if fitted 30 40 Figure 2 Removing the Control Knob Item Part Number Description Qty 1...

Page 23: ...t s full extent Fit control knob in the position shown below AlphaRelief AlphaBed AlphaCare AlphaTrancell ALT10 No pin fitted Turn knob arbour counter clockwise to it s full extent Fit control knob in...

Page 24: ...20 40 30 Figure 3 Removing and Replacing the Pump Filter Item Part Number Description Qty 10 500340 Felt Filter 1 20 500327 Filter Plate 1 30 500317 Rear Case 1 40 FAS223 Pan Head Screw PT 3 Dia x 10...

Page 25: ...hen fit the filter plate to the rear case Fig 3 Item 30 and secure with the screw Fig 3 Item 40 6 Disassembling the Rear Case Note It is necessary to remove the rear case from the front case to allow...

Page 26: ...0 20 50 Figure 4 Replacing the New Style Bed Hook Item Part Number Description Qty 10 500495 Bed Hook New Style 1 20 500496 Hook Plate Left Hand 1 30 500497 Hook Plate Right Hand 1 40 FAS223 Pan Head...

Page 27: ...sitions will be reversed when they are presented to the rear case assembly 9 1 Assembly of the new Pump Filter is in the reverse order of disassembly Make sure the slots in the Filter Housing Plates F...

Page 28: ...Chap 3 Issue 2 Page 8 SER0004 Nov 2001 Pump Repair Mini Pump Service Manual 10 30 30 20 40 Figure 5 Replacing the Old Style Bed Hooks...

Page 29: ...eeds the new rear case assembly 11 Installing the Old Style Bed Hook 11 1 When refitting the old bed hook brackets replacement is the reversal of the above procedure 11 2 Ensure correct orientation of...

Page 30: ...Filter Assembly Item Part Number Description Qty 10 502003 Compressor Assy 230V 50Hz 11K T 1 502002 Compressor Assy 110V 60Hz 5K T USA 1 502007 Compressor Assy 100V 50 60Hz 4 5K T Japan 1 20 500320 F...

Page 31: ...t Filter 13 1 Locate a new inlet filter Fig 6 Item 40 over the air intake hole in the case of the compressor assembly Fig 6 Item 10 13 2 Carefully reposition the filter retaining Clip Fig 6 Item 30 on...

Page 32: ...pair Mini Pump Service Manual 10 20 20 30 20 20 Figure 7 Replacing the New Style AV Mounts Item Part Number Description Qty 10 500124 Compressor Mounting Bracket 1 20 500416 AV Mount 4 30 N A Mounting...

Page 33: ...and discard them 15 Replacing the New Style AV Mounts 15 1 Fit new AV mounts Fig 7 Item 20 of the same type to the mounting bracket Fig 7 Item 10 15 2 Carefully fit the compressor mounting bracket and...

Page 34: ...20 20 20 30 30 10 10 40 40 Figure 8 Replacing the Old Style AV Mounts Item Part Number Description Qty 10 N A AV Mounting Bracket 2 20 198375 AV Mount 4 30 N A AV Mount Nut 8 40 N A Washer 12 50 Ref T...

Page 35: ...AV mount nuts and washers and remove the four AV mounts from the compressor mounting bracket Fig 8 Item 60 17 Installing the Old Style AV Mounts 17 1 Fit four replacement AV mounts Fig 8 Item 20 to t...

Page 36: ...Chap 3 Issue 2 Page 16 SER0004 Nov 2001 Pump Repair Mini Pump Service Manual 10 40 50 20 60 30 50 40 Figure 9 Replacing Mounting Brackets and Bump Stops...

Page 37: ...bump stop Fig 9 Items 50 40 20 to the mounting bracket 19 3 Assemble AV mounts and fit the compressor AV bracket assembly into the pump case as described in Section 15 new style AV mounts or Section...

Page 38: ...d 21 2 Fit screw washer and replacement lower bump stop Fig 9 Items 50 40 10 to the compressor mounting bracket 21 3 Refit the compressor AV bracket assembly to the pump case as described in Page 13 S...

Page 39: ...Fit a new silencer bag and gasket then replace the compressor lid by reversing operations detailed in Section 22 4 22 3 and 22 2 22 6 Refit the compressor AV bracket assembly to the pump case Refer t...

Page 40: ...t Number Description Qty 10 502054 Bellows Armature Assembly Left Hand 230V 50Hz 1 BP215 Bellows Armature Assembly Left Hand 110V 60Hz 1 20 502053 Bellows Armature Assembly Right Hand 230V 50Hz 1 BP21...

Page 41: ...low pressure performance the new bellows may have to be heated with a hot air gun whilst operating This anneals the bellows permanently and alters the pressure flow characteristics Caution The bellows...

Page 42: ...ody Assy Blue Each valve body contains items 20 to 70 2 20 BP351 Valve Body 1 30 FAS027 Screw Hex Head 4BA x 3 4 1 40 FAS013 4BA Full Nut 1 50 BP039 Valve Body Washer 2 60 BP037 Valve Flap 2 70 BP038...

Page 43: ...ype 25 7 Repeat Sections 25 3 to 25 6 as necessary to replace the other valve body 25 8 When replacing the valve flaps and valve flap securing pads make sure that the valve flap sits flat over the hol...

Page 44: ...Description Qty 10 BP028 E Stack 1 20 FAS048 Pan Head Screw M3 x 25 mm Pozi 2 30 FAS002 Washer 6BA Anti Vib 2 40 502050 Coil Assembly 230V 50Hz black white leads 1 502062 Coil Assembly 110V 60Hz grey...

Page 45: ...e 15 Section 17 3 17 4 and 17 5 old style AV mounts 27 Replacing the Coil Assembly 27 1 Remove disassemble the compressor AV bracket assembly and remove the silencer bag Refer to Page 19 Section 22 1...

Page 46: ...ssembly from the pump case Refer to Page 13 Section 14 1 14 2 and 14 3 new style AV mounts or Page 15 Section 16 1 16 2 and 16 3 old style AV mounts 28 4 Remove the compressor mounting bracket Refer t...

Page 47: ...6 and disconnect the adjacent switch wire terminal 5 Fig 14 Item 10 29 9 Disconnect the mains power lead wires from the terminal block terminals L and N Fig 14 Item 10 29 10 Remove three screws Fig 14...

Page 48: ...ing PCB Item Part Number Description Qty 10 FAS083 Screw No 6 x 5 16 Pozi Pan Head PT 1 20 500346 PCB Alarm Monitoring 230 V 1 500345 PCB Alarm Monitoring 100 120 V 1 30 N A Signal Connectors REF 40 N...

Page 49: ...mp 30 1 Remove the pressure control module as described in Page 27 Section 29 1 to 29 7 30 2 Disconnect PCB power wires Fig 15 Item 60 from PCB 30 3 Disconnect the three signal connectors from the PCB...

Page 50: ...p Repair Mini Pump Service Manual 10 20 30 Figure 16 Replacing the Power Failure Alarm Battery Item Part Number Description Qty 10 151457 Battery 1 20 N A Cable Tie 1 30 N A Battery Plug to PCB 1 Tabl...

Page 51: ...ttery power failure alarm is only applicable to electronic versions of the mini pump 31 1 Remove the PCB Refer to Page 29 Section 30 31 2 Remove the battery plug Fig 16 Item 30 from the PCB 31 3 Cut a...

Page 52: ...10 30 RE ENS THIS SI E Figure 17 Replacing the Neon Indicator Light Item Part Number Description Qty 10 FAS083 Screw No 6 x 5 16 Pozi Pan Head PT 1 20 500324 Plate Neon Mounting 1 30 500373 Neon Asse...

Page 53: ...Micro switch Fig 18 Item 10 32 3 Release the screw Fig 17 Item 20 attaching the neon mounting plate Fig 17 Item 10 and remove the neon Fig 17 Item 30 and mounting plate assembly 32 4 Note the orientat...

Page 54: ...3 Figure 18 Replacing the Micro switch and Terminal Block Item Part Number Description Qty 10 500338 Micro switch Sub Min 230 V 0 1A 1 20 FAS224 Screw 2 2 Dia x 14 mm Pozi Pan Head PT 2 30 500347 Term...

Page 55: ...not necessary to remove the pressure control module from the pump case 34 1 Disconnect all wires from the terminal block Fig 18 Item 30 34 2 Release two securing screws Fig 18 Item 40 and remove the t...

Page 56: ...rol Arbour 1 20 500312 Upper Pressure Control Flap 1 30 500318 Pivot Pin Pressure Control 1 40 500303 Lower Pressure Control Flap 1 50 500341 Spring 0 024 Diameter 1 60 151339 Pressure Control Disc 1...

Page 57: ...g assembly Fig 19 Item 80 Replace with a new item Ensure the air bag is secure by pushing in the centre and rotate it slightly to ensure it is seated 35 4 Ensure that the low pressure adjustment screw...

Page 58: ...nob Cam and Arbour Item Part Number Description Qty 10 FAS225 Control Adjustment Screw 3 Dia x 16 mm Pozi Pan Head PT 1 20 500305 Knob Control Cam 1 30 500411 Cup Arbour Drive Spring 1 40 500339 Sprin...

Page 59: ...arbour cam spring cup and spring Fig 20 Items 20 30 and 40 36 5 Renew replace components with the same type Note Early versions may have a nylon washer in lieu of the spring cup Discard the washer and...

Page 60: ...Description Qty 10 FAS223 Screw 3 Dia x 10 mm Pozi Pan Head 2 20 500097 Gearbox 240V and Ferrule Assembly 1 500098 Gearbox 120V and Ferrule Assembly 1 500099 Gearbox 100V and Ferrule Assembly 1 151409...

Page 61: ...ressure assembly module 37 6 Depress the motor drive cup Fig 21 Item 70 toward the motor and remove the drive shaft pin Fig 21 Item 80 37 7 Carefully remove the rotor drive cup star washer Fig 21 Item...

Page 62: ...500343 Switch Mains Power Rocker 230 V Green Illuminated 1 500359 Switch Mains Power Rocker 110 V Green Illuminated 1 20 198315 Grommet 1 30 BP532 Cordset Standard Moulded UK Cable 1 CAS041 Mains Pow...

Page 63: ...em 30 through the mains lead power cord grommet 39 3 Carefully withdraw the mains power lead grommet Fig 22 Item 20 through the side panel 39 4 Replace the lead with the same part number Replacement i...

Page 64: ...0 20 Part 10 Part Figure 23 Snap lock Connectors Item Part Number Description Qty 10 500350 Connector Panel Female 1 4 Flow 1 20 504316 Connector Panel Male 1 4 Flow 1 30 500361 Tube Sil Blue ID 6 OD...

Page 65: ...he PCB 41 3 Remove screw Fig 15 Item 10 and remove the PCB 41 4 Undo locknut and withdraw connector through side panel with tube 41 5 Remove tube from connector 41 6 Replace with the same type Replace...

Page 66: ...ote For Alpharelief Alphabed Alphacare and AlphaTrancell ALT10 pumps the pin is not needed This allows 270 movement of the Pressure Control Knob 43 2 Fit a front label to the front case Refer to Table...

Page 67: ...phaXcell ALX017 1 500393 Label set Australia AlphaXcell ALX08 1 500394 Label set Rest of the World AlphaXcell ALX09 1 500395 Label set Holland AlphaXcell ALX10 1 500472 Label set Rest of the World Alp...

Page 68: ...Alpha Relief ALR02 1 500470 Label set USA Alpha Relief ALR03 1 500476 Label set Euro Alpha Relief ALR04 1 AlphaCare Series 500401 Label set USA AlphaCare ALC03 1 500402 Label set Euro AlphaCare ALC04...

Page 69: ...Possible Cause Action Mattress Seat not Inflating Applicable to all pumps 1 CPR not inserted mattress only Check CPR See Mattress Service Manual SER0005 2 Tubes kinked Check 3 Pump not switched on Che...

Page 70: ...nated but there is no audible alarm Applicable to ALR 01 10 ALX 01 10 ALS 01 10 There has been a mains power failure but power has been restored Check if electrical plug is correctly fitted and if pum...

Page 71: ...the bellows armature assemblies and valve bodies must be replaced Refer to Chap 3 Section 23 If the required pressure is obtained then the silencer bag must be replaced Refer to Chap 3 Section 22 Note...

Page 72: ...nflate and deflate during a 10 minute cycle then the timer motor may be defective not rotating 5 1 Check the timer motor electrical connections for security and integrity If all are sound and the time...

Page 73: ...evant circuit and repair as appropriate Issue 2 Chap 4 Nov 2001 SER0004 Page 5 Mini Pump Service Manual Troubleshooting Live Gearbox Sounder PCB Microswitch Mains Power Switch Compressor Terminal Bloc...

Page 74: ...ual Live Mains Power Lead Neon Microswitch Gearbox Compressor Terminal Block Fuse Mains Power Switch Neutral L L L L L 1 1 1 6 2A 2A 4B 4B 4 N N N N N 2 3 3 2 5 1A 1A 3B 3B 3 Figure 25 Circuit diagram...

Page 75: ...3 Close the valve and operate the pressure control knob on the pump from minimum to maximum setting The pressure indicated on the gauge in mmHg should be as specified in Table 31 Issue 2 Chap 5 Nov 20...

Page 76: ...age 2 SER0004 Nov 2001 Testing Mini Pump Service Manual MINI PUMP PRESSURE ADJUSTMENT SCREW MANOMETER mmHg 9V BATTERY FLOW METER DAMPER FOR EVEN FLOW Stop Pin If fitted Figure 26 Typical Test Rig setu...

Page 77: ...he minimum setting and the stop pin if fitted 1 4 5 Check the indicated pressure at minimum and maximum settings Refer to Table 32 and readjust if necessary 1 4 6 Variation between the ports is to be...

Page 78: ...1 8 2 Connect a buzzer or LED to the microswitch terminals to indicate microswitch operation see Chap 4 Fig 24 for microswitch terminal connections 1 8 3 Ensure that the bleed valve is fully closed En...

Page 79: ...Appliance Tester Also check the continuity of the mains cable Dielectric Strength Test Flash Test This test shows the response of the insulation to high ac voltage stress to the effects of the capaci...

Page 80: ...indicator and the LOW PRESSURE indicator will remain on The POWER FAIL indicator light should extinguish Power Fail Alarm Check 3 3 With the pump operating disconnect the power supply at the power soc...

Page 81: ...t ports are open to atmosphere 4 2 Connect the mains power cable to a suitable power socket outlet and then set the on off switch to on Verify that the green indicator in the switch is illuminated Ver...

Page 82: ...Chap 5 Issue 2 Page 8 SER0004 Nov 2001 Testing Mini Pump Service Manual...

Page 83: ...lief pump is available to countries 01 02 03 and 04 UK Germany USA and Europe general respectively A complete breakdown of the pump model three letter codes and two digit codes is given in Chap 1 Tabl...

Page 84: ...y in accordance with UL 2601 1 Canada CSA C22 2 No 601 1 Classified by Underwriters Laboratories Inc with respect to electric shock fire and mechanical and other hazards only in accordance with CAN CS...

Page 85: ...a to 1060 hPa Storage conditions for all pump models Temperature range 40 C to 70 C Relative humidity 10 to 100 non condensing Atmospheric pressure 500 hPa to 1060 hPa Disposal All units must be dispo...

Page 86: ...Chap 6 Issue 2 Page 4 SER0004 Nov 2001 Technical specification Mini Pump Service Manual...

Page 87: ...crew PT 3 Dia x 10 4 40 8 500381 Rubber foot 4 50 8 Label Sets See Chap 3 Page 47 Table 28 Compressor Assembly 502003 Compressor Assy 230V 50Hz 11K T 6 10 10 10 1 502002 Compressor Assy 110V 60Hz 5K T...

Page 88: ...Case 13 60 1 502301 Compressor Lid 10 20 1 BP032 Compressor Gasket 10 40 1 502055 Silencer Bag 10 50 1 500320 F Tube Connector 6 20 10 60 1 500410 Filter Retaining Clip 6 30 1 500417 Inlet Filter 6 4...

Page 89: ...50303 Lower Pressure Control Flap 19 40 1 500341 Spring 0 024 Diameter 19 50 1 151339 Pressure Control Disc 19 60 1 PRE022 Rubber Valve Disc 19 70 1 500103 Bag Pressure with Restrictor Assembly 19 80...

Page 90: ...o 6 x 5 16 Pozi Pan Head PT 15 10 1 Neon Indicator Mechanical versions only 500324 Plate Neon Mounting 17 20 1 500373 Neon Assembly Red 230 V 17 30 1 500371 Neon Assembly Red 110 V FAS083 Screw No 6 x...

Page 91: ...4 Flow 23 20 1 500361 Tube Sil Blue ID 6 OD 10 24 LG 1 23 30 1 500360 Tube Sil Blue ID 6 OD 10 15 LG 1 23 40 1 Service Kit 500135 Service Kit 240v only BP043 Armature Pivot 2 502055 Silencer Bag 1 502...

Page 92: ...Chap 7 Issue 2 Page 6 SER0004 Nov 2001 Parts list Mini Pump Service Manual...

Page 93: ...8486 F 45 4 913 8487 Sweden Huntleigh Liljenberg AB Limhammsg rdens alle 15 21610 Limhamm Malmo Sweden T 46 40 49 57 80 F 46 40 49 43 75 France HNE M dical SA Parc d affaires Silic 6 1 Rue des Vergers...

Page 94: ...Chap 8 Issue 2 Page 2 SER0004 Nov 2001 Service Contact Details Mini Pump Service Manual...

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