ALPHA ACTIVE 4 SYSTEM

ALPHA ACTIVE

®

4 SYSTEM

Service Manual

Alpha Active 4 Service Manual

CONTENTS

CHAPTER 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Numbering and Cross-Referencing in this Manual . . . . . . . . . . . . . . . . . . . . . 1

Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Alpha Active 4 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Cycle Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Alpha Active 4 Mattress Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Pneumatic and Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Alarm/Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mode Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Auto-firm Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Cycle Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Alarms and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service Indicator/Pump Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Fail Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CHAPTER 2

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mattress Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mattress Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Alarm Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Power Fail Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Low Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Service Pump/Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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CHAPTER 4

Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mattress Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump Flow, Pressure, and Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Flow and Pressure Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Safety Checks - Class II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Power Fail Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Low Pressure Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Service Alarm Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mattress Inflation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

End Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHAPTER 5

Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Removing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removing The Bed Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Replacing the Bed Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Removing the Mains/Power Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installing the Mains/Power Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removing the Front Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Replacing the Front Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Removing the Display PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installing the Display PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Removing the Compressor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing the Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Removing the Microswitch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installing the Microswitch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Removing the Rotor/Stator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installing the Rotor/Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Removing the Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installing the Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Removing the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Installing the Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Removing the Main PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Replacing the Main PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Removing Power Fail Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Replacing Power Fail Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Removing the On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Installing the On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Removing the Fuse Holder Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installing the Fuse Holder Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Removing the Mains/Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installing the Mains/Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Removing the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installing the Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CHAPTER 6

Mattress Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Alpha Active 4 Cell Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Removing The Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removing Cell Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installing Cell Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Replacing Manifold Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Removing CPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installing CPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Removing Static Feed Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installing Static Feed Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Removing 3-Way Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installing 3-Way Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CHAPTER 7

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mattress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Mattress Size Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Cover Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cleaning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 8

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pump Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Mattress Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHAPTER 9

Service Contact Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Alpha Active 4 Service Manual Introduction

CHAPTER 1

INTRODUCTION

1 About This Manual

ArjoHuntleigh 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 ArjoHuntleigh be responsible for any service performed by customers or third parties.

This manual contains information on maintenance, servicing, repair, troubleshooting and testing for the

Alpha Active 4

system, which comprises of a pump and a mattress replacement.

Read and understand this manual before attempting to service or repair the equipment.

Numbering and Cross-Referencing in this Manual

For all chapters in this manual:

• Page, section and paragraph numbering re-start at “1”.

• Figure and table numbering continue from the previous chapter.

• Cross-references, which include a chapter number (and/or chapter title) refer to text in a different chapter. Cross-references which do NOT include any chapter number (or chapter title) refer to text within the same chapter.

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.

WARNING: 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.

2 Technical Description

The Alpha Active 4 system comprises of a mattress replacement and pump. The product can be used on hospital and domestic beds in both domestic and care environments. The bed base must be suitable for the specified mattress size.

Alpha Active 4 Pump

The Alpha Active 4 pump comprises of a moulded case with non slip feet on the base and integral hanging brackets.

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Introduction Alpha Active 4 Service Manual

The controls are situated on the front of the pump and a sophisticated alarm system differentiates between normal operation and genuine system faults. If an alarm situation is detected an indicator will illuminate on the front of the pump and an audible warning will sound.

Cycle Options

The pump has a user selectable option for operating on either a ten minute, or twenty minute cycle.

10 minutes Cycle

In this alternating mode, the system has a cycle time of 10 minutes. Each full cycle consists of 4.5 minutes inflate, 30 seconds change over, 4.5 minutes deflate and 30 seconds changeover.

20 minutes Cycle

In this alternating mode, the system has a cycle time of 20 minutes. Each full cycle consists of 9.5 minutes inflate, 30 seconds change over, 9.5 minutes deflate and 30 seconds changeover.

Alpha Active 4 Mattress Replacement

Each of the air cells is split into two sections. The base section of each being linked together to provide a static section which provides protection from the effects of bottoming out.

The Alpha Active 4 cover is water resistant and vapour permeable to enhance patient comfort whilst protecting the cells from ingress of contaminants. The cover is simple to clean in situ, but may easily be removed for laundering, preventing cross contamination.

In the event of cardiac arrest the mattress replacement can be rapidly deflated to allow cardiac resuscitation procedure (CPR) to be performed.

Part No.

648322

648324

648326

Table 1 - Available Mattress Sizes

Description

ALPHA ACTIVE 4 MR 90


ALPHA ACTIVE 4 MR 85 PU

Spare

Cover

648437

648461

648461

Length mm

Width mm

Height mm

1950 (77") 900(35") 200 (8")

1950 (77") 850(33") 200 (8")

1950 (77") 850(33") 200 (8")

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3 Pneumatic and Electrical Diagrams

Introduction

Figure 1 - Pneumatic System Diagram

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*Connectors J1, J2 and J7 must be connected to their relevant terminals on the Main PCB.

Figure 2 - Electrical Diagram

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Alpha Active 4 Service Manual Introduction

4 Front Panel

4.1

Below is a diagram of the Alpha Active 4 pump front panel. For more detail on the function of each button, see below.

Cycle Time Alarm Mute Mode Selector Auto-firm Mode

Comfort Control Alarms

5 Controls and Indicators

On/Off Switch

Located on the right side of the pump unit, the On/Off switch will illuminate green when the pump is on.

Alarm/Mute

During an alarm condition the sound of the alarm can be muted by pressing this button.

The yellow indicator will then flash intermittently but the alarm will be muted.

Mode Select

The mode selector allows the mode of operation to be selected.

Two modes of operation are available, Alternating or Static (non-alternating) .

The indicator next to the respective icon indicates the currently selected mode.

Auto-firm Mode

Selects the Auto-firm, non-alternating mode. The orange indicator will illuminate when the pump is in this mode. Autofirm operates for 30 minutes.

Pressure Control

Two buttons (+ and -) are used to set the pressure inside the mattress replacement and therefore the amount of support the patient receives.

The pressure setting is indicated by the green indicator above the selected setting.

Cycle Time

A single button allows the cycle time to be selected for the most appropriate patient therapy.

The cycle time setting is indicated by the green indicator above the selected setting.

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6 Alarms and Indicators

Low Pressure Indicator

The red Low Pressure indicator is illuminated whenever the pump detects low pressure within the mattress replacement. An audible alarm will sound unless cancelled by the mute button.

The indicator will extinguish once normal pressure is reached. Refer To

“Troubleshooting” on page 14 for possible causes of Low Pressure.

Service Indicator/Pump Fault

The yellow Service/pump fault indicator will illuminate and remain on if the pump has detected an internal fault. An audible alarm will sound unless cancelled by the mute button.

Power Fail Indicator

The red Power Fail indicator will illuminate when a mains power failure has been detected. An audible alarm will sound until power is restored or the pump is switched off using the on/off switch.

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Alpha Active 4 Service Manual Troubleshooting

CHAPTER 2

TROUBLESHOOTING

1 Troubleshooting Table

The following table contains fault symptoms, their possible causes and suggests steps to rectify the problem. These may occur during initial installation and power up.

Table 2 - Troubleshooting Table

Symptom

Low Pressure Alarm

(Mattress)

Low Pressure Alarm

(Pump)

Power Fail Alarm

Service Alarm

Possible Cause

Tube-set not connected securely

CPR not fully closed.

Cell Leak.

Damaged/Disconnected tube.

Faulty Compressor

Blocked Air Filter

Power has been removed from the pump.

Blown Fuse.

Pump has detected an internal fault.

Faulty Microswitch

Faulty Gearbox

Action

Check the tube-set connector and ensure it is securely fitted to the pump.

Close CPR Unit

Trace and replace faulty part.

Check/Replace.

Check/Replace.

(Chapter 5, Page 13, Section 12).

Check/Replace.


Re-apply power or switch the pump off.

Check/Replace.


Trace and replace faulty part.

Test and Replace if required.


Check/Replace if required.


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Troubleshooting Alpha Active 4 Service Manual

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Alpha Active 4 Service Manual Maintenance

CHAPTER 3

MAINTENANCE

WARNING: BEFORE DISMANTLING THE PUMP, ENSURE UNIT HAS BEEN ISOLATED

FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE

WALL OUTLET.

WARNING: A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS WHEN THE BACK

COVER IS REMOVED, EVEN WITH THE PUMP SWITCHED OFF.

CAUTION: Static Sensitive Devices

This pump should only be opened by personnel trained in ESD methods and with appropriate equipment and anti-static protection.

1 Pump Service

A pump should be serviced every 12 months. To carry out a service on the pump, do the following:

1.1

Carry out the Pump Maintenance Checks (Refer to Page 1, Section 2).

1.2

Replace the air inlet filter.

2 Pump Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Pump Repair.

2.1

Visually inspect the following for damage, wear and potential faults:

• Base of Pump

• Inlet Filter

• Compressor

• Electrical Connections

• Tubing

• Power Switch

• Wiring

• Air flow

• Outlet Tubes

Check base is free from debris.

Check condition.

Check compressor seating.

Check connections are secure and completely insulated.

Check completely pushed on and are kink free.

Check switch illuminates when ON.

Check wiring is intact.

Check electrical insulation are not damaged.

Check air flow is alternating.

Check tubes are secure.

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Maintenance Alpha Active 4 Service Manual

3 Mattress Service

To carry out a service on the mattress, do the following:

3.1

Carry out the Mattress Maintenance Checks (Refer to Page 2, Section 4).

4 Mattress Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Mattress Repair.

4.1

Visually inspect the following for damage, wear and potential faults:

• Base and Top Cover

• Base/Top cover Zip

• Fixing Straps

• Connectors

• Tubing

• Cells

• Manifold

• Press Studs

• CPR

• Tubeset Assembly

Check for tears, staining, clarity of printed labels.

Check the zip runs freely and condition of zip teeth.

Check condition and security.

Check for damage and security.

Check for security and ensure no kinks or twists.

Check for damage.

Check for damage and security.

Check condition.

Check operation of Fast Deflate mechanism.

Check for damage and security of connection.

4.2

Carry out a function test on the pump/mattress system in accordance with Chapter 4.

5 Alarm Functions

Power Fail Alarm

Switch pump off at mains/power socket, leaving the pump switched on. The red power fail indicator will illuminate when a mains power failure has been detected. An audible alarm will sound until power is resumed or the pump is switched off using the on/off button.

Low Pressure Indicator

5.1

Block the air outlets on the pump.

5.2

Switch the pump on and allow Low Pressure indicator to extinguish.

5.3

Remove the blockage from the air outlets. The red Low Pressure indicator will illuminate and and audible alarm will sound.

Service Pump/Fault

The yellow service/pump fault indicator will illuminate and remain on if the pump has detected an internal fault. Refer to Troubleshooting to help diagnose the fault, refer to Chapter 2.

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CHAPTER 4

TESTING

CAUTION: Electrostatic discharge can seriously damage the Main PCB. Prior to replacing it, adequate earthing precautions must be taken.

Note: In all cases the pump and mattress must be tested together as a system.

Testing

1 Mattress Visual Inspection

Ensure that the mattress is checked as follows:

1.1

All studs must be secure and all inlet connectors fitted securely.

1.2

The mattress contains 19 cells which are studded to both sides of the mattress. The bottom of each cell connected to the static feed, the top half connected to the alternating feed (the head section cells top half are connected to the static feed). Ensure that the cells are retained centrally by the loops in the base cover.

2 Pump Visual Inspection

2.1

Ensure there are no cracks or marks on the pump case. Ensure the labels are intact and readable. Check there are no marks or fractures in the Pump outlet module.

2.2

Ensure the mains lead is fully secure and there are no cuts or damage to the cable.

3 Pump Flow, Pressure, and Function Test

You will also need:

• A sphygmomanometer or pressure gauge (0-160mmHg)

• A flow meter (0-10 litres/minute)

To carry out a system functional test complete the following procedures:

• Flow and Pressure Checks

• Electrical Testing

• Functional Test

The following procedures must be carried out after a service or major repair of the pump. To test/ calibrate pump correctly, the following equipment (or equivalent) is required:

Note: All test equipment must be calibrated to national or international standards.

Flow and Pressure Checks

3.1

Set the pressure control on the pump to maximum (200kg) setting.

3.2

Connect a dual flow pressure meter, via a valve, to whichever outlet is working.

3.3

Open the valve fully. The free flow rate should not be less than specified in the table below.

Air Flow @

20mmHg

6 litres/min

Air Flow @

50mmHg

3 litres/min

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Testing Alpha Active 4 Service Manual

3.4

Close the valve and operate the pressure control on the pump from minimum (20kg) to maximum (200kg) setting. The pressure indicated on the gauge (in mmHg) should be as specified in the table below.

Minimum Pressure

@ 20kg

25mmHg ± 5mmHg

Maximum Pressure

@ 200kg

75mmHg ± 5mmHg

3.5

Repeat for the remaining ports.

4 Electrical Testing

To test and calibrate the pump unit correctly, the following equipment is required:

Item

3

4

1

2

Test Equipment

Insulation Resistance Tester (Megger), 500 Vdc

Portable Appliance Tester

Multimeter / Continuity Tester

Dielectric strength tester (Flash tester) 3.0 kVac with current limit (CHECK 4.0kVac??)

Electrical Safety Checks - Class II

There are several electrical safety checks that must be carried out after breakdown repairs, rental rechecks and servicing. Where alternatives are given, the test will depend upon the available equipment.

The tests are as follows:

• Insulation Resistance Test (Megger Test) or

• Dielectric Strength (Flash Test)

Insulation Resistance Test

This test checks the integrity of the appliance’s insulation.

For all appliances, this test is applied between the connected Live and Neutral wires and the appliance’s metal compressor assembly box.

Specification:

500 Vdc is applied to the insulation and the measured resistance must be greater than

2MΩ. This test can be conducted by using a Portable Appliiance 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 efforts of the capacitive current and gives an early warning of any electrical problems developing in the appliance.

WARNING: DANGER OF ELECTRIC SHOCK. DO NOT TOUCH ANY EXPOSED PARTS

WHILE CONDUCTING THIS TEST. DO NOT TOUCH ANY PART OF YOUR

BODY WITH THE CONTACTS OF THE PROBES.

WARNING: THIS EQUIPMENT SHOULD NOT BE USED IF YOU HAVE A HEARING AID

OR PACEMAKER FITTED, DUE TO THE POSSIBILITY OF

ELECTROMAGNETIC DISTURBANCE.

Specification:

4.0 kVac is applied between the connected Live and Neutral wires and the foil applied to the device's enclosure. No breakdown should occur.

Chap 4

Page 2 SER0018

Issue 1

April 2010

Alpha Active 4 Service Manual Testing

Note: The voltage levels used for this test, may stress and weaken the insulation. This test is therefore not recommended as a routine test. It should only be used after a major assembly/disassembly has been carried out.

Functional Test

Tests must be carried out using a 220-240V 50Hz power supply.

Test Setup and Initial Switch On

4.1

Set the pressure control to minimum (20kg) and ensure that all three outlet 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. Verify that the red LOW

PRESSURE

indicator is illuminated. Use the fingers or flowtron stopper (part number CAS077) to close all three ports and verify that the LOW PRESSURE indicator goes off.

Power Fail Alarm Check

4.3

With the pump operating, disconnect the power supply at the power socket outlet. Verify that, within 5 seconds, the red POWER FAIL indicator flashes in conjunction with an audible alarm.

Reconnect the power supply. Verify the POWER FAIL indicator is extinguished.

Low Pressure Alarm Check

4.4

Close all three ports. Operate the on/off switch to ‘on’. verify that, after 10 seconds, the SOLID

LOW PRESSURE

indicator is extinguished.

4.5

Open all ports to atmosphere. Verify that, after 10 seconds, the red LOW PRESSURE indicator flashes in conjunction with the audible alarm.

Service Alarm Check

To check the operation of the Service alarm it is necessary to have the case halves open.

WARNING: ENSURE PUMP IS DISCONNECTED FROM THE POWER SUPPLY.

4.6

Open the case halves (Refer to Chapter 5, Page 9, Section 8).

4.7

Disconnect the micro switch from the PCB connector, J4 (Chapter 1, Page 4, Section 2).

4.8

Close the case halves.

4.9

Connect the mains/power cable to a suitable power socket outlet and close all three ports.

Operate the on/off switch to ‘on’.

4.10

The service indicator should operate within 10 seconds.

4.11

Operate the on/off switch to ‘off’ position, disconnect the power supply at the power socket outlet.

4.12

Open the case halves and reconnect the micro switch to the PCB connector, J4.


4.13

Close the case halves (Refer to Chapter 5, Page 9, Section 8).

4.14

Connect the mains/power cable to a suitable power socket outlet and close both ports. Operate the on/off switch to ‘on’.

4.15

The service indicator should be extinguished.

5 Mattress Inflation Test

5.1

Test the complete system to ensure correct operation.

Issue 1

April 2010 SER0018

Chap 4

Page 3

Testing Alpha Active 4 Service Manual

6 End Setting

6.1

Disconnect the mattress from the pump and coil up the mains cable. Expel all the air from the mattress. The system is now ready to be packed.

Chap 4

Page 4 SER0018

Issue 1

April 2010

Alpha Active 4 Service Manual Pump Repair

CHAPTER 5

PUMP REPAIR



WALL OUTLET.

1 General

This chapter details repair procedures for the Alpha Active 4 Pump Unit. All repairs should be carried out by ArjoHuntleigh approved service personnel.

If any cable ties are cut so as to enable removal of parts, replacement ties must be fitted as part of the install procedure.

Table 3 defines the test requirements which must be carried out following certain repairs:

To carry out a flow, pressure and function test on the pump refer to Chapter 4, Page 1, Section 3.

To carry out the electrical tests on the pump refer to Chapter 4, Page 2, Section 4.

Table 3 - Repair to Testing Requirements

Components / Assemblies

Front Casing

Rear Casing

Display PCB

Main PCB

Bed Hooks

Compressor

Rotor/Stator Assembly

Mains Lead

Mains Switch

Terminal Block

Transformer

Air Filter

Oulet Connector

Function Test

No

Yes

Yes

No

Yes

No

Yes

Yes

No

No

No

Yes

Yes

Electrical Safety Tests

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Issue 1

April 2010 SER0018

Chap 5

Page 1

Pump Repair

10


20

Item

10

20

-

Figure 3 - Replace the Air Filter

Part Number

648402

648405

648404

Table 4 - Replace the Air Filter Parts List

Description

Rear Case Alpha Active 3 and 4

Air Filter Cover

Air Filter Replacement

Qty

1

1

1

Chap 5

Page 2 SER0018

Issue 1

April 2010


2 Removing the Air Filter

2.1

Place the pump unit face down on a clean, flat surface.

2.2

Press firmly on the retaining clip of the air filter housing, and lift the Air Filter housing

(Fig 3, Item 20) away.

2.3

Carefully lever out the the Air Filter from the housing (Fig 3, Item 20).

3 Replacing the Air Filter

3.1

Place the new air filter in the air filter housing (Fig 3, Item 20).

3.2

Place the air filter housing (Fig 3, Item 20) into the rear case (Fig 3, Item 10) by ensuring that the two securing lugs align with the holes provided.

3.3

Carefully press down on the air filter housing retaining clip and ensure it the housing has been securely fitted into the rear case (you should hear a ‘CLICK’ confirming proper fitment).

Issue 1

April 2010 SER0018

Chap 5

Page 3

Pump Repair

10

30


20

Item

10

20

30

Figure 4 - Replacement of Bed Hooks

Part Number

648402

REF

648403

Table 5 - Bed Hook Parts List

Description


Bed Hook Cover

Bed Hook Alpha Active 3 and 4

Qty

1

2

2

Chap 5

Page 4 SER0018

Issue 1

April 2010


4 Removing The Bed Hooks

4.1


4.2

Ensure the Bed Hook is folded against the pump.

4.3

Using a small flat tool, remove the Bed Hook Cover by inserting the tool into the aperture on the top edge of the cover.

4.4

Remove the two securing screws from the Bed Hook Bracket.

Note: You may be required to gently lever the bracket away from the pump in order to fully remove it. If so, do this via the top edge of the recess, and ensure you place a free hand over the bracket to prevent its loss.

4.5

Rotate the hook 90° and remove from the pump casing.

4.6

Repeat Para 4.2 to Para 4.5 for the other Hook.

5 Replacing the Bed Hooks

5.1

Firmly insert the new Hook (Fig 4, Item 30) at 90° to the pump case, into the corresponding recess.

5.2

Whilst applying pressure to the hook, rotate it so it is folded in against the pump.

5.3

Position the Bed Hook Bracket and fit the two retaining screws.

5.4

To refit the Bed Hook Cover.

5.4.1

Clean all previous glue residue off from both the cover and the recess lip.

5.4.2

Apply an instant adhesive (Loctite 460 or similar) to the lip within the recess of the pump case.

5.4.3

Firmly press the Bed Hook cover into position.

5.5

Repeat for the other Hook.

5.6

Assemble the case (Refer to Page 9, Section 9).

Issue 1

April 2010 SER0018

Chap 5

Page 5

Pump Repair Alpha Active 4 Service Manual

10

Item

10

20

20

Figure 5 - Position of Mains/Power Fuses

Part Number

648402

MIS106

Table 6 - Mains/Power Fuses Parts List

Description

Rear Case

Mains Fuse (1A Time Lag T Fuse)

Qty

1

2

Chap 5

Page 6 SER0018

Issue 1

April 2010


6 Removing the Mains/Power Fuses



WALL OUTLET.

6.1


6.2

Using a flatbladed screwdriver, remove the fuse holder from the back of the rear case by unscrewing anti-clockwise.

6.3

Pull the blown fuse from its holder.

7 Installing the Mains/Power Fuses

7.1

Firmly push the new fuse into its holder.

7.2

Place the fuse holder into position on the back of the rear case.

7.3

Using a flatbladed screwdriver tighten clockwise until tight.

Issue 1

April 2010 SER0018

Chap 5

Page 7

Pump Repair

30


30

60

20

30

10

40

30

50

Item

10

20

30

40

50

60

Figure 6 - Front Case Removal/Fitment

Part Number

648401

648402

REF

648420

REF

648423

Table 7 - Case Assembly

Description

Front Case Alpha Active 4


Screw (M3x15mm Pozi Pan Head, PT Type)

Display PCB Alpha Active 4

Main PCB - Display PCB Ribbon Connector

Hose Connector - Alpha Active 4

Chap 5

Page 8 SER0018

Qty

5

1

1

1

1

1

Issue 1

April 2010


8 Removing the Front Case



WALL OUTLET.

8.1


8.2

Unscrew the five screws (Fig 6, Item 30).

8.3

Carefully turn the pump over, collecting the five screws (Fig 6, Item 30), keeping them in a safe place.

8.4

Carefully pull apart the two cases, ensuring the compressor remains in the rear case.

Note: The front case contains a PCB connected via a ribbon to the main PCB in the rear case.

8.5

Within the front case, on the Display PCB pull apart the two ribbon securing clips.

8.6

Remove the ribbon from the Display PCB.

8.7

The front case is now removed.

9 Replacing the Front Case

9.1

Place the pump rear case (Fig 6, Item 20) on a flat surface with the inner components facing upward.

9.2

Plug the Main PCB - Display PCB ribbon cable into the rear of the display PCB ribbon connector

(Fig 6, Item 50) within the front case.

9.3

Using thumbs carefully push down on the ribbon connector until the two securing clips ‘click’ into place over it.

9.4

Place the front case (Fig 6, Item 10) on top of the rear case (Fig 6, Item 20) ensuring that no wires are trapped.

9.5

Carefully turn the pump over so the front is face down. Install the five screws (Fig 6, Item 30) to the rear case and tighten.

Issue 1

April 2010 SER0018

Chap 5

Page 9

Pump Repair

30

20


10

Figure 7 - Replacing Display PCB

Item

10

20

30

Part Number

648420

REF

REF

Table 8 - Display PCB Parts List

Description

Display PCB


Location Lug

Qty

1

8

-

Chap 5

Page 10 SER0018

Issue 1

April 2010


10 Removing the Display PCB

10.1

Remove the Front case (Refer to Page 9, Section 8).

10.2

Remove the eight fixing screws (Fig 7, Item 20) from the display PCB.

10.3

Carefully lift the Display PCB (Fig 7, Item 10) out of the front casing.

Pump Repair

11 Installing the Display PCB

11.1

Insert the base of the Display PCB (Fig 7, Item 10) into position within the front casing, guiding the square holes on the PCB to the location lugs (Fig 7, Item 30) within the front case.

11.2

Refit the eight fixing screws (Fig 7, Item 20).

11.3

Replace the Front case (Refer to Page 9, Section 9).

Issue 1

April 2010 SER0018

Chap 5

Page 11


10

20

30

50

40

Item

10

20

30

40

50

Figure 8 - Compressor Fitment/Removal

Part Number

648408

REF

REF

648425

REF

Table 9 - Compressor Assembly

Description

Compressor

Compressor Outlet

Compressor Mounting Plate

Terminal Block

T-Piece Connector

Chap 5

Page 12 SER0018

Qty

-

1

1

-

1

Issue 1

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12 Removing the Compressor Assembly

12.1

Remove the front case (Refer to Page 9, Section 8).

12.2

Remove the two red wires from the Terminal Block terminals T5 and T6.

12.3

Pull these wires free from other wiring within the rear case, noting the routing of the wires.

12.4

Remove the Compessor air outlet feed (Fig 8, Item 20) from the compressor (Fig 8, Item 10).

12.5

Lift the compressor assembly (Fig 8, Item 10) away.

13 Installing the Compressor Assembly

13.1

Place the compressor assembly into the rear case, ensuring the mounting plate (Fig 8, Item 30) sits in its moulding within the case.

13.2

Replace the compressor air feed (Fig 8, Item 20) to the new compressor (Fig 8, Item 10).

13.3

Route the compressor wires as required and connect to the appropriate terminals on the

Terminal Block.

13.4

Reassemble the case (Refer to Page 9, Section 9).

Issue 1

April 2010 SER0018

Chap 5

Page 13


40

D

B

C

A

Item

10

20

30

40

50

60

10

60

50

Microswitch omitted for clairity

Figure 9 - Removing the Rotor/Stator Assembly

30

Part Number

648422

REF

REF

648427

648417

REF

Table 10 - Rotor/Stator Assembly

Description

Rotor/Stator Alpha Active 4


Rotor/Stator Spade Connectors

Gearbox Assembly

Microswitch

Microswitch Securing Screw

(M3x15mm Pozi Pan Head, PT Type)

20

Qty

-

1

1

2

1

2

Chap 5

Page 14 SER0018

Issue 1

April 2010


14 Removing the Microswitch Assembly

14.1


14.2

Remove the two spade connectors from the Rotor/Stator microswitch, noting wires/connections.

14.3

Remove the two securing screws (Fig 9, Item 60) that hold the microswitch in place.

14.4

You can now remove the Microswtich (Fig 9, Item 50).

15 Installing the Microswitch Assembly

15.1

Place the microswitch (Fig 9, Item 50) into position and secure with the two securing screws.

15.2

Re-connect the two spade connectors to the microswitch.

15.3

Re-fit the front case (Refer to Page 9, Section 9).

16 Removing the Rotor/Stator Assembly

16.1


16.2

Remove the four tubing connections to the Rotor/Stator, noting their connection locations.

16.3

Remove the two spade connectors from the Rotor/Stator microswitch, noting wires/connections.

16.4

Push down on the Rotor/Stator assembly Fig 9, Item 10, and remove the securing pin (D).

16.5

Remove the complete rotor/stator assembly (C,B,A) from the top of the gearbox.

17 Installing the Rotor/Stator Assembly

17.1

Refering to Figure 9:

17.1.1

Place the spring (A) onto the gearbox spindle as shown.

17.1.2

Place the bottom of the Rotor/Stator (B) onto the gearbox spindle.

17.1.3

Pushing down on the bottom section of the Rotor/Stator, place the top half of the Rotor/

Stator (C) onto the gearbox spindle AND while applying pressure, slide the securing pin

(D) through the spindle as shown.

17.1.4

Ensure the securing pin (D) is seated within the recess on the top of the rotor/stator assembly.

17.2

Re-connect the two spade connectors to the Rotor/Stator microswitch.

17.3

Connect the four tubing connections to the Rotor/Stator.

17.4


18 Removing the Gearbox Assembly

18.1

Remove the rotor/stator assembly (Refer to Page 15, Section 16).

18.2

Remove the two securing screws (Fig 9, Item 20).

18.3

Remove the Gearbox-PCB connector from J3 on the Main PCB.

18.4

You can now remove the Gearbox Assembly (Fig 9, Item 40).

19 Installing the Gearbox Assembly

19.1

Place Gearbox assembly (Fig 9, Item 40) into position in the rear case, ensuring the wires exit the Gearbox in the direction of the compressor.

19.2

Secure with the two securing screws (Fig 9, Item 20).

19.3

Refer to “Installing the Rotor/Stator Assembly”.

Issue 1

April 2010 SER0018

Chap 5

Page 15


20

10

Item

10

20

Figure 10 - Removing the Transformer

Part Number

648429

REF

Table 11 - Transformer

Description

Transformer Alpha Active 4


Qty

1

2

Chap 5

Page 16 SER0018

Issue 1

April 2010


20 Removing the Transformer

20.1


20.2

On the main PCB, disconnect the transformer connection from J1.

20.3

Remove the red wires from Terminals T3 and T4 on the Terminal Block.

Note: Ensure the capacitor remains connected to Terminals T3 and T4.

20.4

Remove the two securing screws (Fig 10, Item 20) that hold the transformer (Fig 10, Item 10) in place.

20.5

You can now remove the transformer (Fig 10, Item 10).

21 Installing the Transformer

21.1

Place the transformer (Fig 10, Item 10) into position in the rear case, ensuring it is correctly seated and orientation is so that the Main PCB wires are in the direction of the PCB.

21.2

Fit the two securing screws (Fig 10, Item 20).

21.3

Re-connect the red wires to Terminals T3 and T4 on the Terminal Block.

Note: Ensure red wires run under all tubing, and that the capacitor remains connected to

Terminals T3 and T4.

21.4

Re-connect the transformer connection to the Main PCB J1.

21.5


Issue 1

April 2010 SER0018

Chap 5

Page 17

Pump Repair

10

20

30

A


Item

10

20

30

Figure 11 - Removing the Main PCB

Part Number

648421

REF

REF

Table 12 - Main PCB Parts List

Description

Main PCB Alpha Active 4

Stator To Pressure Switch Tubing


Qty

1

1

4

Chap 5

Page 18 SER0018

Issue 1

April 2010


22 Removing the Main PCB

22.1


22.2

On the Main PCB (Fig 11, Item 10), pull apart the two ribbon securing clips, at connector ‘A’.

22.3

Remove the ribbon cable from the Main PCB (Fig 11, Item 10).

22.4

On the main PCB, disconnect:

22.4.1

The transformer connection from J1.

22.4.2

The Rotor/Stator microswitch cable from J4.

22.4.3

The Rotor/Stator cable from J3.

22.4.4

The twin live connector from J7.

22.4.5

The 4-way connector from J2.

22.4.6

The Rotor/Stator tubing (Fig 11, Item 20) from U3.

22.5

Remove the four corner fixing screws (Fig 11, Item 30) and lift the Main PCB (Fig 11, Item 10) out of the pump case.

23 Replacing the Main PCB

23.1

Place the Main PCB with its component side facing upward, into position in the rear case, ensuring alignment of the four corner fixing holes in Main PCB (Fig 11, Item 10) with the pillars in the rear case. Fit the four retaining screws (Fig 11, Item 30).

23.2

Connect to the Main PCB:

23.2.1

The Rotor/Stator tubing to U3.

23.2.2

The 4-way connector to J2.

23.2.3

The twin live connector to J7.

23.2.4

The Rotor/Stator cable to J3.

23.2.5

The Rotor/Stator microswitch cable to J4.

23.2.6

The transformer connection to J1.

23.3

Plug the ribbon cable into the connector on the Main PCB within the rear case.

Note: If Main PCB - Display PCB ribbon cable has been disconnected from both the PCB’s, ensure upon re-connecting that the location keys are in correct orientation.

23.4

Using thumbs, carefully push down on the ribbon connector until the two securing clips ‘click’ into place over it.

23.5


Issue 1

April 2010 SER0018

Chap 5

Page 19

Pump Repair

10


20

30

Item

10

20

30

Figure 12 - Removing the Power Fail Battery

Part Number

648421

648428

BP196

Table 13 - Power Fail Battery Parts List

Main PCB Alpha Active 4

Battery

Cable Tie

Description Qty

1

1

1

Chap 5

Page 20 SER0018

Issue 1

April 2010


24 Removing Power Fail Battery

24.1


24.2

Remove the Main PCB (Refer to Page 19, Section 22).

24.3

De-solder the battery connections from the PCB.

Pump Repair

25 Replacing Power Fail Battery

25.1

Place the battery (Fig 12, Item 20) onto the PCB (Fig 12, Item 10) ensuring the correct polarity.

25.2

Solder both the positive and negative connections.

25.3

Secure battery to PCB using tie wrap (Fig 12, Item 30).

25.4

Replace the PCB (Refer to Page 19, Section 23).

25.5


Issue 1

April 2010 SER0018

Chap 5

Page 21


10

Rear of On/Off Switch

Item

10

Figure 13 - Removing the On/Off Switch

Part Number

648407

Table 14 - On/Off Switch Parts

Description

Mains (On/Off) Switch

Qty

1

Chap 5

Page 22 SER0018

Issue 1

April 2010


26 Removing the On/Off Switch

26.1


26.2

Lift the On/Off switch (Fig 13, Item 10) away from the rear pump case.

26.3

Remove the two live spade connectors from the back of the On/Off Switch (terminals 1 and 1A).

26.4

Remove the two neutral spade connectors from the back of the On/Off Switch (terminals 2 and

2A).

26.5

You can now remove the On/Off Switch (Fig 13, Item 10).

27 Installing the On/Off Switch

27.1

Re-connect the live spade connector that runs from the Main PCB to terminal 1

(Refer to Figure 13)on the rear of the On/Off Switch.

27.2

Re-connect the live spade connector that runs from a fuse holder to terminal 1a

(Refer to Figure 13) on the rear of the On/Off Switch.

27.3

Re-connect the neutral spade connector that runs from the Terminal block and Main PCB to spade terminal 2 (Refer to Figure 13) on the rear of the On/Off Switch.

27.4

Re-connect the neutral spade connector that runs from a fuse holder to spade terminal 2a

(Refer to Figure 13) on the rear of the On/Off Switch.

27.5

Place the On/Off Switch (Fig 13, Item 10) into position in the rear case, ensuring the two live wires are facing outwards from the case.

27.6


Issue 1

April 2010 SER0018

Chap 5

Page 23


10

Item

10

Figure 14 - Removing the Fuse Holder Housings

Part Number

648406

Table 15 - Fuse Holder Housings

Description

Fuse Holder

Qty

2

Chap 5

Page 24 SER0018

Issue 1

April 2010


28 Removing the Fuse Holder Housing

28.1


28.2

For the right Fuse Holder Housing:

28.2.1

Remove the live Mains/Power Cable spade connector from the side of the fuse holder.

28.2.2

Remove the live On/Off Switch spade connector from the top of the fuse holder.

28.2.3

Unscrew nut and remove the Fuse Holder from the pump.

28.3

For the left Fuse Holder Housing:

28.3.4

Remove the neutral Mains/Power Cable spade connector from the side of the fuse holder.

28.3.5

Remove the neutral On/Off Switch spade connector from the top of the fuse holder.

28.3.6

Unscrew nut and remove the Fuse Holder from the pump.

29 Installing the Fuse Holder Housing

29.1

For the right Fuse Holder Housing:

29.1.1

Secure the Fuse Holder to the pump.

29.1.2

Connect the live On/Off Switch spade connector to the top of the fuse holder.

29.1.3

Connect the live Mains/Power Cable spade connector to the side of the fuse holder.

29.2

For the left Fuse Holder Housing:

29.2.4

Secure the Fuse Holder to the pump.

29.2.5

Connect the neutral On/Off Switch spade connector to the top of the fuse holder.

29.2.6

Connect the neutral Mains/Power Cable spade connector to the side of the fuse holder.

29.3


Issue 1

April 2010 SER0018

Chap 5

Page 25


10

20

Item

10

20

30

Figure 15 - Removing the Mains/Power Cable

Part Number

648410

648447

648449

Table 16 - Mains/Power Cable

Description

Mains Cable Euro - Alpha Active 4

Ferrite 28mm

Ferrite 12mm

30

Qty

1

1

1

Chap 5

Page 26 SER0018

Issue 1

April 2010


30 Removing the Mains/Power Cable

30.1


30.2

Remove the live spade connection from the side of the right fuse holder.

30.3

Remove the neutral spade connection from the side of the left fuse holder.

30.4

Remove the two ferrite beads from the Mains/Power Cable.

30.5

You can now remove the Mains/Power Cable.

31 Installing the Mains/Power Cable

31.1

Place the Mains/Power Cable in position in the side of the rear case.

31.2

Re-connect the neutral spade connector to the side of the left fuse holder.

31.3

Re-connect the live spade connector to the side of the right fuse holder.

31.4


Pump Repair

Issue 1

April 2010 SER0018

Chap 5

Page 27


30

30

20

10

Item

10

20

30

Figure 16 - Removing the Terminal Block

Part Number

648425

REF

648449

Table 17 - Terminal Block

Description

Terminal Block Alpha Active 4


Filter Capacitor

Qty

1

1

1

Chap 5

Page 28 SER0018

Issue 1

April 2010


32 Removing the Terminal Block

32.1


32.2

Remove the red Transformer wires and the capacitor from Terminals T3 and T4 on the Terminal

Block (Fig 16, Item 10).

32.3

Remove the red Main PCB wires from Terminals T1 and T2 on the Terminal Block

(Fig 16, Item 10).

32.4

Remove the two live wires from Terminal T8 on the Terminal Block (Fig 16, Item 10).

32.5

Remove the neutral wire from Terminal T7 on the Terminal Block (Fig 16, Item 10).

32.6

Remove the two red compressor wires from Terminals T5 and T6 on the Terminal Block

(Fig 16, Item 10).

32.7

Remove the single securing screw (Fig 16, Item 20).

32.8

You can now remove the Terminal Block (Fig 16, Item 10).

33 Installing the Terminal Block

CAUTION: Whilst completing the installation, ensure all wires are free from entrapment.

33.1

Place the Terminal Block (Fig 16, Item 10) into position ensuring it is seated correctly.

33.2

Replace the single securing screw (Fig 16, Item 20).

33.3

Replace the two red compressor wires to Terminals T5 and T6 on the Terminal Block

(Fig 16, Item 10).

33.4

Replace the neutral wire from the Main PCB Connector J2 and the On/Off switch to Terminal T7 on the Terminal Block (Fig 16, Item 10).

33.5

Replace the two live wires from the Main PCB Connector J2 and the On/Off switch to Terminal

T8 on the Terminal Block (Fig 16, Item 10).

33.6

Replace the red Transformer wires, and the capacitor to Terminals T3 and T4 on the Terminal

Block (Fig 16, Item 10).

33.7

Replace the red Main PCB wires to Terminals T1 and T2 on the Terminal Block

(Fig 16, Item 10).

33.8


Issue 1

April 2010 SER0018

Chap 5

Page 29


Chap 5

Page 30 SER0018

Issue 1

April 2010

Alpha Active 4 Service Manual Mattress Repair

CHAPTER 6

MATTRESS REPAIR

1 General

This chapter details repair procedures for the Alpha Active 4 Mattress Replacement. All repairs should be carried out by ArjoHuntleigh approved service personnel.

It is easier to carry out the repair procedures in this chapter if the mattress is fully deflated first.

Disconnect the tubeset between the mattress and the pump to deflate the mattress.

After carrying out a service or any of these repairs on the mattress, check the following:

1.1

All press studs on the mattress are connected.

1.2

All cell assemblies are securely held by their straps. The repair will normally have disturbed the position of the other cells, and they should be re-positioned accordingly.

2 Alpha Active 4 Cell Layout

Issue 1

April 2010

Figure 17 - Mattress Cell Layout

SER0018

Chap 6

Page 1

Mattress Repair

50

10


40

20

Item

10

-

20

30

40

50

Figure 18 - Alpha Active 4 Mattress

Part Number

648437

648461

648438

648463

648465

REF

648442

648443

Table 18 - Alpha Active 4 Mattress

Description

Mattress Top Cover (90cm Wide)

Mattress Top Cover (85cm Wide)

Mattress Base Cover (90cm Wide)

Mattress Base Cover (85cm Wide)

Mattress Base Cover PU (85cmWide)

Zip

Tubeset Connector - Alpha Active 4

Tri bore tubing. 9.5mm ID x 14.5mm OD x 1370mm

30

Qty

1

-

1

2

1

1

Chap 6

Page 2 SER0018

Issue 1

April 2010


3 Removing The Top Cover

3.1

Fully unroll the mattress on a suitable surface.

3.2

Undo the zips (Fig 18, Item 30) on both sides of the top cover.

3.3

Remove the top cover.

Mattress Repair

4 Installing the Top Cover

4.1

Position the top cover (Fig 18, Item 10) on to the mattress. Make sure the feet symbol is at the foot end of the mattress.

4.2

Secure the two zips on the long sides of the mattress (Fig 18, Item 30) to the correct side of the top cover (Fig 18, Item 10).

Issue 1

April 2010 SER0018

Chap 6

Page 3

Mattress Repair Alpha Active 4 Service Manual

10

60

50

30

20

40

Feed To Head End

Figure 19 - Cell Assembly

Cell

20 30

Feed From Foot End

Chap 6

Page 4 SER0018

Issue 1

April 2010


5 Removing Cell Assembly

5.1

Remove the top cover, (Refer to Page 3, Section 3).

5.2

Disconnect the press studs from each end of the cell ((Fig 19, Item 60).

5.3

Disconnect the lower (Fig 19, Item 30) and upper (Fig 19, Item 20) cell feed connectors from the

T-Pieces (Fig 19, Item 40).

5.4

Pull the cell out of the retaining loop in the base cover and remove from the mattress.

6 Installing Cell Assembly

6.1

Pass the cell through the loop on the air pad cover and centralise the cell.

6.2

Connect the upper (Fig 19, Item 20) and lower (Fig 19, Item 30) cell feed connectors to each T-

Pieces (Fig 19, Item 40).

Note: Installing the cell feeds is made easier if the cell connector and/or T-Piece is wetted immediately prior to insertion.

6.3

Reconnect the male press studs to the female studs (Fig 19, Item 60) at the end of the cell.

6.4

Install the top cover (Refer to Page 3, Section 4).

20

30

40

50

-

60

Item

10

Part Number

648439

648440

648467

648468

648470

648471

REF

REF

REF

REF

REF

REF

Table 19 - Cell Assembly Parts List

Description

Standard Cell (90cm Wide)

Ventilated Cell (90cm Wide)

Standard Cell (85cm Wide)

Ventilated Cell (85cm Wide)

Standard Cell PU(85cm Wide)

Ventilated Cell PU (85cm Wide)

Upper Cell Feed (Part of Item 10)

Lower (Static) Cell Feed (Part of Item 10)

T-Piece

Single Bore Tubing

Press Stud Male

Press Stud Female (Located Inside Mattress Base Cover)

Qty

11

8

38

-

-

-

1

1

Issue 1

April 2010 SER0018

Chap 6

Page 5


20

20

20

20

20

20

10

80

20

20

Chap 6

Page 6

A

60

20

30

30

20

60

20

20

60

60

20

20

70

60

60

20

20

60

20

B

- Continued from point ‘A’

Figure 20 - Manifold Tubing

SER0018

40

30

90

50

30

80

80

20

50

20

Issue 1

April 2010


7 Replacing Manifold Tubing

7.1


7.2

Disconnect the press studs from each end of the cell ((Fig 19, Item 60).

7.3

Disconnect the lower (Fig 19, Item 30) and upper (Fig 19, Item 20) cell feed connectors from the

T-Pieces (Fig 19, Item 40).

7.4

Connect the upper (Fig 19, Item 20) and lower (Fig 19, Item 30) cell feed connectors to each T-

Pieces (Fig 19, Item 40).

Note: Installing the cell feeds is made easier if the cell connector and/or T-Piece is wetted immediately prior to insertion.

7.5

Reconnect the male press studs to the female studs (Fig 19, Item 60) at the end of the cell.

7.6


Item

50

60

-

70

10

20

30

40

80

90

Part Number

REF

REF

REF

REF

REF

REF

648436

648443

648444

648441

Table 20 - Cell Assembly Parts List

Description

50mm (Cut to length from 648436)






Single bore tubing: ID 9.5mm x OD14.5mm

Tri Bore Tubing

Static Check Valve

CPR

Qty

3

1

Issue 1

April 2010 SER0018

Chap 6

Page 7


10

Head Cells Removed For Drawing Clarification

Item

10

Figure 21 - CPR Assembly

Part Number

648441

Table 21 - CPR Assembly Parts List

Description

CPR

Qty

1

Chap 6

Page 8 SER0018

Issue 1

April 2010


8 Removing CPR Assembly

8.1


8.2

Disconnect the press studs from cells either side of the CPR assembly.

8.3

Disconnect the feed tubes from either side of the CPR unit.

8.4

Remove CPR Assembly from mattress (Fig 21, Item 10).

Mattress Repair

9 Installing CPR Assembly

9.1

Connect the feed tubes from either side of the CPR unit.

Note: Installing the feed tubes is made easier if the CPR unit connectors are wetted immediately prior to insertion.

9.2

Reconnect the press studs to each end of the cell.

9.3


Issue 1

April 2010 SER0018

Chap 6

Page 9

Mattress Repair

Red

10

Yellow


To Cells To Pump

20

Item

10

20

Figure 22 - Static Feed Check Valve

Part Number

648444

BP196

Table 22 - Static Section Feed Valve Parts List

Static Feed Check Valve

Tie Wrap

Description Qty

3

6

Chap 6

Page 10 SER0018

Issue 1

April 2010


10 Removing Static Feed Check Valves

Note: There are 3 Static Feed Check Valves on the Alpha Active 4. Two at the head end, and one at the foot end.

10.1


10.2

Release the pop studs on three surrounding cells for easier access to the Check Valve.

10.3

Remove the two cable ties (Fig 22, Item 20) located on either side of the Check Valve

(Fig 22, Item 10) barbs.

10.4

Seperate the tubes away from the Check Valve.

10.5

Remove the Check Valve (Fig 22, Item 10).

11 Installing Static Feed Check Valves

CAUTION: Ensure correct orientation is followed during this installation

(Refer to Page 10, Figure 22).

11.1

Place the Check Valve (Fig 22, Item 10) in position.

11.2

Connect the two tubes to the Check Valve (Fig 22, Item 10) barbs.

11.3

Secure the tubing with two cable ties (Fig 22, Item 20).

11.4

Secure the three cells pop studs that were released in Para 10.2.

11.5


Issue 1

April 2010 SER0018

Chap 6

Page 11


20

20

10

10

10

Item

10

20

Figure 23 - 3-Way Connector

Part Number

648442

648443

Table 23 - 3-Way Connector Parts List

Description

3-Way Connector

Tri bore tubing. 9.5mm ID x 14.5mm OD x 1370mm

Qty

1

1

Chap 6

Page 12 SER0018

Issue 1

April 2010


12 Removing 3-Way Connector

12.1

With the tubeset (Fig 23, Item 20) held securely in one hand, pull the top of the 3-way connector

(Fig 23, Item 10) away from the tubeset as shown in Figure 23

1

.

12.2

Pull the bottom of the 3-way connector away from the tubeset (Figure 23

2

).

12.3

You can now pull the 3-way connector away

3

(Fig 23, Item 10).

13 Installing 3-Way Connector

Note: Orientation of this part is un-important.

13.1

Align the tubeset (Fig 23, Item 20) with the barbs on the rear of the 3-way connector

(Fig 23, Item 10).

13.2

Push the tubeset fully onto the connector until all three tubes contact the base of the connector.

13.3

Ensure the 3-way connector (Fig 23, Item 10) is securely fitted to the tubeset (Fig 23, Item 20).

Issue 1

April 2010 SER0018

Chap 6

Page 13


Chap 6

Page 14 SER0018

Issue 1

April 2010


CHAPTER 7

TECHNICAL SPECIFICATION

PUMP

Model:

Part Numbers:

Supply Voltage:

Supply Frequency:

Power Input:

Size:

Weight:

Case Material:

Plug Fuse Rating:

Pump Fuse Rating:

Degree of protection against electric shock:

Degree of protection against liquid ingress:

Mode of operation:

Cycle Times:

Alpha Active 4

648311

648314

648315

648319AU

230V

50-60Hz

230VA

UK

German

Euro

Australia

(L)280mm x (W)205mm x (H)112mm

2.5kg

ABS Plastic

5A to BS1362 (UK ONLY)

T1AL 250V

Class II, Double Insulated

Type BF

IPX0

Continuous

10 mins

Inflate - 4.5 mins

Crossover - 30 secs

Deflate - 4.5 mins

Crossover - 30 secs

20 mins

Inflate - 9.5 mins

Crossover - 30 secs

Deflate - 9.5 mins

Crossover - 30 secs

SYMBOLS

O

(Off)

I

(On)

Power

Disconnects from the mains supply

Power

Connects to the mains supply

Dangerous voltage

Technical Specification

i

Do not dispose of in the domestic refuse

Refer to accompanying documents

Fuse

(If shown on pump label)

Alternating Current

Type BF

Ref:

Model number

Double Insulated

Refer to the User

Manual

SN:

Serial Number

Issue 1

April 2010 SER0018

Chap 7

Page 1

Technical Specification Alpha Active 4 Service Manual

ENVIRONMENTAL INFORMATION

Condition Temperature Range

+10°C to +40°C

Operating

(Pump)

Storage and Transport

(Pump)

-40°C to +70°C

Relative Humidity

30% to 75%

10% to 95%

(non-condensing)

MATTRESS

Description



ALPHA ACTIVE 4 MR Non PVC 85

MATTRESS SIZE INFORMATION

Cell Material

Polyurethane

Polyurethane

Polyurethane

Part No.

Description

Spare

Cover

648322 ALPHA ACTIVE 4 MR 90 648437

648324

648326


ALPHA ACTIVE 4 MR 85 PU

648461

648461

Atmospheric Pressure

700hPa to 1060 hPa

500 hPa to 1060 hPa

Base Pad Material

PVC Nylon Coated

PVC Nylon Coated

PU Coated

Length mm

1950

(77")

1950

(77")

1950

(77")

Width mm

900(35")

Height mm

200 (8")

850(33") 200 (8")

850(33") 200 (8")

Chap 7

Page 2 SER0018

Issue 1

April 2010

Alpha Active 4 Service Manual Technical Specification

COVER SPECIFICATION

Feature

Removable Cover

Moisture Vapour Permeable

Air Permeable

Low Friction

Water Resistant / Repellent

Infection

Control

Fire Retardant

2-Way Stretch

Washing Conditions

Drying Conditions

Life Span

Application Area

Standard Cover

(Dartex)

®

Yes

Yes

No

Yes

Yes

Material coating is Bacteriostatic, fungistatic, antimicrobial

BS 7175: 0,1 & 5

Yes

MAX 95°C (203°F) for 15 mins

(1)

Tumble Dry up to 130°C (266°F) or Air Dry

50 Wash Cycles

(minimum)

Acute and Homecare

1. Check your local policy to determine the time/temperature ratio required to achieve thermal disinfection.

CLEANING SYMBOLS

Wash at 80°C (176°F) Do not tumble dry above 50°C.

Do not iron Do Not Use Phenol-based cleaning Solutions

Wipe surface with damp cloth

Use solution diluted to 1000 ppm of Available

Chlorine

Issue 1

April 2010 SER0018

Chap 7

Page 3

Technical Specification Alpha Active 4 Service Manual

Chap 7

Page 4 SER0018

Issue 1

April 2010


CHAPTER 8

SPARE PARTS

1 Pump Assembly Parts List

Part Number

648404

648405

648420

648421

648428

648425

648408

648422

648410

648418

648419

648447

648449

648401

648402

648403

648429

648449

MIS106

648423

648406

648407

Description

• Mains/Power Cable - Euro

• Mains/Power Cable - UK

• Mains/Power Cable - AUS

• Ferite 28mm

• Ferite 12mm

• Front Case

• Rear Case

• Bed Hook

• Air Filter

• Air Filter Grill

• Display PCB

• Main PCB

• Battery

• Terminal Block

• Compressor

• Rotor/Stator Assembly

• Transformer

• Filter Capacitor

• Mains Fuse (1A Time Lag T Fuse)

• Hose Connector Alpha Active 4

• Fuse Holder

• Mains Switich

2 Mattress Assembly Parts List

Part Number

648437

648461

648438

Description

• Top Cover (195cm x 90cm) - printed with logo

• Top Cover (195cm x 85cm) - printed with logo

• Base Cover (195cm x 90cm)

Issue 1

April 2010 SER0018

Spare Parts

Fig - Item Qty

3-NA

3-20

6-40

11-10

12-20

16-10

8-10

9-10

-

15-10

-

15-20

15-30

6-10

3-10

4-30

10-10

16-30

5-20

6-60

14-10

13-10

1

1

1

1

1

1

1

1

1

2

1

1

-

1

1

-

2

1

1

1

2

1

Fig - Item Qty

-

18-10

18-20

1

-

1

Chap 8

Page 1

Spare Parts

Part Number

648463

648465

648442

648444

648441

648439

648440

648467

648468

648470

648471

648436

648443

BP196

Description

• Base Cover (195cm x 85cm)

• Base Cover PU (195cm x 85cm)

• Tubeset Connector Alpha Active 4

• Static Feed Check Valve

• CPR Assembly

• Standard Cell (90cm Wide)

• Ventilated Cell (90cm Wide)

• Standard Cell (85cm Wide)

• Ventilated Cell (85cm Wide)

• Standard Cell PU (85cm Wide)

• Ventilated Cell PU (85cm Wide)

• Single bore tubing

•

• Tri bore tubing

• Tie Wrap


Fig - Item Qty

-

-

23-10

22-10

21-10

19-10

-

19-10

-

-

-

20-NA

20-70

8

-

1

11

1

3

-

-

-

-

-

-

-

20-21 6

Chap 8

Page 2 SER0018

Issue 1

April 2010

Alpha Active 4 Service Manual Service Contact Details

Africa

Huntleigh Africa (Pty) Ltd

William Cruywagen Avenue

Stand 120, Klerksoord, Pretoria

T +27 12 542 4680

F +27 12 542 4982

Belgium

ArjoHuntleigh NV SA

Stapelplein 70, 9000 Gent, Belgium

T +32 9 265 8770

F +32 9 265 8771

France

HNE Médical

451 Chemin de Champivost

BP20, 69579 Limonest, Cedex, France

T +33 (0)4 78 66 62 66

F +33 (0)4 78 66 62 67

Holland

ArjoHuntleigh BV

Antennestraat 45, 1322 AH Almere, Holland

T +31 36 533 5588

F +31 36 547 5075

Middle East

Huntleigh Technology PLC

307 Sh. Zayed Road

Dubai

United Arab Emirates

Singapore

ArjoHuntleigh Pte Limited

Block 603, Elias Road, #08-232

Singapore 510603

T +61 8 9 309 3083

F +60 8 9 309 4582

CHAPTER 9

SERVICE CONTACT DETAILS

Australia

ArjoHuntleigh Pty Limited

PO Box 330

Hamilton Hill

Western Australia 6963

T +61 8 9 337 4111

F +61 8 9 337 9077

Denmark

ArjoHuntleigh A/S

Vassingerødvej 52, 3540 Lynge, Denmark

T +45 4 913 8486

F +45 4 913 8487

Germany

HNE Huntleigh Nesbit Evans

Healthcare GmbH

Im Hülsenfeld 19, 40721 Hilden, Germany

T +49 (0)2103 97 11 0

F +49 (0)2103 97 11 80

India

ArjoHuntleigh India Pvt. Ltd

8, Shah Industrial estate

Off, Shah Industrial estate

Off Veera Desai Road

Andheri (West)

Mumbai – 400 053

India

New Zealand

ArjoHuntleigh Ltd

Unit 6/38 Eaglehurst Road

Ellerslie, Auckland, NZ

T +64 9 525 2488

F +64 9 525 2433

Sweden

Huntleigh Liljenberg AB

Box 30012

200 61 Limhamm, Sweden

T +46 40 36 03 50

F +46 40 49 43 75

Issue 1

April 2010 SER0018

Chap 9

Page 1

Service Contact Details

UK

ArjoHuntleigh Limited

310-312 Dallow Road

Luton

Bedfordshire

LU1 1TD

T +44 (0)1582 413104

F +44 (0)1582 459100

Spain

ArjoHuntleigh SL

C/ de la Creueta 25

08130-Santa Perpetua de la Mogoda,

Barcelona,

T +34 93 5745754

F +34 93 5745861


United States of America

ArjoHuntleigh

2349 W Lake Street- Suite 250

Addison, IL 60101, USA

Tel: +1 630 307 2756

Toll Free US: (800) 323 1245

Fax: +1 630 307 6195

Japan

ArjoHuntleigh Japan K.K.

4-1-15 Goko-Dori

Chuoku

Kobe 651-0087

T +81 78 231 8735

F +81 78 231 8736

Chap 9

Page 2 SER0018

Issue 1

April 2010

No results