Chiltern Invadex Wispa Lite Portable Ceiling Mounted Electric Hoist Service Manual

WISPA LITE PORTABLE

CEILING MOUNTED ELECTRIC HOIST

SERVICE MANUAL

Issue 1 September 2004

CONTENTS:

1. Introduction.

2. Operating Instructions

3. Routine Maintenance.

4. Servicing and Repair.

5. Load testing.

6. Spare Parts Listing

7. Appendix

2 Issue 1 September 2004

This manual is a controlled document loaned by Chiltern Invadex Ltd for the sole use of approved personnel who have attended the Chiltern Invadex training course on this product.

It must not be copied in whole or part and it remains the property of Chiltern Invadex Ltd.

Preface

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

Warnings, Cautions and Notes

WARNINGS given in this manual identify possible hazards in procedures or conditions which, if not correctly followed, could result in loss of life or severe personal injury.

Cautions given in this manual identify procedures or conditions which, if not correctly followed, could result in equipment damage.

Notes given in this manual are used to explain or amplify a procedure or condition.

General Warnings

The installation must be carried out by a competent person and be in accordance with the relevant requirements of local Building Regulations and Health and Safety at Work Act 1974 and associated regulations

All electrical work must be carried out by a competent electrical engineer in accordance with the current edition of IEE Wiring Regulations.

1.0 Introduction.

The Wispa Lite Portable hoist was designed to improve the independence of the disabled person, with the help of a carer. It should be used in conjunction with a Wispa sling and other lifting accessories from the Chiltern Invadex range, as assessed by a trained person.

Note: Not all slings and accessories are compatible with the hoist. If you are unsure please contact your nearest Chiltern Invadex Office.

Using an appropriate sling, available from Chiltern Invadex, the overhead hoist will raise the user from a bed or wheelchair and transfer them to the bath or toilet where the hoist will lower them under total control.

The hoist has a Safe Working Load of 200Kgs (31 stones) (440lbs) and power is supplied by two rechargeable 12 volt batteries which are contained within the hoist.

Issue 1 September 2004 3

Wispa Lite Portable: Powered Lifting - Manual Traversing

Wispa Lite Introduced in 2004 with significant changes from previous portable:

Remote charger, emergency lowering, battery LED, dual controls, new handset styling, improved electronics with fault diagnostic alarms

FEATURES W

P

MANUAL TRAVERSING

CORDLESS BATTERY OPERATION

DUAL CONTROLS

EMERGENCY LOWERING

200kgs (440lb) SAFE WORKING LOAD

LOW BATTERY WARNING INDICATOR

SELF DIAGNOSTIC ALARMS

15 x 600mm (2ft) LIFTS @ 91 kgs ON FULLY

CHARGED BATTERY

2. Operating Instructions

4 Issue 1 September 2004

2.1 For Wispa Lite Portable

Ensure that the Emergency Stop – On/Off switch is in the on position by pressing in the red on/off button on the side of the unit. Notice that the battery indicator shows a green light. If showing

Red, charge the batteries immediately.

Check the sling and lifting tape for fraying or broken stitching. Select the appropriate sling and position it around the individual (refer to the sling instructions if this procedure is unfamiliar)

Pull the lifting tape to the required length by operating the hand control or the cover controls, ensuring that the tape is kept tight. Attach the tape hook to the ceiling fixing. Caution: Check that the tape hook is securely attached to the ceiling fixing before lifting commences.

To obtain the ideal position for the sling loops to the hoist; adjust the height of the Wispa Lite

Portable with the hand controls, using either the up or down functions. Maximum lifting travel

2.6mtrs (102 ins)

The hoist is equipped with limit switches on the lifting tape.

1 Maximum lift limit

2

3

Maximum lower limit

Slack lifting tape

Should any of the above limit switches be activated the hoist will stop.

After use, switch on the hoist by pressing the red on/off button, and put on charge if required.

2

.

2

EMERGENCY LOWERING

In the unlikely event of a component failure, the individual can be lowered using the emergency lowering button as described below. The individual may be lowered, whilst suspended in the sling.

Remove the grommet cover, push and hold the button, which is on one end of the case, until the client is lowered safely.

The emergency lowering facility will only work if there is sufficient capacity in the batteries.

The emergency device should not be used for normal lowering except in an emergency situation.

3. Routine Maintenance.

3.1 The Hoist Service Sheet

A typical hoist service sheet is shown in the appendix, this shows an example of the information required forming a service record or database. The purpose of this sheet is to retrieve as much information about the hoist installation with a quick reference checklist.

When servicing hoists in large numbers you may be asked to service all types and make of hoist, this is why the hoist service sheet covers all aspects of hoist servicing. There are a number of

Issue 1 September 2004 5

checks listed, however this report is used for overhead and mobile hoists, so some of the checks do not apply to all overhead or mobile hoists which have to be carried out during a biannual or annual hoist service. Each check has been abbreviated to keywords to jog the mind of the experienced service engineer, if further instructions are required refer to "The Check List

Explained". This provides an in depth technical support relating to all servicing, repairs and maintenance.

When carrying out any type of servicing to a hoist, the first action is a visual inspection of all mechanical fixings to ensure that they are tight and secure. The outer casing must always be removed for a closer inspection, and to bear in mind that any component part must last until the next service.

The load test should be carried out using at least 100% of the maximum load. An example of a hoist and lift test certificate is shown in the appendix.

3.2 An operator’s guide for checking the safety of the equipment. a) Heavy Duty Areas: - Institutional / Hospital Utilisation

Above average activity.

Abnormal environment (E.g. Corrosive atmospheres such as hydrotherapy pools etc.)

Heavy weight patients.

In the above case the routine maintenance should be carried out at 6 monthly intervals. b) Light to Standard Duty areas:-

Domiciliary Utilisation Light to standard activity environment and the patient's weight.

In the above case the routine maintenance should be carried out at 12 monthly intervals

Note: Lifting Operations & Lifting Equipment Regulations 1998. These regulations came into force in December 1998. They apply to all types of lifting equipment used at work, including patient hoists, irrespective of whether they are new, second-hand or existing items of equipment.

Further details can be obtained from the Health and Safety Executive in a booklet called ‘Simple

Guide to the Lifting Operations and Lifting Equipment Regulations 1998’.

Detailed records must also be maintained of all inspections and servicing especially if equipment is moved about from location to location.

3.3 The Service Check List Explained

1. Carry Bar condition/cover must be tested under load with the rated capacity. Check welds are secure and that the covers are complete and without any splits or tears. Check that distance between carry handles and cover is equal.

2. Boom Condition - Mobile Hoists only

3. Mast Condition - Mobile Hoist only

4. Leg adjustment - Mobile Hoist only

5. Castor Security - Mobile Hoist only

Issue 1 September 2004 6

6. Ram/Actuator condition - Mobile Hoist only

7. Spline disengagement - Mobile Hoist only

8. On/Off switch operation check that it works and the terminals are not corroded.

9. Condition of Batteries - these should last for at least 3 years if correctly maintained, however, this is often not the case due to deep discharging and infrequent re-charging. There is no danger of over charging the batteries due to the electronic regulator circuit. It is the role of the Installer and Service Engineer to educate the user or carer to always put the hoist on charge when not in use. If you suspect a faulty battery, check the terminal voltage of each battery independently and if one of the batteries is one volt or more lower, then it is faulty and needs replacing.

10. Charger leads and plugs - involves inspecting to ensure that the leads and plugs are not damaged. The transformer should be checked that it has the correct rating for load applied.

The minimum requirement is a 240VAC transformer with an output of 29v AC-output charger.

11. Clean & lubricate the hoist taking care not to trap any wires when replacing the cover.

Always remove any greasy finger marks from hoist and track.

12. Carry bar fixing - not applicable to portable hoist

13. Brakes - Mobile Hoist only

14. Creep test pass - Mobile Hoist only

15. Correct range of travel - ensure that the hoist tape operates over its full range. Any traversing should also be checked to ensure smoothness of travel.

16. Visual/Audio battery indicator - check operation if fitted.

17. All other indicators - ensure that the LED’s are working correctly.

18. Hand controls condition - Up & Down Control should be operated on and off load.

19. Boom alignment - Mobile Hoist only

20. Mast alignment - Mobile Hoist only

21. Bumpers - Mobile Hoist only

22. Oil seals may weep one or two drops of oil through their lifetime, but if oil can be seen on the inside cover, the motor/gearbox should be replaced.

23. Correct descent rate - applicable to non portable overhead hoists only

24. Audible battery indicator - ensure that it is working correctly when the battery voltage is low or faulty.

25. Limit Switches - All limit switches should be checked on and off load.

- ensure that the up limit switch operates as the magnet in the tape enters the hoist.

7 Issue 1 September 2004

If more tape is required due to high ceilings, a lanyard can be fitted from the track trolley to the Handley bar, the hoist is then connected to the other side of the Handley bar as normal.

26. Max. Load labelled as - this should be entered onto the service label that is attached to the cover of the hoist to indicate the rating of the hoist and when it was last serviced and next due.

Also check that the serial number is correct with the label inside the hoist.

27. Charging rate (v) to check that there is an output from the charger, test across the batteries to see if there is any increase in voltage.

28. Overall hoist condition will vary depending on the environment; if installed over hydro/swimming pools etc. the electrical components may require additional protection against corrosion.

29. Track & Track fixing - check alignment of track, condition of moving parts (trolleys and turntables), check all parts for corrosion especially if fitted in hydrotherapy pools and other corrosive atmospheres. Track fittings should be inspected to see that they are tight and secure, the track fixings may become loose if the timber strengthening beams have shrunk due to seasoning. If studding is used, check that locking nuts are present. Coach screws may need a quarter turn to close up any gaps between brackets and plasterboard. Always check the installation has sufficient number of bracket fixings and the spacing is no more than one metre or a minimum of three fixings. Where tracks are fixed between walls or on a gantry frame, always check the deflection is not greater than the specified figure shown on chart. Finally, check all the Allen cap screws that secure the fixing bracket to the track are tight to 10Nm

30. End stops are one of the most important safety aspects of any installation. If you need to remove the hoist trolley from the track for repairs, and then refit, Never forget to replace the stop end as someone's life could depend on it. Check the bolts are tight with a 13mm torque spanner or wrench to 26Nm and traverse the hoist into both end stops.

31. Trolley bearings/nuts. Trolley Bearings rarely require lubrication as they are greased when assembled from new. However, if a bearing becomes dry and starts to squeak then a few drops of light oil applied in between the drive wheel and bearing housing will cure the problem. The non-driven trolleys are sealed units and are maintenance free. Trolley Nuts must be inspected to see that they are tight and that half nuts and lock nuts have been fitted.

32. Traverse motor/drive - Non portable overhead hoists only

33. Gear/chain lubrication - Lubricate all gears

34. Motor fixings should be checked for tightness, also pay attention to the motor and gearbox casting as cracks may appear if fatigue is occurring. Check during load test.

35. Wiring internal/mains - All portable hoists are supplied with a charger with a moulded plug attached. Check that the correct fuse is fitted in the plug top and the mains cable is free from damage.

NOTE: - Consult the current IEEE wiring regulation for the correct protection.

35. Lifting tape wear can vary depending on application, but it is recommended that they should be replaced every other service or every 2 years.

36. Condition of accessories - any accessories attached to the hoist must be checked for damage.

Slings, lanyards, etc. Check for pulled stitching where loops attached to the net and polyester

8 Issue 1 September 2004

fabric.

37. Emergency lowering must be tested with the load attached, raise the load pressing the up button and lower by pulling the cord to its fullest extent.

38. Emergency stop not fitted to portable hoists

39. Weight tested to maximum load by lifting 100% of the maximum load. Raise the weight to the up limit and lower to within 50mm (2”) of the floor, traverse the hoist along the track to either end. If the hoist completes this test successfully a Hoist test certificate form must be completed.

40. Date of last inspection/service - enter the date of the last inspection or service

41. Date of next inspection/service - enter the next due date for inspection or service

42. SWL labelled as - enter the maximum load of the hoist

43. Certificate No. - of the hoist weight test certificate

44. Safe to use - mark Yes or No if the hoist is safe to use

45. Lifting tape replacement due date - enter the date when the lifting tape is due to be replace.

Normally this is every two years or sooner if worn or damaged.

AFTER THE SERVICE HAS BEEN CARRIED OUT THE CUSTOMER OR

AUTHORITY MAY REQUIRE A SIGNATURE OF ACCEPTANCE FROM THE END

USER.

3.4 SERVICE RECORD LABEL

Apply a service record label to the case and complete the details as required

4. Servicing and Repair

4.1

Issue 1 September 2004 9

a) This section gives information and procedures for the removal and installation of replacement parts and sub-assemblies. Setting up procedures, which may be necessary following component replacement, are included. a) Minor procedures, which may be deemed self-evident, have not been included. b) Do not dismantle more than necessary to replace a defective item c) Before removing any electric wire, make a note of its position and identification to assist reassembly.

4.2 Handset

The handset is removed from the hoist by unscrewing the two securing screws on the hand control plug.

4.3 Cover Removal

Remove two screws from the side covers

The end covers are retained by moulded lugs so it may require easing with a small coin to get them over the lugs.

Ease the covers off and disconnect the membrane leads from their plugs

Feed the carry bar levers through the aperture in the cover.

The top cover requires the handle to be unscrewed first and then the top screw can be removed.

The bottom cover is retained by two screws each side with spacers.

1

2

Re-fitting is the reverse procedure as above.

When refitting ensure that there are no wires trapped between the covers

4.4 Lifting Tape Removal

3

4

Remove the covers as detailed in 4.3

Press the down button on the handset or side controls and pull the tape out from the hoist to its maximum length or use the emergency lowering switch to activate the hoist.

Disconnect one lead from the battery

Slacken the battery clamp retaining nut and slide the battery to clear the lower limit switch

5

6

7

8 pin.

Remove the push on fix and remove the pin which releases the lover tape limit lever and spring.

Unscrew the lower limit switch bracket from the chassis

Push the tape through the main shaft to allow you to remove the retaining pin

Pull the tape back through the shaft slot until it is clear

Re-fitting

1 Place the tape loop through the top slot and into spool recess ensuring the tape passes the

10 Issue 1 September 2004

2

3

4

5 slack tape pin

Push the tape through the shaft slot and fit the tape pin retainer

Pull the tape back through the slot ensuring that the tape pin is located correctly

Re-fit lead to battery

Rewind the tape back onto the spool, using the lift button on the handset to obtain the

6

7 correct rotation, otherwise when the emergency button is pressed the hoist will not come down.

Refit the lower limit switch lever and adjust as required

Re-fit cover and test the hoist

8 Check the correct operation of the lower tape limit switch and slack tape switch

4.5 Battery replacement

1 Remove the covers as detailed in 4.3

2 Disconnect the leads from the battery terminals

3 Remove the nut from battery clamp

4 Disconnect the remaining leads from the terminals

5 Remove the foam packing from the bottom battery and refit to the new battery

Refitting is the reverse procedure of the above

Put hoist on charge

4

5

6

4.6 Motor/Gearbox removal

1

2

3

Remove all the covers as detailed in 4.3

Disconnect one lead from the battery

Remove the two wires from the motor connection plug

Remove three screws that hold the gearbox to the chassis

Remove collar from motor gearbox shaft

Swing the motor/gearbox down and slide sideways out of the chassis

Re-fitting is the reverse procedure of the above

3.2 Main PCB removal

1

2

3

4

Remove all the covers as detailed in 4.3

Disconnect one lead from the battery to isolate the supply

The PCB is retained by double sticky backed tape, replace as required

Disconnect the wires from the connector block on the main board noting their positions

Refitting is the reverse procedure of the above

3.3 Membrane Switches Replacement

1 Remove the end covers as detailed in 4.3

2 Disconnect one lead from the battery to isolate the supply

3

4

Remove two screws that retain board onto the side of the motor

Disconnect wires from connector block noting their location

Re-fitting is the reverse procedure of the above

3.4 Tape Limit Switches

11 Issue 1 September 2004

If the tape is wound in too far, the double thickness of the tape contains a magnet which operates a reed switch. This breaks the motor circuit and stops the motor instantly.

There is also a lower limit switch to prevent the lifting tape to unwind too far, this is controlled by a metal lever which rests on the wound tape until it reduced sufficiently to operate the switch which stops the motor. This switch can be adjusted so that there is sufficient tape wound around the shaft to hold the hoist correctly.

Also there is a slack tape switch which is operated should the hoist lower onto something and the tape goes slack. This again turns off the motor until the tape is tight again.

3.5 Emergency Stop On/Off Switch

1

2

3

4

Remove the covers as detailed in 4.3

Disconnect one lead from the battery to isolate the supply

Unsolder the leads to the switch making a note of their positions

Press the sides of the switch locating lugs inwards to disengage from the side cover

Refitting is the reverse procedure of the above

3.6 Emergency Lowering Switch

1

2

3

4

Remove the top cover as detailed in 4.3

Disconnect one lead from the battery to isolate the supply

Disconnect the wires on the switch

Squeeze the switch locking arms in to allow the switch to pass through its holder

Refitting is the reverse procedure of the above

4. Electrical Wiring

See the attached schematic drawing

5. Load Testing

All installations/hoists should be proof load tested to at least 100% of its maximum load along the entire track length to ensure that the installation is safe.

To carry out this test, a weight of 200kg (440lbs) is attached to the sling support arms. Raise the weight to the up limit and lower to within 50mm (2”) of the floor, traverse the hoist along the track to either end. If the hoist completes this test successfully a Hoist test certificate form should be completed.

6. Spare Parts

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13 Issue 1 September 2004

14 Issue 1 September 2004

COM0066

COM0067

350-00036

350-00020

350-00024

350-00031

350-00032

350-00033

0H0008

350-00035

350-00034

COM0058

350-00025

COM1015

OH0088

350-00028

OH0011

OH0017

COM1137

N/A

OH0034

300-00042-CI

COM1470

350-00006

350-00019

350-00003

350-00004

350-00008

350-00017

350-00018

350-00021

350-00022

350-00023

350-00027

350-00011

350-00026

306-00100

MHWMES27

350-00012

COM0075

OH0034

27

28

29

30

31

32

32A

33

34

35

36

37

38

39

40

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

3

4

1

2

5

6

Wispa Lite Spare Parts

ITEM PART No. QTY DESCRIPTION

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

2

2

4

1

1

2

1

2

1

1

1

2

1

2

1

1

1

2

2

1

1

1

2

Chassis

Tape Shaft

Bush – 15mm Internal Diameter

Bush – 20mm Internal Diameter

Worm Shaft

Pin – 4mm diameter x 90.5mm long

Push-On Fixing – 4mm diameter

Gear Wheel

Spool Guide Disc - 20 Internal Diameter

Spool Guide Disc – 26 Internal Diameter

Lanyard & Handle Bracket

Governor Arm

Pin

Motor

Battery - 12V, 2A

Stop Block Arm

M5 Nylon Pillar

Micro Switch

Circlip – 20mm diameter

Circlip – 8mm diameter

Main PCB

Wheel Pin

Governor Arm Pin

Hanger Arm Left

Hanger Arm Right

Strap Retainer

Reed Switch (Part of loom)

Membrane Panel LH

Membrane Panel RH

Thrust Bearing

Slack tape shaft

Spring

Governor Arm Spring

Carry Handle

On / Off Switch

Emergency Lower Switch

Covered Push –On Fixing

Hand Control Connector

Micro switch with lever

Hand Control

R Clip

15 Issue 1 September 2004

ITEM

51

52

53

54

55

56

57

58

59

60

61

62

45

46

47

48

49

50

41

42

43

44

63

64

65

66

67

68

69

Not Shown

Not Shown

PART No. QTY

350-00015

350-00040

350-00041

350-00038

350-00039

N/A

COM1560

COM1628

COM1124

COM1170

COM0072

COM1105

350-00030

COM0071

COM1178

COM0073

COM0070

COM1175

COM0028

OH0090

350-00018

350-00016

COM0076

N/A

COM1110

COM1105

350-00013

COM1124

1

2

300-00207-CI 1

300-00207-BF 1

5

1

N/A

2

2

1

1

1

1

1

1

1

2

3

3

4

4

1

2

1

1

1

2

1

4

1

2

DESCRIPTION

Lifting Tape

Push-On Fixing M4

Nylon Washer

Ball Spring Plunger

M6 Hex Head Screw x 55mm

M6 Nylok

Tape Securing Pin

Battery Cushion Pad – self adhesive foam

Micro switch Plate

Cover Retaining Bar

Battery Bracket

Top Cover

Bottom Cover

LH Side Cover

RH Side Cover

Charger Socket – Part of loom

M6 Countersunk Head Screw x 12mm long

M5 Button Head Screw x 10mm long

M4 Switch adjust Screw x 12mm long

M6 Governor arm washer Washer

M3 Pozi Driv Button Head Screw x 14mm long

M3 Plain Washer

Cover screws

M4 Bolt x 18mm long

Not Available

M3 Reed switch screw x 12mm long

Reed switch plain washer

Emergency Lowering Switch Bracket

M4 EL screws x 12mm long

Charger Unit

Charger Unit – USA 110 volt

16 Issue 1 September 2004

7. Appendix

17 Issue 1 September 2004

Slack Tape

Switch

Top Limit

Switch

OHWLP01 WIRING DIAGRAM

Battery

Connections

Low Limit

Switch

On / Off

Switch

Membrane

Connections

PCB-Loom

Connections

18

Charge

Socket

Emergency

Lowering

Motor

Connections

D. MILNER

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20 Issue 1 September 2004