Plexus P2500
Aire Select System
Service Manual
PN 11615-000
Plexus Aire Select
Table of Contents
Section Description Page
1.0 Contraindications/Indications/Precautions -----2
4.0 Specifications ------------------------------------------3
6.0 Cleaning-------------------------------------------------5
7.0 Maintenace and Function Testing ----------------5
8.0 Test Check Sheet-------------------------------------7
11.0 Troubleshooting ---------------------------------------9
12.0 Calibration -------------------------------------------- 11
Figures
Figure Description Page
1
2
6
7
C/2500 Front Control Panel
C/2500 Rear Panel
Testing
4 Function
5
Testing
Blower Side View
4
5
6
6
12
Blower Front View 12
AP valve assembly and PV board and motor
13
8
9
10
11
Rotor center position
Rotor side position
Rotor side position
PC Board Assembly
14
14
14
14
©
2002. Plexus Medical. All Rights reserved
Important
Before using the Plexus C/2500 please read and understand the Plexus 2500 Manual and the SAFETY
PRECAUTIONS in section 1.0 (page 2) prior to each application.
Only qualified medical service personnel should repair the Plexus C/2500.
In the event of any questions, contact our Technical
Service Department for assistance:
USA Only:
Phone 1 800 828-7341
Fax 1 800 993-7890
Outside USA:
Phone (716) 662 8636
Fax
Page 1
Plexus Aire Select
1.0 Contraindications
Refer to Operator’s Manual
1.1 Indications for Use/Theory of
Operation
Refer to Operator’s Manual for proper operation of system.
Review the following SAFETY
PRECAUTIONS prior to servicing the
Plexus C2500.
DANGER
• Explosion hazard. Do not use in the presence of flammable anesthetics.
• Risk of electric shock. Refer servicing to qualified service personnel.
CAUTION
• Disconnect power before servicing the
Plexus 2500 control unit
• Repairs should be performed only by qualified personnel familiar with repair practices for servicing medical devices. Do not attempt to repair the Plexus C2500 Control Unit unless you possess these skills. Otherwise, damage to or malfunction of the control unit may result.
Upon receipt, unpack the Plexus C2500 Control Unit and inspect for concealed damage. Save all packing material. If any damage is found, notify the carrier at once and ask for a written inspection. Prepare a written description of any damage. Photograph any damage.
Failure to take the above action within 15 days of receipt may result in loss of claim.
Do not return the Plexus C2500 Control Unit to
Plexus Medical. Contact Plexus Medical's Technical
Service Department for instructions.
USA only
Outside USA
1 800 828-7341
(716) 662-8636
The Plexus C2500 Control Unit is warranted free of defects in material and workmanship for a period of two
(2) years and M2500 mattress one (1) year.
The Control Unit and mattress is warranted under the terms and conditions of the Plexus Medical warranty in place at the time of purchase. A copy of the warranty is available upon request. Plexus Medical disclaims all implied warranties including, but not limited to, the implied warranties of merchantability and of fitness for a particular purpose.
Control units and mattress may be returned to the factory for servicing (see Return Authorization).
For customers who choose to repair Aire Select systems at their location, this manual contains information to allow a qualified technician to make necessary repairs.
For technical support, contact Plexus Medical's
Technical Service Department.
All in-warranty repairs must be authorized by Plexus
Medical's Technical Service Department before proceeding.
The following repair options are available when servicing
Plexus Aire Select Control Units and mattress:
• Defective Components - replacement parts may be ordered by specifying the Plexus Medical part number as shown in the parts lists .
• Plexus C2500 Control Unit Repairs - If the
Plexus C2500 Control Unit becomes inoperative and the cause cannot be determined, the complete control unit may be returned to the factory for servicing at the purchaser's expense
(see Return Authorization).
Please be sure to obtain a return goods (RG) authorization number from Plexus Medical's Customer
Service Department before returning the Aire Select control unit or mattress or any component parts to
Plexus Medical.
USA only 1 800 828-7341
Outside 662-8636
Page 2
Plexus Aire Select
4.0 Specifications
Physcial
Dimensions
Weight
12" x 10" x 5"
(30 cm x 25 cm x 13 cm)
9 lbs. (4.08 kg)
Operating Ambient
Temperature Range
65°F to 75°F
Storage Conditions
Ambient Temperature 40°F to 105°F Range
Relative Humidity 30% to 75% Non-condensing
Electrical
Power
Frequency
Domestic
120 V~
60 Hz
European
220 V~
50 Hz
Current 1A .5A
Type BF Equipment
Attention, Consult Accompanying
Documents
IPXO
Protection Against Harmful Ingress of
Liquids Ordinary Protection (IPX0)
Agency Approval
TUV IEC 60601.1 (220V only)
UL 544, C22.22 No. 125
Page 3
5.1 Front Panel Features
(see figure 1)
• ON/STANDBY
∙ Used to turn the system on and off.
- The amber LED indicates the unit is in standby mode.
- The green LED indicates the unit is in normal running mode.
• FULLY ILLUMINATED POWER AND
SOFT/FIRM CONTROLS
∙ The Plexus 2500 provides the added benefit of patient comfort control.
- The soft button is used to decrease the pressure in the mattress, and the firm button is used to increase the pressure in the mattress, with a range between approximately 10mmHg and 32mmHg max.
- Nine pressure settings are available to enable the user to select the lowest possible pressure that will still support the patient.
∙ An LED panel reminds the caregiver of the system settings that are correct for their patient.
Plexus Aire Select
• MAX INFLATE
∙ The air mattress can be maximally inflated (32mmHg) by pushing the “MAX INFLATE” button on the control unit, to assist in patient ingress/egress as well as normal nursing procedures.
∙ Upon initiating the maximum inflate condition, the mattress will rapidly inflate to its highest (firmest) level and maintain that setting.
- “MAX INFLATE” button will remain illuminated while system is in maximum inflation mode.
- If the “MAX INFLATE” button is pushed during max inflation mode, the button will cease illuminating and the system will return to previously chosen settings.
- After 30 minutes in the “MAX INFLATE” mode, the system is programmed to automatically return to the therapeutic settings. This fail-safe feature prevents a high-risk patient from inadvertently being left on a firmer than therapeutic surface.
ON DEMAND ALTERNATING LOW
PRESSURE THERAPY
· The Plexus Aire Select system gives the caregiver the option of whether or not to use alternating lowpressure therapy.
· A simple push of a button on the control unit transforms the Plexus Aire Select system from a low air loss therapy system to one that provides alternating pressure therapy.
Figure 1 – C/2500 Front Control Panel
Page 4
Plexus Aire Select
5.2 Rear Panel Features
(see figure 2)
1. WASHABLE FILTER ELEMENT
Requires periodic cleaning between patient uses or every 30 days.
2. MODEL/SERIAL NUMBER /IDENTIFICATION
PLATE
This barcode label must not be removed from the unit. The model and serial number information is needed to arrange for returns to the factory.
3. CURRENT LEAK TEST ACCESS POINT
Figure 2 - C/2500 Rear Panel
1
3
2
6.0 Cleaning
To clean, use soap and water and a clean cloth to wipe down the pump, power cord and hoses. Wipe dry with a clean dry cloth. Do not autoclave.
NOTE: Blood and other fluids must be thoroughly cleaned from all surfaces before applying the disinfectant. Apply a hospital grade disinfectant according to the manufacturer's instructions and hospital protocol. Allow to completely dry. The contact time is what makes the solution effective.
6.2 Mattress
Outside surfaces of mattress may be cleaned with a damp cloth and mild detergent. Do not disinfect with alcohol, which may cause mattress material degradation.
Cushions are made of plastic. If it is necessary to sterilize cushions, use ETO sterilization and/or handle like any other plastic product. Sterilization temperatures must not exceed 57°C (135°F).
See appropriate mattress service literature for additional cleaning instructions.
7.0 Routine Maintenance and
Testing
(see figures 3 and 4)
Visually check the unit for physical damage.
Specifically inspect the power cord , power inlet connector, hose connectors and O-rings.
Repair, replace
end of this section to document testing. If the unit passes the tests outlined in this section it can be considered functional and ready for service. If the unit does not pass the following described tests it should be removed from service and calibrated or repaired. Mattresses should also be periodically inspected in accordance with the instructions outlined in the appropriate mattress manual.
Required Tools:
Manometer pressure gauge
0-100 mmHg range
Mattress Simulator
Plexus P/N 10329
Plexus P/N 11667-000
Or
M2500 mattress with P/N 11668-000 (see figure 4)
Test Conditions:
The following tests should be performed in a 70 degree room after the unit has been allowed to operate for 15 minutes.
Page 5
Plexus Aire Select
Test Procedure:
Connect the unit to the mattress simulator or test mattress as shown in figures 3 and 4.
1. With the unit operating in the Low Air Loss mode (AP light off), press the appropriate soft/firm key until one LED bar is lit on the comfort control indicator. After a moment verify the test manometer reads 9 ± 4 mmHg.
2. Adjust the soft/firm keys until all the LED bars are lit on the comfort control indicator. After a moment verify the test manometer reads 27 ± 4 mmHg.
3. Press the max inflate key. After a few moments verify the test manometer reads 28 ± 4 mmHg.
4. Disconnect the mattress simulator or test mattress from the unit. Press the AP key and verify that there is a noticeable decrease in the airflow (pressure) from one of the outlets on the machine. Leave the unit in AP mode and verify that the higher/lower airflow alternates from one port to the other. The alternating cycle time is approximately 4 minutes. (note: unlike some APP pumps the airflow does not completely shut off from one port to the other on this unit).
5. Perform electrical safety testing with an approved testing device. Current leakage values should not exceed
100uAmps for 120V units or 500uAmps for 220V units. Ground line resistance should be less than .5 ohms.
6. Fill out a copy of the check sheet, documenting the serial number of the machine and results. File for future reference.
If any of the tests outlined above were not satisfactory, the unit should not be put into service. Refer to the calibration and or troubleshooting sections of this manual for assistance in determining, repairing the problem.
Figure 3 – C/2500 Function Test
Figure 4 – C/2500 Function Test
Page 6
Plexus Aire Select
Function Test Check Sheet
Model:
Serial:
Test Procedure Results:
Manometer Readings (steps 1-3).
1. ________ mmHg
2. ________ mmHg
3. ________ mmHg
AP mode functions properly (step 4).
Pass______ Fail _______
Electrical safety test results (step 5).
Pass______ Fail _______
Max current leakage reading ________ µ Amps
Ground resistance less than 0.5 ohms
Pass______ Fail ________
Tested by _______________________________________ Date ______________
Page 7
Plexus Aire Select
9.0 Mattress Storage and Care
Roll the mattress up, starting at the head, and secure with straps provided at the feet. Store in a plastic bag to prevent contamination.
10.0 Mattress Troubleshooting
Mattress testing on this low air loss mattress is extremely simple and requires only the use of a good control unit or other device to inflate the mattress. The only possible problem conditions are unintended leaks in the system, disconnected cells, and kinked or twisted hoses or manifold.
Diagnostic Procedure 1.0
Low Air loss Mattress - Leaks in Mattress, Manifold,
or hoses
1.0.0 Unintended leaks can be felt and heard without the use of any special equipment. There should be no detectable air escaping from any portion of the system except for the four holes in the top of each air cell. Any component with a hole should be replaced. Also Verify that there are actually four holes in the air cells; if the mattress was unintentionally assembled with sealed cells form an APM mattress, overheating, damage and malfunction will occur to the control unit.
Low Air loss Mattress - Disconnected Cells
(see also leaks, 1.0.0)
1.1.0 Disconnected air cells should be reconnected.
Occasionally the white quick connect fittings can come out of the red/orange flange in either the cells or the manifold, if not damaged the fittings may be glued into the flange superglue. Note:
Care should be taken so that excess glue does not leak into the air cells during reassembly.
Alternatively a replacement manifold may be purchased.
Diagnostic Procedure 1.2
Low Air loss Mattress - Kinks/Twists in Manifold
1.2.0 Kinked or twisted manifolds and hoses will restrict airflow. If this condition occurs untwist the manifold or hose assy. and verify proper mattress operation.
Topsheet
Air Cells
Foam
Female Couplings and Clamps
Sleeve
Manifold
Cover
Air 30008 30008-39 30008-42 30008-48 30008-54 30008-60
Coupler Spiral to
Manifold
10113 10113-39 10113-42 10113-48 10113-54 10113-60
Sleeve 30159 30159-39 30159-42 30159-48 30159-54 30159-60
Base 30065-NF 30065-39 30065-42 30065-48 30065-54 30065-60
Foam 20001 20001-39 20001-42 20001-48 20001-54 20001-60
* For private label components contact customer service.
Page 8
Plexus Aire Select
11.0 Control Unit Troubleshooting
Apply power to unit.
Do any lights on control panel illuminate.
No
See Diagnostic procedure 2.0
Yes
Does the blower spin? Is there air flow out of the connectors?
Yes
Does the blower get too hot?
No
No
See Diagnostic procedure 2.1
See Diagnostic procedure 2.2
Yes
Is the blower excessively noisy? Is there excessive vibration?
Yes
Does the unit meet calibration specifications?
No
No
Yes
Page 9
THE UNIT IS
READY FOR
SERVICE
See Diagnostic procedure 2.3
See 12.0
Calibration
Diagnostic Procedure 2.0
P2500 – Unit Apparently Dead/No Indication of
Power in Lights on Main Panel
2.0.1 Apply power and test for line cord/mains voltage
110V/230V at input side of primary fuses (5A on
110 VACmodels, 2.5A on 230 VAC models).
See figure 2.0.1 for test points. If appropriate line voltage is present, continue to 2.0.2. If no voltage is present, check power supply or wall outlet and check for loose terminals on supply lines from power entry module.
2.0.2 Test for 110 VAC/230 VAC at output of fuses.
See figure 2.0.2 for test points. If voltage is present, continue to test 2.0.3. If no voltage is present, disconnect power, remove and inspect fuses.
2.0.3 Test for 14 VAC at input side of secondary fuses
(1A). See figure 2.0.3a. If 14 VAC is present, continue to 2.0.4. If 14 VAC is not present, check for 14 VAC across secondary terminals (7
& 12) of transformer. See figure 2.0.3b. If voltage is not present, disconnect power and check resistance across primary (terminals 1 &
6, and then 2 & 5) and secondary (terminals 7 &
12 and then 8 & 11) of transformer. If any of the four transformer coils are open, replace transformer. If transformer coils are not open, check for loose terminals on supply wires to transformer. Check wiring diagram to ensure transformer is wired correctly.
2.0.4 Test for 14 VAC at output side of secondary fuses (1A). If 14V is present, continue to 2.0.5,
If voltage is not present, disconnect power, remove and inspect fuses.
2.0.5 Test for 14 VAC at J4 on main circuit board in front panel. See figure 2.0.5. If 14 VAC is present, and no LEDs illuminate on front panel, replace circuit board.
Diagnostic Procedure 2.1
P2500 – No Air Flow, Blower Does not Spin
2.1.0 Test for Line voltage (110 VAC/230VAC) at output of primary fuses (5A at 110 VAC, 2.5A at
230 VAC). See figure 2.1.0. If voltage is present, continue to 2.l.1. If no voltage is present, check the following: power supply, condition of primary fuses, and inspect for loose connections or broken wires on supply lines from power entry module to fuses.
2.1.1 Test for voltage between 0-10 VDC at J3 on main circuit board at front panel. See figure
2.1.1. This voltage is an analog speed control signal to the blower; 0V is off and, 10V is max
(max voltage for a calibrated unit is typically 7.5 to 8.5 volts, depending on altitude). If a nonzero voltage less than 10V is present, continue to 2.1.2. If voltage is not present, check for “on” condition on front panel. If main circuit board will not generate a signal in the appropriate range, (test also with the connector removed from J3 if correct signal is not found when attached), replace main circuit board.
2.1.2 Check for loose connections in supply wires to blower from fuses and in signal wires from J3 to blower. If no loose connections or breaks in the circuit are found, replace blower.
NOTE: Blower may be bench tested by applying line voltage (110 VAC or 230VAC, see blower information on underside) to the 18ga. Black and white wires, and connecting the 22ga. Red and black wires to a power supply between 0 and 10V, red is positive. A dry cell battery between 1.5v and 9v may also be used.
Diagnostic Procedure 2.2
P2500 – Blower too Hot.
2.2.0 Use a thermocouple to measure the output temperature of the airflow exiting the blower at the pressure tap shown in figure 2.2.0 (screw must be removed). The unit must be fully assembled, attached to a properly functioning mattress, at least 15 minutes allowed for normal operating temperature to be reached, and ambient temperature must be between 65-75°F or 18-24°C for any temperature measurement to be valid. Blower exhaust temperature under these conditions should not exceed 120°F or
49°C (Temperatures in the mattress will be substantially lower due to convection and radiation from the manifold and air cells). If the exhaust temperature is below this limit, the unit is operating normally. If the exhaust temperature exceeds this limit, continue to 2.2.1.
2.2.1 Inspect the air filter for dirt and lint accumulation. If the filter is clean, continue to 2.2.2. If the filter is dirty, clean it according to the instructions in the operator’s manual. A failing blower that is generating excessive heat due to failing bearings or other internal problem will generally be noisy as well as hot. See also procedure 2.3.0 regarding blower noise. Any obstruction to airflow, particularly a dirty filter, will cause excessive heat and greatly shorten the life of the blower. If cleaning the filter, or clearing an obstruction lowers the
Plexus Aire Select
operating temperature to an acceptable value, the unit may be put back into service.
2.2.2 Inspect for an obstruction to airflow in the unit or hoses after the blower. If an obstruction is present, remove it. If no restriction to airflow is found and temperatures exceed the limit stated above, the blower should be replaced. Any obstruction to airflow, particularly a dirty filter, will cause excessive heat and greatly shorten the life of the blower. If cleaning the filter, or clearing an obstruction lowers the operating temperature to an acceptable value, the unit may be put back into service.
Diagnostic Procedure 2.3
P2500 – Excessive Noise or Vibration.
2.3.0 Any whistling or sound of moving air is generally caused by a leak in the air path from the blower to the mattress. These noises/leaks are easily identified by feeling around inside the enclosure until escaping air is found somewhere in the unit. If the noise is not due to leaking air, continue to 2.3.1. Extreme care must be taken to avoid touching the current carrying elements, such as the fuse blocks, inside the unit to avoid electric shock. Care must also be taken to avoid touching the rotating machinery. If a leak can be identified, it should be repaired by replacement of the damaged component. The most common noise producing failure is the self adhesive foam
AP gasket, see figure 2.3.0. Occasionally the gasket adhesive will release, typically due to excessive heat, see also procedure 2.2.0.
2.3.1 If any unusual noise or vibration is found coming from the blower itself, it should be replaced immediately. Parts of the blower rotate at high speed and any physical damage due to wear or other causes warrants replacement to ensure safe operation. The unit is constructed with sealed bearings that will normally give years of trouble free service, but unusual noise is generally a sign of bearing failure. Neglecting to clean the filter as specified in the operator’s manual can result in premature blower failure.
Page 10
Plexus Aire Select
Diagnostic Procedure 2.4
P2500 – Verify Proper Operation AP mode
2.4.0 Press the AP button to turn on the AP. Test for
6 VDC across the AP motor terminals on the AP valve. If 6 VDC is not present, for at least a few seconds, replace the Main PCB in the front panel. If 6 VDC is present, at least for a few seconds, and the airflow from top and bottom ports on side of unit do not change, return AP valve to factory for rebuilding and repair. If 6
VDC is present, at least for a few seconds, and the airflow from top and bottom ports on side of unit is not as expected, i.e.; both ports change airflow continuously or only one port will change when AP is fully cycled, continue to next step below.
2.4.1 If airflow from both ports change continually in
AP mode, check the filtered sensor output from the PCB on the AP valve as follows:
1. Check for 5VDC across pin 3 (orange wire) and pin 6 (blue wire) of the AP ribbon cable connector. The wires may be probed by taking the PCB out of the front panel and picking up the pins on the other side. Pin 1 is next to the arrow at the base of the blue connector, and the pins are numbered as shown below. If voltage is less than 4.5, or more than 6.5 volts, replace the main PCB in the front panel.
1 2
3 4
5 6
7 8
9 10
2. Check for voltage polarity change between 0 and 5 VDC across pins 3 (orange) and 7
(purple) at least once every 2.5 minutes. If airflow is constantly changing and voltage polarity change is not present, repair/replace
AP valve assembly. If voltage switch is present, replace main PCB in front panel.
12.0 Calibration
The calibration procedure should only be performed if the unit does not pass the functional check and safety inspection testing (see Section 8.0, page x).
Attach a mattress or approved mattress simulator to the unit and allow 25 minutes of operation for the system to come to stable operating temperatures. If a mattress is used, insert two pressure gages between two adjacent
Page 11
cells and the manifold in the center of the mattress.
Each gage must be attached to both the air cell and the manifold via a tee in order to develop appropriate back pressure on the unit. If a mattress simulator is used, attach the simulator to the unit and attach two pressure gages to the simulator using the fittings provided. Verify proper AP operation as follows:
1. Start with the AP off (light under button off), and verify the pressures are equal on both gages. If the pressure difference between the two measurements exceeds three mmHg, see procedure 2.4.0 to troubleshoot the AP valve.
2. When the AP is turned on and all nine comfort control lights are on (max inflate off), the pressure in one side should drop by at least 5 mmHg, and no more than 20 mmHg relative to the other side. If the pressure does not drop, see procedure 2.4.0, totroubleshoot the AP valve.
3. When AP is pressed again, the pressures should equalize and the light should go out under the AP button. If the pressures do not equalize, see procedure 2.4.0, to troubleshoot the AP valve.
4. When the AP is turned on again, the pressure in the other side should drop by at least 5 mmHg, and no more than 20mmHg. If the pressure does not drop, see procedure to troubleshoot the AP valve.
NOTE: The following calibration procedure is intended to be performed only if the machine does not pass the function testing outlined in section 8.0.
It is not intended to be performed on a routine basis.
NOTE: Unit must be warmed up for proper calibration and accurate pressure readings.
Adjustments must be made for the high end of the ranges called out in the procedure, as the pressures will drop slightly when the unit is closed. Final pressure readings should be taken with the unit
closed.
1
2
Connect unit to mattress simulator or appropriate mattress. Insure the connections used on the manifold do not contain orifices.
Set unit for "Firm" (all nine LED's lighted, MAX and
AP off). Change pressure using adjustment potentiometer located on the blower under the cap at the eight o'clock position (potentiometer located at two o'clock on 230V units). Firm should be set for 27 ± 4mmHg.
5
3
4
Turn on the MAX INFLATE function and adjust the left-hand potentiometer on main PCB. MAX should be set for 28 ± 4mmHg.
Turn off MAX INFLATE and reduce the pressure setting to SOFT (one LED lighted, MAX and AP off). Adjust right-hand potentiometer on the main
PCB. soft should be set for 10 ± 3 mmHg.
Close unit and verify reading are within specifications.
Plexus Aire Select
Important:
The AP valve PC board contains electronic components that are highly sensitive to static discharge. It is mandatory that the technician opening the unit, employ a grounding strap to avoid damaging the PC board. AP valve PC boards damaged by static discharge will not be covered by warranty.
13.1 Replacing the Blower
see figures 5 and 6
1. Remove male couplings from outside of enclosure.
2. Remove three screws that anchor the blower to the mounts.
3. Cut tie-wraps securing wire harness.
4. Release connectors from main PCB
5. Lift out blower and AP valve assembly
6. Separate blower from AP value.
Installing Replacements:
1. Insert replacement blower nozzle into AP valve.
NOTE: Care should be taken not to damage
gasket on AP valve.
2. Lower blower and AP valve into place in the rear enclosure.
3. Install male couplings through rear enclousre and tighten into value body.
4. Secure blower to mounts with three screws.
NOTE: Make sure ground jumper and wire to
main PCB are secured at the lower left mount.
5. Reattach connectors from wireless harness to main
PCB and secure wires to the anchor points.
NOTE: After replacing the blower or main PCB, the calibration procedure must be completed.
Figure 5 - Blower Side View
13.0 Repair procedures
Repairs of Plexus Medical products should only be performed by qualified and experienced technicians familiar with repairing medical equipment. Before attempting repair of Plexus medical products it is recommended that technicians review this service manual completely and have the necessary test tools called out in the manual.
Function testing of the machine for proper operation is required after all repairs. If you do not have the required technical skills and test tools it is recommended that the machine be returned to the factory for servicing.
Improper servicing can result in improper clinical performance of the system, premature failure of system components and invalidated warranties.
Replacement/repair of many of the components in this machine do not require specific detailed instructions.
Some of them do. Following are instructions for some of the more complex replacement/repair items in this machine.
Figure 6 – Blower Front View
Page 12
Plexus Aire Select
13.2 Replacing the AP Valve
Assembly or PC Board and see figure 7
Replace AP Board and Rotor Only - PN 30058
CAUTION
• THE AP BOARD IS EXTREMELY SENSITVE
TO STATIC.
Under normal conditions the valve body and bottom plate will not need to be replaced. Only the board and rotor will need to be changed.
1. Remove three screws.
2. Release cable from blower by cutting tie-wrap.
Disconnect cable from board.
3. AP Board should now lift from valve body; rotor will come out with board.
4. Pull rotor off existing board.
NOTE: There are two washers on the shaft that will be reused.
Installing Replacements:
1. Place two washers on shaft of motor on replacement board. Press rotor onto shaft aligning keywar. Rotor should be seated firmly against washers and hub on motor shaft.
2. Connect cable to main board on front enclosure.
Cable should be oriented with the wire proceding from the bottom of the connector and running toward the bottom of the main board.
3. Insert AP Board assembly into valve body and secure with three screws.
4. Secure wire to anchor points on blower and tiewraps.
Replace AP complete assembly - PN 30059
1. Remove male couplings from outside of enclosure.
2. Remove three screws that anchor the blower to the mounts.
3. Cut tie-wraps securing wire harness.
4. Release connectors from main PCB.
5. Lift out blower and AP valve assembly.
6. Separate blower from AP valve.
Installing Replacements:
1. Insert blower nozzle intor replacement AP valve.
2. Lower blower and AP valve into place in the rear enclosure.
3. Install male couplings through rear enclosure and tighten into valve body.
4. Secure blower to mounts.
NOTE: Insure ground jumper and wire to main
PCB are secured at the lower left mount.
5. Reattch connectors from wire harness to main PCB and secure wires to the anchor points.
Page 13
Figure 7 – AP valve assembly, PC board and motor assembly parts
AP valve assembly pre-installation test:
Before reinstalling the AP valve assembly it is recommended to perform the following test to ensure the rotor will not hang up and the value operates properly.
1. Conne ct cable from PBC/Rotor assembly to main board on front enclosure. Cable should be oriented with the wire proceeding from the bottom of the connector and running toward the bottom of the main board.
2. Turn unit on and make sure the unit is not in AP mode. The rotor should revolve and stop at the
"center" positon (see Figure 8, below).
Plexus Aire Select
3. Turn on the AP function. The rotor should turn to the left or right side positions (see Figure 9 or10, below).
4. Turn the AP function off and the rotor should return to the center. Turn the AP function on again and the rotor should turn to the opposite side position turned in number 3 (see Figure 9 or 10, below).
Figure 8 – rotor center
position
Figure 9 – rotor side position
13.3 Installing a New Control PC
Upon installing a new control PC board it will be necessary to perform the PC board calibration procedure.
(Please see section 12.0 Calibration Procedures).
Figure 10 – rotor side position
Figure 11 – PC Board
Page 14
Plexus Aire Select
14.0 Parts List
14.1 Rear Enclosure
Wire Harness
Page 15
Item Description
1 Enclosure Rear
2 Sound Foam Set
4 Baffle
9 Fuse Label 5A (120 V~) or 2.5A (230 V~)
10 Fuse 5A (120 V~) or 2.5A (230 V~)
16 Standoff
20 3/8 NPT Male Connector
21 O-Ring
24 #10 Lock washer, internal tooth
25 Power entry module
Plexus Aire Select
Plexus PN 120 V~ Model
20214-2500
Plexus PN 220 V~ Model
20214-2500
20218
20228
20218
20228
20215 20215
N/A N/A
N/A
10056
10069
50038
10065
50039
10064
N/A
10056
10069
50038-2.5
10219
50039
10064
10055
10362
11496-2500
10047
10048
10070
30059
10037
10055
10362
11675-2500
10047
10048
10070
30059
10037
10081 10081
30297 30297
10070-BOSS 10070-BOSS
10387
10049-SNAP
50041
30080
10387
10259-SNAP
50041
N/A
Page 16
Plexus Aire Select
14.2 Front Enclosure
Page 17
Item Description
1 Sound Foam Set
6 PCB Mounting Plate
7 Spacer
8 Nylon 4-40 Nut
9 #4 Washer
* For private label components contact Technical Service.
Plexus Aire Select
Plexus PN 120 V~ Model
20218
20037*
20054*
20047
20041
10087
10088
10089
30096
20213
Plexus PN 220 V~ Model
20218
20037*
20054*
20047
20041
10087
10088
10089
30096
20213
Page 18
10 Centre Drive
Orchard Park, NY
14127-2295
Phone:
1 800 828-7341
(716) 662-2551
FAX:
1 800 993-7890
(716) 662-0748
