Huntleigh Mini Pump User manual

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Huntleig

HEALTHCARE

Mini Pump

Service Manual

Issue 2

SER0004 Nov 2001

Mini Pump Service Manual Contents

AMENDMENT RECORD

Amendment Incorporated by Date

Issue 2 Contents Nov 2001 SER0004 Page (i)

Contents Mini Pump Service Manual

Contents Issue 2 Page (ii) SER0004 Nov 2001

Mini Pump Service Manual Contents

Contents

CHAPTER 1

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

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

Warnings, Cautions and Notes ............................2

Technical Description .....................................3

Operating Principle...................................3

System Start Up Sequence ..............................5

Low Pressure Alarm (Electronic Units Only) ......................6

Low Pressure Alarm (All Units) ............................6

Low Pressure Alarm Protocol (Electronic Units Only) .................6

Power Failure Alarm (Electronic Units Only)......................6

Battery Management (Electronic Units Only) .....................7

CHAPTER 2

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

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

Pump Soak/Break-in Times..................................2

Pump Service .........................................2

CHAPTER 3

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

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

Removing the Pressure Control Knob ............................3

Installing the Pressure Control Knob .............................3

Disassembling the Pump Filter ................................5

Assembling the Pump Filter .................................5

Disassembling the Rear Case ................................5

Assembling the Rear Case ..................................5

Disassembling the New Style Bed Hook ...........................7

Installing the New Style Bed Hook ..............................7

Removing the Old Style Bed Hook ..............................9

Installing the Old Style Bed Hook...............................9

Removing the Compressor Inlet Filter............................11

Installing the Compressor Inlet Filter ............................11

Removing the New Style AV Mounts ............................13

Replacing the New Style AV Mounts ............................13

Removing the Old Style AV Mounts .............................15

Issue 2 Contents Nov 2001 SER0004 Page (i)

Contents Mini Pump Service Manual

Installing the Old Style AV Mounts .............................15

Removing the Compressor Mounting Bracket........................17

Installing the Compressor Mounting Bracket ........................17

Removing the Compressor Bump Stops ..........................17

Installing the Compressor Bump Stops ...........................18

Replacing the Compressor Silencer Bag ..........................19

Replacing the Bellows Armature Assemblies and Pivots ..................21

Replacing the Compressor Armature Pivots ........................21

Replacing the Compressor Valve Bodies ..........................23

Replacing the ‘E’ Stack Assembly..............................25

Replacing the Coil Assembly ................................25

Replacing the Compressor Assembly ............................25

Replacing the Pressure Control Module...........................27

Replacing the Alarm Monitoring PCB ............................29

Changing the Battery ....................................31

Replacing the Neon Indicator Light .............................33

Replacing the Microswitch..................................35

Replacing the Terminal Block ................................35

Replacing the Pressure Control Flaps and Air Bag .....................37

Replacing the Pressure Control Assembly .........................39

Replacing the Synchronous Motor (Gearbox), Rotor Stator Assembly ...........41

Replacing the Side Panel Mains/Power On/Off Switch ...................43

Replacing the Side Panel Mains/Power Lead ........................43

Replacing the Fuses.....................................43

Replacing the Snap-lock Connectors ............................45

Removing the Front Case ..................................46

Installing the Front Case ..................................46

Pump Label Sets ......................................47

CHAPTER 4

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

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

Low Pressure fault indicated (checks without dismantling the pump) ............2

Loss of Output Pressure (checks by dismantling the pump) .................3

Low Pressure Alarm Fault ..................................4

Air Not Alternating (continuous pressure fault) ........................4

Loss of Electrical Power ...................................4

Contents Issue 2 Page (ii) SER0004 Nov 2001

Mini Pump Service Manual Contents

Circuit Diagrams .......................................5

CHAPTER 5

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

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

Electrical Testing .......................................5

PCB Functional Tests (Electrical Units Only) .........................6

Functional Tests (Mechanical Units Only) ..........................7

CHAPTER 6

Technical specification..............................1

CHAPTER 7

Parts list ......................................1

CHAPTER 8

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

Issue 2 Contents Nov 2001 SER0004 Page (iii)

Contents Mini Pump Service Manual

Contents Issue 2 Page (iv) SER0004 Nov 2001

Mini Pump Service Manual Introduction

CHAPTER 1

INTRODUCTION

1 About This Manual

Huntleigh Healthcare strongly recommend that their equipment is only serviced by trained personnel and provide courses for customers who wish to become licensed to service their own equipment. In no event will Huntleigh Healthcare be responsible for any service performed by customers or third parties.

This manual contains information on maintenance, servicing, repair, troubleshooting and testing for the range of pressure regulated pump units; pump models within the range are as follows:

AlphaXcell (Electronic)AlphaXcell (Mechanical)

•

AlphaRelief (Electronic)

•

Aura (Electronic)

•

AlphaTrancell (Mechanical)

•

AlphaBed (Mechanical)

•

AlphaCare (Mechanical)

•

Pump models are available for use world wide – model codes are shown in Table 1, while for country codes and power supply details refer to Table 2.

Table 1 - Product Range Distribution

Model Code Country Code

AlphaXcell (Electronic) ALX 01 to 10

AlphaXcell (Mechanical) ALX 11

AlphaRelief ALR 01 - 10

Aura ALS 01 - 10

AlphaTrancell ALT 01 - 10

AlphaBed ALB 01 - 10

AlphaCare ALC 01 - 10

Issue 2 Chap 1 Nov 2001 SER0004 Page 1

Introduction Mini Pump Service Manual

Table 2- Country Codes/Power Supplies

Mains Power

Country Code Country

Voltage (Volts AC) Frequency (Hz)

01 UK 220 - 240 50

02 Germany 220 - 240 50

03 USA 110 - 120 60

04 Euro 220 - 240 50

05 France 220 - 240 50

06 Japan 100 50/60

07 Italy 220 - 240 50

08 Australia 220 - 240 50

09 Rest of World 220 - 240 50

10 Holland 220 - 240 50

11 Rest of World 110 - 120 60

Warnings, Cautions and Notes

WARNINGS given in this manual identify possible hazards in procedures or conditions which, if not

correctly followed, could result in death, injury or other serious adverse reactions.

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

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

WARNINGS:

BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES, ENSURE THAT THE EQUIPMENT HAS BEEN ADEQUATELY DECONTAMINATED.

VOLTAGES IN EXCESS OF 30 VOLTS RMS OR 50 VOLTS DC CAN, IN CERTAIN CIRCUMSTANCES, BE LETHAL. WHEN WORKING ON EQUIPMENT REQUIRING EXPOSURE TO LIVE, UNPROTECTED CONDUCTORS WHERE SUCH VOLTAGES ARE PRESENT, EXTREME CARE MUST BE EXERCISED.

WHEN AN UNSERVICEABLE MAINS LEAD/POWER CORD FITTED WITH A NON-REWIREABLE PLUG IS REMOVED FROM THIS EQUIPMENT, THE LEAD/CORD AND THE PLUG MUST BE DESTROYED AND DISPOSED OF SAFELY. TO AVOID THE DANGER OF ELECTRIC SHOCK THE PLUG MUST NEVER BE INSERTED IN ANY POWER OUTLET.

Chap 1 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Introduction

2 Technical Description

The pressure regulated pump units listed in section 1 provide pressurised air for alternating pressure mattress systems which are used in aiding the prevention, treatment and management of pressure ulcers.

Pressurised air is fed to a range of support systems, mattresses, seat cushions etc., which support patients at risk of developing pressure ulcers.

All pumps are self-contained units powered by the single phase mains/power supply. Low air pressure and power failure alarm functions are included in some models, and pump output pressure is adjustable by means of a rotary control mounted on the unit front panel.

Operating Principle

Refer to Figure 1 for details of the pneumatic circuit. All pumps have two pressurised air outlets, air from the outlets is fed to separate cells or groups of cells in the mattress or cushion via a rotary valve. The support cells are continuously inflated and deflated utilising a ten minute cycle. During the cycle, air is pumped from one outlet for 4 minutes 10 seconds, there is then a period of 50 seconds where air is pumped from both outlets. Air is then pumped from the other outlet for 4 minutes 10 seconds, followed by a 50 second period where air is supplied from both outlets. During the period when air is suppled from a single outlet to one group of cells, the opposing outlet is vented to atmosphere, deflating the corresponding cells.

Issue 2 Chap 1 Nov 2001 SER0004 Page 3

Introduction Mini Pump Service Manual

COMPRESSOR

PRESSURE CONTROL

PRESSURE CONTROL MODULE

MICROSWITCH

ALTERNATING CELLS

EXCEPTION: Aura has 9 alternating cells but no static cells.

ROTOR/ STATOR

OUTLET

PORTS

HEAD

SECTION

(STATIC)

KEY

= INFLATED

= DEFLATED

Figure 1 - Pneumatic Diagram and Pressure Variations

For the Aura mini pump small adjustments can be made to cell pressure using the comfort control knob on the pump unit. This is a patient comfort feature to make small adjustments to the softness or firmness of the support cells. All other mini pumps have a pressure adjustment control that must be set to the patient weight in accordance with the instructions given in the relevant user manual and/or the pump labels.

The range of air pressure delivered by the series of pumps varies, as does the achievable flow rate. One extreme of pressure range can be adjusted by obtaining access to a screw under the pressure control knob; see Table 3 for details of pressure variations. The range achievable is fixed by the pressure control spring, only the set pressure can be reset.

Chap 1 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Introduction

Table 3 - Air Pressure/Flow Rates

Pump Model

ALX 20-24 57-73 Yes 6 3

ALR 20-24 72-92 Yes 6 3

ALS 83-87 Less than 110 Comfort

ALT 25-35 65-81* Yes 6 3

ALB 25-35 80-100 Yes 6 3

ALC 25-35 80-100 Yes 6 3

* Holland pumps (ALT10) only - max pressure is 80-100 mmHg

Pump units may be divided, into two types, Mechanical and Electronic. Major differences between the two types of pump unit are as follows:

Alarm indicators - mechanical type has a neon indicating low air pressure, also an illuminated

•

mains/power on/off switch. The electronic type incorporates an alarm monitoring PCB driving a number of LED indicators and audible warning sounder. See Table 4 for visual indicator details.

Minimum Pressure

(mmHg)

Maximum

Pressure

(mmHg)

Adjustable

Pressure

Range

control only

Minimum Flow

Rate at 20 mmHg

back pressure

(litres/minute)

3.25 2.25

Minimum Flow

Rate at 50

mmHg

(litres/minute)

• Air outlets - mechanical type has simple push-on connectors (except ALX11 which has

snap-lock type connectors). The electronic type utilises snap-lock type connectors.

Table 4 - Product Visual Indicators

Model Code ALB ALC ALT ALR ALX ALX ALS

Mechanical (M) or Electrical (E)

Indicator

Illuminated Mains/Power Switch X X X X

On X X X

Wait X X

Low Pressure X X XXXXX

Power Fail X X X

System Start Up Sequence

All pump types must be connected to the appropriate mains/power supply via a suitable plug.

After a mechanical pump is switched on the start up sequence is as follows:

MMME EME

•

The ON/OFF switch lever will be illuminated green.

Issue 2 Chap 1 Nov 2001 SER0004 Page 5

Introduction Mini Pump Service Manual

The red ‘low pressure’ indicator will be illuminated. When operating pressure is achieved, the

•

low pressure indicator will be extinguished automatically.

After an electronic pump is switched to ‘Run’ the start up sequence is as follows:

The unit performs a diagnostic self test, illuminating all LED indicators and sounding the

•

audible alarm. If an internal fault is sensed or a problem with the wiring of the mains/power sense switch, the pump will remain in this state. If the self test is successful then the start up sequence will proceed.

On start up, the low pressure alarm will be inhibited until one minute after the low pressure

•

signal is deactivated. The amber WAIT indicator will be illuminated while the low pressure alarm is inhibited. (See Low pressure Protocol) Other functions will work as normal.

Note: Aura (ALS) model has no WAIT indicator; apart from this one difference, however, the Aura

pump performs the same as the other electronic pump units.

Low Pressure Alarm (Electronic Units Only)

When the alarm is activated, the red LOW PRESSURE indicator will flash, in combination with an audible warning which increases in pitch with time. The alarm can be reset by momentarily switching the pump to ‘Stand by’ and then back to ‘Run’. Alternatively, the alarm will automatically reset after 15 minutes provided that the low pressure switch is not activated during this time. If however the low pressure switch is activated (for more than 15 seconds) during this time, the timer will reset to zero and the alarm will continue for a further 15 minutes.

Low Pressure Alarm (All Units)

On all pump units except the ALS model the low air pressure alarm will be activated on or before 5 mmHg and deactivated before the pressure reaches 17 mmHg.

For the ALS model only, the low air pressure alarm will be activated on or before 50 mmHg and deactivated at or before 82 mmHg.

Low Pressure Alarm Protocol (Electronic Units Only)

The low pressure alarm will be activated only when the requirements of the low pressure alarm protocol have been met by a sequence of low pressure signals. The system is designed to detect low pressure fault conditions without responding to spurious signals due to patient movement, mattress cell crossover, short term tube disconnection etc.

In order to generate a low pressure alarm the system must detect three low pressure switch closure, of 15 seconds duration each, within a 25 minute period. There will be a 2 minute lockout between the first and second switch closures as well as between second and third switch closures. The lockout period is to allow temporary disconnection of tubing.

In addition to the above, a wait period of 25 minutes is allowed on start up. During this time the low pressure alarm is inhibited to allow inflation of the mattress to operating pressure. If, during this wait period, the low pressure switch is activated (i.e., the system is up to pressure), the wait period will be terminated 1 minute later, and normal protocol is obeyed thereafter.

Power Failure Alarm (Electronic Units Only)

In the event of a power failure, the red POWER FAIL indicator will flash in combination with an audible warning which increases with time.

If the power supply is restored, the audible alarm will stop, but the indicator will remain illuminated (continuously) until the system is reset. Resetting, by switching the pump to ‘Stand by’ and then back to ‘Run’, will clear all alarm indications.

Chap 1 Issue 2 Page 6 SER0004 Nov 2001

Mini Pump Service Manual Introduction

The power failure alarm is initiated by the removal of the mains/power supply from the unit for a period of more than 5 seconds, by a means other than operation of the ‘Run/Standby’ switch. A drop in the supply voltage below the minimum supply specification will be interpreted as a supply failure. If power is restored within 5 seconds, no alarm is given and normal operation is resumed.

A battery backup supply provides power to operate the visual and audible alarm.

Battery Management (Electronic Units Only)

On switching the pump to ‘Run’, the processor automatically initiates a standard charge sequence (3 mA) for a predetermined period. On completion of the standard charge period, a trickle charge (0.9 mA) will be applied to the battery for the remainder of the operating period.

When discharging during a power failure alarm, the battery supply will be shut down in a controlled manner if the terminal voltage falls below 4.6 V before the alarm duration has expired.

Issue 2 Chap 1 Nov 2001 SER0004 Page 7

Introduction Mini Pump Service Manual

Chap 1 Issue 2 Page 8 SER0004 Nov 2001

Mini Pump Service Manual Maintenance

CHAPTER 2

MAINTENANCE

1 Pump Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Chapter 3, Pump Repair.

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

Note : If any parts require repairing or replacing then refer to the Huntleigh Healthcare service

manual.

1.1.1 Check outer casings for damage.

1.1.2 Functionally check switches and control knobs.

1.1.3 Ensure hanging brackets are secure and located.

1.1.4 Check outlet ports and connecting points for damage.

1.1.5 Ensure feet are secure and present.

1.1.6 Check fuses are satisfactory.

1.1.7 If a gauge is fitted ensure the glass is not cracked or damaged.

1.1.8 Check that there is no damage to the mains/power connector if fitted.

1.1.9 Check labels are present, located correctly and legible.

1.1.10 Ensure LED’s are not cracked.

1.2 Remove the compressor lid (Refer to Chap. 3, Section 22) and visually inspect the following for damage, wear, and potential faults:

Note : If any parts require repairing or replacing then refer to Chap 3, Pump Repair.

1.2.1 Coil/’E’ stack assembly.

1.2.2 Elbows and connectors.

1.2.3 Bellows.

1.2.4 Security of compressor.

1.2.5 Integrity of filters and gaskets.

1.2.6 Valve body assembly.

1.2.7 Armature blades.

1.2.8 Pivot points.

1.2.9 Silencer bags.

1.2.10 Valve shuttle assembly.

Issue 2 Chap 2 Nov 2001 SER0004 Page 1

Maintenance Mini Pump Service Manual

Once the compressor has been visually inspected connect to a power supply and run, this is to ensure the compressor is working and that there is flow/pressure at the outlet port of the pump.

Check for any excessive noise and vibration.

2 Pump Soak/Break-in Times

2.1 A pump must be soaked/broken-in for the following reasons:

Note : Soaking/breaking-in consists of running the pump with the outlet ports blocked.

To ensure that the pump is at normal running temperature prior to pneumatic performance

•

tests being carried out. To stress test major/critical parts which have been replaced or repaired.

•

2.2 All pumps should be soaked/broken-in for a period of 30 to 60 minutes prior to any pneumatic performance test being carried out. This is because the compressor bellows need to warm up to reach normal output.

2.3 If any of the following major/critical components have been replaced or repaired, then it is recommended that the pump be soaked/broken-in for 12 hours prior to being tested:

Valve body.

•

Silencer Bag.

•

Printed Circuit Boards (PCB) if applicable.

•

Compressor.

•

Rotary Valve Assembly.

•

3 Pump Service

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

3.1 Carry out the Pump Maintenance Checks (Section 1).

3.2 Replace the following components:

3.2.1 Silencer bag (Refer to Chapter 3, Section 22).

3.2.2 Pivot points (Refer to Chapter 3, Section 24).

3.2.3 Bellow assemblies (Refer to Chapter 3, Section 23).

3.2.4 Valve bodies (Refer to Chapter 3, Section 25).

3.2.5 Compressor filter (Refer to Chapter 3, Section 12).

3.2.6 Compressor gasket (Refer to Chapter 3, Section 22).

3.2.7 Pump case filter (Refer to Chapter 3, Section 4).

3.2.8 AV mounts (Refer to Chapter 3, Section 14 - new style, Section16 - old style).

3.2.9 Internal rechargeable battery (Refer to Chapter 3, Section 31).

Chap 2 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Maintenance

3.3 Reassemble the pump and soak/break-in for the recommended time (Refer to Section 2).

3.4 Carry out a flow, pressure and function test on the pump in accordance with Chapter 5.

3.5 Carry out electrical tests on the pump in accordance with Chapter 5.

Issue 2 Chap 2 Nov 2001 SER0004 Page 3

Maintenance Mini Pump Service Manual

Chap 2 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

CHAPTER 3

PUMP REPAIR

1 General

This chapter details repair procedures for the range of pump units listed in Chapter 1, Page 1, Table 1. All repairs should be carried out by Huntleigh approved service personnel.

After carrying out a service or any repairs, the pump must be soak tested/broken-in for the recommended time (Refer to Chapter 2) and tested for serviceability. The table below 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 5.

To carry out the electrical tests on the pump refer to Chapter 5.

Table 5- Repair to Testing Requirements

Components / Assemblies

Compressor Yes Yes

Pressure Control Yes Yes

Rotors & Stators Yes Yes

Silencer Bag Yes No

Coils Yes Yes

Elbows & Connectors Yes No

AV Mounts Yes Yes

PCB Yes Yes

Front Casing Yes No

Rear Casing No No

Battery No Yes

Switches No Yes

Fuse No Yes

Flow/Pressure & Function

Test

Electrical Safety

Electrical Connectors No Yes

Mains/Power Lead No Yes

Issue 2 Chap 3 Nov 2001 SER0004 Page 1

Pump Repair Mini Pump Service Manual

Pin (if fitted)

Figure 2 - Removing the Control Knob

Table 6 - Control Knob Part List

Item Part Number Description Qty

10 500484 Control Knob (MK2) 1

20 500304 Knob Arbour 1

30 500318 Pin (if fitted) 1

40 500316 Front Case 1

Note : The obsolete MK1 control knobs are fully interchangeable with the MK2 control knobs. If the

MK1 control knob needs replecing, replace it with the MK2 version.

Chap 3 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

2 Removing the Pressure Control Knob

Note : Removing the control knob avoids possible damage and allows the pump to sit on a flat

surface without rocking.

2.1 Locate the slot at the rear of knob (Fig 2, Item 10) and inserta3mmflatpoint screwdriver.

2.2 Lever the screwdriver upward to lift the knob off the three retaining prongs.

3 Installing the Pressure Control Knob

Note : When installing the pressure control knob, ensure that the small prong sits in its own housing.

Then, the two larger prongs will line up correctly.

Aura (Pin fitted)

Turn knob arbour clockwise to it’s full extent. Fit control knob in the position shown below.

ENSURE 90° MOVEMENT

SMALL PRONG

AlphaRelief / AlphaBed / AlphaCare / AlphaTrancell ALT10 (No pin fitted)

Turn knob arbour counter-clockwise to it’s full extent. Fit control knob in the position shown below.

ENSURE

SMALL PRONG

270° MOVEMENT

AlphaXcell / AlphaTrancell ALT01-09 (Pin fitted)

Turn knob arbour counter-clockwise to it’s full extent. Fit control knob in the position shown below.

ENSURE

SMALL PRONG

180° MOVEMENT

3.1 Carefully position the knob (Fig 2, Item 10) so that the prongs are correctly aligned with the recesses in the knob arbour (Fig 2, Item 20)

3.2 Press the knob into place on the arbour and ensure that it is correctly seated.

Issue 2 Chap 3 Nov 2001 SER0004 Page 3

Pump Repair Mini Pump Service Manual

Figure 3 - Removing and Replacing the Pump Filter

Table 7 - Pump Filter Part List

Item Part Number Description Qty

10 500340 Felt Filter 1

20 500327 Filter Plate 1

30 500317 Rear Case 1

40 FAS223 Pan Head Screw PT 3 Dia x 10 Pozi 1

50 FAS225 Pan Head Screw PT 3 Dia. x 16 Pozi 4

Chap 3 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

4 Disassembling the Pump Filter

4.1 Remove the centre screw (Fig 3, Item 40) retaining the filter plate (Fig 3, Item 20) in the rear case (Fig 3, Item 30).

4.2 Carefully remove the filter plate and felt filter (Fig 3, Item 10) from the rear case. Discard the old filter.

5 Assembling the Pump Filter

5.1 Install a new filter (Fig 3, Item 10) in the filter plate (Fig 3, Item 20) ensuring that the curved edge is at the top.

5.2 Ensure that the filter is correctly positioned over the boss in the filter plate then fit the filter plate to the rear case (Fig 3, Item 30) and secure with the screw (Fig 3, Item 40).

6 Disassembling the Rear Case

Note : It is necessary to remove the rear case from the front case to allow access to all internal pump

connections.

6.1 Remove the front panel control knob (Refer to Page 3, Section 2).

6.2 Place the pump on a flat, clean surface with the case front face down.

6.3 Unscrew and remove the four corner screws (Fig 3, Item 50).

6.4 Carefully remove the rear case assembly (Fig 3, Item 30) from the case front.

7 Assembling the Rear Case

7.1 Assembly of the rear case is in the reverse order of disassembly.

Issue 2 Chap 3 Nov 2001 SER0004 Page 5

Pump Repair Mini Pump Service Manual

Figure 4 - Replacing the New Style Bed Hook

Table 8 - New Style Bed Hook Part List

Item Part Number Description Qty

10 500495 Bed Hook (New Style) 1

20 500496 Hook Plate (Left Hand) 1

30 500497 Hook Plate (Right Hand) 1

40 FAS223 Pan Head screw PT 3 Dia. x 10 8

50 500381 Rubber foot 8

Chap 3 Issue 2 Page 6 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

8 Disassembling the New Style Bed Hook

8.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2).

8.2 Remove the pump rear case (Refer to Page 5, Section 6).

Note : The bed hook brackets are right and left handed.

8.3 Hold a hook plate (Fig 4, Item 20 or 30) in position and remove the four securing screws (Fig 4, Item 40) from the inside of the pump rear case. Release the hook plate from the rear case and lift clear.

8.4 If necessary repeat Section 8.3 to remove the other hook plate and bed hook (Fig 4, Item 10).

9 Installing the New Style Bed Hook

Note : Replacement Old Style Bed Hooks are no longer available. The Old Style Rear Case

assembly will not accommodate the New Style Bed Hook so where Old Style Bed Hooks must be replaced it will be necessary to obtain all the parts listed in Table 8, plus the rear case (Item 30 in Table 6).

Note : For step 9.2, remember to place the left-hand bracket on the right and the right-hand bracket

on the left, since their relative positions will be reversed when they are presented to the rear case assembly.

9.1 Assembly of the new Pump Filter is in the reverse order of disassembly. Make sure the slots in the Filter Housing Plates (Fig 4, Item 20) are uppermost in the positions shown in Fig 4.

9.2 Lay the left-hand (Fig 4, Item 20) and the right-hand (Fig 4, Item 30) brackets on a hard flat surface with their rubber pads face down and their shaped heads pointing inward.

9.3 Ensure the bed hook (Fig 4, Item 10) is correctly placed to the left-hand and right-hand slots where the coating has been removed. Firmly press home the bed hook until it clicks into place.

9.4 Lay the rear case assembly, on a hard flat surface, with its back uppermost. Turn over the bed hook subassembly and place into the rear case assembly.

9.5 Position one bracket and press it firmly until it clicks into place. Repeat this process for the other bracket.

9.6 Turn over the rear case assembly and fit four securing screws to each bracket.

9.7 Assemble the rear case to the pump (Refer to Page 5, Section 7).

9.8 Install the pressure control knob (Refer to Page 3, Section 3).

Issue 2 Chap 3 Nov 2001 SER0004 Page 7

Pump Repair Mini Pump Service Manual

Figure 5 - Replacing the Old Style Bed Hooks

Chap 3 Issue 2 Page 8 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

Table 9 - Old Style Bed Hook Part List

Item Part Number Description Qty

10 N/A Bed Hook - Left Hand 1

20 N/A Bed Hook - Right Hand 1

30 N/A Hook Plate 1

40 N/A Pan Head screw PT 3 Dia. x 10 Pozi 6

Note :The old bed hook bracket assemblies are left and right handed. Replacements are no longer

available.

10 Removing the Old Style Bed Hook

10.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2).

10.2 Remove the pump rear case (Refer to Page 5, Section 6).

10.3 Hold a hook plate (Fig 5, Item 30) in position and remove the three securing screws (Fig 5, Item 40) from the inside of the rear case.

10.4 Carefully remove the hook plate and its bed hook (Fig 5, Item 10 or 20).

10.5 Repeat Section 10.3 and 10.4 for the other hook plate and bed hook if required.

Note : The above procedure will not be necessary when changing the old bed hooks for the new bed

hook which needs the new rear case assembly.

11 Installing the Old Style Bed Hook

11.1 When refitting the old bed hook brackets, replacement is the reversal of the above procedure.

11.2 Ensure correct orientation of the left and right-handed assemblies. (The spring on the right hand assembly is colour coded red).

11.3 Position the hook and spring assembly on the rear case, install the hook plate and hold it in place while inserting the three securing screws from the inside of the rear case.

11.4 Assemble the rear case to the pump (Refer to Page 5, Section 7).

11.5 Install the pressure control knob (Refer to Page 3, Section 3).

Issue 2 Chap 3 Nov 2001 SER0004 Page 9

Pump Repair Mini Pump Service Manual

Figure 6 - Replacing the Compressor Filter Assembly

Table 10 - Compressor Filter Assembly Part List

Item Part Number Description Qty

10 502003 Compressor Assy 230V 50Hz 11K/T 1

502002 Compressor Assy 110V 60Hz 5K/T (USA) 1

502007 Compressor Assy 100V 50/60Hz 4.5K/T (Japan) 1

20 500320 ‘F’ Tube Connector REF

30 500410 Filter Retaining Clip 1

40 500417 Inlet Filter 1

Chap 3 Issue 2 Page 10 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

12 Removing the Compressor Inlet Filter

12.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2).

12.2 Remove the rear case assembly (Refer to Page 5, Section 6).

12.3 Carefully pull the filter retaining clip (Fig 6, Item 30) from the ‘F’ tube connector (Fig 6, Item 20).

12.4 Remove and discard the old inlet filter (Fig 6, Item 40).

13 Installing the Compressor Inlet Filter

13.1 Locate a new inlet filter (Fig 6, Item 40) over the air intake hole in the case of the compressor assembly (Fig 6, Item 10).

13.2 Carefully reposition the filter retaining Clip (Fig 6, Item 30) on the ‘F’ tube connector (Fig 6, Item 20) to retain the inlet filter (Fig 6, Item 40). Make sure the clip is fitted with the longer arm downward if appropriate.

13.3 Assemble the rear case to the pump (Refer to Page 5, Section 7).

13.4 Install the pressure control knob from the pump (Refer to Page 3, Section 3).

Issue 2 Chap 3 Nov 2001 SER0004 Page 11

Pump Repair Mini Pump Service Manual

20 20

Figure 7 - Replacing the New Style AV Mounts

Table 11 - New Style AV Mounts Part List

Item Part Number Description Qty

10 500124 Compressor Mounting Bracket 1

20 500416 AV Mount 4

30 N/A Mounting Pins 4

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Mini Pump Service Manual Pump Repair

14 Removing the New Style AV Mounts

14.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2).

14.2 Remove the rear case assembly (Refer to Page 5, Section 6).

14.3 Carefully lift the compressor, mounting bracket (Fig 7, Item 10) and AV mounts (Fig 7, Item 20) from the mounting pins (Fig 7, Item 30).

14.4 Remove the AV mounts from the mounting bracket and discard them.

15 Replacing the New Style AV Mounts

15.1 Fit new AV mounts (Fig 7, Item 20) of the same type to the mounting bracket (Fig 7, Item 10).

15.2 Carefully fit the compressor, mounting bracket and AV mounts to the mounting pins (Fig 7, Item 30) in the pump case. Ensure that all four AV mounts are correctly located on the mounting pins.

15.3 Assemble the rear case to the pump (Refer to Page 5, Section 7).

15.4 Assemble the pressure control knob to the pump (Refer to Page 3, Section 3).

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Figure 8 - Replacing the Old Style AV Mounts

Table 12 - Old Style AV Mounts Part List

Item Part Number Description Qty

10 N/A AV Mounting Bracket 2

20 198375 AV Mount 4

30 N/A AV Mount Nut 8

40 N/A Washer 12

50 Ref Table 14 Compressor 1

60 N/A Compressor Mounting Bracket (Part) 1

70 N/A Spacers 4

Chap 3 Issue 2 Page 14 SER0004 Nov 2001

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16 Removing the Old Style AV Mounts

Note : Replacements are not available for the old style AV mounts.

16.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2).

16.2 Remove the rear case assembly (Refer to Page 5, Section 6).

16.3 Remove the securing spacers (Fig 8 Item 70) and carefully lift the compressor (Fig 8, Item 50) and AV bracket assembly (Fig 8, Items 10, 20, 30, 40, 60) from the mountings.

16.4 Release the to AV mount nuts (Fig 8, Item 30) and washers (Fig 8, Item 40) and remove the two AV mounting brackets (Fig 8, Item 10) from the AV mounts (Fig 8, Item 20).

16.5 Release the bottom AV mount nuts and washers and remove the four AV mounts from the compressor mounting bracket (Fig 8, Item 60).

17 Installing the Old Style AV Mounts

17.1 Fit four replacement AV mounts (Fig 8, Item 20) to the compressor mounting bracket (Fig 8, Item 60) and secure with washers (Fig 8, Item 40) and nuts (Fig 8, Item 30).

17.2 Fit the two AV mounting brackets (Fig 8, Item 10) to the AV mounts and secure with washers and nuts.

17.3 Carefully fit the compressor (Fig 8, Item 50) and AV bracket assembly (Fig 8, Items 10, 20, 30, 40, 60) to the mountings in the pump case and fit securing spacers (Fig 8 Item 70).

17.4 Assemble the rear case to the pump (Refer to Page 5, Section 7).

17.5 Install the pressure control knob (Refer to Page 3, Section 3).

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Pump Repair Mini Pump Service Manual

Figure 9 - Replacing Mounting Brackets and Bump Stops

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Table 13 - Compressor Mounting Brackets and Bump Stops Part List

Item Part Number Description Qty

10 165310 Upper Bump Stop 1

20 165310 Lower Bump Stop 1

30 500124 Compressor Mounting Bracket (New Style) 1

N/A Compressor Mounting Bracket (Old Style) 1

40 FAS160 Washer M4 Plain 2

50 FAS051 Screw Pan Head Pozi M4x6mm 2

60 FAS095 Screw Pan Head Pozi M4 x 10 mm 3

18 Removing the Compressor Mounting Bracket

18.1 Remove the compressor/AV bracket assembly from the pump case and disassemble AV mounts as described on Page 13, Section 14 (new style AV mounts) or Page 15, Section 16 (old style AV mounts. Section 16.4 should be omitted if old style AV mounts are not to be replaced.

Note : Figure 7 Illustrates the new style AV mount system. Compressor mounting bracket to

compressor assembly methods are the same for both old and new style AV mount systems.

18.2 Remove screw, washer and lower bump stop (Fig 9, Items 50, 40, 20) from the compressor mounting bracket (Fig 9, Item 30).

18.3 Remove three screws (Fig 9, Item 60) and detach the mounting bracket from the compressor.

19 Installing the Compressor Mounting Bracket

19.1 Fit replacement mounting bracket (Fig 9, Item 30) same type (if required) to the compressor. Ensure that the four pegs are correctly located and secure the mounting bracket to the compressor with three screws (Fig 9, Item 60).

19.2 Fit the screw, washer and lower bump stop (Fig 9, Items 50, 40, 20) to the mounting bracket.

19.3 Assemble AV mounts and fit the compressor/AV bracket assembly into the pump case as described in Section 15 (new style AV mounts) or Section 17 (old style AV mounts). Section

17.2 may be omitted.

20 Removing the Compressor Bump Stops

20.1 Remove the compressor/AV bracket assembly from the pump case as described in Section

14.1, 14.2 and 14.3 (new style AV mounts) or Section 16.1, 16.2 and 16.3 (old style AV mounts).

Note : Figure 7 illustrates the new style AV mount system. Bump stop to compressor and bump stop

to compressor mounting bracket assembly methods are the same for both old and new style AV mount systems.

20.2 Remove screw, washer and upper bump stop (Fig 9, Items 50, 40, 10) from the compressor lid.

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Pump Repair Mini Pump Service Manual

20.3 Remove screw, washer and lower bump stop (Fig 9, Items 50, 40, 20) from the compressor mounting bracket.

21 Installing the Compressor Bump Stops

21.1 Fit screw, washer and replacement upper bump stop (Fig 9, Items 50, 40, 10) to the compressor lid.

21.2 Fit screw, washer and replacement lower bump stop (Fig 9, Items 50, 40, 10) to the compressor mounting bracket.

21.3 Refit the compressor/AV bracket assembly to the pump case as described in Page 13, Section

15.2, 15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts).

Figure 10 - Compressor Silencer Bag

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Mini Pump Service Manual Pump Repair

Table 14 - Compressor Silencer Bag Part List

Item Part Number Description Qty

10 502003 Compressor Assy 230V 50Hz 11K/T 1

502002 Compressor Assy 110V 60Hz 5K/T (USA)

502007 Compressor Assy 100V 50/60Hz 4.5K/T (Japan)

20 502301 Compressor Lid 1

30 FAS054 Screw Countersunk Pozi M4 x 12 mm 4

40 BP032 Compressor Gasket 1

50 502055 Silencer Bag 1

60 500320 ‘F’ Tube Connector 1

70 N/A Silencer Bag Outlet Tubes REF

80 N/A Silencer Bag Inlet Tubes REF

22 Replacing the Compressor Silencer Bag

22.1 Remove the compressor/AV bracket assembly from the pump case (Refer to Page 13, Section

14.1, 14.2 and 14.3 (new style AV mounts) or Page 15, Section 16.1, 16.2 and 16.3 (old style AV mounts)).

22.2 Remove four screws (Fig 10, Item 30) and carefully lift off the compressor lid (Fig 10, Item 20) and gasket (Fig 10, Item 40) from the compressor assembly (Fig 10, Item 10). Discard the gasket.

22.3 Disconnect the outlet tubes (Fig 10, Item 70) of the silencer bag (Fig 10, Item 50) from the ‘F’ tube connector (Fig 10, Item 60).

22.4 Disconnect the inlet tubes (Fig 10, Item 80) of the silencer bag from the valve bodies.

22.5 Fit a new silencer bag and gasket, then replace the compressor lid by reversing operations detailed in Section 22.4, 22.3 and 22.2.

22.6 Refit the compressor/AV bracket assembly to the pump case (Refer to Page 13, Section

15.2,15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts)).

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Pump Repair Mini Pump Service Manual

Figure 11 - Bellows Armature Assembly and Pivots

Table 15- Bellows Armature Assembly Part List

Item Part Number Description Qty

10 502054 Bellows Armature Assembly Left-Hand 230V 50Hz 1

BP215 Bellows Armature Assembly Left-Hand 110V 60Hz 1

20 502053 Bellows Armature Assembly Right-Hand 230V 50Hz 1

BP214 Bellows Armature Assembly Right-Hand 110V 60Hz 1

30 BP043 Armature Pivot 2

40 BP554 Valve Body 2

Chap 3 Issue 2 Page 20 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

23 Replacing the Bellows Armature Assemblies and Pivots

23.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2,22.3 and 22.4).

23.2 Using long nosed pliers, extract the armature blade, part of bellows armature assembly (Fig 11, Item 10 or 20) from the armature pivot (Fig 11, Item 30)

23.3 Unclip the bellows, part of bellows armature assembly from the valve body (Fig 11, Item 40) and lift the bellows armature assembly clear of the compressor.

23.4 Repeat 23.2 and 23.3 as required to remove the other bellows armature assembly.

23.5 Discard the old bellows armature assembly and fit a replacement of the same type by reversing the actions carried out in Section 23.3 and 23.2.

23.6 Fit a new silencer bag and gasket, then replace the compressor lid (Refer to Page 19 and reverse the operations carried out in Section 22.4, 22.3 and 22.2).

23.7 Refit the compressor/AV bracket assembly to the pump case (Refer to Page 13, Section 15.2,

15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts)).

23.8 Test the assembly. Note, in order to achieve flow/pressure performance, the new bellows may have to be heated with a hot air gun whilst operating. This anneals the bellows permanently and alters the pressure/flow characteristics.

Caution: The bellows will be damaged if overheated.

24 Replacing the Compressor Armature Pivots

24.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2, 22.3 and 22.4).

24.2 Extract the armature blade from the pivot (Refer to Section 23.2).

24.3 Use a sharp, pointed tool and carefully extract the pivot (Fig 11, Item 30) from the hole in the compressor casing.

24.4 Discard old armature pivots and replace with same type. Carefully insert the new pivot into the compressor casing using a small screwdriver to ensure the slot in the pivot is aligned to accept the armature blade.

24.5 Fit the armature blade to the pivot reversing the actions carried out in Section 23.2.

24.6 Fit a new silencer bag and gasket, then replace the compressor lid (Refer to Page 19 and reverse the operations carried out in Section 22.4, 22.3 and 22.2).

24.7 Refit the compressor/AV bracket assembly to the pump case (Refer to Page 13, Section 15.2,

15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts)).

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Pump Repair Mini Pump Service Manual

Figure 12 - Compressor Valve Bodies

Table 16 - Compressor Valve Bodies Part List

Item Part Number Description Qty

10 BP554 Valve Body Assy, Blue

(Each valve body contains items 20 to 70)

20 BP351 Valve Body 1

30 FAS027 Screw, Hex Head 4BA x 3/4 1

40 FAS013 4BA Full Nut 1

50 BP039 Valve Body Washer 2

60 BP037 Valve Flap 2

70 BP038 Valve Flap Securing Pad 2

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Mini Pump Service Manual Pump Repair

25 Replacing the Compressor Valve Bodies

25.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2, 22.3 and 22.4).

25.2 Unclip the bellows, part of bellows armature assembly from the valve body (Refer to Page 20, Fig 11, Items 10 or 20 and 40).

25.3 Unscrew and remove the securing nut (Fig12, Item 40) on the side of the compressor housing.

25.4 Remove the valve body (Fig 12, Item 20) and Valve body washers (Fig 12, Item 50).

25.5 Remove the valve flap securing pads and the valve flaps (Fig 12, Items 70 and 60)

25.6 Discard the old valve body and replace with the same type.

25.7 Repeat Sections 25.3 to 25.6 as necessary to replace the other valve body.

25.8 When replacing the valve flaps and valve flap securing pads, make sure that the valve flap sits flat over the hole in the valve body and the valve securing pad is pushed fully on to the lug.

25.9 Position the replacement valve body and secure with screw (Fig 12, Item 20) and nut. Fit the bellows to the valve body.

25.10 Fit a new silencer bag and gasket, then replace the compressor lid (Refer to Page 19 and reverse the operations carried out in Section 22.4, 22.3 and 22.2).

25.11 Refit the compressor/AV bracket assembly to the pump case (Refer to Page 13, Section 15.2,

15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts)).

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Pump Repair Mini Pump Service Manual

Figure 13 - ‘E’ Stack and Coil Assembly

Table 17 - ‘E’ STACK and Coil Assembly Part List

Item Part Number Description Qty

10 BP028 ‘E’ Stack 1

20 FAS048 Pan Head Screw M3 x 25 mm Pozi 2

30 FAS002 Washer - 6BA Anti-Vib. 2

40 502050 Coil Assembly 230V 50Hz (black/white leads) 1

502062 Coil Assembly 110V 60Hz (grey leads) 1

BP275 Coil Assembly 100V 50/60Hz (blue leads) 1

50 165303 Grommet 1

60 502304 Compressor Case 1

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Mini Pump Service Manual Pump Repair

26 Replacing the ‘E’ Stack Assembly

Note : After doing work in either Section 26 or 27 the pressure/flow characteristics can be altered by

moving the coil assembly/’E’ stack nearer or further from the armature magnets. This can be done by adjusting screws (Fig 13, Item 20). Ensure the screws are tightened afterwards.

26.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2, 22.3 and 22.4).

26.2 Unscrew and remove the two screws and anti-vibration washers (Fig 13, Items 20 and 30) which secure the ‘E’ stack/coil assembly (Fig 13, Items 10 and 40).

26.3 Withdraw the ‘E’ stack/coil assembly from the compressor case as far as the electrical wires will allow.

26.4 Carefully remove the ‘E’ stack from the coil assembly.

26.5 Replace the ‘E’ stack by reversing the operations carried out in Section 26.4, 26.3 and 26.2.

26.6 Fit a new silencer bag and gasket, then replace the compressor lid (Refer to Page 19 and reverse the operations carried out in Section 22.4, 22.3 and 22.2).

26.7 Refit the compressor/AV bracket assembly to the pump case (Refer to Page 13, Section 15.2,

15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts)).

27 Replacing the Coil Assembly

27.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2, 22.3 and 22.4).

27.2 Remove the ‘E’ stack/coil assembly as described in Section 26.2 and 26.3.

27.3 Disconnect the compressor electrical wires from the terminal block. Carefully cut the cable ties from the pneumatic tubing/cable loom as required.

27.4 Feed the compressor electrical wires through the compressor case cable grommet (Fig 13, Item 50).

27.5 Remove the ‘E’ stack/coil assembly from the compressor case (Fig 13, Item 60) and carefully separate the coil from the ‘E’ stack.

27.6 Replace the coil assembly by reversing the operations carried out in Section 27.5, 27.4, 27.3 and 27.2; fit new cable ties where required.

27.7 Fit a new silencer bag and gasket, then replace the compressor lid (Refer to Page 19 and reverse the operations carried out in Section 22.4, 22.3 and 22.2).

27.8 Refit the compressor/AV bracket assembly to the pump case (Refer to Page 13, Section 15.2,

15.3 and 15.4 (new style AV mounts) or Page 15, Section 17.3, 17.4 and 17.5 (old style AV mounts)).

28 Replacing the Compressor Assembly

28.1 Disconnect the compressor electrical wires as described in Section 27.3.

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Pump Repair Mini Pump Service Manual

28.2 Remove the compressor air inlet filter and clip from the ‘F’ tube connector, then disconnect the ‘F’ tube connector from the silencer bag outlet tubes (Refer to Page 11, Section 12.1, 12.2,

12.3 and 12.4).

28.3 Remove the compressor/AV bracket assembly from the pump case (Refer to Page 13, Section

14.1, 14.2 and 14.3 (new style AV mounts) or Page 15, Section 16.1, 16.2 and 16.3 (old style AV mounts)).

28.4 Remove the compressor mounting bracket (Refer to Page 17, Section 18).

28.5 Fit a replacement compressor assembly by reversing the actions detailed above.

40 80

Figure 14 - Pressure Control Module

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Mini Pump Service Manual Pump Repair

Table 18 - Pressure Control Module Part List

Item Part Number Description Qty

10 500347 Terminal Block 5 way 1

20 BP196 Cable Tie 2

30 500362 Tube Sil ID 3/16” 135 mm ± 5 mm LG 1

40 FAS145 Screw 3 Dia.x8mmPozi Pan Head PT 1

50 FAS223 Screw 3 Dia. x 10 mm Pozi Pan Head PT 3

60 500315 Panel Side Colder 1

70 500328 Panel Side Push On 1

80 151309 Fixing Cap 1

29 Replacing the Pressure Control Module

29.1 Remove the pressure control knob as described in Page 3, Section 2.

29.2 Remove the rear case assembly as described in Page 5, Section 6.

29.3 Remove the compressor wires (Fig 14, Item 10) from the terminal block (terminals 3 and 4). This also releases two switch wires.

29.4 Carefully cut the cables ties from the wiring loom as required (Fig 14, Item 20).

29.5 Remove the tube (Fig 14, Item 30) between the pressure control module and the ‘F’ connector.

29.6 Remove the module securing screw (Fig 14, Item 40) and the fixing cap (Fig 14, Item 80).

29.7 Carefully lift the module with the side panel attached from the pump case.

29.8 Disconnect the fuse wire from the terminal block (terminal 6) and disconnect the adjacent switch wire (terminal 5) (Fig 14, Item 10).

29.9 Disconnect the mains/power lead wires from the terminal block (terminals L and N) (Fig 14, Item 10).

29.10 Remove three screws (Fig 14, Item 50) and detach (pull off the pressure control module from the side panel assembly (Fig 14, Item 70).

29.11 Replacement is the reversal of the above procedures. Refer to the wiring diagram (Chap. 4, Fig 23 (electronic) or 24 (mechanical)) when reconnecting the wires to the terminal block.

Issue 2 Chap 3 Nov 2001 SER0004 Page 27

Pump Repair Mini Pump Service Manual

Figure 15 - Removing the Alarm Monitoring PCB

Table 19 - Removing the Alarm Monitoring PCB Part List

Item Part Number Description Qty

10 FAS083 Screw No. 6 x 5/16” Pozi Pan Head PT 1

20 500346 PCB Alarm Monitoring 230 V 1

500345 PCB Alarm Monitoring 100/120 V 1

30 N/A Signal Connectors REF

40 N/A Side Panel Slotted Mounts REF

50 N/A Lug REF

60 N/A PCB Power Wires Socket REF

Chap 3 Issue 2 Page 28 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

30 Replacing the Alarm Monitoring PCB

CAUTION : Electrostatic discharge can seriously damage the alarm monitoring PCB. Prior to

replacing or handling, adequate earth/grounding precautions must be taken.

Notes:1Itisnotnecessary to remove the side panel in order to replace the alarm monitoring PCB.

2 The alarm monitoring PCB is only applicable to electronic versions of the mini pump.

30.1 Remove the pressure control module as described in Page 27, Section 29.1 to 29.7.

30.2 Disconnect PCB power wires (Fig 15, Item 60) from PCB.

30.3 Disconnect the three signal connectors from the PCB (Fig 15, Item 30).

30.4 Remove the PCB securing screw (Fig 15, Item 10) and withdraw the PCB (Fig 15, Item 20).

30.5 Replacement is the reverse procedure to removal. Ensure that the PCB is seated in the two slotted mounts of the side panel (Fig 15, Item 40) and the lug (Fig 15, Item 50) on the pressure control module.

Issue 2 Chap 3 Nov 2001 SER0004 Page 29

Pump Repair Mini Pump Service Manual

Figure 16 - Replacing the Power Failure Alarm Battery

Table 20 - Battery (Power Failure Alarm) Part List

Item Part Number Description Qty

10 151457 Battery 1

20 N/A Cable Tie 1

30 N/A Battery Plug to PCB 1

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Mini Pump Service Manual Pump Repair

31 Changing the Battery

Caution : Electrostatic discharge can seriously damage the alarm monitoring PCB. Prior to

replacing or handling, adequate earth/grounding precautions must be taken.

Notes:1Itisnotnecessary to remove the side panel in order to change the battery.

2 The battery (power failure alarm) is only applicable to electronic versions of the mini pump.

31.1 Remove the PCB (Refer to Page 29, Section 30,).

31.2 Remove the battery plug (Fig 16, Item 30) from the PCB.

31.3 Cut and remove the cable tie (Fig 16, Item 20) and remove the battery (Fig 16, Item 10).

31.4 Replacement is the reverse procedure to removal.

Note : The cable tie must be renewed/replaced when changing the battery.

Issue 2 Chap 3 Nov 2001 SER0004 Page 31

Pump Repair Mini Pump Service Manual

ENS

THISSIE

Figure 17 - Replacing the Neon Indicator Light

Table 21 - Neon Indicator Part List

Item Part Number Description Qty

10 FAS083 Screw No. 6 x 5/16” Pozi Pan Head PT 1

20 500324 Plate Neon Mounting 1

30 500373 Neon Assembly Red 230 V 1

500371 Neon Assembly Red 110 V

Chap 3 Issue 2 Page 32 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

32 Replacing the Neon Indicator Light

Note : The neon indicator light is only applicable to the mechanical versions of the pump. The

electronic version of the pump has two red indicators, a green indicator and a yellow indicator. These are wired directly into the PCB and are replaced only by exchanging the complete PCB.

32.1 Disconnect the indicator lead from the terminal block (terminal 2) (Fig 14, Item 10).

32.2 Disconnect the indicator lead from the Micro switch (Fig 18, Item 10).

32.3 Release the screw (Fig 17, Item 20) attaching the neon mounting plate (Fig 17, Item 10) and remove the neon (Fig 17, Item 30) and mounting plate assembly.

32.4 Note the orientation of the components, unclip the neon (Fig 17, Item 30) from the lens and push the lens out of the mounting plate.

32.5 Replacement is the reverse procedure of the above. Ensure the correct orientation of components. Connect the wires to the terminal block and the Micro switch in accordance with the wiring diagram for the mechanical version of the pump unit (Chap. 4, Fig 25).

Issue 2 Chap 3 Nov 2001 SER0004 Page 33

Pump Repair Mini Pump Service Manual

Figure 18 - Replacing the Micro switch and Terminal Block

Table 22 - Micro switch and Terminal Block Part List

Item Part Number Description Qty

10 500338 Micro switch Sub Min 230 V/0.1A 1

20 FAS224 Screw 2.2 Dia. x 14 mm Pozi Pan Head PT 2

30 500347 Terminal Block 5 Way 1

40 FAS225 Screw 3 Dia. x 16 mm Pozi Pan Head PT 2

Chap 3 Issue 2 Page 34 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

33 Replacing the Microswitch

Note : It is not necessary to remove the pressure control module from the pump case.

33.1 Pull off connectors from the Micro switch terminals 1 and 3 (Fig 18, Item 10).

33.2 Release two screws (Fig 18, Item 20) and remove the Micro switch from the pressure control module.

33.3 Replacement is the reverse of the above procedure.

34 Replacing the Terminal Block

Note : It is not necessary to remove the pressure control module from the pump case.

34.1 Disconnect all wires from the terminal block (Fig 18, Item 30).

34.2 Release two securing screws (Fig 18, Item 40) and remove the terminal block from the pressure control module.

34.3 Replacement is the reversal of the above procedure. Refer to the wiring diagram (Chap. 4, Fig 24) when reconnecting the wires for the electronic version of the pump and wiring diagram (Chap. 4, Fig 25) when reconnecting the wires for the mechanical version of the pump.

Issue 2 Chap 3 Nov 2001 SER0004 Page 35

Pump Repair Mini Pump Service Manual

(Aura Pumps Only)

100

Figure 19 - Pressure Control Flaps, Air Bag, Control Knob Cam and Arbour

Table 23 - Pressure Control Flaps, Air Bag, Control Knob Cam and Arbour Part List

Item Part Number Description Qty

10 500304 Knob Control Arbour 1

20 500312 Upper Pressure Control Flap 1

30 500318 Pivot Pin, Pressure Control 1

40 500303 Lower Pressure Control Flap 1

50 500341 Spring 0,024” Diameter 1

60 151339 Pressure Control Disc 1

70 PRE022 Rubber Valve Disc 1

80 500103 Bag Pressure with Restrictor Assembly 1

90 500355 Screw M3 x16 mm Socket Cap Hd Black 1

100 403306 Restrictor (Aura Pumps Only) 1

Chap 3 Issue 2 Page 36 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

35 Replacing the Pressure Control Flaps and Air Bag

35.1 Turn the control knob arbour fully counter-clockwise (Fig 19, Item 10). Hold the upper pressure control flap (Fig 19, Item 20) in position and withdraw the pivot pin (Fig 19, Item 30). Carefully remove the upper flap and the lower flap (Fig.19, Item 40) together with the low pressure operating spring and brass disc (Fig 19, Items 50 and 60).

35.2 Remove and discard the pressure control disc (Fig 19, Item 70) from the upper flap. Replace with new item.

35.3 Remove and discard the air bag assembly (Fig 19, Item 80). Replace with a new item. Ensure the air bag is secure by pushing in the centre and rotate it slightly to ensure it is seated.

35.4 Ensure that the low pressure adjustment screw (Fig 19, Item 90) is fully disengaged. Carefully locate the brass disc (Fig 19, Item 60), boss uppermost in the rebate in the upper flap. Locate the spring (Fig 19, Item 50) on the disc and position the lower flap (Fig 19, Item 40) against the spring.

35.5 Refitting is the reverse of the above procedure. When refitting, hold the group of components together and position them on the pressure control module. Insert the pivot pin (Fig 19, Item

30) to retain the flaps.

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Pump Repair Mini Pump Service Manual

NEW

OLD

Figure 20 - Control Knob Cam and Arbour

Table 24 - Control Knob Cam and Arbour Part List

Item Part Number Description Qty

10 FAS225 Control Adjustment Screw, 3 Dia x 16 mm Pozi Pan Head PT 1

20 500305 Knob Control Cam 1

30 500411 Cup Arbour Drive Spring 1

40 500339 Spring Comp 1.07 Diameter 1

50 500349 Pressure Assembly Module 1

60 500304 Knob Control Arbour 1

Chap 3 Issue 2 Page 38 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

36 Replacing the Pressure Control Assembly

Note:Itisnot necessary to remove the side panel assembly from the pressure control module.

36.1 Remove the pressure control module from the pump case as described in Section 29.

36.2 Remove the pressure control flaps as described in Section 35.

36.3 Release the control adjustment screw on the control knob arbour (Fig 20, Item 10).

36.4 Carefully remove the arbour, cam, spring cup and spring (Fig 20, Items 20, 30 and 40).

36.5 Renew/replace components with the same type.

Note : Early versions may have a nylon washer in lieu of the spring cup. Discard the washer and

replace with the cup.

36.6 Replacement is the reverse of the above procedure. Refit the pressure control flaps as described in Section 35.

Note : The new control knob arbour will NOT fit the old pressure assembly module because of the

moulded wall on the old pressure assembly module. The old control knob abour will fit both.

Issue 2 Chap 3 Nov 2001 SER0004 Page 39

Pump Repair Mini Pump Service Manual

110

100

Figure 21 - Synchronous Motor (Gearbox), Rotor/Stator Assembly

Table 25 - Synchronous Motor (Gearbox), Rotor/Stator Assembly Part List

Item Part Number Description Qty

10 FAS223 Screw 3 Dia x 10 mm Pozi Pan Head 2

20 500097 Gearbox 240V and Ferrule Assembly 1

500098 Gearbox 120V and Ferrule Assembly 1

500099 Gearbox 100V and Ferrule Assembly 1

151409 Motor Gearbox 100V, 50 Hz, 1/10 RPM 1

30 500308 Rotor Module 1

40 500307 Stator Module 1

50 500332 Felt Rotor Silencer 1

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Mini Pump Service Manual Pump Repair

Table 25 - Synchronous Motor (Gearbox), Rotor/Stator Assembly Part List (continued)

Item Part Number Description Qty

60 500319 Stator Gasket 1

500418 Stator Gasket (Restricted) 1

70 500356 Rotor Drive Cup 1

80 500322 Pin Rotor Drive 1

90 500354 Washer Starlock O/D 21 mm 1

100 500358 Spring Comp 1.6 Diameter FL 22.36 1

110 TIM017 Oil Seal Cap 1

37 Replacing the Synchronous Motor (Gearbox), Rotor Stator Assembly

Note:Itisnot necessary to remove the side panel assembly from the pressure control module.

37.1 Remove the pressure control module from the pump case as described in Section 29.

37.2 Remove any relevant cable ties.

37.3 Identify the synchronous motor electrical lead from the terminal block (terminals 1 and 2) (Fig 18, Item 30). remove the relevant cable ties and release the synchronous motor electrical lead.

37.4 Remove the two screws securing the gearbox motor (Fig 21, Item 10).

37.5 Carefully remove the synchronous motor, rotor and stator (Fig 21, Items 20, 30 and 40) from the pressure control module. Remove the felt rotor silencer (Fig 21, Item 50) from the rotor. Remove the stator gasket (Fig 21, Item 60) from the pressure assembly module.

37.6 Depress the motor drive cup (Fig 21, Item 70) toward the motor and remove the drive shaft pin (Fig 21, Item 80).

37.7 Carefully remove the rotor drive cup, star washer (Fig 21, Item 90), spring (Fig 21, Item 100) and oil seal cap (Fig 21, Item 110) from the motor.

37.8 Replace any faulty parts with same type.

37.9 Discard the stator gasket and replace with a new one before reassembly.

37.10 Replacement is the reverse of the above procedure. Ensure that the stator is correctly located in the key and cables are secured with relevant cable ties.

Issue 2 Chap 3 Nov 2001 SER0004 Page 41

Pump Repair Mini Pump Service Manual

BROWN

ORANGE

Figure 22 - Replacement of the Side Panel On/Off Switch

Table 26 - Side Panel On/Off Switch, Mains/Power Lead and Fuses Part List

Item Part Number Description Qty

10 500351 Switch Mains/Power Rocker 230 V Black (All electronic pumps) 1

500343 Switch Mains/Power Rocker 230 V Green (Illuminated) 1

500359 Switch Mains/Power Rocker 110 V Green (Illuminated) 1

20 198315 Grommet 1

30 BP532 Cordset Standard Moulded UK (Cable) 1

CAS041 Mains/Power Cable - European “Shuko” Socket 1

BP087 Mains/Power Cable - USA 2 pin 1

CAS020 Mains/Power Cable - Japan 2 pin 1

BP171 Mains/Power Cable - Australia 1

40 500344 Fuse Holder 1

50 CAS011 Fuselink 20x5mm500mAQB 1

Chap 3 Issue 2 Page 42 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

38 Replacing the Side Panel Mains/Power On/Off Switch

38.1 Remove the pressure control module and remove the side panel as described in Section 29.

38.2 Pull off the electrical connections from the On/Off switch (Fig 22, Item 10).

38.3 Squeeze together the retaining flanges located on either side of the switch body and push the switch through the side panel.

38.4 Replace the switch with same type. Ensure correct orientation of the switch (symbol nearest the fuse). Ensure that the retaining flanges snap into position. Refer to the wiring diagram (Chap. 4, Fig 23) when reconnecting the electrical wires for the electronic version of the pump and (Chap. 4, Fig 24 ) when connecting the electrical wires for the mechanical version of the pump.

39 Replacing the Side Panel Mains/Power Lead

39.1 Remove the pressure control module, and remove the side panel as described in Section 29.

39.2 Carefully withdraw the mains/power lead (Fig 22, Item 30) through the mains lead/power cord grommet.

39.3 Carefully withdraw the mains/power lead grommet (Fig 22, Item 20) through the side panel.

39.4 Replace the lead with the same part number. Replacement is the reverse of the above procedure. Ensure adequate cable length so that wires are not strained.

WARNING:

WHEN AN UNSERVICEABLE MAINS/POWER LEAD FITTED WITH A NON-REWIREABLE PLUG IS REMOVED FROM THIS EQUIPMENT, THE LEAD/CORD AND THE PLUG MUST BE DESTROYED AND DISPOSED OF SAFELY. TO AVOID THE DANGER OF ELECTRIC SHOCK THE PLUG MUST NEVER BE INSERTED IN ANY POWER OUTLET.

40 Replacing the Fuses

Note : The side panel assembly is supplied complete with fuse holder fitted. The fuse holder is not a

replaceable item.

40.1 To replace the pump fuse undo the fuse holder (Fig 22, Item 40) and remove the fuse (Fig 22, Item 50). Replace with fuse of same type.

40.2 To replace the mains/power lead plug fuse in moulded plugs use a small bladed electrical screwdriver and carefully lever off the fuse cover on the pin side of the plug. Replace with fuse of same type.

Issue 2 Chap 3 Nov 2001 SER0004 Page 43

Pump Repair Mini Pump Service Manual

20Part

10Part

Figure 23 - Snap-lock Connectors

Table 27- Snap-lock Connectors

Item Part Number Description Qty

10 500350 Connector Panel, Female 1/4” Flow 1

20 504316 Connector Panel, Male 1/4” Flow 1

30 500361 Tube Sil Blue ID 6 OD 10 24 LG ± 1 1

40 500360 Tube Sil Blue ID 6 OD 10 15 LG ± 1 1

Chap 3 Issue 2 Page 44 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

41 Replacing the Snap-lock Connectors

Note : Older versions have a pump connectors moulded within the side panel and are not

replaceable.

41.1 Remove pressure control module with side panel (Refer to Section 29.1 to 29.7)

41.2 Refer to Fig 15, disconnect the three signal connectors (Fig 15, Item 30 ) and the power wires from the PCB.

41.3 Remove screw (Fig 15, Item 10) and remove the PCB.

41.4 Undo locknut and withdraw connector through side panel with tube.

41.5 Remove tube from connector.

41.6 Replace with the same type. Replacement is the reverse of the above procedure. Ensure that the snap lock release clip on the female (lower) connector is pointing toward the rear of the case. Make sure the locknut is on the pressure module before the connector and tube is inserted.

Issue 2 Chap 3 Nov 2001 SER0004 Page 45

Pump Repair Mini Pump Service Manual

42 Removing the Front Case

42.1 Remove the pressure control knob (Page 3, Section 2).

42.2 Disassemble the rear case (Page 5, Section 6).

42.3 Remove the screw and the fixing cap (Refer to Fig 14, Items 40 and 80) from the pressure control module.

42.4 Remove the pressure control module, together with the side panel, and the compressor from the front case (Fig 2, Item 40).

43 Installing the Front Case

43.1 For Aura, AlphaXcell, AlphaTrancell ALT01-09, fit the pin (Fig 2, Item 30) to the new front case.

Note : For Alpharelief, Alphabed, Alphacare and AlphaTrancell ALT10 pumps, the pin is not needed.

This allows 270° movement of the Pressure Control Knob.

43.2 Fit a front label to the front case (Refer to Table 28 for the correct label set).

43.3 Install the pressure control module, together with the side panel, and the compressor in the front case.

43.4 Install the fixing cap and the screw (Refer to Fig 14, Items 80 and 40) to the pressure control module.

43.5 Assemble the rear case (Page 5, Section 7).

43.6 Install the pressure control knob (Page 3, Section 3).

43.7 Fit rubber feet to the base of the front case (Fig 4, Item 50).

Chap 3 Issue 2 Page 46 SER0004 Nov 2001

Mini Pump Service Manual Pump Repair

44 Pump Label Sets

The following table gives the part numbers for the pump label sets:

Table 28 - Pump Label Sets

Part Number Description Qty

AlphaXcell

Series

500386 Label set UK - AlphaXcell (ALX01) 1

500387 Label set Germany - AlphaXcell (ALX02) 1

500388 Label set USA - AlphaXcell (ALX03) 1

500389 Label set Euro - AlphaXcell (ALX04) 1

500390 Label set France - AlphaXcell (ALX05) 1

500391 Label set Japan - AlphaXcell (ALX06) 1

500392 Label set Italy - AlphaXcell (ALX017) 1

500393 Label set Australia - AlphaXcell (ALX08) 1

500394 Label set Rest of the World - AlphaXcell (ALX09) 1

500395 Label set Holland - AlphaXcell (ALX10) 1

500472 Label set Rest of the World - AlphaXcell (ALX11) 1

AlphaBed

Series

500397 Label set UK - AlphaBed (ALB01) 1

500398 Label set Euro - AlphaBed (ALB04) 1

500441 Label set Poland - AlphaBed (ALB04 - PL) 1

500399 Label set Australia - AlphaBed (ALB08) 1

500400 Label set Rest of the World - AlphaBed (ALB09) 1

Alpha Trancell

Series

500412 Label set UK - Alpha Trancell (ALT01) 1

500396 Label set Germany - AlphaTrancell (ALT02) 1

500414 Label set Holland - Alpha Trancell (ALT10) 1

500440 Label set Poland - Alpha Trancell (ALT01-PL) 1

Issue 2 Chap 3 Nov 2001 SER0004 Page 47

Pump Repair Mini Pump Service Manual

Table 28 - Pump Label Sets (continued)

Part Number Description Qty

Alpha Relief

Series

500475 Label set UK - Alpha Relief (ALR01) 1

500478 Label set Germany - Alpha Relief (ALR02) 1

500470 Label set USA - Alpha Relief (ALR03) 1

500476 Label set Euro - Alpha Relief (ALR04) 1

AlphaCare

Series

500401 Label set USA - AlphaCare (ALC03) 1

500402 Label set Euro - AlphaCare (ALC04) 1

500473 Label set Japan - AlphaCare (ALC06) 1

Aura Series

500474 Label set UK - Aura (ALS01) 1

500479 Label set USA - Aura (ALS03) 1

500477 Label set Euro - Aura (ALS04) 1

Chap 3 Issue 2 Page 48 SER0004 Nov 2001

Mini Pump Service Manual Troubleshooting

CHAPTER 4

TROUBLESHOOTING

1 General

This section details some problems which may occur after a long period of use and the appropriate procedures to correct them.

The Alpha Relief, Aura and AlphaXcell (electronic) pump units are fitted with a visual and audible alarm for LOW PRESSURE and POWERFAIL alarm conditions. The alarm for the AlphaBed, Care and Trancell (mechanical) pump units are limited to a visual red LOW PRESSURE (!) lamp indicator. The alarm automatically resets when the operating pressure is regained. See Table 4 for details of the each product’s visual indicators.

Table 29 gives a quick reference to common problems, possible causes and actions. Refer to the table first when carrying out troubleshooting on a pump.

Table 29 - Troubleshooting

Problem Possible Cause Action

Mattress/Seat not Inflating.

Applicable to all pumps.

Low pressure alarm.

Applicable to all pumps.

Wait indicator does not go out not allowing the system to pressurize.

Applicable to:

ALR 01-10 ALX 01-10

1. CPR not inserted (mattress only). Check CPR (See Mattress Service Manual SER0005).

2. Tubes kinked. Check.

3. Pump not switched on. Check.

4. No pump output. Check. See ‘Pump not operating’ below.

5. Tubes not correctly fitted. Check.

1. CPR not inserted (mattress only). Check CPR (See Mattress Service Manual SER0005).

2. Tubes not correctly fitted. Check.

3. Leakage. Check (See Mattress Service Manual SER0005).

1. CPR not inserted (mattress only). Check CPR (See Mattress Service Manual SER0005).

2. Tubes not correctly fitted. Check.

3. Leakage. Check CPR (See Mattress Service Manual SER0005).

Mains/Power Fail

indicators (audible and visual) are active.

Applicable to:

ALR 01-10 ALX 01-10 ALS 01-10

Issue 2 Chap 4 Nov 2001 SER0004 Page 1

1. Mains/power failure has occurred. Check.

2. The mains/power lead has been

removed from the wall socket.

Check.

Troubleshooting Mini Pump Service Manual

Table 29 - Troubleshooting (continued)

Problem Possible Cause Action

Mains/Power Fail indicator

remains illuminated but there is no audible alarm.

Applicable to:

ALR 01-10 ALX 01-10 ALS 01-10

Pump is very noisy and/or is causing excessive vibration.

Applicable to all pumps.

Pump not operating

Applicable to all pumps.

There has been a mains/power failure but power has been restored.

System is damaged or dirty. 1. Check compressor

1. Pump run switch not on. Switch on.

2. Plug not inserted correctly. Check.

3. Fuse blown. Replace the fuse (Refer to

Check if electrical plug is correctly fitted and if pump is running correctly.

mounts for wear (Refer to Ch 3, Pg 13).

2. Check compressor is

not loose on its mounting plate (Refer to Ch 3, Pg 17).

3. Check the compressor

bellows are not split (Refer to Ch 3, Pg 21).

Ch 3, Pg 43).

4. Loss of output pressure. Refer to Section 2 and 3 below.

All indicators/lights remain illuminated on initial switch-on.

Applicable to:

ALR 01-10 ALX 01-10 ALS 01-10

Internal fault Test the pump (Refer to

Ch 5).

Check PCB.

2 Low Pressure fault indicated (checks without dismantling the pump)

Check the following before dismantling the pump unit.

Perform the pressure, flow and low pressure alarm tests as specified in Chap. 5 (Testing). If the results are satisfactory, the mattress is at fault.

Note : All testing must be done when pumps are warm, ie. they have been running with closed ports

for at least 1 hour.

Check:

2.1 All tubing connections on pump and mattress are securely fastened and snap locked into place.

2.2 Check that the rapid deflate stopper or CPR is fitted correctly (Refer to Mattress Service Manual, SER0005).

Chap 4 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Troubleshooting

2.3 If the alarm still indicates, visually inspect tubing and mattress cells for punctures or tears and check they are fitted to the manifold correctly. Refer to the mattress service manual SER0005 for full details.

WARNING:

DANGER OF ELECTRIC SHOCK. DURING THE FOLLOWING TESTS, LIVE TERMINALS AND CONDUCTORS MAY BE EXPOSED. EXERCISE EXTREME CAUTION.

3 Loss of Output Pressure (checks by dismantling the pump)

If the low pressure alarm operates when both pump outlets are blocked or the pump does not pass the flow test in Chapter 5 (Testing), the pump unit internal compressor should be tested as follows:

3.1 Remove the rear case (Refer to Chap 3, Page 5).

3.2 Disconnect the white pneumatic tube from the compressor F-Tube connector.

3.3 Connect the pressure gauge to the compressor F-Tube connector and switch the pump unit on. The pressure reading should be at least 100 mmHg.

3.4 If the pressure does not reach 100 mmHg, the compressor is at fault. Either replace the compressor or remove the compressor lid, remove the silencer bag from the valve bodies and connect the pressure gauge to each valve body in turn. The pressure should be approximately 100 mmHg in each case. (Refer to Chap 3, Section 22).

3.5 If the required pressure cannot be reached then the bellows/armature assemblies and valve bodies must be replaced (Refer to Chap 3, Section 23). If the required pressure is obtained then the silencer bag must be replaced. (Refer to Chap 3, Section 22).

Note : The flow/pressure performance of a compressor may be altered by heating the new bellows

and adjusting the ‘E’ stack gap.

3.6 If the compressor is operating correctly but the correct pressure cannot be obtained at the pump outlet then the rotor/stator, pressure control module and snap-lock connectors must be checked. Reassemble the compressor and attach pressure rig to pump outlet again.

3.7 Remove the gearbox and rotor/stator, clean all dust off rotor/stator and reassemble with new gasket. If rotor/stator is chipped or damaged, replace components (Refer to Chap 3, Section

37). If this does not correct the problem, check the pressure control.

3.8 Push on the pressure control flap (Fig 19, Item 20) to press the seal (Fig 19, Item 70) against the valve seat. Check the pressure control bag inflates fully and pushes on the flap, if not, the bag could be split - check and replace as necessary.

3.9 If the snap-lock connectors or tubing show signs of damage, replace. If there is still a problem, re-check in the following order:

•

compressor

•

rotor/stator assembly

•

pressure control assembly

•

connections

If pressure/flow still cannot be achieved, return pump to Service department.

Issue 2 Chap 4 Nov 2001 SER0004 Page 3

Troubleshooting Mini Pump Service Manual

4 Low Pressure Alarm Fault

If the low pressure alarm does not function correctly after recalibration as described in Chap. 5 (Testing), check:

4.1 The electrical connections and leads between the low pressure micro-switch and the printed circuit board.

4.2 Check that switch is operating and n/o terminals (1-3) are in use.

4.3 Check free movement of lower flap.

4.4 Check low pressure switching point with an external pressure meter.

4.5 Check the pressure control module for leaks.

4.6 Check the location and orientation of low pressure spring and disc by removing upper and lower flaps.

5 Air Not Alternating (continuous pressure fault)

Should the cells of the mattress not inflate and deflate during a 10-minute cycle, then the timer motor may be defective (not rotating).

5.1 Check the timer motor electrical connections for security and integrity. If all are sound and the timer motor still does not rotate, then the timer motor must be replaced.

Notes : The timer motor is a sealed unit and cannot be repaired.

When replacing the timer motor it is advisable to replace the stator gasket at the same time. Refer to Chap. 3 (Pump Repair).

6 Loss of Electrical Power

Power loss can be due to any of the following:

6.1 No electricity supply at wall socket.

6.2 Faulty wall socket.

6.3 Damaged plug or mains/power cable.

6.4 Defective fuse link in pump or plug.

6.5 Damaged internal wiring.

6.6 Loose connections at the terminal block, micro-switch or PCB.

6.7 Faulty PCB component.

Chap 4 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Troubleshooting

7 Circuit Diagrams

The circuit diagram for the electronic models is given in Fig 24. The circuit diagram for mechanical models is given in Fig 25. Check for the above faults against the relevant circuit and repair as appropriate.

Mains/Power

Lead

Live Neutral

Gearbox

Terminal Block

Compressor

Fuse

Mains/Power

Switch

1A 3B

2A 4B

Microswitch

Sounder

PCB

Figure 24 - Circuit diagram for Alpha Relief, Aura and AlphaXcell (Electronic) Mini Pumps

Issue 2 Chap 4 Nov 2001 SER0004 Page 5

Troubleshooting Mini Pump Service Manual

Mains/Power

Lead

Microswitch

Live Neutral

Neon

Terminal Block

Gearbox

Fuse Mains/Power Switch

2A4B

1A3B

Compressor

Figure 25 - Circuit diagram for AlphaXcell, AlphaBed, AlphaCare and Alpha TranCell

(Mechanical) Mini Pumps

Chap 4 Issue 2 Page 6 SER0004 Nov 2001

Mini Pump Service Manual Testing

CHAPTER 5

TESTING

1 Pump Flow, Pressure and Function Test

This procedure must be carried out after a service or major repair of a pump. To test/calibrate the pump unit correctly, the following equipment or equivalent is required:

Table 30 - Pump Flow, Pressure and Function Test Equipment

Equipment Part Number

Typical Test Kit (including):- PRE 060

Digital Manometer (pressure gauge) 0-199 mmHg, resolution 0.1, accuracy ± 0.2% of range.

Flowmeter 0-10 litre/minute, resolution 0.2, accuracy ± 2% of measured value.

Battery, 9V Lantern

Male Connector BP431

Female Connector BP432

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

Flow and Pressure Checks

1.1 Connect the flowmeter, via a valve, to whichever outlet is working. Connect the pressure gauge to measure the pressure at the outlet.

1.2 Open the valve fully. The free flow rate should not be less than specified in Table 31.

Table 31 - Minimum Flow Rates

AlphaBed AlphaCare Alpha Trancell Alpha Relief Aura AlphaXcell

Pump

Airflow at

20 mmHg (ltr/min)

6 6 6 6

3.25 6

Airflow at

50 mmHg (ltr/min)

3 3 3 3

2.25 3

1.3 Close the valve and operate the pressure control knob on the pump from minimum to maximum setting. The pressure indicated on the gauge (in mmHg) should be as specified in Table 31.

Issue 2 Chap 5 Nov 2001 SER0004 Page 1

Testing Mini Pump Service Manual

PRESSURE ADJUSTMENT SCREW

MINI PUMP

Stop Pin (If fitted)

DAMPER (FOR EVEN FLOW)

MANOMETER (mmHg)

9V BATTERY

FLOW METER

Figure 26 - Typical Test Rig setup for Mini Pumps

Chap 5 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Testing

Table 32 - Pressure Range

Pump Min. (mmHg) Max. (mmHg)

AlphaBed

AlphaCare

Alpha Trancell

ALT01-09

ALT10

Alpha Relief

Aura

AlphaXcell

If the pressure readings are incorrect then calibrate the pressure control as described below.

Calibration

1.4 If the pressure readings are incorrect then calibrate the pressure control as follows:

1.4.1 Turn the pressure control knob to the minimum setting.

1.4.2 Using a small, flat bladed screwdriver, carefully remove the pressure control knob. Be

careful not to move the arbour.

1.4.3 Rotate the screw in the centre of the pressure control arbour (counter-clockwise to

increase) until the indicated pressure is as specified in Table 33.

30±5

22±2

85±2

22±2

90±10

73±8

90±10

82±10

< 110

65±8

Note : Ensure that the pressure control arbour does not move.

Table 33 - Indicated Pressure

Pump Indicated Pressure

AlphaBed

AlphaCare

Alpha Trancell

Alpha Relief

Aura

AlphaXcell

1.4.4 Carefully replace the pressure control knob, ensuring that the control knob rotation is

limited between the minimum setting and the stop pin (if fitted).

1.4.5 Check the indicated pressure at minimum and maximum settings (Refer to Table 32)

and readjust if necessary.

1.4.6 Variation between the ports is to be no greater than 4 mmHg.

1.4.7 Attach the flow meter tube to whichever outlet is the duty port and check the free flow

again. The flow readings should be as specified in Table 31. Variation between the ports is to be no greater than 1 litre/minute.

30 mmHg

22 mmHg

55 mmHg

22 mmHg

Set at dead

centre value

Issue 2 Chap 5 Nov 2001 SER0004 Page 3

Testing Mini Pump Service Manual

Low Pressure Indicator Test (Mechanical Units Only)

1.5 With the test equipment set up as in Section 1.1, set the pressure control knob in the mid position and use the flowmeter valve to adjust the pressure slowly up and down.

1.6 Observe the LOW PRESSURE warning light to indicate the operation of the Micro switch.

1.7 The micro switch should activate at or before the pressure reaches 5 mmHg descending and deactivate at or before the pressure reaches 20 mmHg ascending.

Low Pressure Indicator Test (Electronic units only)

WARNING

DANGER OF ELECTRIC SHOCK. DURING THE FOLLOWING TESTS, LIVE TERMINALS AND CONDUCTORS MAY BE EXPOSED. EXERCISE EXTREME CAUTION.

Note: Pump units fitted with an alarm monitoring PCB should have the low pressure alarm

settings tested within 60 seconds of switching the pump on.

1.8 Remove the rear case assembly (Refer to Chap 3, Section 6).

1.8.1 Fit snap-lock connectors to both outlet ports. Connect the pressure gauge and a

bleed valve to the duty port.

1.8.2 Connect a buzzer or LED to the microswitch terminals to indicate microswitch

operation (see Chap 4, Fig 24 for microswitch terminal connections).

1.8.3 Ensure that the bleed valve is fully closed, Ensure that the low pressure adjustment

screw (on the upper flap) is fully disengaged. Turn the arbour clockwise and counter-clockwise over the full range three or four times. Leave it in the fully counter-clockwise position.

1.8.4 Turn the pressure control knob until the indicated pressure is 50 mmHg (maximum

setting for Aura models only).

1.8.5 Open the bleed valve to induce a leak, until the pressure is 10 mmHg (60 mmHg for

Aura models only).

1.8.6 The microswitch should activate before the pressure reaches X mmHg descending

and deactivate before the pressure reaches Y mmHg ascending, as specified in Table 34.

1.8.7 Set the low pressure adjustment screw so that the microswitch activates at this set

level. Do this very slowly. Adjust the pressure up and down by means of the bleed valve and verify that the microswitch goes on and off accordingly.

1.8.8 Replace the rear cover (Refer to Chap 3, Section 7).

Chap 5 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Testing

Table 34 - Descending and Ascending Pressures

Pump Pressure X Pressure Y

AlphaBed

AlphaCare

Alpha Trancell

Alpha Relief

Aura

AlphaXcell

5 mmHg

50 mmHg

5 mmHg

2 Electrical Testing

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

Table 35 - Electrical Test Equipment

Equipment

Insulation resistance tester (Megger) 500 Vdc

Portable appliance tester

Multimeter/Continuity tester

Dielectric strength tester (Flash tester) 3.0 kVac with current limit

17 mmHg

82 mmHg

17 mmHg

Electrical Safety Checks – Class ll

There are several electrical safety checks that must be carried out after breakdown repairs, rental re-checks 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 2 MW. This test can be conducted by using a Portable Appliance Tester. Also check the continuity of the mains cable.

Dielectric Strength Test (Flash Test)

This test shows the response of the insulation to high ac-voltage stress, to the effects of the capacitive current and gives an early warning of any electrical problems developing in the appliance.

Leakage Circuit Test (USA)

Measure the risk currents in accordance with the ANSI-AAMI ESI-1993 Standard (American National Standard Safe Current Limits for Electromedical Apparatus) or as specified in UL 2601-1.

Issue 2 Chap 5 Nov 2001 SER0004 Page 5

Testing Mini Pump Service Manual

WARNINGS:

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.

THIS EQUIPMENT SHOULD NOT BE USED IF YOU HAVE A HEARING AID OR PACEMAKER FITTED, DUE TO THE POSSIBILITY OF ELECTROMAGNETIC DISTURBANCE.

Specification: 3.0 kVac is applied between the connected Live and Neutral wires and the appliance’s metal compressor assembly box. No breakdown should occur.

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 completed.

3 PCB Functional Tests (Electrical Units Only)

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

Test Setup and Initial Switch On

3.1 Install the mating parts of the snap-lock connectors on the pump outlets so that both outlets are open to atmosphere. Set the pressure control knob fully counterclockwise.

3.2 Connect the mains/power cable to a suitable power socket outlet and then set the run/standby switch to ‘run’. All four indicator lights should illuminate and the audible alarm should sound for about 3 seconds. The green ON indicator, the amber WAIT indicator and the LOW

PRESSURE indicator will remain on. The POWER FAIL indicator light should extinguish.

Power Fail Alarm Check

3.3 With the pump operating, disconnect the power supply at the power socket outlet then reconnect it after 4 seconds. Verify that no alarms are given and normal operation is resumed.

3.4 Again disconnect the power supply at the power socket outlet. Verify that, after 5 seconds, the red POWER FAIL indicator flashes in conjunction with the audible alarm. The WAIT indicator should go off when the POWER FAIL alarm indicator flashes. Reconnect the power supply. Verify that the POWER FAIL indicator is extinguished.

3.5 Operate the run/standby switch to ‘standby’ and verify that all indicators are off. After 5 seconds, operate the switch back to ‘run’. Verify that all alarm indications are cleared and normal operation is resumed. Operate the run/standby switch to ‘standby’.

Low Pressure Alarm Check

3.6 Use suitable sealing caps to close the ports. Operate the run/standby switch to ‘run’. Verify that, after 1 minute, the WAIT indicator is extinguished.

3.7 Open both ports to atmosphere. Verify that, after 4 minutes and 45 seconds, the red LOW PRESSURE indicator flashes in conjunction with the audible alarm.

3.8 Operate the run/standby switch to ‘standby’ and back to ‘run’. Verify that all alarm indications are cleared and normal operation is resumed.

Chap 5 Issue 2 Page 6 SER0004 Nov 2001

Mini Pump Service Manual Testing

4 Functional Tests (Mechanical Units Only)

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

Test Setup and Initial Switch On

4.1 Set the pressure control knob fully counter-clockwise and ensure that both 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 to close both outlet ports and verify that the LOW PRESSURE indicator goes off.

Issue 2 Chap 5 Nov 2001 SER0004 Page 7

Testing Mini Pump Service Manual

Chap 5 Issue 2 Page 8 SER0004 Nov 2001

Mini Pump Service Manual Technical specification

CHAPTER 6

TECHNICAL SPECIFICATION

Pump Models

The pump models covered in this series are:-

Alpha Relief

•

Aura

•

AlphaXcell (Electronic)

•

AlphaXcell (Mechanical)

•

AlphaBed

•

AlphaCare

•

Alpha Trancell

•

Notes : Each model has a three letter code. For example, the Alpha Relief pump has the code ALR.

Following the three letter code is a two digit code representing customer country’s power supply system. For example, the Alpha Relief pump is available to countries 01, 02, 03 and 04 (UK, Germany, USA and Europe-general respectively).

A complete breakdown of the pump model three letter codes and two digit codes is given in Chap. 1, Tables 1 and 2.

Size

All pumps are 248 x 160 x 116 mm (9.8 x 6.3 x 4.6 inches).

Weight

All pump models are 2.75 kg (6 lb).

Pressure Ranges

Model Min (mmHg) Max (mmHg)

Alpha Relief 22 ± 2 82 ± 10

Aura 85 ± 2 <110

AlphaXcell 22 ± 2 65 ± 8

AlphaBed 30 ± 5 90 ± 10

AlphaCare 30 ± 5 90 ± 10

Alpha Trancell

ALT01-09

30±5 73±8

Alpha Trancell

ALT10

Issue 2 Chap 6 Nov 2001 SER0004 Page 1

30±5 90±10

Technical specification Mini Pump Service Manual

Cycle Time

The cycle time for all pump models is 10 minutes.

Rated Voltages

The voltage ratings for each of the customer (two digit) codes is given in Chap. 1, Table 2.

Rated Frequency

The mains/power frequency ratings for each of the customer (two digit) codes is given in Chap. 1, Table 2.

Rated Input Power

The rated input power for all pump models is 14 VA.

Running Time

All pump models are designed for continuous consumption.

Test Standards

All pumps are tested to:

Europe En 60601-1

USA UL 2601-1 (Classified by Underwriters Laboratories Inc.

) with respect to electric

shock, fire and mechanical hazards only in accordance with UL 2601-1.

Canada CSA C22.2 No. 601-1 (Classified by Underwriters Laboratories Inc.

) with respect to electric shock, fire and mechanical and other hazards only in accordance with CAN/CSA C22.2 No. 601.1.

For the AlphaBed, AlphaCare and Alpha Trancell pumps, standards BS 5724 (part 1) 1989 and VDE 0750: Teill also apply.

Protection Class

The protection class for all pump models is Class ll, type BF. The pumps are not protected against the ingress of water.

Indicator Lights

The Alpha Relief, Aura and AlphaXcell (electronic) have four indicator lights:

Power On Wait (except Aura) Low Pressure Power Fail

The AlphaXcell (mechanical), AlphaBed, AlphaCare and Alpha Trancell have one indicator light:

Low Pressure

Chap 6 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Technical specification

Environmental Conditions

Operating conditions for all models:

Temperature range: +10° C to +40° C Relative humidity: 30% to 75% Atmospheric pressure: 700 hPa to 1060 hPa

Storage conditions for all pump models:

Temperature range: -40° C to +70° C Relative humidity: 10% to 100% (non-condensing) Atmospheric pressure: 500 hPa to 1060 hPa

Disposal: All units must be disposed of in accordance with local environmental regulations.

Issue 2 Chap 6 Nov 2001 SER0004 Page 3

Technical specification Mini Pump Service Manual

Chap 6 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Parts list

CHAPTER 7

PARTS LIST

Part Number Description Fig-Item Qty

Front and Rear Case

500316 Front Case 2 - 40 1

500318 Pin (if fitted) 2 - 30 1

500484 Control Knob (MK2) 2 - 10 1

500304 Knob Arbour 2 - 20 1

500317 Rear Case 3 - 30 1

500340 Felt Filter 3 - 10 1

500327 Filter Plate 3 - 20 1

FAS223 Pan Head Screw PT 3 Dia x 10 Pozi 3 - 40 1

FAS225 Pan Head Screw PT 3 Dia. x 16 Pozi 3 - 50 4

500495 Bed Hook (New Style) 4 - 10 1

500496 Hook Plate (Left Hand) 4 - 20 1

500497 Hook Plate (Right Hand) 4 - 30 1

FAS223 Pan Head screw PT 3 Dia. x 10 4 - 40 8

500381 Rubber foot 4 - 50 8

Label Sets (See Chap 3, Page 47, Table 28)

Compressor Assembly

502003 Compressor Assy 230V 50Hz 11K/T 6 - 10

10-10

502002 Compressor Assy 110V 60Hz 5K/T (USA) 6 - 10

10-10

502007 Compressor Assy 100V 50/60Hz 4.5K/T (Japan) 6 - 10

10-10

502054 • Bellows Armature Assembly Left-Hand 230V 50Hz 11 - 10 1

BP215 Bellows Armature Assembly Left-Hand 110V 60Hz 1

502053 • Bellows Armature Assembly Right-Hand 230V 50Hz 11 - 20 1

BP214 Bellows Armature Assembly Right-Hand 110V 60Hz 1

BP043 • Armature Pivot 11 - 30 2

BP554 • Valve Body Assy, Blue 11 - 40

12-10

BP351 •• Valve Body 12 - 20 1

Issue 2 Chap 7 Nov 2001 SER0004 Page 1

Parts list Mini Pump Service Manual

Part Number Description Fig-Item Qty

FAS027 •• Screw, Hex Head 4BA x 3/4 12 - 30 1

FAS013 •• 4BA Full Nut 12 - 40 1

BP039 •• Valve Body Washer 12 - 50 2

BP037 •• Valve Flap 12 - 60 2

BP038 •• Valve Flap Securing Pad 12 - 70 2

BP028 •‘E’ Stack 13 - 10 1

FAS048 • Pan Head Screw M3 x 25 mm Pozi 13 - 20 2

FAS002 • Washer - 6BA Anti-Vib. 13 - 30 2

502050 • Coil Assembly 230V 50Hz (black/white leads) 13 - 40 1

502062 Coil Assembly 110V 60Hz (grey leads) 1

BP275 Coil Assembly 100V 50/60Hz (blue leads) 1

165303 • Grommet 13 - 50 1

502304 • Compressor Case 13 - 60 1

502301 • Compressor Lid 10 - 20 1

BP032 • Compressor Gasket 10 - 40 1

502055 • Silencer Bag 10 - 50 1

500320 ‘F’ Tube Connector 6 - 20

10-60

500410 Filter Retaining Clip 6 - 30 1

500417 Inlet Filter 6 - 40 1

500124 Compressor Mounting Bracket (New style) 7 - 10 1

500416 AV Mount (New style) 7 - 20 4

198375 AV Mount (Old style) 8 - 20 4

165310 Upper Bump Stop 9 - 10 1

165310 Lower Bump Stop 9 - 20 1

FAS160 Washer M4 Plain 9 - 40 2

FAS051 Screw Pan Head Pozi M4x6mm 9-50 2

FAS095 Screw Pan Head Pozi M4 x 10 mm 9 - 60 3

FAS054 Screw Countersunk Pozi M4 x 12 mm 10 - 30 4

Pressure Control Module

500347 Terminal Block 5 way 14 - 10

18-30

Chap 7 Issue 2 Page 2 SER0004 Nov 2001

Mini Pump Service Manual Parts list

Part Number Description Fig-Item Qty

BP196 Cable Tie 14 - 20 2

500362 Tube Sil ID 3/16” 135mm±5mmLG 14-30 1

FAS145 Screw 3 Dia.x8mmPozi Pan Head PT 14 - 40 1

FAS223 Screw 3 Dia. x 10 mm Pozi Pan Head PT 14 - 50 3

500315 Panel Side Colder 14 - 60 1

500328 Panel Side Push On 14 - 70 1

151309 Fixing Cap 14 - 80 1

500338 Micro switch Sub Min 230 V/0.1A 18 - 10 1

FAS224 Screw 2.2 Dia. x 14 mm Pozi Pan Head PT 18 - 20 2

500347 Terminal Block 5 Way 18 - 30 1

FAS225 Screw 3 Dia. x 16 mm Pozi Pan Head PT 18 - 40 2

500304 Knob Control Arbour 19 - 10

20-60

500312 Upper Pressure Control Flap 19 - 20 1

500318 Pivot Pin, Pressure Control 19 - 30 1

550303 Lower Pressure Control Flap 19 - 40 1

500341 Spring 0,024” Diameter 19 - 50 1

151339 Pressure Control Disc 19 - 60 1

PRE022 Rubber Valve Disc 19 - 70 1

500103 Bag Pressure with Restrictor Assembly 19 - 80 1

500355 Screw M3 x16 mm Socket Cap Hd Black 19 - 90 1

403306 Restrictor (Aura Pumps Only) 19 - 100 1

FAS225 Control Adjustment Screw, 3 Dia x 16 mm Pozi Pan Head

20-10 1

500305 Knob Control Cam 20 - 20 1

500411 Cup Arbour Drive Spring 20 - 30 1

500339 Spring Comp 1.07 Diameter 20 - 40 1

500349 Pressure Assembly Module 20 - 50 1

FAS223 Screw 3 Dia x 10 mm Pozi Pan Head 21 - 10 2

500097 Gearbox 240V and Ferrule Assembly 21 - 20 1

500098 Gearbox 120V and Ferrule Assembly 1

500099 Gearbox 100V and Ferrule Assembly 1

151409 Motor Gearbox 100V, 50 Hz, 1/10 RPM 1

Issue 2 Chap 7 Nov 2001 SER0004 Page 3

Parts list Mini Pump Service Manual

Part Number Description Fig-Item Qty

500308 Rotor Module 21 - 30 1

500307 Stator Module 21 - 40 1

500332 Felt Rotor Silencer 21 - 50 1

500319 Stator Gasket 21 - 60 1

500418 Stator Gasket (Restricted) 1

500356 Rotor Drive Cup 21- 70 1

500322 Pin Rotor Drive 21- 80 1

500354 Washer Starlock O/D 21 mm 21- 90 1

500358 Spring Comp 1.6 Diameter FL 22.36 21- 100 1

TIM017 Oil Seal Cap 21- 110 1

PCB (Electronic versions only)

500346 PCB Alarm Monitoring 230 V 15 - 20 1

500345 PCB Alarm Monitoring 100/120 V 1

151457 • Battery 16 - 10 1

FAS083 Screw No. 6 x 5/16” Pozi Pan Head PT 15 - 10 1

Neon Indicator (Mechanical versions only)

500324 Plate Neon Mounting 17 - 20 1

500373 Neon Assembly Red 230 V 17 - 30 1

500371 Neon Assembly Red 110 V

FAS083 Screw No. 6 x 5/16” Pozi Pan Head PT 17 - 10 1

Mains/Power Switch and Supply

500351 Switch Mains/Power Rocker 230 V Black (All electronic

22-10 1

pumps)

500343 Switch Mains/Power Rocker 230 V Green (Illuminated) 1

500359 Switch Mains/Power Rocker 110 V Green (Illuminated) 1

198315 Grommet 22 - 20 1

BP532 Cordset Standard Moulded UK (Cable) 22 - 30 1

CAS041 Mains/Power Cable - European “Shuko” Socket 1

BP087 Mains/Power Cable - USA 2 pin 1

CAS020 Mains/Power Cable - Japan 2 pin 1

Chap 7 Issue 2 Page 4 SER0004 Nov 2001

Mini Pump Service Manual Parts list

Part Number Description Fig-Item Qty

BP171 Mains/Power Cable - Australia 1

500344 Fuse Holder 22 - 40 1

CAS011 Fuselink 20x5mm500mAQB 22-50 1

Snap-lock Connectors

500350 Connector Panel, Female 1/4” Flow 23 - 10 1

504316 Connector Panel, Male 1/4” Flow 23 - 20 1

500361 Tube Sil Blue ID 6 OD 10 24 LG ± 1 23 - 30 1

500360 Tube Sil Blue ID 6 OD 10 15 LG ± 1 23 - 40 1

Service Kit

500135 Service Kit (240v only)

BP043 • Armature Pivot 2

502055 • Silencer Bag 1

502053 • Bellows Armature Assembly Right-Hand 230v 50Hz 1

502054 • Bellows Armature Assembly Left-Hand 230v 50Hz 1

500340 • Felt Filter (Case) 1

500417 • Inlet Filter (Compressor) 1

Issue 2 Chap 7 Nov 2001 SER0004 Page 5

Parts list Mini Pump Service Manual

Chap 7 Issue 2 Page 6 SER0004 Nov 2001

Mini Pump Service Manual Service Contact Details

CHAPTER 8

SERVICE CONTACT DETAILS

Africa

Huntleigh Africa (Pty) Limited 126 B Sarel Baard Crescent Rooishuiskraal, Pretoria, South Africa

T +27 1266 10368 F +27 1266 10380

Australia

Huntleigh Healthcare Pty Limited 63 Buckingham Drive, Wangara, Western Australia 6065 T +61 8 9 309 3083 F +61 8 9 309 4582

Belgium

Huntleigh Healthcare NV SA Stapelplein 70, 9000 Gent, Belgium T +32 9 265 8770 F +32 9 265 8771

Denmark

Huntleigh Healthcare, Denmark Hejreskovvej 18A DK-3490 Kvistgard, Denmark T +45 4 913 8486 F +45 4 913 8487

Middle East

Huntleigh Technology PLC 307 Sh. Zayed Road Dubai, United Arab Emirates

New Zealand

Huntleigh Healthcare Ltd Unit 6/38 Eaglehurst Road, Ellerslie, Auckland, NZ T +64 9 525 2488 F +64 9 525 2433

Singapore

Huntleigh Healthcare, Singapore 6 Temasek Boulevard, Fourth Floor Sunlee Tower Four, Singapore T +61 8 9 309 3083 F +60 8 9 309 4582

Sweden

Huntleigh Liljenberg AB Limhammsgårdens alle 15 21610 Limhamm, Malmo, Sweden T +46 40 49 57 80 F +46 40 49 43 75

France

HNE Médical SA Parc d’affaires Silic 6, 1 Rue des Vergers 69760 Limonest, France T +33 (0)4 78 66 62 66 F +33 (0)4 78 66 62 67

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

Holland

Huntleigh Healthcare BV Flevolaan 8, 1382 JZ Weesp, Holland T +31 294 415001 F +31 294 430475

India

Indian Liaison Office 61 Goldmist, Gulmohar Road Juha Scheme, Mumbai 400 049, India

Huntleigh Healthcare Limited 310-312 Dallow Road, Luton, Bedfordshire, LU1 1TD T +44 (0)1582 413104 F +44 (0)1582 459100

United States of America

Huntleigh Healthcare Inc 40 Christopher Way Eatontown, NJ 07724, USA T +1 732 578 9898 F +1 732 578 9889

Huntleigh Latin America Inc 2602 North West 97th Avenue, Miami, Florida, 33172, USA T +1 305 463 0526 F +1 305 463 0216

Issue 2 Chap 8 Nov 2001 SER0004 Page 1

Service Contact Details Mini Pump Service Manual

Chap 8 Issue 2 Page 2 SER0004 Nov 2001

Huntleigh Mini Pump User manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

MAINTENANCE

PUMP REPAIR

TROUBLESHOOTING

TESTING

TECHNICAL SPECIFICATION

PARTS LIST

SERVICE CONTACT DETAILS