Huntleigh Healthcare Nimbus II, Nimbus 3, DFS2, DFS3 User manual

Huntleig

HEALTHCARE

Nimbus II, Nimbus 3,

DFS2 and DFS3

Service Manual

Issue 1

SER0001 Jun 2001

Nimbus / DFS Service Manual Amendment Record

AMENDMENT RECORD

Amendment Incorporated by Date

Issue 1 Amendment Record Jun 2001 SER0001 Page (i)

Amendment Record Nimbus / DFS Service Manual

Amendment Record Issue 1 Page (ii) SER0001 Jun 2001

Nimbus / DFS Service Manual Contents

Contents

CHAPTER 1

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

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

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

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

Operating Principle...................................1

Dynamic Mode .....................................2

Static Mode ......................................3

Auto-Matt........................................4

System Start Up Sequence ..............................4

Alternating Head Cells Modification ..........................4

CHAPTER 2

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

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

Pump Soak Times ......................................2

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

Mattress Maintenance Checks ................................3

Mattress Service .......................................3

CHAPTER 3

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

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

Removing the Hanging Bracket................................3

Installing the Hanging Bracket ................................3

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

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

Disassembling the Pump Filter ................................7

Assembling the Pump Filter .................................7

Removing the Double Compressor Assembly ........................9

Installing the Double Compressor Assembly .........................9

Removing the AV Mounts ..................................10

Installing the AV Mounts...................................10

Replacing the Compressor Filters ..............................13

Removing the Compressor Bump Stops ..........................13

Installing the Compressor Bump Stops ...........................13

Replacing the Shuttle Assemblies..............................15

Issue 1 Jun 2001 SER0001 Page (i)

Contents Nimbus / DFS Service Manual

Replacing the Coil Assemblies ...............................15

Replacing the Manifold Gasket ...............................17

Removing the Rotary Valve Assembly ...........................18

Installing the Rotary Valve Assembly ............................19

Circuit Boards ........................................21

Removing the Old Style Display Panel PCB, the PCB Transformer and Daughter Board (if

fitted). ............................................21

Removing the New Style Display Panel PCB........................25

Installing the New Style Display Panel PCB ........................26

Removing the Pressure Control Assembly .........................29

Installing the Pressure Control Assembly ..........................29

Removing the High Pressure Switch ............................31

Installing the High Pressure Switch .............................31

Replacing the Mains/Power Switch .............................33

Replacing the Mains/Power Inlet Socket and Cordset (Moulded Cordset Versions Only) . 35

Replacing the Mains/Power Fuses (All Versions) ......................37

Replacing the Mains/Power Inlet Fuse Holders (Moulded Cordset Versions Only) .....37

Removing the Mains/Power Cable (Hard wired versions only) ...............39

Installing the Mains/Power Cable (Hard wired versions only) ................39

Removing the Mains/Power Fuseholders (Hard wired versions only)............41

Installing the Mains/Power Fuseholders (Hard wired versons only).............42

Removing the Mains/Power Filter (Hard wired versons only) ................42

Installing the Mains/Power Filter (Hard wired versions only) ................43

Removing the 5-Way Connector and Support (Hard wired versions only) .........45

Installing the 5-Way Connector and Support (Hard wired versions only) ..........45

Replacing the Silencer Bag .................................47

Removing the Bio Filter (Nimbus 3 and DFS 3 Pumps Only) ................49

Installing the Bio Filter (Nimbus 3 and DFS 3 Pumps Only).................49

Changing the Battery ....................................51

Replacing the Sounder ...................................51

Replacing the Pump Case..................................52

Pump Label Sets ......................................53

CHAPTER 4

Mattress repair ..................................1

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

Removing the Top Cover ...................................3

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

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Page (ii) SER0001 Jun 2001

Nimbus / DFS Service Manual Contents

Removing the Base Cover ..................................3

Installing the Base Cover ...................................7

Replacing the Soft Foam Sheet ...............................9

Cell Replacement ......................................11

Removing a Cell .......................................11

Installing a Cell .......................................11

Removing the Manifold Assembly ..............................12

Installing the Manifold Assembly ..............................12

Removing the Partial Non-Return Valve Assemblies ....................14

Installing the Partial Non-Return Valve Assemblies .....................14

Removing the Loop Sheet Assembly ............................15

Installing the Loop Sheet Assembly .............................15

Replacing the Elastic Loops (Nimbus 3/DFS 3 Only) ....................16

Removing the Sensor Pad Assembly ............................17

Installing the Sensor Pad ..................................17

Removing the CPR Unit ...................................18

Installing the CPR Unit ...................................18

Replacing the Release Button................................19

Replacing the Tubeset ...................................20

Replacing the CPR O-Rings.................................23

Replacing the Transport Assembly .............................23

Repairing the CPR Handle Sub-Assembly .........................24

Replacing the CPR Manifold Gasket ............................25

Alternating Head Cells....................................27

Modification Kit ....................................27

Installing the Alternating Head Cell Modification - Configuration 1 .............27

Installing the Alternating Head Cell Modification - Configuration 2 .............30

CHAPTER 5

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

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

CHAPTER 6

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

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

Test Setup .......................................1

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

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

Issue 1 Jun 2001 SER0001 Page (iii)

Contents Nimbus / DFS Service Manual

High/Low Pressure Setpoint and Mute Mode Checks .................2

Static and Dynamic Mode Pressure Tests .......................2

High/Low Pressure Setpoint Checks and Mute Mode Check using the Psion Organiser . . 3

Psion Organiser Setup .................................3

High Pressure Switch Setpoint Check .........................3

Low Pressure Switch Setpoint Check .........................3

Mute Mode Check ...................................4

High/Low Pressure Setpoint Checks and Mute Mode Check using the IR Interface Module. 4

IR Interface Setup ...................................4

High Pressure Switch Setpoint Check .........................5

Low Pressure Switch Setpoint Check .........................5

Mute Mode Check ...................................5

Static and Dynamic Mode Pressure Tests using the Psion Organiser ............5

Static and Dynamic Mode Calibration Readings....................5

Adjusting the Pressure .................................5

Psion Organiser Setup .................................5

Static Mode Pressure Tests ..............................6

Dynamic Mode Pressure Tests ............................7

Check Pump Serial Number ..............................8

Static and Dynamic Mode Pressure Tests using the IR Interface ..............8

Static and Dynamic Mode Calibration Readings....................8

Adjusting the Pressure .................................8

IR Interface Setup ...................................8

Static Mode Pressure Tests ..............................8

Dynamic Mode Pressure Tests ............................9

Check Pump Serial Number .............................10

Psion Organiser Setup ...................................11

IR Interface Setup and Passwords for ProNimbus .....................11

Electrical Testing ......................................13

Electrical Safety Checks - Class I ..........................13

Earth Continuity Tests ................................13

Insulation Resistance Tests .............................13

Dielectric Strength Test (Flash Test) .........................14

Leakage Circuit Test (USA) .............................14

Mattress Pressure and Function Test ............................15

Test Procedure ....................................15

CHAPTER 7

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

CHAPTER 8

Parts List .....................................1

Issue 1

Page (iv) SER0001 Jun 2001

Nimbus / DFS Service Manual Contents

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

Mattress Assembly Parts List .................................7

CHAPTER 9

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

Issue 1 Jun 2001 SER0001 Page (v)

Contents Nimbus / DFS Service Manual

Issue 1

Page (vi) SER0001 Jun 2001

Nimbus / DFS 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 Nimbus and understand this manual before attempting to service or repair the equipment.

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.

2, Nimbus 3, DFS 2 and DFS 3 systems which comprise a pump and a mattress. Read

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.

2 Technical Description

The Nimbus 2, Nimbus 3, DFS 2 and DFS 3 are Dynamic Flotation Systems for use in aiding the prevention, treatment and management of pressure sores.

It is a powered, air-filled mattress replacement system with microprocessor-aided control and alarm functions which have LED indication on the front panel of the pump.

Operating Principle

The patient is supported by twenty cells which are enclosed by a polyurethane coated fabric cover. This cover has waterproof, vapour permeable, and two-way stretch properties.

The system incorporates a sensor that automatically adjusts the support pressure within the system to accommodate different weight patients and their weight density or distribution. This sensor pad, known as the Auto-Matt minimum to support that patient in a given position.

Issue 1 Chap 1 Jun 2001 SER0001 Page 1

sensor, optimises the pressure to which the cells are inflated to be the

Introduction Nimbus / DFS Service Manual

Small adjustments can be made to the mattress pressure, using the comfort control knob on the pump. This is a patient comfort feature to make small adjustments to the softness or firmness of the mattress.

The Nimbus 3 and DFS 3 mattress also includes the HeelGuard which is designed to maximise pressure relief under the heels.

Dynamic Mode

In dynamic mode the support surface beneath the patient is cycled every 10 minutes providing periods of pressure relief for the whole body.

Figures 1 and 2 show how the system operates in dynamic and static modes. Fig 2 shows the pneumatic circuit in principle. A dual compressor system is used to provide a source of air supply. This is fed to a high pressure switch, the Auto-Matt sensor and a rotary valve. The high pressure switch is used to detect system over-pressures through blockages. The low pressure switch, which is located in the pressure control assembly, is used to detect if the air pressure in the system falls below minimum. The rotary valve channels the air supply as shown below:

C to outlet A with B at atmosphere (D) - A & C Cells Inflated

•

C to outlet A and B - All Cells Inflated (A,B&C)

•

C to outlet B with A at atmosphere (D) - B & C Cells Inflated

•

C to outlet A and B - All Cells Inflated (A,B&C)

•

special powered-down feature

This then allows cells A and B in the mattress to be inflated and deflated in a cycle period of ten minutes.

Anti-sink

Torso Section

Upper cells alternate,

lower cells semi-dynamic

CCCC

Head Section

Semi-dynami

AAAA CCC

AAAA

CCCCCC

CCC

lternating

Static

Alternating

Lower Body Section

Upper and lower cells

alternate

BBBB

AAAA

AAABB BBA

All cells constantly inflated

AAA

BBBB

Semi-dynamic cells

BBBB

Static

Chap 1 Issue 1 Page 2 SER0001 Jun 2001

AAABB BBA

All cells constantly inflated

Figure 1 - Mattress Cell Inflation Cycle

BBBB

CCCC

AAAA CCC

CCC

Nimbus / DFS Service Manual Introduction

In the mattress there is a third section of cells labelled as C. These are fed through partial non-return valves from cells A and B and are therefore never at zero pressure. These are positioned as shown in Fig 1 to prevent the torso section from ‘bottoming’ during dynamic mode and when a patient is sitting upright. Semi-dynamic pressure is also applied to the head cells (C) and the heel protector (above CPR unit) for added patient comfort.

On Nimbus 3 and DFS 3, loop sheets, the heel cells have a special powered-down feature to facilitate fast deflation and thereby improve pressure relief under the heels.

Static Mode

In static mode the support surface is kept constant and provides pressure reduction without cycling. The rotary valve is held in a constant position so that cells A, B, C and the heel protector are equally inflated.

Compressor 1

High Pressure

Switch

Pressure Control

Adjuster

Compressor 2

Restrictor

Atmosphere

Low Pressure

Switch

(Atmosphere)

Rotary

Valve

52314

Not

Used

Pump

Tubeset

Cells A

Cells B

Partial Non

Return Valves

Sensor Pad (Auto Matt)

Cells C

Mattress

Figure 2 - Pneumatic System Diagram

Issue 1 Chap 1 Jun 2001 SER0001 Page 3

Introduction Nimbus / DFS Service Manual

Auto-Matt

The Auto-Matt sensor consists of a flexible air sensor pad which is located underneath the mattress cells. This acts as a pressure regulator and accommodates changes in patient weight and position in the following manner:

It is pneumatically connected in parallel to the mattress cells and when it is not occluded it channels the air supply away from the cells. Occlusion of the Auto-Matt sensor is by patient weight and position. In this manner it allows internal mattress air pressures to be compensated to that required to support the patient.

With no patient on the mattress the Auto-Matt sensor is not occluded and pressure in the mattress is governed by the pressure control shown in Fig 2. This is in turn set to a pressure range which can be slightly adjusted to change mattress pressures for patient comfort.

With a patient on the mattress, pressure is exerted onto the cells and this can partially or totally occlude the Auto-Matt sensor. This results in more air being supplied to the cells increasing their internal pressure until full patient support is achieved. Should the patient change to a position which necessitates a lower pressure, air is released via the Auto-Matt sensor through the pressure control valve until the correct lower pressure is achieved in the cells.

System Start Up Sequence

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

All display indicators illuminate for a few seconds.

•

Low Pressure and Wait indicators remain illuminated while the mattress inflates (approx

•

20 Min). All the other indicators go out.

• The pump runs one compressor until the rotor turns to the cross over position (within 5 Min).

•

The rotor then depresses the microswitch which stops the rotor and activates the second compressor.

•

Both compressors run for 20 minutes or when the mattress reaches the minimum pressure setting.

•

When the minimum pressure setting is reached the Low Pressure and Wait indicators go out.

•

The pump cuts down to one compressor and the rotor starts to rotate.

•

In Dynamic Mode the compressors will alternate every 4 hours.

•

In Static Mode the Coils (4 off) will alternate every 4 hours (one at a time). The compressors alternate depending on which coil is working (there are two coils in each compressor).

Alternating Head Cells Modification

The Nimbus and DFS beds are normally supplied with the top three (head) cells configured so that they are inflated to a specific pressure. Although the pressure in the head cells normally remains constant, the pressure in the rest of the cells slowly alternates.

The Alternating Head Cells Modification converts the static head cells into alternating cells. The modification can be applied in two configurations that follow:

Configuration 1 converts all three head cells from static pressure to alternating pressure.

Configuration 2 converts the second and third cells from static pressure to alternating pressure. The

top head cell remains as a static pressure cell.

Chap 1 Issue 1 Page 4 SER0001 Jun 2001

Nimbus / DFS 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:

1.1.1 Outer Casing Check for damage and security.

1.1.2 Switches, Control Knobs Check function.

1.1.3 Hanging Bracket Check for damage and security.

1.1.4 Outlet ports Check for damage and free from obstructions.

1.1.5 Rubber feet (8 0ff) Check for security.

1.1.6 Fuses Check condition.

1.1.7 Front panel Check for damage to LED’s and buttons.

1.1.8 Mains/Power lead Check for damage and security of plug.

1.1.9 Labels Check all labels are present and legible.

1.2 Disassemble the Rear Case (Refer to Page 5, Section 4) and visually inspect the following for damage, wear, security and potential faults:

1.2.1 Compressor

1.2.2 Rotary Valve Assembly

1.2.3 Printed Circuit Boards (PCB’s)

1.2.4 Pressure Control Assembly

1.2.5 High Pressure Switch

1.2.6 Silencer Bag

1.2.7 Bio Filter (Nimbus 3 and DFS 3 Only)

1.2.8 Tubing and Wiring

1.2.9 Screws, Nuts and bolts

1.3 Remove the compressor lids and visually inspect the following for damage, wear and potential faults:

1.3.1 Coils

1.3.2 Elbows and connectors

1.3.3 Filters and gaskets

Issue 1 Chap 2 Jun 2001 SER0001 Page 1

Maintenance Nimbus / DFS Service Manual

1.3.4 Shuttle Valve Assemblies

2 Pump Soak Times

2.1 A pump must be soaked with its ports occluded for the following reasons:

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 for a period of 30 to 60 minutes prior to any pneumatic performance test being carried out.

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

Valve Shuttle Assemblies

•

Silencer Bags

•

Printed Circuit Boards (PCB’s)

•

Compressor

•

Rotary Valve Assembly

•

3 Pump Service

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

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

3.2 Replace the following components:

3.2.1 Case Seal (Refer to Chapter 3, Page 5, Section 4 and 5).

3.2.2 Valve Shuttle Assemblies (Refer to Chapter 3, Page 15, Section 15).

3.2.3 Compressor AV Mounts (Refer to Chapter 3, Page 10, Section 10 and 11).

3.2.4 Compressor Filters (Refer to Chapter 3, Page 13, Section 12).

3.2.5 Case Filter (Refer to Chapter 3, Page 7, Section 6).

3.2.6 Pump Manifold Gasket (Refer to Chapter 3, Page 17, Section 17).

3.3 Reassemble the pump and soak 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 6, Page 1, Section 1.

3.5 Carry out electrical tests on the pump in accordance with Chapter 6, Page 13, Section 8.

Chap 2 Issue 1 Page 2 SER0001 Jun 2001

Nimbus / DFS Service Manual Maintenance

4 Mattress Maintenance Checks

If any parts are found to be damaged they must be replaced in accordance with Chapter 4, Mattress Repair.

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

4.1.1 Base and Top Cover Check for tears, staining, clarity of printed labels.

4.1.2 Base/Top Cover Zip Check the zip runs freely and condition of zip teeth.

4.1.3 Anti-slip pads Check for damage.

4.1.4 Fixing straps Check condition and security.

4.1.5 Loop sheet Check for broken/torn loops.

4.1.6 Sensor Pad Check condition and security of tubes.

4.1.7 Soft/Hard Foam Check condition.

4.1.8 Connectors Check for damage and security.

4.1.9 Tubing Check for security and ensure no kinks or twists.

4.1.10 Cells Check for damage and security.

4.1.11 Manifold Check for damage and security.

4.1.12 Partial Non-Return Valves Check for condition.

4.1.13 Heel Protector Check for damage and security.

4.1.14 Pop Studs Check condition.

4.1.15 CPR Unit Check operation of Fast Deflate mechanism.

4.1.16 CPR Transport Knob Check operation.

4.1.17 CPR Inlet Manifold Check for damage and free from obstructions.

4.1.18 Tubeset assembly Check for damage and security of connection.

4.1.19 Alternating Head Cells If fitted, Check the security of all the connectors.

5 Mattress Service

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

5.1 Carry out the Mattress Maintenance Checks (Refer to Section 4).

5.2 Check the following components and replace if necessary:

5.2.1 CPR ‘O’ rings (Refer to Chapter 4, Page 4, Section 23).

5.2.2 CPR Manifold Gasket (Refer to Chapter 4, Page 25, Section 26).

5.3 Carry out an inflation test on the mattress in accordance with Chapter 6, Page 15, Section 9.

Issue 1 Chap 2 Jun 2001 SER0001 Page 3

Maintenance Nimbus / DFS Service Manual

Chap 2 Issue 1 Page 4 SER0001 Jun 2001

Nimbus / DFS Service Manual Pump Repair

CHAPTER 3

PUMP REPAIR

1 General

This chapter details repair procedures for the Nimbus 2, Nimbus 3, DFS 2 and DFS 3 pumps. All repairs should be carried out by Huntleigh approved service personnel.

After carrying out a service or any repairs, the pump must be soaked for the recommended time (Refer to Chapter 2, Page 2, Section 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 6, Page 1, Section 1.

To carry out the electrical tests on the pump refer to Chapter 6, Page 13, Section 8.

Table 1- Repair to Testing Requirements

Components / Assemblies

Compressor Yes Yes

Pressure Control Yes Yes

Rotors & Stators Yes Yes

Silencer Bag Yes No

High / Low Pressure Switches Yes Yes

Shuttle Assembly Yes Yes

Coils Yes Yes

Elbows & Connectors Yes No

AV Mounts Yes Yes

PCB Yes Yes

Front Casing Yes Yes

Rear Casing No No

Battery No Yes

Flow/Pressure & Function

Test

Electrical Safety

Switches No Yes

Fuses No Yes

Electrical Connectors No Yes

Mains/Power Lead No Yes

Issue 1 Chap 3 Jun 2001 SER0001 Page 1

Pump Repair Nimbus / DFS Service Manual

40 50

Figure 3 - Removing and installing the Hanging Bracket

Table 2 - Hanging Bracket Part List

Item Part Number Description Qty

10 151123 Hanging Bracket Assembly 1

20 151427 Bracket 1

30 151428 Wire 1

40 FAS046 Screw M3 x 10 CSK 2

50 FAS216 Nut M3 x 0.5 Euro Series 2

Chap 3 Issue 1 Page 2 SER0001 Jun 2001

Nimbus / DFS Service Manual Pump Repair

2 Removing the Hanging Bracket

2.1 Ease the bottom of the hanging bracket off of the base of the pump.

2.2 Rotate the hanging bracket (Fig 3) and remove it from the handle recess in the back of the pump.

3 Installing the Hanging Bracket

3.1 Lay the pump face down and insert the bridge of the hanging bracket (Fig 3) into the handle recess of the pump.

3.2 Pull the bottom of the hanging bracket over the bottom of the pump and push firmly downwards so that the bracket clips into place around the base of the pump.

Issue 1 Chap 3 Jun 2001 SER0001 Page 3

Pump Repair Nimbus / DFS Service Manual

Ends of cord meet at this poin

Figure 4 - Rear Case Assembly

Chap 3 Issue 1 Page 4 SER0001 Jun 2001

Nimbus / DFS Service Manual Pump Repair

4 Disassembling the Rear Case

WARNING:

BEFORE DISMANTLING THE PUMP UNIT , ENSURE THE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE MAINS/POWER PLUG FROM THE WALL SOCKET.

4.1 Remove the hanging bracket from the pump (Refer to Page 3, Section 2).

4.2 Place the pump unit on a flat surface with the front case (Fig 4, Item 20) face down.

4.3 Unscrew the 8 pan head screws (Fig 4, Item 30) and lift the rear case (Fig 4, Item 10) away from the front case (Fig 4, Item 20). Keep the screws (Fig 4, Item 30) in a safe place.

4.4 Carefully remove the neoprene sponge cord (Fig 4, Item 40) and inspect for damage.

5 Assembling the Rear Case

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

5.2 Install the hanging bracket to the pump (Refer to Page 3, Section 3).

Table 3 - Rear Case Parts List

Item Part Number Description Qty

10 151052 Rear Case Assembly 1

20 151307 Front Case 1

30 FAS 188 Pan Head Screws M4 x 30 mm 8

40 151105 Neoprene Sponge Cord (Dia 2 mm) 1

50 500381 Rubber foot 8

Issue 1 Chap 3 Jun 2001 SER0001 Page 5

Pump Repair Nimbus / DFS Service Manual

Slots

Figure 5 - Pump Filter Assembly

Chap 3 Issue 1 Page 6 SER0001 Jun 2001

Nimbus / DFS Service Manual Pump Repair

6 Disassembling the Pump Filter

6.1 Disassemble the Rear Case (Refer to Page 5, Section 4).

6.2 Lay the Rear Case on a flat surface and remove the six screws (Fig 5, Item 40) and keep them in a safe place.

6.3 Remove the Filter Housing Plates (Fig 5, Item 20) and the Filter (Fig 5, Item 30).

6.4 Discard the old Filter.

7 Assembling the Pump Filter

7.1 Assembly of the new Pump Filter is in the reverse order of disassembly. Make sure the slots in the Filter Housing Plates (Fig 5, Item 20) are uppermost in the positions shown in Fig 5.

7.2 Assemble the Rear Case (Refer to Page 5, Section 5).

Table 4 - Pump Filter Parts List

Item Part Number Description Qty

10 151308 Rear Case 1

20 151311 Filter Housing Plate 2

30 151312 Filter 1

40 FAS179 Pan Hd Self Tapping Screw (Dia 2.5mm x 10 mm) 6

Issue 1 Chap 3 Jun 2001 SER0001 Page 7

Pump Repair Nimbus / DFS Service Manual

Compressor Earth Wire

140

160

Rotor Assembly

140

150

110

Compressor

Earth Wires

PCB Board

Front Panel

170

100

110

120

Power Supply

160

140

130

Figure 6 - Remove the Double Compressor Assembly and

Disassemble the AV mounts

Chap 3 Issue 1 Page 8 SER0001 Jun 2001

Nimbus / DFS Service Manual Pump Repair

8 Removing the Double Compressor Assembly

8.1 Disassemble the Rear Case (Refer to Page 5, Section 4).

8.2 Remove the screws (Fig 6, Item 50) and the compressor lids (Fig 6, Item 20). Lift the four pairs of power cables, together with the rubber grommets, out from the side of each compressor casing. Make sure the blanking grommets (Fig 6, Item 40) on the inner side of each compressor remain in the compressor casing.

8.3 If necessary, replace the items that follow:

8.3.1 The compressor Shuttles (Refer to Page 15, Section 15).

8.3.2 The compressor Coils (Refer to Page 15, Section 16).

8.4 Disconnect the high pressure switch hose and the compressor hose from the compressor (Fig 6, A and B) and disconnect the silencer bag (Page 46, Fig 26, Item 10) from the compressor hose.

8.5 For Nimbus 3 and DFS 3 pumps only, remove the Bio Filter (Refer to Page 49, Section 41).

8.6 Cut and remove any cable ties as necessary and disconnect the 2 compressor power cables from the PCB.

8.7 Remove the items that follow from the left compressor bracket:

8.7.1 Screw (Fig 6, Item 80) and washers (Fig 6, Items 90 and 100).

8.7.2 ‘P’ Clip (Fig 6, Item 110).

8.8 Remove the nuts, washers (Fig 6, Items 140 and 160) and the compressor earth wire from the top of the compressor.

8.9 Remove the nuts, washers and ‘P’ clips (Fig 6, Items 140, 150 and 110) together with the compressor hose. The ‘P’ clips can remain on the hose.

8.10 Remove the double compressor assembly (Fig 6, Item 10).

9 Installing the Double Compressor Assembly

9.1 Carefully install the double compressor assembly into the pump onto the AV mounts on the compressor brackets in the pump casing.

9.2 Install the screw, the washers and the ‘P’ Clip (Fig 6, Items 80, 90, 100 and 110) to the left compressor bracket. Make sure that the ‘P’ Clip is around the 2 of the compressor power cable wires which form the longer loop from point C in Fig 6.

9.3 Connect the 2 compressor power cables to the PCB (Refer to Fig 11 or Fig 15).

9.4 Attach the high pressure switch hose to the compressor (Fig 6, A) and the silencer bag to the compressor hose (Page 46, Fig 26, Item 10). Attach the compressor hose to the compressor (Fig 6, B).

9.5 If necessary, replace the compressor lid gaskets (Fig 6, Item 30) as follows:

9.5.1 Remove the old gasket and clean the compressor lid.

9.5.2 Peel the back off of the new gasket (Fig 6, Item 30) and stick in position on the lid.

Issue 1 Chap 3 Jun 2001 SER0001 Page 9

Pump Repair Nimbus / DFS Service Manual

9.6 Make sure that the blanking grommets (Fig 6, Item 40) are installed in the compressor casings and install the compressor lids (Fig 6, Item 20). Secure the lids with screws (Fig 6, Item 50).

9.7 Install cable ties where they were removed.

9.8 Assemble the rear case (Refer to Page 5, Section 5).

10 Removing the AV Mounts

10.1 Remove the double compressor assembly (Refer to Page 9, Section 8).

10.2 Remove the items that follow from the earthing stud on the right compressor bracket:

10.2.1 The nut and washer (Fig 6, Items 60 and 70).

10.2.2 The 4 earth wire connectors (PCB, Compressor, Front Panel and Rotary).

Note : On Nimbus 3 and DFS 3 pumps there is only one earth wire for the PCB and Front

Panel.

10.2.3 The nut, washer (Fig 6, Items 60 and 70) and the Power Supply earth wire connector.

10.3 Remove the screws (Fig 6, Item 120) and the left compressor bracket (Fig 6, Item 130) from the pump casing.

10.4 Remove the screw and washers (Fig 6, Items 80, 90 and 100) from the right compressor bracket

10.5 Remove the screws (Fig 6, Item 120) and the right compressor bracket from the pump casing

10.6 Remove the nuts, washers and AV mounts (Fig 6, Items 140, 160 and 170) from each compressor bracket.

11 Installing the AV Mounts

11.1 Install the AV mounts, the washers and the nuts (Fig 6, Items 170, 160 and 140) to each compressor bracket (Fig 6, Item 130).

11.2 Install the right compressor bracket (with the earth label) into the pump casing. Secure the bracket with a screw and washers (Fig 6, Items 80, 90 and 100) at the back, nearest the PCB.

11.3 Install screws (Fig 6, Item 120) to the remaining holes in the bracket.

11.4 Install the items that follow to the earthing stud on the right compressor bracket:

11.4.1 The Power Supply earth wire connector.

11.4.2 The washer and nut (Fig 6, Items 70 and 60).

11.4.3 The 4 earth wire connectors (Rotary, Front Panel, Compressor and PCB).

Note : On Nimbus 3 and DFS 3 pumps there is only one earth wire for the PCB and Front

Panel.

11.4.4 The washer and nut (Fig 6, Items 70 and 60).

11.5 Install the left compressor bracket and secure with the screws (Fig 6, Item 120).

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Nimbus / DFS Service Manual Pump Repair

Note : Do not install the screw, washers and ‘P’ clip to the left compressor bracket at this stage.

11.6 Install the double compressor assembly (Refer to Page 9, Section 9).

Table 5 - Compressor Parts List

Item Part Number Description Qty

10 165076 Double Compressor Assembly - 220V (UK, EURO) 1

165074 Double Compressor Assembly - 120V (USA)

165077 Double Compressor Assembly - 100V (Japan 60Hz) 1

165078 Double Compressor Assembly - 100V (Japan 50Hz) 1

20 165311 Compressor Lid 2

30 165312 Compressor Lid Gasket 2

40 165300 Grommet Blank 4

45 165303 Grommet Blank - Lead through 4

50 FAS177 Screw M4 8mm Pozi C’SK Head 8

60 FAS144 Nut M4 Full 2

70 FAS053 Washer M4 Anti-Vib 2

80 FAS093 Screw M4 12mm 2

90 FAS053 Washer M4 Anti-Vib 2

100 FAS160 Washer M4 Plain 2

110 151386 ‘P’ Clip No.6 3

120 FAS095 Screw M4 10mm Pan Head Pozi 4

130 151310 Compressor Mounting Bracket 2

140 FAS178 Nut 8/32 UNC 8

150 FAS160 Washer M4 Plain 6

160 FAS053 Washer M4 Anti-Vib 2

170 151364 AV Mount 4

Issue 1 Chap 3 Jun 2001 SER0001 Page 11

Pump Repair Nimbus / DFS Service Manual

Figure 7 - Replacing the Compressor Bump Stops

Table 6 - Compressor Bump Stops Parts List

Item Part Number Description Qty

10 FAS051 Screw M4 6mm Pan Head 4

20 FAS160 Washer M4 Plain 4

30 165310 Bump Stop 4

40 165324 Bump Stop Plate 2

50 FAS177 Screw M4 8mm C’SK Head 4

60 FAS193 Screw M3 5mm Pan Head 8

70 165314 Filter Lid 8

80 165313 Filter 8

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