Plexus C1000D SERIES
Contents
1. 800 828 7341 716 662 2551 Fax 800 993 7890 716 662 07482. 0135 10 TIMING MOTOR ASSEMBLY 11523 000 11523 001 Call technical service 11 FUSE 10146 10146 10146 12 TUBING 10140 10140 10140 Pressure control knob Not Shown 20068 20068 20068 Power Cord 10053 Call technical service 10053 EURO 13 Power entry module Snap in type 10049 SNAP 10259 SNAP 10049 SNAP 13 Power entry module Screw in type 10049 10259 10049 14 Brass Connector 20156 20156 20156 Coupling Male to mattress Not Shown 10044 10044 10044 Coupling Female to mattress Not Shown 10045 10045 10045 21 Control 20111 Call technical service Call technical service 15 PCB Assembly Power Fail Float N A N A 30232 16 Pressure switch N A N A 10358 17 Screw 10363 10363 N A 18 Front Housing 20213 20213 N A 19 Rear Housing 20214 SFTT 20214 SFTT N A 20 Fuse Holder 10056 10056 10056 22 Chassis 20235 20235 N A Switch retrofit kit is available for older push button switches PN 30292 Not for use on units with float Page 16 Plexus C 1000D Figure 8 Plexus C 1000D Figure 9 Control Valve Detail ITEM DISCRIPTION Plexus PN 120V Models Plexus PN 240V Models 3 KNOB RECESS PLATE 20181 20181 4 4 40 SCREW 10336 10336 5 VALVE SEAT 10250 10250 6 T 10 SELF TAPPING SCREW 10352 10352 7 VALVE 10137 10137 8 RETAINER 10317 10317 Page 18 Plexus C 1000D GAYMAR COMPANY 10 Centre Drive Orchard Park NY 14127 2295 Phone
3. 30 minutes is required before the following tests are performed 12 4 1 16 4 1 If rattling or vibrating noise is apparent replace pump If no problem is detected continue with test procedure 12 4 2 Locate the hose coming out of the pump and attach it to a flow meter the flow should read gt 3 LPM If flow is below minimum requirement replace pump If no problem is detected continue with test procedure 12 5 12 6 12 7 12 8 Plexus C 1000D 12 4 3 Attach unit to test gauge See FIGURE 5 set comfort control to MIN The unit should provide a pressure of 21 3 mmHg to one port Pressure should alternate between gauges approximately every 2 5 minutes If unit does not achieve pressure attempt calibration See 17 0 replace pump if pressures can not meet calibration specs If no problem is detected continue with test procedure Timing Motor 12 5 1 Units with float function Verify that power in being supplied to both the pump and timing motor using a voltmeter Place meter to read VAC and touch both terminals marked as motor on the PCB Voltage should read 120 or 230 VAC depending on the line voltage If no voltage is detected replace PCB If no problem is detected continue with test procedure 12 5 2 For standard units Check voltage by touching the two outside terminals on the switch with voltmeter probes Readings should match line voltage being supplied 110 or 220 If reading is less than supplied voltage
4. Outside USA 716 662 8636 3 0 Repair Policy The Plexus C1000D Control Unit is warranted free of defects in material and workmanship for a period of two 2 years The Control Unit is warranted under the terms and conditions of the Plexus Medical warranty in place at the time of purchase A copy of the warranty is available upon request Plexus Medical disclaims all implied warranties including but not limited to the implied warranties of merchantability and of fitness for a particular purpose Control units may be returned to the factory for servicing see 4 3 Return Authorization For customers who choose to repair Plexus C1000D Control Units at their location this manual contains information to allow a qualified technician to make necessary repairs For technical support contact Plexus Medical s Technical Service Department 3 1 In Warranty Repairs All in warranty repairs must be authorized by Plexus Medical s Technical Service Department before proceeding 3 2 Out of Warranty Repairs The following repair options are available when servicing Plexus C1000D Control Units 1 Defective Components replacement parts may be ordered by specifying the Plexus Medical part number as shown in the parts lists 2 Plexus C1000D Control Unit Repairs If the Plexus C1000D Control Unit becomes inoperative and the cause cannot be determined the complete control unit may be returned to the factory for servicing at the purchas
5. Plexus C 1000D Plexus C1000D SERIES Control Unit Service PN 11812 000 Plexus C 1000D Table of Contents Section Description Page 1 0 Contraindications Indications Precautions 2 2 0 Receiving Inspection 2 3 0 Repair Policy 2 4 0 Specifications 3 5 0 Control Unit Setup 4 6 0 Cleaning 5 7 0 Rear Panel Features 6 8 0 Routine Maintenance and Function Testing 7 9 0 Function Test Record Sheet 10 10 0 Current Leakage Retrofit 12 11 0 Calibration Procedure 13 12 0 Troubleshooting 14 13 0 Parts List 17 Figures Figure Description Page 1 Front Control Panel 5 2 Rear Panel Features 7 3 Manifold Test 11 4 Mattress Test 11 5 Function Test Calibration 11 6 Float Style Timing Motor 16 7 Parts D or DE Models 17 8 Parts DF Models 18 7 Valve Assembly and parts 19 Page 1 Important Before using the Plexus C1000D please read and understand the Plexus C1000D Operator s Manual and the SAFETY INSTRUCTIONS prior to each application Only qualified medical service personnel should repair the Plexus C1000D In the event of any questions contact our Technical Service Department for assistance USA Only Phone 1 800 828 7341 Fax 1 800 993 7890 Outside USA Phone 716 662 8636 Fax 716 662 0730 Plexus C 1000D 1 0 Contraindications Refer to Operator s Manual 1 1 Indications for Use Theory of Operation Refer to Operator s Manual 1 2 Safety Precautions Review the following SAFE
6. TY PRECAUTIONS prior to servicing the Plexus C1000D Explosion hazard Do not use in the presence of flammable anesthetics Risk of electric shock Refer servicing to qualified service personnel WARNING Never drop or insert any object into any opening of the control unit Doing so may cause fire or electrical shock by shorting internal components Do not spill food or liquids into the Control Unit If spillage does occur turn off the unit disconnect it from its power supply and allow at least 24 hours for drying Keep unit away from radiators or other heat sources CAUTION Repairs should be performed only by qualified personnel familiar with repair practices for servicing medical devices Do not attempt to repair the Plexus C1000D Control Unit unless you possess these skills Otherwise damage to or malfunction of the control unit may result 2 0 Receiving Inspection Upon receipt unpack the Plexus C1000D Control Unit and inspect for concealed damage Save all packing material If any damage is found notify the carrier at once and ask for written inspection Prepare written description of any damage Photograph any damage Failure to take the above action within 15 days of receipt may result in loss of claim Do not return the Plexus C1000D Control Unit to Plexus Medical Contact Plexus Medical s Technical Service Department for instructions USA only 1 800 828 7341
7. Y In the closed position the control unit will be in Alternating Pressure Mode In the open position the control unit functions in float mode 5 4 Power Fail Indicator and Alarm Not shown With Float Option ONLY Visible flashing red LED and audible alarms indicate loss of power to the control unit 5 2 Figure 2 Front Panel C100DF Page 4 Plexus C 1000D 6 0 Cleaning 6 1 Chassis exterior To clean use soap and water and a clean cloth to wipe down the pump power cord and hoses Wipe dry with a clean dry cloth Do not autoclave NOTE Blood and other fluids must be thoroughly cleaned from all surfaces before applying the disinfectant Apply a hospital grade disinfectant according to the manufacturer s instructions and hospital protocol Allow to completely dry The contact time is what makes the solution effective 6 2 Mattress Outside surfaces of mattress may be cleaned with a damp cloth and mild detergent Do not disinfect with alcohol which may cause mattress material degradation Cushions are made of plastic If it is necessary to sterilize cushions use ETO sterilization and or handle like any other plastic product Sterilization temperatures must not exceed 57 C 135 F Plexus C 1000D 7 0 Rear Panel Features see figure 2 below 7 1 7 2 7 3 74 7 5 N Model Serial Number Identification Plate This barcode label must not be removed from the unit The model and serial nu
8. check switch and fuse 12 5 3 Visually check the motor and verify that it is turning If motor is not rotating replace motor If no problem is detected continue with test procedure Control Valve 12 6 1 Attach unit to test gauge See FIGURE 5 set comfort control to MAX pressure should reach 75 15 mmHg If unit is out of spec Refer to calibration procedure 12 6 2 If unit fails pressure test replace valve See FIGURE 6 7 12 6 2 1 Pull knob from front of enclosure 12 6 2 2 Take off retainer attached to valve at base of valve seat 12 6 2 3 Push the valve through to the front of the unit and pull the knob and valve out 12 6 2 4 Install new valve PN 10137 Insure that retainer is fully seated and that valve body does not rotate when stem is turned 12 6 2 5 Set pressure minimum to 21 2 mmHg by turning valve stem 12 6 2 6 Install knob onto into recess on front of enclosure with the indicator at the MIN position 12 6 2 7 Turn knob to verify the indicator stops at MAX position and pressure reads 75 15 mmHg 12 6 3 If comfort knob continually spins return unit for repair If no problem is detected continue with test procedure Fuse 12 7 1 Open the unit and check the fuses 12 7 2 Check fuse by setting the voltmeter for continuity check Touch one end of the fuse with one probe and the other end with the other probe If the fuse is bad the meter will not detect and resistance and will n
9. connectors to the test gauge and wait for system to stabilize Once system has stabilized Approximately 1 min monitor gauge pressure If pressure drop is greater than 2 mmHg in 2 min return manifold for repair or replacement 12 1 6 Reattach manifold to the mattress If no problem is detected continue with test procedure Air Cells or M 200 Overlay 12 2 4 Inflate mattress overlay with an Inflator Deflator to approximately 40 mmHg Kink the mattress hose to prevent mattress from leaking then disconnect the hose from the Inflator Deflator Attach gauge as shown in FIGURE 4 12 2 2 Allow mattress to stabilize for 2 minutes 12 2 3 Monitor pressure If pressure drop is greater than 2 mmHg in 2 min then a leak exists in one or several air cells Inflate each air cell and plug the connector with Female Red Plug PN 30287 then submerge in water and watch for air bubbles Replace defective air cells if needed and reassemble mattress If no problem is detected continue with test procedure Control Unit Test Hoses 13 3 1 Open control unit and check to ensure that no hose inside the unit is kinked or cracked and leaking see FIGURE 5 13 3 2 If hose is kinked pinch and move hose around to remove kink 13 3 3 Attach unit to Test Fixture and verify that mattress pressure has returned to normal Once problem has been corrected continue to step 14 5 If no problem is detected continue with test procedure Main Pump A warm up period of
10. er s expense see 4 3 Return Authorization 3 3 Return Authorization Please be sure to obtain a return goods RG authorization number from Plexus Medical s Customer Service Department before returning the Plexus C1000D Control Unit or any component parts to Plexus Medical USA only 1 800 828 7341 Outside USA 716 662 8636 Page 2 Plexus C 1000D 4 0 Specifications Physcial Dimensions 12 x 10 1 4 x 5 30 5 cm x 26 cm x 13 cm Weight 4 2 to 5 Ibs 1 9 to 2 3 kg Operating Ambient 60 F to 80 F Temperature Range 15 5 C to 26 5 C Storage and Shipping Conditions Ambient Temperature 40 F to 105 F Range 4 5 C to 40 5 C Relative Humidity 10 to 100 Non condensing Electrical C 1000DC1000DE DFE CE Power 115 VAC 230 VAC Frequency 60 Hz 50 Hz Current 1A 5A Fuse F 0 15A F 0 15A Attention Consult Accompanying Documents Type BF Equipment IPXO Protection Against Harmful Ingress of Liquids Ordinary Protection IPXO Page 3 Plexus C 1000D 5 0 Control Panel Features see figure 1 COMFORT CONTROL Lbs Te EU rimus alib MEDIC 240 270 ALTERNATING PRESS MATTRESS SYSTEM 90 gt 300 MIN MAX Figure 1 Front Panel C1000D 5 1 ON OFF Switch When unit is on rocker switch will light 5 2 Comfort Control Selector Selector has built in stop rotation is limited to approximately 320 From MIN setting to MAX 5 3 Float Switch PN 10322 BLAN With Float Option ONL
11. essure control valve located in the center of the knob recess to 21 2 mmHg Rotate the brass stem clockwise to increase and counterclockwise to reduce pressure If the control valve is difficult to adjust use pliers to turn the valve Caution should be taken to avoid damaging the splines on the pressure controller 5 Once pressure is set reinstall nylon washer PN 90151 022 over stem of pressure control valve align knob so indicator is at MIN push knob onto pressure control valve The knob may need to be turned slightly to align the splines on the controler and the knob Knob must be fully seated on the controller Verify pressure at MIN 21 2 mmHg and MAX 75 15 mmHg Page 12 Plexus C 1000D 12 0 Troubleshooting Mattress Test 12 1 12 2 12 3 12 4 Manifold 12 1 1 Remove manifold from the mattress and block ports 20 with Red Plug PN 30258 as shown in FIGURE 3 12 1 2 Connect Inflator Deflator PN 30286 120 VAC 60 Hz or PN 30286 220V for 220 VAC 50 Hz to the fill connectors on the manifold 12 1 3 Inflate manifold to 40 10 mmHg Kink hoses and disconnect Inflator Deflator Connect Male and Female couplings to the gauge to seal the manifold See FIGURE 3 12 1 4 Check each port for signs of air leaking Water and mild soap may be used to aid in detecting leaks 12 1 5 Inflate manifold to approximately 40 mmHg Kink hose to prevent leaking as discussed in 14 1 4 Connect the two hose
12. fold FIGURE 4 Mattress Test Om FIGURE 5 Function Test Calibration Page 10 Plexus C 1000D 10 0 Curent Leakage Retrofit Drill Hole i Here i Use 1 8 Drill i TEMPLATE 1 Cutalong solid lines to remove template from instructions 2 Align template with bottom and side surface of enclosure in corner nearest the PEM power entry module If neccesary hold template in place with tape See pictures below NOTE Template is actuall size Do not reduce or enlarge this 3 Drill hole in area indicated Housing is approximately 1 8 thick Do not drill deeper than 3 8 Hole will need to be cleared of debris before use for testing 1 m 2 HH NPA Sg Plexus C 1000D 11 0 Calibration Procedure C 1000D A Male Connector PN 10329 Gauge 0 100 mmHg PN10392 Female Connector PN 10330 Gauge 0 100 mmHg PN 10392 Procedure NOTE Control unit must be turned on for 1 hour prior to calibration 1 2 3 Turn control knob to MIN Grasp the control knob remove by pulling away from the front panel of the control unit n some of the older units the knob may be glued if this is the case the unit can not be field calibrated Call Cusomer Sevice for assistance Connect gauges to contol unit NOTE Due to the alternating cycles of the control unit pressure will be measurable on one port 4 for approximately 3 minutes Once a pressure is detected adjust the pr
13. hoses Plexus PN 10140 Male Connector Plexus PN 10329 Female Connector Plexus PN 10330 Mattress Pressure test fixture Plexus PN 11668 000 Inflator Deflator Plexus PN 30286 Electrical safety analyzer Flow meter with connector Plexus PN 77484 000 74 male coupling Plexus PN 10001 74 female coupling Plexus PN 10002 Physical Inspection Record results on the Function Test Check Sheet Check the unit for cracks or breaks in the housing Rotate the comfort knob clock wise and counter clockwise to verify that it stops at the appropriate positions and that it is on tight Check the power cord connector for cracks breaks Check the on off switch for proper operation Verify that the bed hooks are in place and tight Check the power cord for breaks and the blades on the plug for looseness Replace or repair any irregularities found during physical inspection C 1000D DE Testing Record results on the Function Test Check Sheet 8 2 1 Connect the unit as shown in FIGURE 5 8 2 2 Turn power on 8 2 3 Adjust comfort control knob to Max setting fully clockwise 8 24 Take initial pressure reading One of the gauges should read 75 15 mmHg and the other gauge should read 0 5 mmHg If these readings cannot be obtained at the fully clockwise position the pump will need to be investigated and repaired before proceeding 8 2 5 Allow unit to cycle at least three complete cycles before taking the next readings 8 2 6 During the cycling of the unit the ga
14. mber information is needed to 3 arrange for returns to the factory Figure 2 Rear Panel Features Hooks Hooks are molded from a high strength plastic These hooks should be used to attach the control unit to the foot of the bed Connectors Male and female connectors are compatible with the couplings from the M 200 and M 1000 series mattresses and overlays Ground access point This point allows access for current leakage ground resistance measurements If your unit does not have this access point it can be added by following the directions in the following section PEM Power Entry Manual Page 6 Plexus C 1000D 8 0 8 1 8 2 8 3 Routine Maintenance and Function Testing The following maintenance and test procedure should be performed by a qualified technician familiar with testing and maintaining medical products Allow unit to warm up for 1 hour prior to performing the following tests To insure proper testing results follow these procedures carefully paying close attention to setups and required test equipment Failure to follow the procedures can lead to inaccurate or misleading results Document the testing results using the checklist at the end of this section Keep a copy of the test results for your records Testing of the C1000M should be performed annually or as prescribed by your facilities maintenance program Equipment requirements 2 each 0 100mmHg gauges Plexus PN 10392 Test fixture
15. n both gauges the pressure should read between 30 and 40 mmHg 8 3 9 With the power switch on and the unit running disconnect the power cord The unit should produce a visible and audible alarm C1000DC Series Testing Record results on the Function Test Check Sheet 8 4 4 Connect the unit as shown in FIGURE 5 8 4 2 Turn power on 8 4 8 Adjust comfort control knob to Max setting fully clockwise 8 4 4 Take initial pressure reading One of the gauges should read 90 10 mmHg and the other gauge should read 0 5 mmHg If these readings cannot be obtained at the fully clockwise position the pump will need to be investigated and repaired before proceeding 8 4 5 Allow unit to cycle at least three complete cycles before taking the next readings 8 4 6 During the cycling of the unit the gauges should alternate between the following readings High pressure 80 100 mmHg Low pressure 0 5 mmHg 8 4 7 Observe the following During the venting cycle gauge going from high to low the high pressure gauge should drop to 0 mmHg while the low pressure is rising 8 4 8 Verify that the unit continues to cycle for several minutes The gauges should alternate back and forth between 60 90 mmHg and 0 5 mmHg Flow Test All Series 8 5 1 Connect control unit to a flow meter as shown below 8 5 2 Turn on control unit and place at max pressure setting The flow will fluctuate during alternation Record the highest flow rate in a 5 minute period Fl
16. ot produce a continuous beeping sound The fuse is good if a resistance across it is detected and a continuous beeping sound is heard If no problem is detected continue with test procedure On Off Switch 12 8 1 Make sure that the unit is not plugged in 12 8 2 Remove all three leads attached to the switch 12 8 3 Push switch out of the panel while pushing in the snaps on the side of the switch Page 14 Plexus C 1000D 12 8 4 Snap the new switch in place and reattach the three leads 12 8 5 Attach the neutral lead to the brass color terminal 12 8 6 Attach the lead from the pump and motor to the center terminal 12 8 7 Attach the line lead to the remaining terminal 12 8 8 Plug unit in Verify if switch is good by turning on the unit Power and the green indicator light should go on 12 9 Float Mode C 1000DFE Only If float mode does not function 12 9 1 Connect unit as shown in Fig 5 Place unit in float mode and wait for 3 minutes 12 9 2 Check that the timing motor stops when metal tab comes in line with sensor If motor does not stop check continuity of Float Switch Verify that the switch is working properly with an ohmmeter With switch closed unit should stop in the float position If motor does not stop replace PCB assembly 12 9 3 After three minutes both ports must be pressurized This is float position 1 Place unit in alternating mode wait for 1 minute Place unit back in float mode After three minutes both por
17. ow must exceed 2 LPM Flowmeter 0 10 LPM From Kit PN 77484 000 Electrical safety inspection Record results on Function Test Check Sheet Connect the unit to an electrical safety analyzer Using the analyzer manufacturer s instructions verify that the unit does not exceed 100 uA at 110 V or 500 uA at 220 V of current leakage in any combination of settings Verify the ground connection does not exceed 5 ohms of resistance Page 8 Plexus C 1000D 9 0 Function Test Check Sheet Model Serial Test Procedure Results see routine maintenance and function test section of manual for details Physical Inspection OK Yes or No Testing All C 1000D 1 High pressure reading observed in step F mmHg 2 Low pressure reading observed in step F mmHg 3 Flow test Pass or Fail Float Power Fail options only 4 Pressure on both gauges Pass or Fail 5 Power fail alarms function Pass or Fail Electrical safety inspection results 1 Max current leakage reading u amps 2 Ground resistance less than 5 ohms Pass Fail Tested by Date If the unit passes all the steps described in the physical inspection testing and electrical safety inspection sections above it should be considered ready for use Any unit that does not pass all the requirements above should be serviced to correct the problem before being returned for use Plexus C 1000D FIGURE 3 Manifold Test PN 11668 000 Mattress Assembly Mani
18. ts must be pressurized This is float position 2 12 9 4 If pressure is not available at both ports in both positions check the location of the reflective tape See Fig 6 or for kinked tubing 12 9 5 Place the unit in alternating mode monitor the pressure gauges until both gauges read pressure Turn unit off with On Off power switch Move photosensor until it is slightly over the leading edge of the reflective tape Restore power and check both float positions Repeat adjustment until both float positions function NOTE The photosensor operates best when a distance of 1 8 inch is maintained between it and the surface to be sensed Caution should be used in moving the sensor to avoid breaking the leads 12 9 6 If LED or Buzzer does not work 12 9 6 1 Check LED or Buzzer connectors make sure that they are secured properly 12 9 6 2 If problem continues replace LED or Buzzer 12 9 6 3 If problem continues replace board If unit is still not functioning Contact technical services for further assistance at 800 828 7341 or 716 662 8739 Leading edge clockwise rotation Retaining Pin 19 23 Typical 2X Exhaust Ports X2 Reflective tape 2 Places Figure 6 17 0 Parts List Plexus C 1000D Figure 7 Parts ITEM DISCRIPTION Plexus PN 120V Plexus PN 240V C 1000DFE Models Models Models See Fig 8 1 SWITCH 20161 20161 20161 9 PUMP 10139 10135 1
19. uges should alternate between the following readings High pressure 60 90 mmHg Low pressure 0 5 mmHg 8 2 7 Observe the following During the venting cycle gauge going from high to low the high pressure gauge should drop to 0 mmHg while the low pressure is rising 8 2 8 Verify that the unit continues to cycle for several minutes The gauges should alternate back and forth between 60 90 mmHg and 0 5 mmHg C 1000DF DFE Testing Record results on the Function Test Check Sheet 8 3 1 Connect the unit as shown in FIGURE 5 8 3 2 Turn power on 8 3 8 Adjust comfort control knob to Max setting fully clockwise Plexus C 1000D 8 4 8 5 8 6 8 3 4 Take initial pressure reading One of the gauges should read 35 5 mmHg and the other gauge should read 0 5 mmHg If these readings cannot be obtained at the fully clockwise position the pump will need to be investigated and repaired before proceeding 8 3 5 Allow unit to cycle at least three complete cycles before taking the next readings 8 3 6 During the cycling of the unit the gauges should alternate between high and low pressure Observe the following During the venting cycle gauge going from high to low the high pressure gauge should drop to 0 mmHg while the low pressure is rising 8 3 7 Verify that the unit continues to cycle for several minutes 8 3 8 Select the float mode the timing motor should stop within 3 minutes In the stopped position there must be pressure o
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