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ALPHA ACTIVE 4 SYSTEM

1. Compressor Atmosphere Low Pressure Switch Bum PCB p Tubeset 1 lt Non Return Cells A Valve Top Top Base Cells B O Non Return Valves O Mattress Head Cells 1 Figure 1 Pneumatic System Diagram Issue 1 Chap 1 April 2010 SERO0018 Page 3 Introduction Alpha Active 4 Service Manual SYNCHRONOUS MOTOR MICRO SWITCH MAIN PCB TRANSFORMER ORANGE ORANGE Connectors J1 J2 and J7 must be connected to their relevant terminals on the Main PCB Figure 2 Electrical Diagram Chap 1 Issue 1 Page 4 SER0018 April 2010 Alpha Active 4 Service Manual Introduction 4 Front Panel 4 1 Below is a diagram of the Alpha Active 4 pump front panel For more detail on the function of each button see below Cycle Time Alarm Mute Mode Selector Auto firm Mode T 4 h Comfort Control Alarms 5 Controls and Indicators js Issue 1 April 2010 On Off Switch Located on the right side of the pump unit the On Off switch will illuminate green when the pump is on Alarm Mute During an alarm condition the sound of the alarm can be muted by pressing this button The yellow indicator will then flash intermittently but the alarm will be muted Mode Select The mode selector allows the mode of operation to be selected Two modes of operation are available Alternating or Static non alternating m The indicator next to the resp
2. gt Figure 16 Removing the Terminal Block Table 17 Terminal Block Part Number Description 648425 Terminal Block Alpha Active 4 REF Screw M3x15mm Pozi Pan Head PT Type 648449 Filter Capacitor Chap 5 Issue 1 Page 28 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 32 32 1 32 2 32 3 32 4 32 5 32 6 32 7 32 8 33 Removing the Terminal Block Remove the front case Refer to Page 9 Section 8 Remove the red Transformer wires and the capacitor from Terminals T3 and T4 on the Terminal Block Fig 16 Item 10 Remove the red Main PCB wires from Terminals T1 and T2 on the Terminal Block Fig 16 Item 10 Remove the two live wires from Terminal T8 on the Terminal Block Fig 16 Item 10 Remove the neutral wire from Terminal T7 on the Terminal Block Fig 16 Item 10 Remove the two red compressor wires from Terminals T5 and T6 on the Terminal Block Fig 16 Item 10 Remove the single securing screw Fig 16 Item 20 You can now remove the Terminal Block Fig 16 Item 10 Installing the Terminal Block CAUTION Whilst completing the installation ensure all wires are free from 33 1 33 2 33 3 33 4 33 5 33 6 33 7 33 8 Issue 1 enirapment Place the Terminal Block Fig 16 Item 10 into position ensuring it is seated correctly Replace the single securing screw
3. A ALDA JO AVE A awh H ad 1 Mattress Visual Inspection 1 Pump Visual Inspection ve ee ee i i s s k k s k k k k k R R R R R R R R R k R 1 Pump Flow Pressure and Function Test 1 Flow and Pressure lt 5 1 Electrical Testing ad K ave RE RR eer RIS AER Nue RUE bo Re Ea rk 2 Electrical Safety lt 5 55 2 Functional Test ss Sup k R R ae ee Sa 3 Power Fail Alami Check l iun a ee Lore e nee La 3 Low Pressure Alarm Check 3 Service Alarm Check e scu v a w a RY T s a sm a 3 Mattress Inflation Test ul ku S la d RR iR orn 3 End Settirig c E a i e a Er Spr e R A K d de d ius 4 CHAPTER 5 Pump Repair i3 tte Wh anena hee he dr CS I c Ar he feed 1 General S A ao fa a Yuhu nu o D Ae Sa te ug upi Rod 1 Removing the Air Filter ers k s as a s k b Rs 3 Replacing the Air Filter is su s ka snak na a aa sa a a a a 5 3 Removing The Bed Hooks iss sss nk a sk saa a e ee is 5 Replacing the Bed 5 5 Removing the Mains Power Fuses 2 2 ee ee ee ee ee ee ee ee ee ee is 7 Installing the Mains Power 7 Re
4. 1 Issue 1 Page iv SER0018 April 2010 Alpha Active 4 Service Manual Introduction CHAPTER 1 INTRODUCTION 1 About This Manual ArjoHuntleigh 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 ArjoHuntleigh be responsible for any service performed by customers or third parties This manual contains information on maintenance servicing repair troubleshooting and testing for the Alpha Active 4 system which comprises of a pump and a mattress replacement Read and understand this manual before attempting to service or repair the equipment Numbering and Cross Referencing in this Manual For all chapters in this manual Page section and paragraph numbering re start at 1 Figure and table numbering continue from the previous chapter Cross references which include a chapter number and or chapter title refer to text in a different chapter Cross references which do NOT include any chapter number or chapter title refer to text within the same chapter 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
5. EN r n DO 9 HOO 1 QO T5 40 T2 D T6 MI T7 T4 DO T8 Figure 8 Compressor Fitment Removal Table 9 Compressor Assembly Part Number Description 30 648408 Compressor REF Compressor Outlet REF Compressor Mounting Plate 648425 Terminal Block T Piece Connector Chap 5 Page 12 SER0018 Issue 1 April 2010 Alpha Active 4 Service Manual Pump Repair 12 12 1 12 2 12 3 12 4 12 5 13 13 1 13 2 13 3 13 4 Issue 1 Removing the Compressor Assembly Remove the front case Refer to Page 9 Section 8 Remove the two red wires from the Terminal Block terminals T5 and T6 Pull these wires free from other wiring within the rear case noting the routing of the wires Remove the Compessor air outlet feed Fig 8 Item 20 from the compressor Fig 8 Item 10 Lift the compressor assembly Fig 8 Item 10 away Installing the Compressor Assembly Place the compressor assembly into the rear case ensuring the mounting plate Fig 8 Item 30 sits in its moulding within the case Replace the compressor air feed Fig 8 Item 20 to the new compressor Fig 8 Item 10 Route the compressor wires as required and connect to the appropriate terminals on the Terminal Block Reassemble the case Refer to Page 9
6. Part Number Figure 23 3 Way Connector Table 23 3 Way Connector Parts List Description Chap 6 Page 12 648442 648443 3 Way Connector Tri bore tubing 9 5mm ID x 14 5mm OD x 1370mm SER0018 Issue 1 April 2010 Alpha Active 4 Service Manual Mattress Repair 12 Removing 3 Way Connector 12 1 With the tubeset Fig 23 Item 20 held securely in one hand pull the top of the 3 way connector Fig 23 Item 10 away from the tubeset as shown in Figure 23 O 12 2 Pull the bottom of the 3 way connector away from the tubeset Figure 23 12 3 You can now pull the 3 way connector away Fig 23 Item 10 13 Installing 3 Way Connector Note Orientation of this part is un important 13 1 Align the tubeset Fig 23 Item 20 with the barbs on the rear of the 3 way connector Fig 23 Item 10 13 2 Push the tubeset fully onto the connector until all three tubes contact the base of the connector 13 3 Ensure the 3 way connector Fig 23 Item 10 is securely fitted to the tubeset Fig 23 Item 20 Issue 1 Chap 6 April 2010 SER0018 Page 13 Mattress Repair Alpha Active 4 Service Manual Chap 6 Issue 1 Page 14 SER0018 April 2010 Alpha Active 4 Service Manual Technical Specification CHAPTER 7 TECHNICAL SPECIFICATION PUMP Model Alpha Active 4 Part Numbers 648311 UK 648314 German 6
7. 22 4 Onthe main PCB disconnect 22 4 14 The transformer connection from J1 22 4 2 The Rotor Stator microswitch cable from J4 22 4 3 The Rotor Stator cable from J3 22 4 4 The twin live connector from J7 22 4 5 The 4 way connector from J2 22 4 6 The Rotor Stator tubing Fig 11 Item 20 from U3 22 5 Remove the four corner fixing screws Fig 11 Item 30 and lift the Main PCB Fig 11 Item 10 out of the pump case 23 Replacing the Main PCB 23 1 Place the Main PCB with its component side facing upward into position in the rear case ensuring alignment of the four corner fixing holes in Main PCB Fig 11 Item 10 with the pillars in the rear case Fit the four retaining screws Fig 11 Item 30 23 2 Connect to the Main PCB 23 2 1 The Rotor Stator tubing to US 23 2 2 The 4 way connector to J2 23 2 3 The twin live connector to J7 23 2 4 The Rotor Stator cable to J3 23 2 5 The Rotor Stator microswitch cable to J4 23 2 6 The transformer connection to J1 23 3 Plug the ribbon cable into the connector on the Main PCB within the rear case Note If Main PCB Display PCB ribbon cable has been disconnected from both the PCB s ensure upon re connecting that the location keys are in correct orientation 23 4 Using thumbs carefully push down on the ribbon connector until the two securing clips click into place over it 23 5 Re fit the front case Refer to Page 9 Section 9 Issue 1 Chap 5 April 2010 SER0018 Page 19 Pump
8. Display PCB Ribbon Connector 1 60 648423 Hose Connector Alpha Active 4 1 Chap 5 Issue 1 Page 8 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 8 Removing the Front Case WARNING BEFORE DISMANTLING THE PUMP ENSURE UNIT HAS BEEN ISOLATED 8 1 8 2 8 3 8 4 8 5 8 6 8 7 9 2 9 3 9 4 9 5 Issue 1 FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET Place the pump unit face down on a clean flat surface Unscrew the five screws Fig 6 Item 30 Carefully turn the pump over collecting the five screws Fig 6 Item 30 keeping them in a safe place Carefully pull apart the two cases ensuring the compressor remains in the rear case Note The front case contains a PCB connected via a ribbon to the main PCB in the rear case Within the front case on the Display PCB pull apart the two ribbon securing clips Remove the ribbon from the Display PCB The front case is now removed Replacing the Front Case Place the pump rear case Fig 6 Item 20 on a flat surface with the inner components facing upward Plug the Main PCB Display PCB ribbon cable into the rear of the display PCB ribbon connector Fig 6 Item 50 within the front case Using thumbs carefully push down on the ribbon connector until the two securing clips click into place over it Place the front case Fig 6 Item 10 on top of the rear case Fig 6 Item 20 ensuring that no wires are trapped Careful
9. Fig 16 Item 20 Replace the two red compressor wires to Terminals T5 and T6 on the Terminal Block Fig 16 Item 10 Replace the neutral wire from the Main PCB Connector J2 and the On Off switch to Terminal T7 on the Terminal Block Fig 16 Item 10 Replace the two live wires from the Main PCB Connector J2 and the On Off switch to Terminal T8 on the Terminal Block Fig 16 Item 10 Replace the red Transformer wires and the capacitor to Terminals T3 and T4 on the Terminal Block Fig 16 Item 10 Replace the red Main PCB wires to Terminals T1 and T2 on the Terminal Block Fig 16 Item 10 Re fit the front case Refer to Page 9 Section 9 Chap 5 April 2010 SERO0018 Page 29 Pump Repair Alpha Active 4 Service Manual Chap 5 Issue 1 Page 30 SER0018 April 2010 Alpha Active 4 Service Manual Mattress Repair CHAPTER 6 MATTRESS REPAIR 1 General This chapter details repair procedures for the Alpha Active 4 Mattress Replacement All repairs should be carried out by ArjoHuntleigh approved service personnel It is easier to carry out the repair procedures in this chapter if the mattress is fully deflated first Disconnect the tubeset between the mattress and the pump to deflate the mattress After carrying out a service or any of these repairs on the mattress check the following 1 1 All press studs on the mattress are connected 1 2 All cell assemblies are securely held by their straps The repair will normally have di
10. NaDCC Issue 1 Chap 7 April 2010 SER0018 Page 3 Technical Specification Alpha Active 4 Service Manual Chap 7 Issue 1 Page 4 SER0018 April 2010 Alpha Active 4 Service Manual CHAPTER 8 SPARE PARTS 1 Pump Assembly Parts List Part Number 648410 648418 648419 648447 648449 648401 648402 648403 648404 648405 648420 648421 648428 648425 648408 648422 648429 648449 MIS106 648423 648406 648407 Description Mains Power Cable Euro Mains Power Cable UK Mains Power Cable AUS Ferite 28mm Ferite 12mm Front Case Rear Case Bed Hook Air Filter Air Filter Grill Display PCB Main PCB Battery Terminal Block Compressor Rotor Stator Assembly Transformer Filter Capacitor Mains Fuse 1A Time Lag T Fuse Hose Connector Alpha Active 4 Fuse Holder Mains Switich 2 Mattress Assembly Parts List Part Number 648437 648461 648438 Issue 1 April 2010 Description Top Cover 195cm x 90cm printed with logo Top Cover 195cm x 85cm printed with logo Base Cover 195cm x 90cm SERO0018 Spare Parts Fig Item 15 10 15 20 15 30 6 10 3 10 4 30 3 NA 3 20 6 40 11 10 12 20 16 10 8 10 9 10 10 10 16 30 5 20 6 60 14 10 13 10 Fig Item 18 10 18 20 Qty Qty Chap 8 Page 1 Spare Parts Part Number 648463 648465 648442 648444 648441 648439 648440 648467 648468 648470 648471 648436 648443 BP196 Chap 8 Page 2 Description Base Cover 19
11. 4 Service Manual 10 Figure 14 Removing the Fuse Holder Housings Table 15 Fuse Holder Housings Part Number Description 648406 Fuse Holder Chap 5 Issue 1 Page 24 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 28 Removing the Fuse Holder Housing 28 1 Remove the front case Refer to Page 9 Section 8 28 2 Forthe right Fuse Holder Housing 28 2 1 Remove the live Mains Power Cable spade connector from the side of the fuse holder 28 2 2 Remove the live On Off Switch spade connector from the top of the fuse holder 28 2 3 Unscrew nut and remove the Fuse Holder from the pump 28 3 For the left Fuse Holder Housing 28 34 Remove the neutral Mains Power Cable spade connector from the side of the fuse holder 28 3 5 Remove the neutral On Off Switch spade connector from the top of the fuse holder 28 3 6 Unscrew nut and remove the Fuse Holder from the pump 29 Installing the Fuse Holder Housing 29 1 Forthe right Fuse Holder Housing 29 1 1 Secure the Fuse Holder to the pump 29 1 2 Connect the live On Off Switch spade connector to the top of the fuse holder 29 1 3 Connect the live Mains Power Cable spade connector to the side of the fuse holder 29 2 Forthe eft Fuse Holder Housing 29 2 4 Secure the Fuse Holder to the pump 29 2 5 Connect the neutral On Off Switch spade connector to the top of the fuse holder 29 2 6 Connect
12. Chap 2 Page 1 Troubleshooting Alpha Active 4 Service Manual Chap 2 Issue 1 Page 2 SER0018 April 2010 Alpha Active 4 Service Manual Maintenance CHAPTER 3 MAINTENANCE WARNING BEFORE DISMANTLING THE PUMP ENSURE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET WARNING A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS WHEN THE BACK COVER IS REMOVED EVEN WITH THE PUMP SWITCHED OFF CAUTION Static Sensitive Devices This pump should only be opened by personnel trained in ESD methods and with appropriate equipment and anti static protection 1 Pump Service A pump should be serviced every 12 months To carry out a service on the pump do the following 1 1 Carry out the Pump Maintenance Checks Refer to Page 1 Section 2 1 2 Replace the air inlet filter 2 Pump Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with Pump Repair 2 1 Visually inspect the following for damage wear and potential faults Base of Pump Check base is free from debris nlet Filter Check condition Compressor Check compressor seating Electrical Connections Check connections are secure and completely insulated Tubing Check completely pushed on and are kink free Power Switch Check switch illuminates when ON Wiring Check wiring is intact Check electrical insulation are not damaged Air flow Check air flow is alternating Outlet Tubes Ch
13. Repair Alpha Active 4 Service Manual J4 J3 J7 ES 00 Figure 12 Removing the Power Fail Battery Table 13 Power Fail Battery Parts List Part Number Description 648421 Main PCB Alpha Active 4 648428 Battery Cable Tie Chap 5 Issue 1 Page 20 SERO0018 April 2010 Alpha Active 4 Service Manual Pump Repair 24 24 1 24 2 24 3 25 25 1 25 2 25 3 25 4 25 5 Issue 1 Removing Power Fail Battery Remove the front case Refer to Page 9 Section 8 Remove the Main PCB Refer to Page 19 Section 22 De solder the battery connections from the PCB Replacing Power Fail Battery Place the battery Fig 12 Item 20 onto the PCB Fig 12 Item 10 ensuring the correct polarity Solder both the positive and negative connections Secure battery to PCB using tie wrap Fig 12 Item 30 Replace the PCB Refer to Page 19 Section 23 Re fit the front case Refer to Page 9 Section 9 Chap 5 April 2010 SER0018 Page 21 Pump Repair Alpha Active 4 Service Manual 2A 1A Figure 13 Removing the On Off Switch Table 14 On Off Switch Parts Item Part Number Description Qty 10 648407 Mains On Off
14. S Vassingeredvej 52 3540 Lynge Denmark T 45 4 913 8486 F 45 4 913 8487 Germany HNE Huntleigh Nesbit Evans Healthcare GmbH Im H lsenfeld 19 40721 Hilden Germany T 49 0 2103 97 11 0 F 49 0 2103 97 11 80 India ArjoHuntleigh India Pvt Ltd 8 Shah Industrial estate Off Shah Industrial estate Off Veera Desai Road Andheri West Mumbai 400 053 India New Zealand ArjoHuntleigh Ltd Unit 6 38 Eaglehurst Road Ellerslie Auckland NZ T 64 9 525 2488 F 64 9 525 2433 Sweden Huntleigh Liljenberg AB Box 30012 200 61 Limhamm Sweden T 46 40 36 03 50 F 46 40 49 43 75 Chap 9 SERO0018 Page 1 Service Contact Details UK ArjoHuntleigh Limited 310 312 Dallow Road Luton Bedfordshire LU1 1TD T 44 0 1582 413104 F 44 0 1582 459100 Spain ArjoHuntleigh SL C de la Creueta 25 08130 Santa Perpetua de la Mogoda Barcelona T 34 93 5745754 F 34 93 5745861 Chap 9 Page 2 Alpha Active 4 Service Manual United States of America ArjoHuntleigh 2349 W Lake Street Suite 250 Addison IL 60101 USA Tel 1 630 307 2756 Toll Free US 800 323 1245 Fax 1 630 307 6195 Japan ArjoHuntleigh Japan K K 4 1 15 Goko Dori Chuoku Kobe 651 0087 T 81 78 231 8735 F 81 78 231 8736 Issue 1 SERO018 April 2010 ARJOHUNTLEIGH GETINGE GROUP With people in mind Therapy amp Prevention Product Division ArjoHuntleigh 310 312 Dallow Road Luton Bedfordshire
15. connectors to the microswitch Re fit the front case Refer to Page 9 Section 9 Removing the Rotor Stator Assembly Remove the front case Refer to Page 9 Section 8 Remove the four tubing connections to the Rotor Stator noting their connection locations Remove the two spade connectors from the Rotor Stator microswitch noting wires connections Push down on the Rotor Stator assembly Fig 9 Item 10 and remove the securing pin D Remove the complete rotor stator assembly C B A from the top of the gearbox Installing the Rotor Stator Assembly Refering to Figure 9 17 1 1 Place the spring A onto the gearbox spindle as shown 17 1 2 Place the bottom of the Rotor Stator B onto the gearbox spindle 17 1 3 Pushing down on the bottom section of the Rotor Stator place the top half of the Rotor Stator C onto the gearbox spindle AND while applying pressure slide the securing pin D through the spindle as shown 17 1 4 Ensure the securing pin D is seated within the recess on the top of the rotor stator assembly Re connect the two spade connectors to the Rotor Stator microswitch Connect the four tubing connections to the Rotor Stator Re fit the front case Refer to Page 9 Section 9 Removing the Gearbox Assembly Remove the rotor stator assembly Refer to Page 15 Section 16 Remove the two securing screws Fig 9 Item 20 Remove the Gearbox PCB connector from J3 on the Main PCB You can now remove the Gearbo
16. that hold the transformer Fig 10 Item 10 in place You can now remove the transformer Fig 10 Item 10 Installing the Transformer Place the transformer Fig 10 Item 10 into position in the rear case ensuring it is correctly seated and orientation is so that the Main PCB wires are in the direction of the PCB Fit the two securing screws Fig 10 Item 20 Re connect the red wires to Terminals T3 and T4 on the Terminal Block Note Ensure red wires run under all tubing and that the capacitor remains connected to Terminals T3 and T4 Re connect the transformer connection to the Main PCB J1 Re fit the front case Refer to Page 9 Section 9 Chap 5 April 2010 SERO0018 Page 17 Pump Repair Alpha Active 4 Service Manual eZ F T J4 J3 J7 ES 00 Figure 11 Removing the Main PCB Table 12 Main PCB Parts List Part Number Description 648421 Main PCB Alpha Active 4 REF Stator To Pressure Switch Tubing Screw M3x8mm Pozi Pan Head PT Type Chap 5 Issue 1 Page 18 SERO0018 April 2010 Alpha Active 4 Service Manual Pump Repair 22 Removing the Main PCB 22 1 Remove the front case Refer to Page 9 Section 8 22 2 On the Main PCB Fig 11 Item 10 pull apart the two ribbon securing clips at connector 22 3 Remove the ribbon cable from the Main PCB Fig 11 Item 10
17. 0018 Page 1 Pump Repair Alpha Active 4 Service Manual Figure 3 Replace the Air Filter Table 4 Replace the Air Filter Parts List Part Number Description 648402 Rear Case Alpha Active 3 and 4 648405 Air Filter Cover 648404 Air Filter Replacement Chap 5 Issue 1 Page 2 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 2 1 2 2 2 3 3 1 3 2 3 3 Issue 1 Removing the Air Filter Place the pump unit face down on a clean flat surface Press firmly on the retaining clip of the air filter housing and lift the Air Filter housing Fig 3 Item 20 away Carefully lever out the the Air Filter from the housing Fig 3 Item 20 Replacing the Air Filter Place the new air filter in the air filter housing Fig 3 Item 20 Place the air filter housing Fig 3 Item 20 into the rear case Fig 3 Item 10 by ensuring that the two securing lugs align with the holes provided Carefully press down on the air filter housing retaining clip and ensure it the housing has been securely fitted into the rear case you should hear a CLICK confirming proper fitment Chap 5 April 2010 SERO0018 Page 3 Pump Repair Alpha Active 4 Service Manual Part Number Figure 4 Replacement of Bed Hooks Table 5 Bed Hook Parts List Description 648402 Rear Case Alpha Active 3 and 4 REF Bed Hook Cover 648403 Chap 5 Page 4 Bed Hook Alpha Activ
18. 439 Standard Cell 90cm Wide 648440 Ventilated Cell 90cm Wide 648467 Standard Cell 85cm Wide 648468 Ventilated Cell 85cm Wide 648470 Standard Cell PU 85cm Wide 648471 Ventilated Cell PU 85cm Wide REF Upper Cell Feed Part of Item 10 REF Lower Static Cell Feed Part of Item 10 REF T Piece REF Single Bore Tubing Issue 1 REF Press Stud Male Press Stud Female Located Inside Mattress Base Cover Chap 6 April 2010 SERO0018 Page 5 Mattress Repair SER0018 Alpha Active 4 Service Manual CORO EO D 60 L RO B Continued from point A Figure 20 Manifold Tubing Issue 1 April 2010 Alpha Active 4 Service Manual Mattress Repair 7 Replacing Manifold Tubing 7 1 Remove the top cover Refer to Page 3 Section 3 7 2 Disconnect the press studs from each end of the cell Fig 19 Item 60 7 3 Disconnect the lower Fig 19 Item 30 and upper Fig 19 Item 20 cell feed connectors from the T Pieces Fig 19 Item 40 7 4 Connect the upper Fig 19 Item 20 and lower Fig 19 Item 30 cell feed connectors to each T Pieces Fig 19 Item 40 Note Installing the cell feeds is made easier if the cell connector and or T Piece is wetted immediately prior to insertion 7 5 Reconnect the male press studs to the female studs Fig 19 Item 60 at the end of the cell 7 6 Install the top cover Refer to Page 3 Section 4 Table 20 Cell Assembly Parts
19. 48315 Euro 648319AU Australia Supply Voltage 230V Supply Frequency 50 60Hz Power Input 230VA Size L 280mm x W 205mm x H 112mm Weight 2 5kg Case Material ABS Plastic Plug Fuse Rating 5A to BS1362 UK ONLY Pump Fuse Rating T1AL 250V Degree of protection Class II Double Insulated against electric shock Type BF Degree of protection against liquid ingress IPXO Mode of operation Continuous Cycle Times 10 mins 20 mins Inflate 4 5 mins Inflate 9 5 mins Crossover 30 secs Crossover 30 secs Deflate 4 5 mins Deflate 9 5 mins Crossover 30 secs Crossover 30 secs SYMBOLS Power Do not dispose of O Off Disconnects from x in the domestic EN 3 Alternating Current Double Insulated the mains supply refuse I On R to the iu M Type BF A a Mende mains supply documents Fuse 4 Dangerous voltage If shown on pump Ref Model number SN Serial Number label Issue 1 Chap 7 April 2010 SERO0018 Page 1 Technical Specification Alpha Active 4 Service Manual ENVIRONMENTAL INFORMATION Condition Temperature Range Relative Humidity Atmospheric Pressure Operating Pump 10 C to 40 C 30 to 75 700hPa to 1060 hPa Storage and Transport Pump 40 C to 70 C 10 to 95 non condensing 500 hPa to 1060 hPa MATTRESS Description Cell Material Base Pad Material ALPHA ACTIVE 4 MR 90 Polyurethane PVC Ny
20. 5cm x 85cm Base Cover PU 195cm x 85cm Tubeset Connector Alpha Active 4 Static Feed Check Valve CPR Assembly Standard Cell 90cm Wide Ventilated Cell 90cm Wide Standard Cell 85cm Wide Ventilated Cell 85cm Wide Standard Cell PU 85cm Wide Ventilated Cell PU 85cm Wide Single bore tubing Tri bore tubing Tie Wrap SERO0018 Alpha Active 4 Service Manual Fig item Qty 23 10 22 10 21 10 19 10 19 10 20 NA 20 70 20 21 Issue 1 April 2010 Alpha Active 4 Service Manual Service Contact Details CHAPTER 9 SERVICE CONTACT DETAILS Africa Huntleigh Africa Pty Ltd William Cruywagen Avenue Stand 120 Klerksoord Pretoria T 27 12 542 4680 F 27 12 542 4982 Belgium ArjoHuntleigh NV SA Stapelplein 70 9000 Gent Belgium T 32 9 265 8770 F 32 9 265 8771 France HNE M dical 451 Chemin de Champivost BP20 69579 Limonest Cedex France T 33 0 4 78 66 62 66 F 33 0 4 78 66 62 67 Holland ArjoHuntleigh BV Antennestraat 45 1322 AH Almere Holland T 31 36 533 5588 F 31 36 547 5075 Middle East Huntleigh Technology PLC 307 Sh Zayed Road Dubai United Arab Emirates Singapore ArjoHuntleigh Pte Limited Block 603 Elias Road 08 232 Singapore 510603 T 61 8 9 309 3083 F 60 8 9 309 4582 Issue 1 April 2010 Australia ArjoHuntleigh Pty Limited PO Box 330 Hamilton Hill Western Australia 6963 T 61 8 9 337 4111 F 61 8 9 337 9077 Denmark ArjoHuntleigh A
21. ALPHA ACTIVE 4 SYSTEM ARJOHUNTLEIGH j GETINGE GROUP Service Manual Alpha Active 4 Service Manual CONTENTS CHAPTER 1 Introduction About This Manual 2 222 Numbering and Cross Referencing in this Manual Warnings Cautions and Notes Technical Description Alpha Active 4 Pump Cycle Options Qu a lan Dana Alpha Active 4 Mattress Replacement Pneumatic and Electrical Diagrams Front Panel s i erga de sb aad Controls and Indicators On Off Switch 2 2 2222 2 k 2 2 Alarm Mute Mode Select Uu S V S 9 ru R V R Auto firm Mode Pressure Contrdl CydeTime Alarms and Indicators Service Indicator Pump Fault Power Fail Indicator CHAPTER 2 Troubleshooting Troubleshooting Table CHAPTER 3 Maintenance Pump Service Pump Maintenance Checks MattressService MattressMaintenanceChecks Alarm Functions Power Fail Alarm Low Pressure Indicator Service Pump Fault Issue 1 April 2010 SERO018 Page i Alpha Active 4 Service Manual CHAPTER 4 Testing ii
22. Alarm Check 4 4 Close all three ports Operate the on off switch to on verify that after 10 seconds the SOLID LOW PRESSURE indicator is extinguished 4 5 Open all ports to atmosphere Verify that after 10 seconds the red LOW PRESSURE indicator flashes in conjunction with the audible alarm Service Alarm Check To check the operation of the Service alarm it is necessary to have the case halves open WARNING ENSURE PUMP IS DISCONNECTED FROM THE POWER SUPPLY 4 6 Open the case halves Refer to Chapter 5 Page 9 Section 8 4 7 Disconnect the micro switch from the PCB connector J4 Chapter 1 Page 4 Section 2 4 8 Close the case halves 4 9 Connect the mains power cable to a suitable power socket outlet and close all three ports Operate the on off switch to on 4 10 The service indicator should operate within 10 seconds 4 11 Operate the on off switch to off position disconnect the power supply at the power socket outlet 4 12 Open the case halves and reconnect the micro switch to the PCB connector J4 Chapter 1 Page 4 Section 2 4 13 Close the case halves Refer to Chapter 5 Page 9 Section 8 4 14 Connect the mains power cable to a suitable power socket outlet and close both ports Operate the on off switch to on 4 15 The service indicator should be extinguished 5 Mattress Inflation Test 5 1 Test the complete system to ensure correct operation Issue 1 Chap 4 April 2010 SER0018 Page 3 Tes
23. E USED IF YOU HAVE A HEARING AID OR PACEMAKER FITTED DUE TO THE POSSIBILITY OF ELECTROMAGNETIC DISTURBANCE Specification 4 0 kVac is applied between the connected Live and Neutral wires and the foil applied to the device s enclosure No breakdown should occur Chap 4 Issue 1 Page 2 SERO0018 April 2010 Alpha Active 4 Service Manual Testing 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 carried out Functional Test Tests must be carried out using a 220 240V 50Hz power supply Test Setup and Initial Switch On 4 1 Set the pressure control to minimum 20kg and ensure that all three 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 or flowtron stopper part number 5077 to close all three ports and verify that the LOW PRESSURE indicator goes off Power Fail Alarm Check 4 3 With the pump operating disconnect the power supply at the power socket outlet Verify that within 5 seconds the red POWER FAIL indicator flashes in conjunction with an audible alarm Reconnect the power supply Verify the POWER FAIL indicator is extinguished Low Pressure
24. Fuse Holder Housing 2 22 Removing the Installing the Mains Power Cable Removing the Terminal Installing the Terminal CHAPTER 6 Mattress Repair General sa m br hr EUER ORAS Alpha Active 4 Removing The Top Cover Installing the Top Removing Cell Assembly 1212 1211 u 2 k k k k k k k k k Installing Cell Assembly u ee k k k k k k k k Replacing Manifold Tubing ii 2 k 2 k 2 k k 004 Removing CPR Assembly ee k k k 2 k k k k Installing CPR Assembly u k k k 2 k Removing Static Feed Check Valves Installing Static Feed Check Valves Removing 3 Way Connector 222 2 2 2 k k k eee Installing 3 Way Connector CHAPTER 7 Cover Cleaning Symbols D c a CHAPTER 8 Spare Paris comu E ld v GRE orada Rein a Pump Assembly Parts List 222 2 2 k 2 k k k k Issue 1 April 2010 SER0018 Page iii Alpha Active 4 Service Manual Mattress Assembly 5 5 1 CHAPTER 9 ServiceContactDetallS
25. LU1 1TD United Kingdom T 44 0 1582 413104 F 44 0 1582 459100 W www arjohuntleigh com ArjoHuntleigh is a branch of Arjo Ltd Med AB Arjo Ltd Med AB Registered No FC024121 ArjoHuntleigh Registered No BRO10203 England Registered Office As Above pril 2010 lt o Q ac C 93 42 EEC 943447 MEMBER OF THE GETINGE GROUP
26. List Part Number Description REF 50mm Cut to length from 648436 REF 84mm Cut to length from 648436 REF 40mm Cut to length from 648436 REF 140mm Cut to length from 648436 REF 64mm Cut to length from 648436 REF 184mm Cut to length from 648436 648436 Single bore tubing ID 9 5mm x OD14 5mm 648443 Tri Bore Tubing 648444 Static Check Valve 648441 CPR Issue 1 Chap 6 April 2010 SER0018 Page 7 Mattress Repair Alpha Active 4 Service Manual N Head Cells Removed For Drawing Clarification Figure 21 CPR Assembly Table 21 CPR Assembly Parts List Part Number Description 648441 Chap 6 Issue 1 Page 8 SER0018 April 2010 Alpha Active 4 Service Manual Mattress Repair 8 1 8 2 8 3 8 4 9 1 Note 9 2 9 3 Issue 1 Removing CPR Assembly Remove the top cover Refer to Page 3 Section 3 Disconnect the press studs from cells either side of the CPR assembly Disconnect the feed tubes from either side of the CPR unit Remove CPR Assembly from mattress Fig 21 Item 10 Installing CPR Assembly Connect the feed tubes from either side of the CPR unit Installing the feed tubes is made easier if the CPR unit connectors are wetted immediately prior to insertion Reconnect the press studs to each end of the cell Install the top cover Refer to Page 3 Section 4 Chap 6 April 2010 SER0018 Page 9 Mattress Repair Alpha A
27. Section 9 Chap 5 April 2010 SERO0018 Page 13 Pump Repair Alpha Active 4 Service Manual Microswitch omitted for clairity Figure 9 Removing the Rotor Stator Assembly Part Number Table 10 Rotor Stator Assembly Description 648422 Rotor Stator Alpha Active 4 REF Screw M3x10mm Pozi Pan Head PT Type REF Rotor Stator Spade Connectors 648427 Gearbox Assembly 648417 Microswitch REF Chap 5 Page 14 Microswitch Securing Screw M3x15mm Pozi Pan Head PT Type Issue 1 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 14 14 1 14 2 14 3 14 4 15 15 1 15 2 15 3 16 16 1 16 2 16 3 16 4 16 5 17 17 1 17 2 17 3 17 4 18 18 1 18 2 18 3 18 4 19 19 1 19 2 19 3 Issue 1 Removing the Microswitch Assembly Remove the front case Refer to Page 9 Section 8 Remove the two spade connectors from the Rotor Stator microswitch noting wires connections Remove the two securing screws Fig 9 Item 60 that hold the microswitch in place You can now remove the Microswtich Fig 9 Item 50 Installing the Microswitch Assembly Place the microswitch Fig 9 Item 50 into position and secure with the two securing screws Re connect the two spade
28. Switch 1 Chap 5 Issue 1 Page 22 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 26 26 1 26 2 26 3 26 4 26 5 27 27 1 27 2 27 3 27 4 27 5 27 6 Issue 1 Removing the On Off Switch Remove the front case Refer to Page 9 Section 8 Lift the On Off switch Fig 13 Item 10 away from the rear pump case Remove the two live spade connectors from the back of the On Off Switch terminals 1 and 1A Remove the two neutral spade connectors from the back of the On Off Switch terminals 2 and 2A You can now remove the On Off Switch Fig 13 Item 10 Installing the On Off Switch Re connect the live spade connector that runs from the Main PCB to terminal 1 Refer to Figure 13 on the rear of the On Off Switch Re connect the live spade connector that runs from a fuse holder to terminal 1a Refer to Figure 13 on the rear of the On Off Switch Re connect the neutral spade connector that runs from the Terminal block and Main PCB to spade terminal 2 Refer to Figure 13 on the rear of the On Off Switch Re connect the neutral spade connector that runs from a fuse holder to spade terminal 2a Refer to Figure 13 on the rear of the On Off Switch Place the On Off Switch Fig 13 Item 10 into position in the rear case ensuring the two live wires are facing outwards from the case Re fit the front case Refer to Page 9 Section 9 Chap 5 April 2010 SER0018 Page 23 Pump Repair Alpha Active
29. ctive 4 Service Manual Yellow To Cells To Pump Figure 22 Static Feed Check Valve Table 22 Static Section Feed Valve Parts List Part Number Description 648444 Static Feed Check Valve BP196 Tie Wrap Chap 6 Issue 1 Page 10 SER0018 April 2010 Alpha Active 4 Service Manual Mattress Repair 10 Note 10 1 10 2 10 3 10 4 10 5 11 Removing Static Feed Check Valves There are 3 Static Feed Check Valves on the Alpha Active 4 Two at the head end and one at the foot end Remove the top cover Refer to Page 3 Section 3 Release the pop studs on three surrounding cells for easier access to the Check Valve Remove the two cable ties Fig 22 Item 20 located on either side of the Check Valve Fig 22 Item 10 barbs Seperate the tubes away from the Check Valve Remove the Check Valve Fig 22 Item 10 Installing Static Feed Check Valves CAUTION Ensure correct orientation is followed during this installation 11 1 11 2 11 3 11 4 11 5 Issue 1 Refer to Page 10 Figure 22 Place the Check Valve Fig 22 Item 10 in position Connect the two tubes to the Check Valve Fig 22 Item 10 barbs Secure the tubing with two cable ties Fig 22 Item 20 Secure the three cells pop studs that were released in Para 10 2 Install the top cover Refer to Page 3 Section 4 Chap 6 April 2010 SER0018 Page 11 Mattress Repair Alpha Active 4 Service Manual
30. e 3 and 4 Issue 1 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 4 1 4 2 4 3 4 4 4 5 4 6 5 1 5 2 5 3 5 4 5 5 5 6 Issue 1 Removing The Bed Hooks Place the pump unit face down on a clean flat surface Ensure the Bed Hook is folded against the pump Using a small flat tool remove the Bed Hook Cover by inserting the tool into the aperture on the top edge of the cover Remove the two securing screws from the Bed Hook Bracket Note You may be required to gently lever the bracket away from the pump in order to fully remove it If so do this via the top edge of the recess and ensure you place a free hand over the bracket to prevent its loss Rotate the hook 90 and remove from the pump casing Repeat Para 4 2 to Para 4 5 for the other Hook Replacing the Bed Hooks Firmly insert the new Hook Fig 4 Item 30 at 90 to the pump case into the corresponding recess Whilst applying pressure to the hook rotate it so it is folded in against the pump Position the Bed Hook Bracket and fit the two retaining screws To refit the Bed Hook Cover 5 4 1 Clean all previous glue residue off from both the cover and the recess lip 5 4 2 Apply an instant adhesive Loctite 460 or similar to the lip within the recess of the pump case 5 4 3 Firmly press the Bed Hook cover into position Repeat for the other Hook Assemble the case Refer to Page 9 Section 9 Chap 5 April 2010 SERO0018 Pa
31. e cable 3 Pump Flow Pressure and Function Test You will also need Asphygmomanometer or pressure gauge 0 160mmHg flow meter 0 10 litres minute To carry out a system functional test complete the following procedures Flow and Pressure Checks Electrical Testing Functional Test The following procedures must be carried out after a service or major repair of the pump To test calibrate pump correctly the following equipment or equivalent is required Note All test equipment must be calibrated to national or international standards Flow and Pressure Checks 3 1 Set the pressure control on the pump to maximum 200kg setting 3 2 Connect a dual flow pressure meter via a valve to whichever outlet is working 3 3 X Open the valve fully The free flow rate should not be less than specified in the table below Air Flow Air Flow 20mmHg 50mmHg 6 litres min 3 litres min Issue 1 Chap 4 April 2010 SERO0018 Page 1 Testing Alpha Active 4 Service Manual 3 4 Close the valve and operate the pressure control on the pump from minimum 20kg to maximum 200kg setting The pressure indicated on the gauge in mmHg should be as specified in the table below Minimum Pressure Maximum Pressure 20kg 200kg 25mmHg x 5mmHg 75mmHg 5mmHg 3 5 Repeat for the remaining ports 4 Electrical Testing To test and calibrate the pump unit correctly the following equipment is required Test E
32. eck tubes are secure Issue 1 Chap 3 April 2010 SERO0018 Page 1 Maintenance Alpha Active 4 Service Manual 3 Mattress Service To carry out a service on the mattress do the following 3 1 Carry out the Mattress Maintenance Checks Refer to Page 2 Section 4 4 Mattress Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with Mattress Repair 4 1 Visually inspect the following for damage wear and potential faults Base and Top Cover Check for tears staining clarity of printed labels Base Top cover Zip Check the zip runs freely and condition of zip teeth Fixing Straps Check condition and security Connectors Check for damage and security Tubing Check for security and ensure no kinks or twists Cells Check for damage Manifold Check for damage and security Press Studs Check condition CPR Check operation of Fast Deflate mechanism Tubeset Assembly Check for damage and security of connection 4 2 Carry out a function test on the pump mattress system in accordance with Chapter 4 5 Alarm Functions Power Fail Alarm Switch pump off at mains power socket leaving the pump switched on The red power fail indicator will illuminate when a mains power failure has been detected An audible alarm will sound until power is resumed or the pump is switched off using the on off button Low Pressure Indicator 5 1 Block the air outlets on the pump 5 2 Switch the
33. ective icon indicates the currently selected mode Auto firm Mode Selects the Auto firm non alternating mode The orange indicator will illuminate when the pump is in this mode Autofirm operates for 30 minutes Pressure Control Two buttons and are used to set the pressure inside the mattress replacement and therefore the amount of support the patient receives The pressure setting is indicated by the green indicator above the selected setting Cycle Time A single button allows the cycle time to be selected for the most appropriate patient therapy The cycle time setting is indicated by the green indicator above the selected setting Chap 1 SER0018 Page 5 Introduction Alpha Active 4 Service Manual 6 Alarms and Indicators Low Pressure Indicator The red Low Pressure indicator is illuminated whenever the pump detects low pressure e within the mattress replacement An audible alarm will sound unless cancelled by the mute button The indicator will extinguish once normal pressure is reached Refer To Troubleshooting on page 14 for possible causes of Low Pressure Service Indicator Pump Fault The yellow Service pump fault indicator will illuminate and remain on if the pump has e A detected an internal fault An audible alarm will sound unless cancelled by the mute button Power Fail Indicator The red Power Fail indicator will illuminate when a mains power failure has been detected An audible alarm will sound un
34. followed could result in equipment failure or damage Notes given in this manual are used to explain or amplify a procedure or condition WARNING BEFORE PERFORMING ANY SERVICE OR MAINTENANCE PROCEDURES ENSURE THAT THE EQUIPMENT HAS BEEN ADEQUATELY DECONTAMINATED WARNING 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 Alpha Active 4 system comprises of a mattress replacement and pump The product can be used on hospital and domestic beds in both domestic and care environments The bed base must be suitable for the specified mattress size Alpha Active 4 Pump The Alpha Active 4 pump comprises of a moulded case with non slip feet on the base and integral hanging brackets Issue 1 Chap 1 April 2010 SERO018 Page 1 Introduction Alpha Active 4 Service Manual The controls are situated on the front of the pump and a sophisticated alarm system differentiates between normal operation and genuine system faults lf an alarm situation is detected an indicator will illuminate on the front of the pump and an audible warning will sound Cycle Options The pump has a user selectable option for operating on either a ten minute or twenty minute cycle 10 minutes Cycle In this alternating mode the system has a cycle time of 10 minu
35. ge 5 Pump Repair Alpha Active 4 Service Manual Figure 5 Position of Mains Power Fuses Table 6 Mains Power Fuses Parts List Part Number Description 648402 Rear Case MIS106 Mains Fuse 1A Time Lag T Fuse Chap 5 Issue 1 Page 6 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair 6 Removing the Mains Power Fuses WARNING BEFORE DISMANTLING THE PUMP ENSURE UNIT HAS BEEN ISOLATED 6 1 6 2 6 3 7 1 7 2 7 3 Issue 1 FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET Place the pump unit face down on a clean flat surface Using a flatbladed screwdriver remove the fuse holder from the back of the rear case by unscrewing anti clockwise Pull the blown fuse from its holder Installing the Mains Power Fuses Firmly push the new fuse into its holder Place the fuse holder into position on the back of the rear case Using a flatbladed screwdriver tighten clockwise until tight Chap 5 April 2010 SER0018 Page 7 Pump Repair Alpha Active 4 Service Manual Figure 6 Front Case Removal Fitment Table 7 Case Assembly Item Part Number Description Qty 10 648401 Front Case Alpha Active 4 1 20 648402 Rear Case Alpha Active 3 and 4 1 30 REF Screw M3x15mm Pozi Pan Head PT Type 5 40 648420 Display PCB Alpha Active 4 1 50 REF Main PCB
36. lon Coated ALPHA ACTIVE 4 MR 85 Polyurethane PVC Nylon Coated ALPHA ACTIVE 4 MR Non PVC 85 Polyurethane PU Coated MATTRESS SIZE INFORMATION Part No Description alee Length Width Height over mm mm mm 648322 ALPHA ACTIVE 4 MR 90 648437 1950 900 35 200 8 77 648324 ALPHA ACTIVE 4 MR 85 648461 1950 850 33 200 8 77 648326 ALPHA ACTIVE 4 MR 85 PU 648461 1950 850 33 200 8 77 Chap 7 Issue 1 Page 2 SERO0018 April 2010 Alpha Active 4 Service Manual Technical Specification COVER SPECIFICATION Feature Standard Rou Dartex Removable Cover Yes Moisture Vapour Permeable Yes Air Permeable No Low Friction Yes Water Resistant Repellent Yes Infection Control Material coating is Bacteriostatic fungistatic antimicrobial Fire Retardant BS 7175 0 1 amp 5 2 Way Stretch Yes Washing Conditions MAX 95 C 203 F for 15 mins Drying Conditions Tumble Dry up to 130 C 266 F or Air Dry Life Span 50 Wash Cycles minimum Application Area Acute and Homecare 1 Check your local policy to determine the time temperature ratio required to achieve thermal disinfection CLEANING SYMBOLS Wash at 80 C 176 F ors Do not tumble dry above 50 C Do not iron Do Not Use Phenol based cleaning Solutions Wipe surface with damp cloth Use solution diluted to 1000 ppm of Available 1000ppm Chlorine NaOCI
37. ly turn the pump over so the front is face down Install the five screws Fig 6 Item 30 to the rear case and tighten Chap 5 April 2010 SERO0018 Page 9 Pump Repair Alpha Active 4 Service Manual en Part Number Figure 7 Replacing Display PCB Table 8 Display PCB Parts List Description 648420 Display PCB REF Screw M3x8mm Pozi Pan Head PT Type REF Chap 5 Page 10 Location Lug Issue 1 SERO0018 April 2010 Alpha Active 4 Service Manual Pump Repair 10 Removing the Display PCB 10 1 Remove the Front case Refer to Page 9 Section 8 10 2 Remove the eight fixing screws Fig 7 Item 20 from the display PCB 10 3 Carefully lift the Display PCB Fig 7 Item 10 out of the front casing 11 Installing the Display PCB 11 1 Insert the base of the Display PCB Fig 7 Item 10 into position within the front casing guiding the square holes on the PCB to the location lugs Fig 7 Item 30 within the front case 11 2 Refit the eight fixing screws Fig 7 Item 20 11 3 Replace the Front case Refer to Page 9 Section 9 Issue 1 Chap 5 April 2010 SER0018 Page 11 Pump Repair Alpha Active 4 Service Manual RARE R AR AI EI AI AI AK AI AK AR A AK A AI ILL mum JA J3 J37 _J2 AN dagin
38. moving the Front Case b Jy less 9 Replacing the Front Case E d a a a dg es e woa s a a RR o aa 9 Removing the 11 Installing the 11 Removing the Compressor Assembly k 2 k k k k k k R k k K k K k k k 13 Installing the Compressor Assembly 1 111 122 i ee k k k k k k k K k K k k K 13 Removing the Microswitch 5 15 Installing the Microswitch Assembly 15 Removing the Rotor Stator 5 15 Installing the Rotor Stator Assembly 15 Removing the Gearbox Assembly 15 Installing the Gearbox Assembly u k k k k k k k k R k R k k R k R k k 15 Removing the 17 Installing the 17 Removing the Main lll ss 19 Issue 1 Page ii SERO0018 April 2010 Alpha Active 4 Service Manual Replacing the Main lens Removing Power Fail Battery Replacing Power Fail Battery Removing the On Off Switch ee 2 2 k k k Installing the On Off Switch Removing the Fuse Holder Housing 2 Installing the
39. pump on and allow Low Pressure indicator to extinguish 5 3 Remove the blockage from the air outlets The red Low Pressure indicator will illuminate and and audible alarm will sound Service Pump Fault The yellow service pump fault indicator will illuminate and remain on if the pump has detected an internal fault Refer to Troubleshooting to help diagnose the fault refer to Chapter 2 Chap 3 Issue 1 Page 2 SERO0018 April 2010 Alpha Active 4 Service Manual Testing CHAPTER 4 TESTING CAUTION Electrostatic discharge can seriously damage the Main PCB Prior to replacing it adequate earthing precautions must be taken Note In all cases the pump and mattress must be tested together as a system 1 Mattress Visual Inspection Ensure that the mattress is checked as follows 1 1 All studs must be secure and all inlet connectors fitted securely 1 2 The mattress contains 19 cells which are studded to both sides of the mattress The bottom of each cell connected to the static feed the top half connected to the alternating feed the head section cells top half are connected to the static feed Ensure that the cells are retained centrally by the loops in the base cover 2 Pump Visual Inspection 2 1 Ensure there are no cracks or marks on the pump case Ensure the labels are intact and readable Check there are no marks or fractures in the Pump outlet module 2 2 Ensure the mains lead is fully secure and there are no cuts or damage to th
40. quipment Insulation Resistance Tester Megger 500 Vdc Portable Appliance Tester Multimeter Continuity Tester Dielectric strength tester Flash tester 3 0 kVac with current limit CHECK 4 0kVac Electrical Safety Checks Class II 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 2MQ This test can be conducted by using a Portable Appliiance 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 efforts of the capacitive current and gives an early warning of any electrical problems developing in the appliance WARNING 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 WARNING THIS EQUIPMENT SHOULD NOT B
41. ress Make sure the feet symbol is at the foot end of the mattress Secure the two zips on the long sides of the mattress Fig 18 Item 30 to the correct side of the top cover Fig 18 Item 10 Chap 6 April 2010 SER0018 Page 3 Mattress Repair Alpha Active 4 Service Manual x ES Feed To Head End Feed From Foot End Figure 19 Cell Assembly Chap 6 Issue 1 Page 4 SERO0018 April 2010 Alpha Active 4 Service Manual Mattress Repair 5 1 5 2 5 3 5 4 6 1 6 2 Note 6 3 6 4 Removing Cell Assembly Remove the top cover Refer to Page 3 Section 3 Disconnect the press studs from each end of the cell Fig 19 Item 60 Disconnect the lower Fig 19 Item 30 and upper Fig 19 Item 20 cell feed connectors from the T Pieces Fig 19 Item 40 Pull the cell out of the retaining loop in the base cover and remove from the mattress Installing Cell Assembly Pass the cell through the loop on the air pad cover and centralise the cell Connect the upper Fig 19 Item 20 and lower Fig 19 Item 30 cell feed connectors to each T Pieces Fig 19 Item 40 Installing the cell feeds is made easier if the cell connector and or T Piece is wetted immediately prior to insertion Reconnect the male press studs to the female studs Fig 19 Item 60 at the end of the cell Install the top cover Refer to Page 3 Section 4 Table 19 Cell Assembly Parts List Part Number Description 648
42. sturbed the position of the other cells and they should be re positioned accordingly 2 Alpha Active 4 Cell Layout Retaining Loops Head end Foot end Head cells Torso cells Leg Foot cells Upper Section Static cells Alternating Micro Air Loss Alternating CI D NO Yi Ya LX D D D DE R I I I 1 I Lower Section Remains Static Remains Static Remains Static Figure 17 Mattress Cell Layout Issue 1 Chap 6 April 2010 SER0018 Page 1 Mattress Repair Alpha Active 4 Service Manual Part Number Figure 18 Alpha Active 4 Mattress Table 18 Alpha Active 4 Mattress Description 648437 Mattress Top Cover 90cm Wide 648461 648438 Mattress Top Cover 85cm Wide Mattress Base Cover 90cm Wide 648463 Mattress Base Cover 85cm Wide 648465 Mattress Base Cover PU 85cmWide REF Zip 648442 Tubeset Connector Alpha Active 4 648443 Chap 6 Page 2 Tri bore tubing 9 5mm ID x 14 5mm OD x 1370mm SERO0018 Issue 1 April 2010 Alpha Active 4 Service Manual Mattress Repair 3 1 3 2 3 3 4 2 Issue 1 Removing The Top Cover Fully unroll the mattress on a suitable surface Undo the zips Fig 18 Item 30 on both sides of the top cover Remove the top cover Installing the Top Cover Position the top cover Fig 18 Item 10 on to the matt
43. tes Each full cycle consists of 4 5 minutes inflate 30 seconds change over 4 5 minutes deflate and 30 seconds changeover 20 minutes Cycle In this alternating mode the system has a cycle time of 20 minutes Each full cycle consists of 9 5 minutes inflate 30 seconds change over 9 5 minutes deflate and 30 seconds changeover Alpha Active 4 Mattress Replacement Each of the air cells is split into two sections The base section of each being linked together to provide a static section which provides protection from the effects of bottoming out The Alpha Active 4 cover is water resistant and vapour permeable to enhance patient comfort whilst protecting the cells from ingress of contaminants The cover is simple to clean in situ but may easily be removed for laundering preventing cross contamination In the event of cardiac arrest the mattress replacement can be rapidly deflated to allow cardiac resuscitation procedure CPR to be performed Table 1 Available Mattress Sizes Spare Width Part No Description Cover mm 648322 ALPHA ACTIVE 4 MR 90 648437 1950 77 900 35 200 8 648324 ALPHA ACTIVE 4 MR 85 648461 1950 77 850 33 200 8 648326 ALPHA ACTIVE 4 MR 85 PU 648461 1950 77 850 33 200 8 Chap 1 Issue 1 Page 2 SERO0018 April 2010 Alpha Active 4 Service Manual Introduction 3 Pneumatic and Electrical Diagrams
44. the neutral Mains Power Cable spade connector to the side of the fuse holder 29 3 the front case Refer to Page 9 Section 9 Issue 1 Chap 5 April 2010 SERO0018 Page 25 Pump Repair Alpha Active 4 Service Manual 1 MH Go e SE co CCL 20 20 P Figure 15 Removing the Mains Power Cable Table 16 Mains Power Cable Part Number Description 648410 Mains Cable Euro Alpha Active 4 648447 Ferrite 28mm 648449 Ferrite 12mm Chap 5 Issue 1 Page 26 SERO0018 April 2010 Alpha Active 4 Service Manual Pump Repair 30 30 1 30 2 30 3 30 4 30 5 31 31 1 31 2 31 3 31 4 Issue 1 Removing the Mains Power Cable Remove the front case Refer to Page 9 Section 8 Remove the live spade connection from the side of the right fuse holder Remove the neutral spade connection from the side of the left fuse holder Remove the two ferrite beads from the Mains Power Cable You can now remove the Mains Power Cable Installing the Mains Power Cable Place the Mains Power Cable in position in the side of the rear case Re connect the neutral spade connector to the side of the left fuse holder Re connect the live spade connector to the side of the right fuse holder Re fit the front case Refer to Page 9 Section 9 Chap 5 April 2010 SER0018 Page 27 Pump Repair Alpha Active 4 Service Manual 9 JA J3 J7 J2 B SS 001000000 See
45. til power is restored or the pump is switched off using the on off switch ese Chap 1 Issue 1 Page 6 SERO018 April 2010 Alpha Active 4 Service Manual Troubleshooting CHAPTER 2 TROUBLESHOOTING 1 Troubleshooting Table The following table contains fault symptoms their possible causes and suggests steps to rectify the problem These may occur during initial installation and power up Table 2 Troubleshooting Table Symptom Possible Cause Action Low Pressure Alarm Mattress e lt Tube set not connected securely Check the tube set connector and ensure it is securely fitted to the pump CPR not fully closed Close CPR Unit Cell Leak Trace and replace faulty part Low Pressure Alarm Pump e lt Damaged Disconnected tube Check Replace Faulty Compressor Check Replace Chapter 5 Page 13 Section 12 Blocked Air Filter Check Replace Chapter 5 Page 3 Section 2 Power Fail Alarm eve Power has been removed from the pump Blown Fuse Re apply power or switch the pump off Check Replace Chapter 5 Page 7 Section 6 Service Alarm Issue 1 April 2010 Pump has detected internal fault Trace and replace faulty part Faulty Microswitch Test and Replace if required Chapter 5 Page 15 Section 14 Faulty Gearbox SER0018 Check Replace if required Chapter 5 Page 15 Section 18
46. ting Alpha Active 4 Service Manual 6 End Setting 6 1 Disconnect the mattress from the pump and coil up the mains cable Expel all the air from the mattress The system is now ready to be packed Chap 4 Issue 1 Page 4 SER0018 April 2010 Alpha Active 4 Service Manual Pump Repair CHAPTER 5 PUMP REPAIR WARNING BEFORE DISMANTLING THE PUMP ENSURE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE CORD PLUG FROM THE WALL OUTLET 1 General This chapter details repair procedures for the Alpha Active 4 Pump Unit All repairs should be carried out by ArjoHuntleigh approved service personnel If any cable ties are cut so as to enable removal of parts replacement ties must be fitted as part of the install procedure Table 3 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 4 Page 1 Section 3 To carry out the electrical tests on the pump refer to Chapter 4 Page 2 Section 4 Table 3 Repair to Testing Requirements Components Assemblies Function Test Electrical Safety Tests Front Casing Yes Yes Rear Casing No Yes Display PCB Yes Main PCB Yes Bed Hooks Yes Compressor Yes Rotor Stator Assembly Yes Mains Lead Yes Mains Switch Yes Terminal Block Yes Transformer Yes Air Filter Yes Oulet Connector Yes Issue 1 Chap 5 April 2010 SER
47. x Assembly Fig 9 Item 40 Installing the Gearbox Assembly Place Gearbox assembly Fig 9 Item 40 into position in the rear case ensuring the wires exit the Gearbox in the direction of the compressor Secure with the two securing screws Fig 9 Item 20 Refer to Installing the Rotor Stator Assembly Chap 5 April 2010 SERO0018 Page 15 Pump Repair Alpha Active 4 Service Manual gt J4 J3 J7 _J2 guon D DO DO 20 L Part Number 10 Figure 10 Removing the Transformer Table 11 Transformer Description 648429 Transformer Alpha Active 4 REF Chap 5 Page 16 Screw M3x10mm Pozi Pan Head PT Type SER0018 Issue 1 April 2010 Alpha Active 4 Service Manual Pump Repair 20 20 1 20 2 20 3 20 4 20 5 21 21 2 21 3 21 4 21 5 Issue 1 Removing the Transformer Remove the front case Refer to Page 9 Section 8 On the main PCB disconnect the transformer connection from J1 Remove the red wires from Terminals T3 and T4 on the Terminal Block Note Ensure the capacitor remains connected to Terminals T3 and T4 Remove the two securing screws Fig 10 Item 20

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