Service Manual
Contents
1. st YS Re e j The following tools are required 1 Switch off power supply to the 2 Using a soft cloth to protect 3 Use a Phillips Head Screwdriver ae Control Unit disconnect the Air the unit from damage place to remove the four screws that Phillips Head Screwdriver Sas Hoses and remove the power the Control Unit on a level secure the housing Place the Wire Clippers cord from the electrical socket in work surface with base facing screws and washers in a safe The following spare parts are the base of the unit upwards place such as small container required or jar to prevent loss Hold the unit firmly and turn it over face 1x PCB in known working upwards on its base condition M8260143 4 Gently loosen the top and bottom Be careful not to drag the internal 5 Disconnect the four electronic 6 Disconnect the remaining three housing Once loose hold the wires and tubing during this power leads by cutting the connections from the PCB two power socket IEC connector process Before continuing ensure cable ties that secure the leads flat digital leads and one air tube to prevent from catching while no electrical leads are stretched to the PCB Carefully pull the Be sure to note the location of all lifting the top cover and leaning it and that all electrical connectors plastic casing not the wiring to seven connections on the circuit back on your work surface on the Printe2. Service Procedure Flowchart Follow the flowchart to establish the recommended steps for system check and repair 0 ruse Bhedkand Printed Circuit Fanei TallS tO activate STILL CONFIRMS when unit is connected Replacement 0 3 PCB Replacement lt to a power source Return to Manufacturer Control Unit is Basic System Checks operational but check power amp STILL LOW standard PRESSURE fails to reach operation power cords Air Hose PRESSURE Pressure Test OK Air Leak Test Attachments CPR Tag pressure or loses pressure Air Cell attachment Compressor Air Cell Replacement Replacement operational but Motor Return to the motor is grinding or Replacement Manufacturer making an unusual sound OTHER PROBLEM Return to Manufacturer SERVICE MANUAL Fuse Check and Replacement Testing fuse for damage and replacing a blown fuse Control Unit failure may be the result of a blown fuse Always check the fuse before opening the unit and performing any other internal component test procedures Note When changing the replaceable fuse use same rating fuse only T1AL 250V mm a 3 The following tools are required 1 Switch off power supply to the 2 Using a level surface place the 3 Insert a small screwdriver into the Control Unit and remove the Control Unit on its base with easy groove on the fuse cap and turn Flat Head Screwdriver foe sees power cord from the electric
3. 1 13 Synchronous Motor Replacement see tantaku antt u natt 1 ana RAA AEA REEEEAREEEEEEEEEEEEEEEEEEEEEEEEEEE EREEREER EEEE EEEE EEEE E 15 Connector Replacement 7 7 1 14 18 Connector Plate 1 11111 0 0 19 APRIO Man ONINO i 7 1 11111 21 111 11111 0 22 Hanging Hook Replacement 1 1 7 7 0 13 24 233 13 1 26 1111 0 29 DYNA FORM AIR PRO PLUS A The following section outlines the steps and procedures to follow if there is a suspected fault in the Control Unit A lf a repair Seems unmanageable or the issue falls outside the scope of serviceable repairs please return the Control Unit to the Manufacturer Malfunction of the Control Unit may be due to the failure of one of the replaceable electrical components of the Control Unit including the compressor print circuit board and timing motor rotary valve Alternatively a lack or loss of system pressure can be attributed to a variety of causes including an incorrectly attached CPR Tag a loosely connected or leaking Air Cell leaking Air Hose or faulty fuse Insufficient system pressure is identified when the Visible LED flashes and the corresponding Pressure Setting Warning signals displa
4. X Direct Healthcare Dyna Form Air Pro Plus Service Manual DIRECTHEALTHCARESERVICES CO UK Dyna Form X Air Pro Plus Definition of Symbols Used A Caution Warning of possible hazard to system patient or staff A Warning of possible electrical hazard A Important operational information Contents COOU tive acs eee 4 EA SS 5 5 EEO A E EE E EE E A E TEE E E A EEEE 7 Fuse Check and Replacement 1 1 1111111111111111 8 Printed Circuit Board PCB 3 1 9 PUD BREDIACCTNBNIE 00 10 11
5. replacing 1 Check the Control Unit is connected to mains power outlet with the correct voltage 2 Check the Control Unit is switched on Switch off and disconnect the unit before restarting 3 Check the Control Unit with a spare power cord in known working condition Control Unit Fuse Check and Replacement Control Unit Printed Circuit Board Check and Replacement Control Unit operational but red Visual LED illuminates Mattress fails to reach or drops below accepted minimum level Mattress fails to inflate The system may have an air leak The Air Filters may need cleaning or replacing 1 Check the Handle is securely attached to the Control Unit 2 Check the CPR Tag is intact ensuring all sealing connectors are fully fitted to the Mattress air pipes 3 Check all pipes along the inside of the Mattress each should be firmly connected 4 Check each Air Cell and or Side Bolster is securely attached to the connecting air pipe 5 Check all cells pipes and pipes for any air leakage 6 Check air filter covers are secure and air filters are clean Control Unit Air Filter Maintenance Control Unit Compressor Check and Replacement The Control Unit is grinding or making an unusual noise The Synchronous Motor timing motor may be damaged Control Unit Synchronous Motor Replacement The Mattress Is inflated but static head cells are still deflated system ma
6. DYNA FORM AIR PRO PLUS Synchronous Motor Replacement Replacing a faulty synchronous motor The synchronous motor runs the rotovalve that operates the timing mechanism for the alternation cycle If the rotovalve becomes worn or damaged it no longer spins smoothly and the unit will emit a distinct grinding noise If you hear an uncharacteristic noise from the motor when the Control Unit is switched on the synchronous motor needs to be replaced _ TY i fr F y ete 3 Use a Phillips Head Screwdriver to remove the four screws that secure the housing Place the screws and washers in a safe place such as small container or jar to prevent loss Hold the unit firmly and turn it over face upwards on its base The following tools are required 1 Switch off power supply to the Control Unit disconnect the Air Hoses and remove the power cord from the electrical socket in the base of the unit 2 Using a soft cloth to protect the unit from damage place the Control Unit on a level work surface with base facing upwards Phillips Head Screwdriver Wire Clippers or sharp knife Flat Head Screwdriver small 7 32 Inch Socket Wrench The following replacement parts are required 1 x Synchronous Motor M8260147 1x Cable Tie 4 Gently loosen the top and bottom housing Once loose hold the power socket IEC connector to prevent from catching while lifting the top cover and leani
7. Unit disconnect the Air unscrew the damaged quick male or female as appropriate Hoses and remove the power release connector from the and turn clockwise to tighten until The following replacement parts cord from the electrical socket in side of the unit by turning it firm are required the base of the unit counterclockwise a degree of Male Connector M8260121 force may be required to initially loosen the connector Female Connector M8260122 DIRECTHEALTHCARESERVICES CO UK 19 DYNA FORM AIR PRO PLUS Connector Plate Replacement Replacing the Connector Plate lf the inset Connector Plate is cracked or damaged or if itis not possible to gain leverage on a damaged or snapped single connector for individual replacement the Connector Plate must be replaced The following tools are required 3 Use a Phillips Head Screwdriver to remove the four screws that secure the housing Place the screws and washers in a safe place such as small container or jar to prevent loss Hold the unit firmly and turn it over face upwards on its base 1 Switch off power supply to the Control Unit disconnect the Air Hoses and remove the power cord from the electrical socket in the base of the unit 2 Using a soft cloth to protect the unit from damage place the Control Unit on a level work surface with base facing upwards Phillips Head Screwdriver Adjustable Wrench The following replacement parts are required C
8. or other defect compressor and reattach the with the Mattress Close the Control internal air hose using gentle Unit and proceed to Mattress pressure to ensure a firm fit procedures 10 Holding the top and bottom 11 Use a Phillips Head Screwdriver housing firmly together turn the to replace the four screws plus Control Unit upside down with washers and tighten to secure base facing upwards the housing together DIRECTHEALTHCARESERVICES CO UK 8 Before closing the housing make sure all power leads and hoses are free from the side edges Ensure the regulator tubing will not kink when the top cover is closed 12 Connect the Control Unit to mains power and switch on the unit to confirm operation 13 DYNA FORM AIR PRO PLUS Compressor Replacement Replacing a faulty compressor Having established a fault with the compressor by following the completing the Standard Pressure Test procedure detailed previously steps 1 through 6 replace the faulty compressor with a new compressor The following tools are required 7 Switch off power supply to the 8 Using Wire Clippers or a sharp 9 Check the internal compressor power Wire Clippers or sharp knife Control Unit and remove the knife carefully cut and remove lead and air hose is disconnected l power cord from the electrical the cable tie securing the power before removing the eight rubber Needle Nosed Pliers socket in the base of the unit leads between the two
9. spring connection spring and base mount DIRECTHEALTHCARESERVICES CO UK 209 DYNA FORM AIR PRO PLUS Hanging Hook Replacement sf 7 Slide the hook into the spring 8 Insert the U shaped silver 9 Replace the plastic housing and 10 Replace the foam mounting and push the hook into the base bracket over the shaft between use the Phillips Head Screwdriver strip by aligning sticky side over mount the teeth and the plastic bracket to replace the three screws to housing and firmly pressing to secure adhere If the original foam mounting is destroyed peel protective back off new foam mounting and adhere 11 Check the smooth movement of the hooks 26 DIRECTHEALTHCARESERVICES CO UK Troubleshooting The following section outlines a list of common troubleshooting issues together with recommended initial checks and subsequent Technical Service steps and procedures to follow if there is a suspected fault in the System A If a repair seems unmanageable the issue falls outside the scope of serviceable repairs or the problem persists following the recommended service checks and repair procedures please return the faulty System Control Unit Mattress or both to the Manufacturer Problem Cause Initial Checks Technical Service Procedure Control Unit does not operate no display lights illuminate The Control Unit may not be attached to a power source The power cord may be damaged A fuse may need
10. upwards to secure the housing together not kink when the top cover is including the air hose connectors closed fuses and power connector DIRECTHEALTHCARESERVICES CO UK DYNA FORM AIR PRO PLUS Air Filter Maintenance Cleaning and replacing the air filters Good filter maintenance is critical to maintain the Control Unit in optimal operating condition Failure to maintain clean filters may result in system downtime and increased repair costs It is recommended that the air filter be replaced each year as a minimum Always check and replace air filters as part of any standard maintenance or service procedure The following tools are required 1 Switch off power supply to the 2 Using a soft cloth to protect 3 Using a suitable tool such as Control Unit disconnect Air Hoses the unit from damage place 2mm flat head screwdriver Fine Flat Head Screwdriver and remove the power cord from the Control Unit on a level gently press the clip on each air The following replacement parts the electrical socket in the base work surface with base facing filter cover to remove are required of the unit upwards 2x Filters M4248829 4 Remove each foam air filter for 5 Replace both air filters and refit cleaning or replacement The the filter covers ensuring the clip foam air filters and filter casings snaps into place may be washed with soap and water Rinse with plain water and dry thoroughly before returning to the Contro
11. Control Unit to 6 After the 30 minute warm up the expected pressure and air mains power and switch on The period has elapsed detach flow measurements If air flow unit must run for a minimum of the internal air hose from the measurements fail to meet the 30 minutes to warm up before compressor some force may specified minimum levels during pressure testing commences be required and replace with any stage of the pressure test the Leave the unit in a safe place the air hose from the Pressure compressor is not operating at full during the warm up period Test Equipment for directly 7 capacity and needs to be replaced connection to the compressor Remember that a 30 minute warm io a To check operational capacity of the compressor test each pressure setting as outlined in the following Steps The table above right summarises a Ensure the equipment is set b Slowly close the valve on the Air 0 Continue to increase back d Finish testing by fully closing to free flow mode i e no Flow Meter to reduce airflow air pressure resistance Slowly close the Air Flow Meter valve resistance or back pressure and simulate back pressure i e the valve on the Air Flow Meter maximum resistance The against the full flow of air from to emulate the weight of a patient until the Sohygmomanometer ball bearing inside the Air Flow the compressor The valve at lying on the mattress which pressure reading reache
12. Phillips Head Screwdriver to replace the four screws plus washers and tighten to secure the housing together 24 DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Hanging Hook Replacement Replacing the hanging hooks on the base of the unit Very rarely the metal hanging hooks located on the base of the Control Unit will become damaged or worn Either one or both hooks can be replaced The following tools are required 1 Switch off power supply to the 2 Using asoft cloth to protect 3 Gently peel back the two foam Phillips Head Screwdriver Control Unit disconnect Air Hoses the unit from damage place mounting strips to reveal the and remove the power cord from the Control Unit on a level plastic housing beneath The following replacement parts the electrical socket in the base work surface with base facing If careful enough the foam are required of the unit upwards mounts can be reused Hanging Hooks M8260117 Ensure the flat side of the teeth sit 4 Use a Phillips Head screwdriver 5 While holding the small silver to unscrew the three screws that bracket at the top of the spring and lay in position over the plastic against the unit secure the plastic housing Place with one hand use the head of the bracket the screws in a safe place Such as hook to push against the spring small container or jar to prevent and release the damaged hook loss Lift the plastic housing to The hook will slide free from the reveal the
13. afe place until time to replace the rotovalve when it can be reattached 8 Gently lift the plastic rotovalve up and over the shaft sliding the L shaped metal bracket through the black plastic handle at the side of the rotovalve to reveal the spring and synchronous motor beneath 9 Remove the spring and place it in a safe place for future replacement 11 Lift the motor off its mounts and remove ensuring the power lead does not get caught in the process Dispose of the faulty motor in an environmentally safe manner 12 Unpack the replacement motor Carefully thread the power lead under the base of the compressor cage before repositioning the new motor over the shaft and on its mounts ensuring bolt holes are correctly aligned 13 Replace the L shaped metal bracket over the bolt hole closest to the compressor it must be positioned to accommodate the plastic handle on the rotovalve If not correctly positioned the rotovalve will move during operation DIRECTHEALTHCARESERVICES CO UK 14 To test correct alignment of the 10 Using the socket wrench unscrew the two bolts that hold the motor in place noting the position of both the bolts and the L shaped metal bracket closest to the compressor This bracket helps secure the plastic rotovalve casing to the motor and should also be removed and placed in a Safe place with bolts for future replacement motor and bracket insert
14. al access to the black round fuse counterclockwise in the direction The following replacement parts socket in the base of the unit cap located on the side of the unit of the arrow quarter turn to are required closest to the connectors remove the fuse plug and single 250V fuse M8260138 ne 4 Visually inspect the fuse check 5 Insert anew fuse or the 6 Reconnect the power cord to the as damage may be due to a faulty if the metal filament inside the undamaged fuse into the plug Control Unit and switch on power compressor Proceed to Standard fuse cylinder is disconnected Push against the force of the supply Pressure Test procedure Or snapped and discard spring and turn clockwise with If Control Unit still fails to operate if damaged or re insert if the screwdriver quarter turn the problem may be due to a undamaged faulty circuit board Proceed to Printed Circuit Board Check procedure If the unit switches on but fuse blows again repeat the steps to replace the damaged fuse but do not reconnect power DIRECTHEALTHCARESERVICES CO UK DYNA FORM AIR PRO PLUS Printed Circuit Board PCB Check Testing for a faulty circuit board by piggybacking a working spare lf the Control Unit still fails to operate after checking and replacing a damaged fuse the next step is to test the Printed Circuit Board PCB for failure To determine if the PCB has failed always test the Control Unit using a working spare
15. both bolts to secure the motor but finger tighten only Gently place the rotovalve over the shaft to check the L shaped bracket is correctly positioned to slide through the plastic handle at the side of the rotovalve Once alignment is verified remove the rotovalve and using the 7 32 inch socket wrench tighten both bolts to firmly secure the motor in place Be careful not to overtighten 17 DYNA FORM AIR PRO PLUS Synchronous Motor Replacement 15 Reposition the spring over the 16 Ifthe top plastic casing of 17 Firmly push down on the 18 Reconnect the motor power lead shaft wider coils at the base the rotovalve has come lose rotovalve while replacing the split to the circuit board and attach a finer coils on top reposition it and hold firmly pin through the top of the shaft new cable tie to secure all power in place before replacing the A significant amount of pressure leads as before rotovalve over the shaft while is required to counteract the Sliding the L shaped bracket force of the spring through the plastic handle at the side of the rotovalve 19 Test the motor before closing the 20 Before closing the housing 21 Align the top and bottom 23 Use a Phillios Head Screwdriver housing Connect the Control make sure all power leads and housing before slowly pushing to replace the four screws plus Unit to mains power and switch hoses are free from the side closed Ensure the seal is washers and tighten to se
16. condition and Replacement Safety General Safety Precautions As Do not use this equipment in the presence of flammable anaesthetics Explosions could result The air intakes for the Control Units are at the sides of the unit To avoid the risk of blocking these intakes it is recommended that the unit be mounted on the footboard of a bed frame Should the bed not have a suitable footboard it is recommended that the unit be placed on a solid surface such as a table or on the floor Protection Against Hazards Fluids Avoid spilling fluids on any part of the Control Unit If spills do occur Disconnect the unit from the mains wall socket Clean fluids from the case Ensure that there is no moisture in or near the power inlet power switch and power plug before reconnecting the power supply Check the operation of controls and other components in the area of the spill Perform applicable checkout procedures Liquids remaining on the electronic controls can cause corrosion that may cause the electronic components to fail Component failures may cause the unit to operate erratically possibly producing hazards to patient and staff Disposal Dispose of the Air Filter Air Cells Foam inserts and or Mattress Top Cover according to local procedures and regulations At the end of useful life dispose of waste according to the European Union Waste Electrical and Electronic Equipment WEEE Directive and in compliance with releva
17. cure on to ensure the motor works edges Ensure the regulator properly aligned around the the housing together and rotovalve is turning with no tubing will not kink when the top housing including the air hose 0860 adverse noise It the Control Unit cover is closed connectors fuses and power mains power and switch on the fails to operate the unit needs to connector Control Unit to check function be returned to the Manufacturer for further repair or replacement Switch off power supply to the Control Unit before closing the housing Return the Control Unit to the manufacturer in line with standard procedures 22 Holding the top and bottom housing firmly together turn the Control Unit upside down with base facing upwards 18 DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Connector Replacement Replacing the air hose quick release connectors Both the male and or female quick release connectors on the side of the Control Unit can be removed and replaced in the event of damage or breakage single connectors can be unscrewed and replaced in the event of individual damage For more significant damage to the connector plate or when damaged connector cannot be removed the Connector Plate should be replaced Proceed to the Connector Plate Replacement procedure The following tools are required 1 Switch off power supply to the 2 Using an Adjustable Wrench 3 Insert the replacement connector Adjustable Wrench Control
18. d Circuit Board PCB disconnect board for easy replacement are firmly connected You may Leave the disconnected PCB in need to prop the top housing case the Control Unit during testing to prevent strain on the electrical cords DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Printed Circuit Board PCB Check 7 Take the working spare PCB and 6 Reconnect mains power switch If the Control Unit still does not reconnect all seven leads into the on the Control Unit and check operate the unit needs to be corresponding connectors four the Display Panel If the unit returmed tothe Manuracturer tor electronic leads two digital one now operates the internal PCB further repair or replacement air hose has failed and needs replacing Proceed to the Printed Circuit a Switch off power supply to the Board Replacement procedure for Control Unit remove the spare next steps PCB and reconnect the internal PCB reconnect the seven power leads to the circuit board before closing the housing b Return the Control Unit to the Manufacturer in accordance with standard procedures DIRECTHEALTHCARESERVICES CO UK DYNA FORM AIR PRO PLUS Printed Circuit Board PCB Check Replacing a faulty circuit board Having established a fault with the PCB by following the Printed Circuit Board Check procedure detailed previously steps 1 through 7 replace the faulty PCB with a new PCB The following tools are required 8 Switch off pow
19. ds base pliers and pulled firmly into place struts Ensure the compressor Replace the two screws before power lead does not get caught in tightening the loosened screws the process Dispose of the faulty compressor in an environmentally Safe manner DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Compressor Replacement 13 Visually check that each mount 14 Reattach the air hose to the 15 Reconnect the compressor 16 Before closing the housing is secure gently move the compressor using gentle power lead to the circuit board make sure all power leads and compressor within the cage pressure to ensure a firm fit and attach a new cable tie hoses are free from the side to ensure all mounts are to secure all power leads as edges Ensure the regulator connected and the compressor before tubing will not kink when the top is correctly suspended with the cover is closed metal cage 17 Align the top and bottom 18 Holding the top and bottom 19 Use a Phillips Head Screwdriver 20 Connect the Control Unit to housing before slowly pushing housing firmly together turn the to replace the four screws plus mains power and switch on closed Ensure the seal is Control Unit upside down with washers and tighten to secure the Control Unit to confirm properly aligned around the base facing upwards the housing together operation housing including the air hose connectors fuses and power connector DIRECTHEALTHCARESERVICES CO UK 15
20. e Lon y Llyn Caerphilly CF83 1BF UK T 44 0 845 459 9831 info directhealthcareservices co uk Asia Pacific Direct Healthcare Services PTY Ltd PO Box 562 Wembley Western Australia 6913 T 61 0 423 852 810 info directhealthcareservices com au
21. e firmly connected Check each Air Cell is Replacement audible warning securely attached to its connecting air pipe 4 Check all cells pipes and hoses for any air leakage 5 Check air filter covers are correctly secured and air filers are clean 6 Switch on Power Warning LED Pressure too 1 Reset the Warning LED turn off Power and press the Control Unit high audible warning mute button Standard Pressure N 2 Disconnect the air hoses to reduce pressure reconnect Test ee when pressure has decreased ABC 3 Check for twists in the air hoses between Control Unit and l l Mattress UA E 4 Switch on Power Warning LED Alternating 1 Reset the Warning LED turn off Power and press the Control Unit Mode Failure audible warning mute button standard Pressure no alternation 2 Disconnect the air hoses to reduce pressure reconnect Test 6 when pressure has decreased ABC audible warning Warning LED Power down 1 Press the audible warming mute button to silence the audible alarm Control Unit N 2 Check the power cord is firmly plugged into the Control Unit Fuse Check and check the Control Unit is connected to mains power outlet with Replacement 5 the correct voltage Control Unit ABO 3 Check the Control Unit is switched on Switch off and Printed Circuit disconnect the unit before restarting Board Check audible warning 4 Check the Control Unit with a spare power cord in Known working
22. e unit For feet Insert the long nose of the power socket IEC connector to process Before continuing damaged feet use the Needle rubber foot into the empty socket prevent from catching while lifting ensure no electrical leads are Nose Pliers to hold the rubber on the base of the unit pushing the top cover and leaning it back stretched and that all electrical base and remove from the casing from outside in on your work surface connectors on the Printed Circuit Board PCB are firmly connected You may need to prop the top housing case to prevent strain on the electrical cords DIRECTHEALTHCARESERVICES CO UK 23 DYNA FORM AIR PRO PLUS Rubber Feet Replacement 8 Once through the hole lay the 9 Before closing the housing make 10 Align the top and bottom 11 Holding the top and bottom bottom housing flat and use the sure all power leads and hoses housing before slowly pushing housing firmly together turn the Needle Nose Pliers to gently pull are free from the side edges closed Ensure the seal is Control Unit upside down with through until the rim of the foot Ensure the regulator tubing will properly aligned around the base facing upwards locks into place Move gently not kink when the top cover is housing including the air hose from side to side while pulling closed connectors fuses and power rather than applying direct connector upward force to avoid snapping the nose of the replacement foot 12 Use a
23. er supply to the 9 Using Needle Nosed Pliers unclip 10 Unpack the replacement PCB 1 Control Unit before disconnecting the PCB from the top housing Align the circuit board against the spare test PCB Disconnect Note the orientation of the PCB the four holes and carefully Phillips Head Screwdriver all seven leads while noting the before removing it from reconnect the clips by pressing The following replacement parts location of each lead the unit firmly into place are required on the circuit board Dispose of the faulty PCB in an 1 x PCB M8260143 environmentally safe manner 11 Reconnect all seven leads into 12 Before closing the housing 13 Align the top and bottom 15 Use a Phillips Head Screwdriver the corresponding connectors make sure all power leads and housing before slowly pushing to replace the four screws plus on the circuit board hoses are free from the side closed Ensure the seal is washers and tighten to secure edges Ensure the regulator properly aligned around the the housing together tubing will not kink when the housing including the air hose E top cover connectors fuses and power ee mains power and switch on ies the Control Unit to confirm 14 Holding the top and bottom operation housing firmly together turn the Control Unit upside down with base facing upwards 10 DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Standard Press
24. feel for a deflated cell under the patient s lower spine Any inner static cell will remain inflated however your hand should easily slide between patient and base c If patient is adequately suspended pressure setting can be lowered however this test should be repeated after approximately 20 minutes Mattress Service Procedures Troubleshooting Control Unit warning indicators Problem Cause Initial Checks Technical Service Procedure Warning LED Initial failure 1 Reset the Warning LED turn off Power and press the Control Unit Fuse audible warning mute button Check 2 Check the CPR Tag is intact ensuring all sealing and Replacement connectors are fully fitted to the Mattress air hoses Control Unit ABC 3 Check all air hoses along inside of the Mattress each Printed Circuit l should be firmly connected Check each Air Cell is Board Check audible warning securely attached to its connecting air pipe and Replacement 4 Check all cells pipes and hoses for any air leakage 5 switch on Power Warning LED Pressure too 1 Reset the Warning LED turn off Power and press the Control Unit Air low audible warning mute button Filter Maintenance N 2 Check the CPR Tag is intact ensuring all sealing Control Unit 6 connectors are firmly fitted to Mattress air hoses Compressor ABC 3 Check all air hoses along inside of the Mattress each Check and should b
25. halves of mounts that secure the compressor Phillips Head Screwdriver before disconnecting the the unit within the metal cage It is easier to The following replacement parts Pressure Test Equipment air extract each mount using a pair of hose needle nosed pliers to gently twist are required ne free rather than pulling directly with 1 x Compressor M8260139 force If rubber mounts break make 1x Cable Tie sure all pieces are removed from inside the unit Undamaged mounts can be reused IEI IF 10 Using a Phillips Head Screwdriver 11 Unpack the replacement 12 Secure the compressor to the metal cage by connecting the eight new loosen the two screws at the end compressor Carefully thread rubber mounts starting with four mounts on one side of the cage bottom of the cage furthest from the air the power lead through the base followed by top then four mounts on opposite side hose inlets Then remove the of the cage before sliding the When connecting mounts it helps to prop or hold the compressor screws Closest to the air hose new compressor into position within the cage to better align the mount holes Insert the tapered end inlets placing carefully aside with power lead closest to the of the rubber mount through the corresponding hole in the cage gently Tilt the cage upwards to slide the PCB and air hose connector pushing through until the mount can be twisted around the nose of the compressor over the housing positioned towar
26. l Unit Alternatively refit with a new filter recommended annually DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Rubber Feet Replacement Replacing the rubber feet on the base of the unit The Control Unit has four rubber feet at each corner of the base of the unit to cushion the unit when hanging against the foot of the bed or standing on the floor or other stable surface On occasion these rubber feet will fall out or become damaged Missing or damaged rubber feet should be replaced to maintain the stability of the Control Unit The following tools are required 1 Switch off power supply to the 2 Using a soft cloth to protect 3 Use a Phillips Head Screwdriver Phillips Head Screwdriver Control Unit disconnect Air Hoses the unit from damage place to remove the four screws that and remove the power cord from the Control Unit on a level secure the housing Place the Needle Nose Pliers the electrical socket in the base work surface with base facing screws and washers in a safe The following replacement parts of the unit upwards place such as small container are required or jar to prevent loss Hold the unit firmly and turn it over face Rubber Feet Set of four upwards on its base M8260118 4 Gently loosen the top and bottom 5 Be careful not to drag the internal 6 Lift the bottom housing up to 7 Unpack the replacement rubber housing Once loose hold the wires and tubing during this access the base of th
27. n connected by Hoses and remove the pore a Y piece to forma single air hose outlet Check all hose attachments are cord from the electrical socket in gt Sphygmomanometer ai the base of the unit mmHg reading secure before commencing the test Initially set the equipment to free flow l mode ensure the airflow valve at the front of the Air Flow Meter is fully open gt Air How Meter turn the valve clockwise to open Lom reading 2 Using a soft cloth to protect 3 Use a Phillips Head Screwdriver 4 Gently loosen the top and bottom housing Once loose hold the power the unit from damage place to remove the four screws that socket IEC connector to prevent from catching while lifting the top cover the Control Unit on a level secure the housing Place the and leaning it back on your work surface work surface with base facing screws and washers in a safe Be careful not to drag the internal wires and tubing during this process upwards place such as small container Bef m or jar to prevent loss Hold the efore continuing ensure no electrical leads are stretched and tha unit firmly and turn it over face all electrical connectors on the Printed Circuit Board PCB are firmly upwards on its base connected You may need to prop the top housing case to prevent strain on the electrical cords DIRECTHEALTHCARESERVICES CO UK 11 DYNA FORM AIR PRO PLUS Standard Pressure Test Base Pressure Air Flow 5 Reconnect the
28. ng it back on your work surface Be careful not to drag the internal wires and tubing during this process Before continuing ensure no electrical leads are stretched and that all electrical connectors on the Printed Circuit Board PCB are firmly connected You may need to prop the top housing case to prevent strain on the electrical cords 5 Using Wire Clippers or a sharp knife carefully cut and remove the cable tie securing the power leads between the two halves of the unit 6 Trace the power lead running from underneath the synchronous motor to its connection on the circuit board Disconnect this lead from the circuit board by carefully pulling the plastic casing not the wiring and gently remove the lead from under the compressor cage and leave it free DIRECTHEALTHCARESERVICES CO UK 7 Using thumb and forefinger push down firmly on the plastic rotovalve casing to release tension while removing the split pin a deal of downward pressure is required While maintaining downward pressure take a small screwdriver or other implement to gently lift the split pin from the top of the motor shaft Place the pin in a safe place for future replacement SERVICE MANUAL Synchronous Motor Replacement z LTA The rotovalve is made of two plastic circular casings held together by lubricant material and should remain attached during removal If the top casing comes free during this process place in a s
29. nt local regulations Power Cord The system should never be operated with a worn or damaged power cord Should the power cord be found to be worn or damaged replace immediately and dispose of the damaged cord Interference Although this equipment conforms to the intent of the Directive IEC 60601 1 2 in relation to Electromagnetic Compatibility all electrical equipment may produce interference If interference is suspected move equipment from sensitive devices or contact the Manufacturer IEC 60601 1 2 Medical Electrical Equipment Part 1 General Requirements for Safety Amendment No 2 Collateral Standard Electromagnetic Compatibility Requirements and Tests Care and Cleaning General Recommendations A Follow the Manufacturer s instructions as detailed below and in the applicable User Manual Failure to do so may result in cross contamination or equipment damage A To prevent cross contamination the Manufacturer recommends that the system be cleaned and laundered between patients according to the instructions below A Always disconnect the Control Unit from mains power before cleaning Do not spray disinfectant directly on to the unit or immerse the unit in any type of liquid Failure do so could result in equipment damage and or electric shock A Do not use high temperature autoclave steam cleaning devices or phenolic based cleaning products Use of either of these items could result in damage to equipment and or loss of
30. onnector Plate 6 Detach both internal air hoses from the inside of the Connector 5 Be careful not to drag the internal wires and tubing during this 4 Gently loosen the top and bottom housing Once loose hold the power 7 Unpack the replacement Connector Plate and slide into socket IEC connector to prevent from catching while lifting the top cover and leaning it back on your work surface process Before continuing ensure no electrical leads are stretched and that all electrical connectors on the Printed Circuit Board PCB are firmly connected You may need to prop the top housing case to prevent strain on the electrical cords Plate and slide the damaged plate from the side of the unit Dispose of the Connector Plate in an environmentally safe manner DIRECTHEALTHCARESERVICES CO UK place Ensure the male and female connectors are securely inserted Press firmly to reattach the internal air hoses as before SERVICE MANUAL Connector Plate Replacement 8 Before closing the housing make 9 Align the top and bottom housing 10 Holding the top and bottom 11 Using the Phillips Head sure all power leads and hoses before slowly pushing closed housing firmly together turn the Screwdriver to replace the four are free from the side edges Ensure the seal is properly Control Unit upside down with screws plus washers and tighten Ensure the regulator tubing will aligned around the housing base facing
31. oth dipped in warm soapy water wipe the Control Unit Handle and Air Pipes A Do not allow fluid to penetrate the Control Unit 9 Ifthe Top Cover or Air Cells have become excessively soiled they may be laundered in a washing machine at up to 80 C using normal domestic washing powder A Do not add bleach to the wash cycle Rinse well using plain water and dry thoroughly before use A Do not dry the Top Cover using the heat cycle or a dryer Air dry or select a low of non heat dry cycle Cleaning and Maintenance Between Patients A Inspect all parts for damage and replace as necessary before returning to service A Do not return the Control Unit to service without replacing air filters A Do not allow fluid to penetrate the Control Unit 1 The Mattress should be dismantled according to the instructions on the previous page 2 Launder the Top Cover and Air Cells as described on the previous page 3 Using warm soapy water or sodium hypochlorite solution at 10 000ppm and a well wrung cloth clean the Mattress Control Unit Handle Air Pipes and Side Bolsters where applicable Rinse with plain water and allow to dry thoroughly 4 Replace air filters see the relevant Air Filter Maintenance procedure for details Direct Healthcare Delivering the Promise ISO 9001 2008 EN ISO 13485 2012 Issue 3 Date September 2015 Sales Offices UK amp Europe Direct Healthcare Services Ltd 6 10 Withey Court Western Industrial Estat
32. s 60 Meter should drop to 0 and the the front of the Air Flow Meter forces pressure back against mmHg At 60 mmHg the ball sphygmomanometer pressure should be fully open If not turn the flow of air from the unit bearing inside the Air Flow Meter reading should rise to 120 clockwise to open the valve to slowly close the valve until the should drop to a minimum of 2 mmHg maximum With the system in free Sphygmomanometer pressure litres per minute flow mode the ball bearing inside reading reaches 30 mmHg At 30 the Air Flow Meter should rise mmHg the ball bearing inside the to a minimum of 4 5 litres per Air Flow Meter should drop to a minute The Sohygmomanometer minimum of 3 litres per minute pressure reading should be low approximately 10 mmHg DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL Standard Pressure Test e If air flow measurements fail to meet the specified minimum levels during any stage of the pressure test the compressor is not operating at full capacity and needs to be replaced Proceed to Compressor Replacement procedure 9 Align the top and bottom housing before slowly pushing closed Ensure the seal is properly aligned around the housing including the air hose connectors fuses and power socket If all pressure and air flow 7 Toclose the Control Unit first measurements met the expected disconnect the Pressure Test levels the problem may be due to Equipment air hose from the a leaking Air Cell
33. ssor materials under high stress and heat conditions which can make the unit susceptible to wear and tear over a long period of time To minimise noise and vibration the compressor is housed within a strong metal cage secured on all sides by rubber mounts These mounts serve to insulate the rest of the unit from the vibration of the compressor 1 Printed Circuit Board PCB 2 Compressor 3 Compressor Cage 4 Static Actuator 5 Alternation Timer Motor 6 Power Socket IEC Connector 7 Audible Warning Speaker Safety Fuse 9 Quick Release Air Hose Connector Female Quick Release Air Hose Connector Male 1 Connector Plate 2 Rubber Feet DIRECTHEALTHCARESERVICES CO UK Basic System Checks Before commencing any service procedure the following basic checks should be completed to ensure that system fault or failure is not due to an oversight on behalf of the user Set up the system and check the following 1 Ensure all power cords and leads 2 Check the Air Hoses are securely 3 Remove the Mattress Top Cover 4 Check each Air Cell is firmly are firmly attached and that the attached to the Control Unit they and check the deflation valve is connected to the internal air system is connected to a working should lick on firmly connected hose s power source with correct Once these simple checks are voltage complete proceed with the service and repair as outlined in the following procedures
34. ure Test Testing airflow and checking for a faulty compressor The Control Unit compressor is designed for long life and backed by a two year warranty from the Manufacturer however compressor failure can occur and will require replacement The Standard Pressure Test should be carried out to check the compressor is working at full operational capacity and that sufficient airflow is being generated to maintain maximum Mattress specifications By directly connecting the compressor to the Pressure Test Equipment Sphygmomanometer and Air Flow Meter this test will confirm system pressure readings at maximum and minimum airflow in free flow mode or with different degrees of back pressure applied If the Pressure Test fails and pressure readings do not match required settings the compressor should be replaced and the test repeated The Control Unit must be allowed to warm up before undertaking the Standard Pressure Test to ensure the diaphragm inside the compressor has loosened and is operating at maximum capacity After opening the unit reconnect power and allow the system to run for a minimum of thirty minutes before commencing this test The following tools are required Pressure Test Equipment Set Up 1 Switch off power supply to the Phillips Head Screwdriver One air hose is connected to the rear of the Sohygmomanometer and another Control Unit disconnect the Air Pens ace to the base of the Air Flow Meter These two air hoses are the
35. waterproof qualities of the Top Cover A The System may be cleaned according to local protocols and regulations procedures for blood borne pathogens provided the Manufacturer s instructions are followed Refer to the Top Cover wash tag for detailed cleaning instructions Cleaning While System in Use A The System should be cleaned every two weeks if in constant use A Allow all parts to dry thoroughly before returning to use 1 Remove patient from the System 2 Unplug the Control Unit from mains power 3 Remove the Top Cover 4 Using a well wrung out cloth dipped in warm soapy water wipe the surface of the Top Cover Rinse with plain water and allow to dry 5 Pull the CPR Tag and disconnect the Handle from the Control Unit to allow the Mattress to deflate completely 6 Inspect the interior of the Mattress for any signs of fluid contamination A If the interior of the Mattress shows signs of fluid contamination inspect the Top Cover for punctures or damage A If the Top Cover is damaged it should be replaced before returning the system to use A If necessary for inspection or cleaning the Air Cells may be removed by carefully disconnecting the air pipes and unsnapping the cell It is not recommended that Side Bolsters be removed for cleaning 7 Using a well wrung out cloth dipped in warm soapy water wipe the Mattress base cells and Side Bolsters where applicable Rinse with plain water and allow to dry 8 Using a well wrung out cl
36. y should the Control Unit fail to operate or system pressure fail to reach normal operating status please follow the steps below to isolate the cause of the problem and make the relevant repair DIRECTHEALTHCARESERVICES CO UK SERVICE MANUAL The electronically controlled Control Unit provides the air supply to the Mattress The unit is operated by a digital touch membrane on the front display panel which controls eight comfort pressure settings Alternating or Static Mode for treatment or transfers respectively Max Firm mode for rapid inflation to maximum pressure to create a firm surface and Control Unit Lockout to prevent accidental changes to the settings The Visual LED indicator and Audible Mute completes the operator controls The visible and audible function has a number of LED indication sequences depending on the cause of the failure On the side of the unit are two air connectors male and female for quick connection of the two hole handle The connectors include a press button release system for ease of use The mains supply to the unit can be easily disconnected and is designed to detach if pulled too firmly protecting the internal wiring from damage The quality of the Control Unit underpins the reliability and pressure reduction capabilities of the System At the centre of the Control Unit lies the compressor which runs at a rapid and continuous rate whenever the unit is operational Continuous rapid movement places compre
37. y need more time to inflate air pressure must build in alternating section before static head cells inflate CPR Tag is not fully connected Valves to static head cells may be damaged or cracked 1 Check system has had sufficient time for initial inflation 40 to 50 minutes 2 Check the CPR Tag is intact ensuring all sealing connectors are fully fitted to the Mattress air pipes 3 Visually check the internal Mattress air pipes that run from the CPR Tag to the static head cells for splits cracks or other damage Return System to Manufacturer for further repairs or replacement Troubleshooting Problem Cause Initial Checks Technical Service Procedure The Mattress is not alternating Static or Max Firm modes may be activated 1 Switch the Control Unit off and disconnect the power before restarting Ensure Alternating Mode is selected synchronous Motor Replacement Patient is sinking or bottoming out while lying flat on Mattress The pressure may be set too low for the patient s weight The system may be losing pressure 1 Increase Pressure Setting an incremental increase is usually sufficient but wait 12 minutes one full cycle before checking 2 Perform bottoming out test a With patient lying supine fold back one side of the Mattress Top Cover just past sacral region lower spine b Slide hand underneath the patient and
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