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Mattress and Seat Systems Service Manual - arjohuntleigh

1. Item Part Number Description Qty REF IC044 ICT18 Harada Mattress Overlay IC109 ICT18 Sanse Do Mattress Overlay 1C116 ICT18 Taiwan Mattress Overlay IC120 ICT18 Ventilated Harada Mattress Overlay 10 IC045 Loop Base Sheet Assembly for 1C044 and IC120 1 IC113 Loop Base Sheet Assembly for IC109 1 IC117 Loop Base Sheet Assembly for 1C116 1 20 IC058 Cell Assembly for IC044 and IC120 18 14 IC090 Cell Assembly for IC109 and IC116 18 30 IC036 Non Return Valve Assembly 2 40 IC017 Manifold Tube Twin Bore End Plug 1 50 IC016 Manifold Tube Twin Bore Non Return Valve Assemblies 1 Manifold Tube Twin Bore Pump End 60 IC050 for IC044 IC109 amp IC120 1 1C121 Manifold Tube Twin Bore Pump End for IC116 only 1 70 IC068 Cell Assembly Ventilated for IC120 only 4 80 IC107 Top Cover Assembly for 1C116 only 1 a There are 18 off Cell Assemblies on the ICT18 Mattress Overlays as follows 1C044 has 18 off IC058 Item 20 IC109 and IC116 have 18 off IC090 Item 20 1C120 has 14 off IC058 Item 20 and 4 off IC068 Item 70 Issue 2 Chap 3 January 2005 SER0005 Page 17 Repair Mattress and Seat Systems Service Manual Part Number Figure 15 Alpha Trancell Seat Table 12 Alpha Trancell Seat Parts List Description IC004 Alpha Trancell Seat SW314 Loop Base Sheet Assembly SP034 Cell Assembly
2. IC001 ICT 6R Standard Mattress Overlay IC061 Loop Base Sheet Assembly IC095 Cell Assembly SP042 Manifold Assembly comprises Items 40 50 BP418 Stopper SP042UF Manifold Tube Twin Bore Issue 2 Chap 3 January 2005 SERO005 Page 5 Repair Mattress and Seat Systems Service Manual Note the orientation of the Non Return Valves Item 70 Figure 9 Alpha Relief Mattress Replacement MR Chap 3 Issue 2 Page 6 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Table 6 Alpha Relief Mattress Replacement MR Parts List Part Number Description 402001DAR Alpha Relief Mattress Replacement Dartex Cover UK 402003HN Alpha Relief Mattress Replacement Hairnet Cover USA 402059 Top Cover Assembly for 402001DAR 402055 Hairnet Cover Assembly for 402003HN 400064 Base Cover Assembly for 402001DAR 402302 Foam Base 402053 Loop Base Sheet Assembly 402050 Cell Assembly 402051 Manifold Assembly comprises Items 70 130 IC036 Non Return Valve Assembly BP431 Connector Male BP432 Connector Female IC033 End Plug 2 way FAS167 Clevis Pin OD 3 16 x 5 8 Long 401309 Swing Label and Web Assembly CPR Pull 402051UF Manifold Tube Twin Bore Issue 2 Chap 3 January 2005 SER0005 Page 7 Repair Mattress and Seat Systems Service Manual Note the orientation of the Non Return
3. 632058 197301 IC017UF 1C128 IC033 FAS167 401309 632302 627415 ICO16 ICO36 401300 403305 IC091 BP431 BP432 SW393 Description Manifold Tube End Assembly CPR e Connector Straight Male Male e Manifold Tube Twin Bore e End Plug Assembly e e End Plug 2 way e e Clevis Pin OD 3 16 x 5 8 Long e e Swing Label and Web Assembly CPR Pull Valve 90 Turn Valve Stopcock Manifold Tube Twin Bore Short Non Return Valve Assembly T Connector Elbow Connector Manifold Tube Twin Bore without connectors Connector Male Connector Female Tube Blue ID6 OD10 7 Aura Seat Part Number 403001 403050 403051 403053 403052 401300 403305 BP431 BP432 403306 403052UF Issue 2 January 2005 Description Aura Seat Top Cover Assembly Loop Base Sheet Assembly Cell Assembly Manifold Assembly e T Connector e Elbow Connector e Connector Male e Connector Female e Restrictor e Manifold Tube Twin Bore SEROO05 Parts List Fig item Qty 12 40 2 12 50 4 12 60 2 12 70 2 12 80 2 12 90 2 12 100 2 12 110 2 12 115 1 12 120 5 12 130 6 12 140 2 12 150 3 12 160 2 12 170 5 12 180 5 12 190 1 Fig Item Qty 16 10 1 16 20 1 16 30 9 16 40 1 16 50 7 16 60 2 16 70 1 16 80 1 16 90 2 16 100 1 Chap 7 Page 5 Parts List Mattress and Seat Systems Service Manual 8 Turbo Puls Mattress Replacement and Overlay Part Number Description Fig Item Qty BB27001 Turbo Puls Mattress Overlay Standard Cover
4. BB27002 Turbo Puls Mattress Replacement Standard Cover BB27004 Turbo Puls Mattress Overlay Luxury Cover BB27055 Top Cover Assembly Standard for BB27001 and BB27002 13 10 1 BB27064 Top Cover Assembly Luxury for BB27004 13 10 1 BB27052 Loop Base Sheet Assembly 13 20 1 IC082 Cell Assembly 13 30 20 BB27054 Manifold Assembly 13 40 1 BP418 Stopper 13 50 2 BB27054UF e Manifold Tube Twin Bore 13 60 1 BB27061 Base Cover Assembly for BB27002 only 13 70 1 402302 Foam Base for BB27002 only 13 80 1 9 Turbo Puls Seat Part Number Description Fig item Qty BB27003 Turbo Puls Seat BB27050 Top Cover Assembly 17 10 1 BB27051 Loop Base Sheet Assembly 17 20 1 BB27053 Cell Assembly 17 30 g SP044 Manifold Assembly 17 40 1 SW050 e T Connector 17 50 7 SW052 e Elbow Connector 17 60 2 SP044UF e Manifold Tube Twin Bore 17 70 1 Chap 7 Issue 2 Page 6 SERO005 January 2005 Mattress and Seat Systems Service Manual 10 ICT 6R Standard Mattress Overlay Part Number IC001 IC061 IC095 SP042 BP418 SP042UF Description ICT 6R Standard Mattress Overlay Loop Base Sheet Assembly Cell Assembly Manifold Assembly Stopper e Manifold Tube Twin Bore 11 ICT18 Mattress Overlay Part Number IC044 IC109 1C116 1C120 1C045 10113 1C117 I1C058 IC090 IC036 1C017 IC016 IC050 1C121 IC068 1C107 Description ICT18 Harada Mattress Overlay ICT18 Sanse Do Mattress Overlay ICT18 Taiwan Mattress Overlay ICT18 V
5. Page 1 Parts List Part Number 400057 400057UF IC036 BP418 400053 400055 Mattress and Seat Systems Service Manual Description Manifold Assembly Short e Manifold Tube Twin Bore e Non Return Valve Assembly Stopper Cell Assembly Non Ventilated Cell Assembly Ventilated 2 Alpha Relief Mattress Replacement Part Number 402001DAR 402003HN 402059 402055 400064 402302 402053 402050 402051 ICO36 BP431 BP432 IC033 FAS 167 401309 402051UF Chap 7 Page 2 Description Alpha Relief Mattress Replacement Dartex Cover UK Alpha Relief Mattress Replacement Hairnet Cover USA Top Cover Assembly for 402001DAR Hairnet Cover Assembly for 402003HN Base Cover Assembly for 402001DAR Foam Base Loop Base Sheet Assembly Cell Assembly Manifold Assembly e Non Return Valve Assembly e Connector Male e Connector Female e End Plug 2 way e Clevis Pin OD 3 16 x 5 8 Long e Swing Label and Web Assembly CPR Pull e Manifold Tube Twin Bore SER0005 Fig Item Qty 6 140 7 140 6 150 7 150 6 70 7 70 6 160 7 160 6 170 7 170 6 180 7 180 1 Fig Item Qty 9 10 9 10 9 20 9 30 9 40 9 50 9 60 9 70 9 80 9 90 9 100 9 110 9 120 9 130 Issue 2 January 2005 Mattress and Seat Systems Service Manual Parts List 3 Alpha Trancell Il Mattress Overlay Part Number Description Fig Item Qty 401001 Alpha Trancell II Mattress Overlay Standard 401002
6. 2 Fig 6 Alpha Relief Dartex Cover 402001DAR Chap 3 Page 6 Fig 9 Alpha Relief Hairnet Cover USA 402003HN Chap 3 Page 6 Fig 9 Alpha Trancell Il 401001 Chap 3 Page 8 Fig 10 Alpha Trancell Il German 401002 Chap 3 Page 8 Fig 10 Alpha Trancell II Ventilated 401003 Chap 3 Page 8 Fig 10 Alpha Trancell II Without Cover 401007 Chap 3 Page 8 Fig 10 Alpha Trancell ICC13 IC004 Chap 3 Page 18 Fig 15 Alphaxcell Studded Cover Euro IC087 Chap 3 Page 10 Fig 11 Alphaxcell Zipped Cover Euro IC137 Chap 3 Page 10 Fig 11 AlphaXcell Studded Cover USA IC076 Chap 3 Page 10 Fig 11 AlphaXcell Double Mattress 632001 Chap 3 Page 12 Fig 12 Aura 403001 Chap 3 Page 19 Fig 16 Turbo Puls Standard Cover BB27001 Chap 3 Page 14 Fig 13 Turbo Puls Luxury Cover BB27004 Chap 3 Page 14 Fig 13 Turbo Puls Standard Cover BB27002 Chap 3 Page 14 Fig 13 Turbo Puls BB27003 Chap 3 Page 20 Fig 17 ICT 6R Standard IC001 Chap 3 Page 5 Fig 8 ICT18 Harada 1C044 Chap 3 Page 16 Fig 14 ICT18 Sanse Do Chap 3 Page 16 Fig 14 ICT18 Taiwan Chap 3 Page 16 Fig 14 ICT18 Ventilated Harada Chap 3 Page 16 Fig 14 a Mattress Type MR Mattress Replacement OL Mattress Overlay Chap 1 Issue 2 Page 2 SERO005 January 2005 Mattress and Seat Systems Service Manual Introduction 3 Mattress Overlay Systems OL A typical mattress
7. 27 Section 9 Static Head Mattress Non return valves installed Check orientation and rectify Cells incorrectly Chapter 3 Page 23 Section 5 Alternate where Non return valves faulty Replace applicable Chapter 3 Page 23 Section 5 Issue 2 Chap 4 January 2005 SERO005 Page 1 Troubleshooting Mattress and Seat Systems Service Manual Chap 4 Issue 2 Page 2 SERO005 January 2005 Mattress and Seat Systems Service Manual Testing CHAPTER 5 TESTING 1 Pressure and Function Test This procedure must be carried out after a service or major repair of a mattress or seat system The test equipment in Table 17 is required Table 17 Pressure and Function Test Equipment Test Equipment Pressure Flow Meter Portable Inflation Test Unit 3 Stopwatch Test Procedure 1 1 Connect a portable inflation test unit to the mattress or seat 1 2 Fully inflate the mattress or seat and connect it to a pressure flow meter 1 3 Test to the following requirements 1 3 1 Inflation test pressure 1 3 1 1 All mattress replacements and overlays 62 to 70 mmHg 1 3 1 2 All seat systems 50 to 60 mmHg 1 3 2 Inflation stabilization period 30 seconds 1 3 3 Inflation test period 3 minutes 1 3 4 Leak rate must not exceed 3 mmHg Note Ifthe mattress or seat fails the tests investigate as to the reason why repair any faults and re test in accordance with the test specification Issue 2 Chap 5 January 2005 SERO005
8. 5 Table 2 for details of which mattresses have static head cells On those mattresses which do have non return valve assemblies they are installed near the head end of the mattress There are two non return valve assemblies which are replaced as follows 5 1 Remove the top cover Refer to Page 21 Section 3 5 2 Onthe last six cells at the head end of the mattress pull apart the press studs that secure the end of the cell to the loop base sheet assembly This will allow access to the non return valve assemblies 5 3 Move the cells away from the manifold assembly 5 4 Remove the two ends of the non return valve assembly from the manifold tubes 5 5 Carefully insert the two ends of the new non return valve assembly into the manifold tubes Note Make sure the arrow mark on the non return valve body points towards the head end of the mattress Refer to Figure 19 Mattress malfunction will occur if the non return valve assemblies are fitted incorrectly 5 6 On the last six cells at the head end of the mattress Connect the press studs together that secure the end of the cell to the loop base sheet assembly 5 7 Install the top cover Refer to Page 22 Section 4 Air Flow Head End of Mattress Manifold Tube Manifold Tube Non Return Valve Body Arrow Mark Figure 19 Orientation of the Non Return Valve Assembly Issue 2 Chap 3 January 2005 SER0005 Page 23 Repair Mattress and Seat Systems Service Manual 6 R
9. Industrial estate Off Shah Industrial estate Off Veera Desai Road Andheri West Mumbai 400 053 India New Zealand Huntleigh Healthcare 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 8 SEROO05 Page 1 Service Contact Details UK Huntleigh Healthcare Limited 310 312 Dallow Road Luton Bedfordshire LU1 1TD T 44 0 1582 413104 F 44 0 1582 459100 Spain Huntleigh Healthcare SL C de la Creueta 25 08130 Santa Perpetua de la Mogoda Barcelona T 34 93 5745754 F 34 93 5745861 Chap 8 Page 2 Mattress and Seat Systems Service Manual United States of America Huntleigh Healthcare LLC 40 Christopher Way Eatontown New Jersey 07724 USA T 1 732 578 9898 F 1 732 578 9889 Huntleigh Latin America Inc 2602 North West 97th Avenue Miami Florida 33172 USA T 1 305 463 0526 F 1 305 463 0216 Japan Huntleigh Healthcare Japan K K 4 1 15 Goko Dori Chuoku Kobe 651 0087 T 81 78 231 8735 F 81 78 231 8736 Issue 2 SERO005 January 2005
10. Manifold Assembly comprises Items 40 60 T Connector Chap 3 Page 18 SP044UF Elbow Connector Manifold Tube Twin Bore SEROO05 Issue 2 January 2005 Mattress and Seat Systems Service Manual Part Number Figure 16 Aura Seat Table 13 Aura Seat Parts List Description Repair Note Female connector Item 80 must be installed on the shorter manifold tube 403001 Aura Seat 403050 Top Cover Assembly 403051 Loop Base Sheet Assembly 403053 Cell Assembly 403052 Manifold Assembly comprises Items 50 100 401300 T Connector 403305 Elbow Connector BP431 Connector Male BP432 Connector Female 403306 403052UF Issue 2 January 2005 Restrictor Manifold Tube Twin Bore SER0005 Chap 3 Page 19 Repair Part Number Mattress and Seat Systems Service Manual Figure 17 Turbo Puls Seat Table 14 Turbo Puls Seat Parts List Description BB27003 Turbo Puls Seat BB27050 Top Cover Assembly BB27051 Loop Base Sheet Assembly BB27053 Cell Assembly SP044 Manifold Assembly comprises Items 50 70 SW050 T Connector Chap 3 Page 20 SW052 SP044UF Elbow Connector Manifold Tube Twin Bore SEROO05 Issue 2 January 2005 Mattress and Seat Systems Service Manual Repair 3 Removing the Top Cover Refer to Figure 18
11. Valves Item 40 Figure 10 Alpha Trancell Il Mattress Overlay OL Chap 3 Issue 2 Page 8 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Table 7 Alpha Trancell Il Mattress Overlay OL Parts List Part Number Description 401001 Alpha Trancell Il Mattress Overlay Standard 401002 Alpha Trancell II Mattress Overlay German 401003 Alpha Trancell II Mattress Overlay Ventilated 401007 Alpha Trancell II Mattress Overlay Without Cover 401068 Top Cover Assembly for 401001 401002 amp 401003 401053 Mattress Overlay Assembly for 401001 401002 amp 401007 401069 Mattress Overlay Assembly Ventilated for 401003 401065 Manifold Assembly comprises Items 40 100 IC036 Non Return Valve Assembly 401300 T Connector 197301 Connector Straight Male Male IC033 End Plug 2 way FAS167 Clevis Pin OD 3 16 x 5 8 Long 401309 Swing Label and Web Assembly CPR Pull 400065UF Manifold Tube Twin Bore Issue 2 Chap 3 January 2005 SER0005 Page 9 Repair Mattress and Seat Systems Service Manual Note the orientation of the Non Return Valves Item 40 Alternative Manifold for IC076 USA Cell Arrangement End OOO 00000000000000000 End Static 3 off Alternating Item 30 17 off Non ventilated Non ventilated IC090 for IC087 and IC137 Item 20 IC082 Ventilated IC068 for ICO76 only Figure 11 Alpha
12. connectors on the manifold assembly with the side entry grommets on the mattress overlay assembly Refer to Figure 10 Carefully insert the 16 T connectors on the manifold assembly into the side entry grommets on the mattress overlay assembly Install the top cover Refer to Page 22 Section 4 All Seat Systems 9 8 Lay the manifold assembly onto the mattress or seat with the tube connections to the pump at the feet end of the mattress and the CPR end plug assembly at the head end Align the T or elbow connectors on the manifold tubes with the side entry grommets on the cells Note On some systems there are no pump connectors just open tubes and or stoppers replace the CPR end plug assembly but the manifold orientation is the same 9 9 On some seat types feed the pump ends of the manifold tubes out of the seat through the hole in the loop base sheet assembly 9 10 Connect all the cells to the manifold assembly as follows 9 10 3 Carefully insert the end of the T connector into the side entry grommet on the cell 9 10 4 Connect the press studs that secure the end of the cell to the loop base sheet assembly on the manifold side 9 11 Install the top cover Refer to Page 22 Section 4 Issue 2 Chap 3 January 2005 SERO005 Page 27 Repair Mattress and Seat Systems Service Manual 10 Replacing the CPR Rapid Deflate End Plug Assembly Most but not all mattress replacement and overlay systems have a cardiopulmonary resuscita
13. entry grommets on the cells is made easier if the parts are wetted with methylated spirit immediately prior to insertion All Mattress Replacement and Overlay Systems except Alpha Trancell Il 9 1 9 2 9 3 9 4 Lay the manifold assembly onto the side of the mattress with the tube connections to the pump at the feet end of the mattress and the CPR end plug assembly at the head end Align the T connectors on the cells with the cut outs in the manifold tubes Note Refer to the relevant figure in this chapter to make sure the loop base sheet assembly and the cells and manifold assembly are in the correct positions Note On some systems there are no pump connectors just open tubes and or stoppers replace the CPR end plug assembly but the manifold orientation is the same On mattresses with a base cover assembly feed the pump ends of the manifold tubes out of the mattress through the hole in the base cover assembly Connect all the cells to the manifold assembly as follows 9 3 1 Carefully insert the two ends of the T connector into the manifold tubes 9 3 2 Connect the press studs that secure the end of the cell to the loop base sheet assembly on the manifold side Install the top cover Refer to Page 22 Section 4 Alpha Trancell Il Mattress Overlay only 9 5 9 6 9 7 Lay the manifold assembly next to the mattress overlay assembly with the CPR end plug assembly at the head end of the mattress Align the T
14. foam block into the base cover 14 6 Install the loop base sheet assembly complete with cells manifold assembly and CPR end plug assembly into the mattress 14 7 Feed the pump ends of the manifold tubes out of the mattress through the hole in the base cover assembly 14 8 Install the top cover Refer to Page 22 Section 4 Chap 3 Issue 2 Page 30 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair 15 Replacing the Base Cover All mattress replacements have a foam base between the loop base sheet assembly and the base cover 15 1 Remove the top cover Refer to Page 21 Section 3 15 2 Pull the ends of the manifold tubes which connect to the pump into the mattress through the hole in the base cover assembly 15 3 Lift the loop base sheet assembly complete with cells manifold assembly and CPR end plug assembly out of the mattress 15 4 Replace the base cover 15 5 Install the loop base sheet assembly complete with cells manifold assembly and CPR end plug assembly into the mattress 15 6 Feed the pump ends of the manifold tubes out of the mattress through the hole in the base cover assembly 15 7 Install the top cover Refer to Page 22 Section 4 16 Replacing the Pump Connectors on the end of the Manifold Tubes Some of the mattress replacement overlay and seat systems have connectors on the end of the manifold tubes which clip onto the pump connectors The remaining systems have open mani
15. for a typical view of the top cover assembly and mattress system Zipped Top Cover 3 1 Pull away the velcro strips at the head and foot end of the mattress and undo the zips along all four sides 3 2 Remove the top cover from the mattress or seat Studded Top Cover 3 3 Pull apart the press studs on all four sides of the mattress or seat 3 4 Remove the top cover from the mattress or seat Strapped Top Cover 3 5 Carry out either of the following procedures depending on the strap configuration 3 5 1 Top covers secured with straps and buckles which pass under the mattress 3 5 1 1 Undo the strap buckles and remove the straps 3 5 1 2 Remove the top cover from the mattress 3 5 2 Top covers secured with elasticated corner straps 3 5 2 3 Remove the elasticated loops from the corners of the mattress 3 5 2 4 Remove the top cover from the mattress Top Cover Press Stud Loop Base Sheet Assembly Cell Base Cover Press Stud Cell Loops Manifold Tubes Figure 18 Removing the Top Cover typical view Issue 2 Chap 3 January 2005 SERO005 Page 21 Repair Mattress and Seat Systems Service Manual 4 Installing the Top Cover All Cover Types 4 1 Position the top cover over the mattress or seat Note Make sure that the cover is placed the correct way round with the feet logo and or Huntleigh logo facing up and situated at the feet end of the mattress or seat 4 2 Ifa CPR plug is fitted to the
16. the normal bed mattress The foam base provides a safety and transport function should the air supply fail or the alternating cells deflate The cell configurations are detailed in Table 2 Cardiopulmonary Resuscitation CPR Pull Tag Static Cells Head Section Cell Loops Alternating Cells Base Cover Foam Base Tube Connections Figure 2 Typical Mattress Replacement MR System 5 Seating Systems A typical seating system is shown in Figure 3 The seat includes a base sheet alternating cells a cover and air inlet tubes with connectors where applicable The cell configurations are detailed in Table 2 Cover Cell Loops Alternating Cells Straps Air Inlet Tubes Base Sheet Tube Connections Figure 3 Typical Seating System Chap 1 Issue 2 Page 4 SERO005 January 2005 Mattress and Seat Systems Service Manual Table 2 Static and Alternating Cell Configurations Product Mattress Type Total Number of Cells Alternating Cells Introduction Static Cells Alpha Active MR 17 14 Alpha Active German OL 17 14 Alpha Relief MR 17 17 Alpha Trancell II OL 16 14 Alpha Trancell Il Ventilated OL 16 14 Alpha Trancell Il Without Cover OL 16 14 Alpha Trancell ICC13 9 9 AlphaXcell Studded Zipped Cover 20 17 AlphaXcell Double Mattress 20 20 Aura Turbo P
17. 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 CAUTION Do not use hypercarbonate and phenolic based cleaning solutions CAUTION Ensure the system is clean and dry prior to storage Note Store the systems in the protective bags provided 2 General Description The mattress replacement overlays and seat systems identified in Table 1 are designed specifically to aid in the prevention treatment and management of pressure ulcers They are air filled alternating pressure mattress and seat systems powered by air pumps Some of the pumps provide an option of microprocessor aided control and sound alarm functions and have LED indications on the front panel The mattresses can be used on standard hospital and normal domestic beds The seat cushions can be used on standard hospital and normal domestic chairs Issue 2 Chap 1 January 2005 SERO005 Page 1 Introduction Mattress and Seat Systems Service Manual Table 1 Mattresses and Seat Pads included in this service manual Product Part Number Figure Number Alpha Active Dartex Cover USA 400001DAR Chap 3 Page 2 Fig 6 Alpha Active Dartex Cover German 400002DAR Chap 3 Page 3 Fig 7 Alpha Active Advantex Cover German 400003ADV Chap 3 Page 2 Fig 6 Alpha Active Dartex Cover German 400003DAR Chap 3 Page
18. until the desired comfort is achieved To replace the turn valves carry out the following procedure Refer to Figure 12 17 1 Remove the top cover Refer to Page 21 Section 3 17 2 To replace the two valves at the feet end of the mattress 17 2 1 At the feet end of the mattress move the base cover assembly and loop base sheet assembly including cells out of the way to reveal the two turn valves in the section of manifold between the sides of the mattress Issue 2 Chap 3 January 2005 SERO005 Page 31 Repair 17 3 18 Mattress and Seat Systems Service Manual 17 2 2 Remove the two ends of the turn valve from the manifold tubes 17 2 3 Carefully insert the two ends of the new turn valve into the manifold tubes 17 2 4 At the feet end of the mattress lay the base cover assembly and loop base sheet assembly including cells back in their correct positions To replace the valve at the head end of the mattress 17 3 5 At the head end of the mattress on the manifold side move the base cover assembly and loop base sheet assembly including cells out of the way to reveal the turn valve by the CPR end plug assembly 17 3 6 Remove the end of the turn valve from the tube 17 3 7 Carefully insert the end of the new turn valve into the tube 17 3 8 At the head end of the mattress lay the base cover assembly and loop base sheet assembly including cells back in their correct positions Install the top cover Refer to Page 22 Se
19. 0064 Base Cover Assy for 400001DAR 400003ADV amp 400003DAR 400061 Base Cover Assy for 400002DAR 402302 Foam Base for 400001DAR 400003ADV amp 400003DAR only 400050 Loop Base Sheet Assembly for 400001DAR amp 400002DAR 400076 Loop Base Sheet Assembly for 400003ADV amp 400003DAR 400062 Top Cover Assembly for 400001DAR 400077 Top Cover Assembly for 400003ADV 400058 Top Cover Assembly for 400002DAR amp 400003DAR 400065 Manifold Assembly Pump End comprises Items 60 100 400065UF IC036 Manifold Tube Twin Bore Non Return Valve Assembly BP432 Connector Female 197301 Connector Straight Male Male IC067 End Plug Assembly comprises Items 110 130 IC033 End Plug 2 way FAS167 Clevis Pin OD 3 16 x 5 8 Long IC300 Swing Label and Web Assembly CPR Pull 400057 400057UF Manifold Assembly Short comprises Items 70 150 160 Manifold Tube Twin Bore BP418 Stopper 400053 Cell Assembly Non Ventilated 400055 Cell Assembly Ventilated a There are two non return valve assemblies Item 70 in each manifold assembly Items 50 and 140 Chap 3 Issue 2 Page 4 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Figure 8 ICT 6R Mattress Overlay OL Table 5 ICT 6R Mattress Overlay OL Parts List Part Number Description
20. A Loop Base Sheet Assembly for IC087 and IC137 Loop Base Sheet Assembly for IC076 Head Cell Assembly Body Cell Assembly Non Ventilated for IC087 and IC137 Body Cell Assembly Ventilated for IC076 Non Return Valve Assembly Manifold Tube Twin Bore End Plug Manifold Tube Twin Bore Non Return Valve Assemblies Manifold Tube Assembly Pump End for IC087 and 1C137 comprises Items 80 90 and 100 Manifold Tube Assembly Pump End for IC076 comprises Items 80 and 110 only e Connector Female e Connector Male e Manifold Tube Twin Bore for IC091 e Manifold Tube Twin Bore for IC054 Top Cover Assembly for IC087 and IC076 Top Cover Assembly for 1C137 Base Cover Assembly for 1C137 only a Different connectors are fitted to the two Manifold Tube Assemblies Item 70 as follows IC091 has 1 off BP432 Item 80 and 1 off BP431 Item 90 IC054 has 2 off BP432 Item 80 only 6 AlphaXcell Double Mattress Overlay Part Number 632001 632052 632057 632050 Chap 7 Page 4 Description Alphaxcell Double Mattress Overlay Top Cover Assembly Loop Base Sheet Assembly Double Cell Assembly SER0005 Fig ltem Qty 11 10 1 11 10 1 11 20 3 11 30 17 11 30 17 11 40 2 11 50 1 11 60 1 11 70 18 11 70 10 11 80 1 28 11 90 18 11 100 1 11 110 1 11 120 1 11 120 1 11 130 1 Fig item Qty 1 12 10 1 12 20 1 12 30 20 Issue 2 January 2005 Mattress and Seat Systems Service Manual Part Number
21. Alpha Trancell II Mattress Overlay German 401003 Alpha Trancell II Mattress Overlay Ventilated 401007 Alpha Trancell II Mattress Overlay Without Cover 401068 Top Cover Assembly for 401001 401002 amp 401003 10 10 1 401053 Mattress Overlay Assembly for 401001 401002 amp 401007 10 20 1 401069 Mattress Overlay Assembly Ventilated for 401003 10 20 1 401065 Manifold Assembly 10 30 1 IC036 e Non Return Valve Assembly 10 40 2 401300 T Connector 10 50 16 197301 e Connector Straight Male Male 10 60 2 IC033 e End Plug 2 way 10 70 1 FAS167 e Clevis Pin OD 3 16 x 5 8 Long 10 80 1 401309 e Swing Label and Web Assembly CPR Pull 10 90 1 400065UF e Manifold Tube Twin Bore 10 100 1 4 Alpha Trancell Seat Part Number Description Fig Item Qty IC004 Alpha Trancell Seat SW314 Loop Base Sheet Assembly 15 10 1 SP034 Cell Assembly 15 20 9 SP044 Manifold Assembly 15 30 1 SW050 e T Connector 15 40 7 SW052 e Elbow Connector 15 50 2 SP044UF e Manifold Tube Twin Bore 15 60 1 Issue 2 Chap 7 January 2005 SERO005 Page 3 Parts List Mattress and Seat Systems Service Manual 5 AlphaXcell Mattress Overlay Part Number IC087 1C137 ICO76 IC088 IC075 IC082 IC090 IC068 IC036 IC017 IC016 IC091 1C054 BP432 BP431 IC091UF ICO54UF IC081 1C133 1C129 Description AlphaXcell Mattress Overlay Studded Cover Euro AlphaXcell Mattress Overlay Zipped Cover AlphaXcell Mattress Overlay Studded Cover US
22. Huntleigh HEALTHCARE mr Mattress and Seat Systems Service Manual SERO005 Issue 2 January 2005 Mattress and Seat Systems Service Manual Introduction CHAPTER 1 INTRODUCTION 1 About This Manual Huntleigh Healthcare strongly recommend that their equipment is only serviced by trained personnel and provide courses for customers who wish to become licensed to service their own equipment In no event will Huntleigh Healthcare be responsible for any service performed by customers or third parties This manual contains information on maintenance servicing repair troubleshooting and testing for the range of pressure relief mattress and seat systems shown in Table 1 The information in this handbook is limited to the mattresses and seat cushions The pumps for this range of systems are described in the appropriate service manual Mattress replacements MR are a replacement for the normal bed mattress Overlays OL are placed on top of a normal bed mattress Read and understand this manual before attempting to service or repair the equipment Warnings Cautions and Notes WARNINGS given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in death injury or other serious adverse reactions CAUTIONS given in this manual identify possible hazards in procedures or conditions which if not correctly followed could result in equipment failure or damage Notes given in
23. Number Figure 23 Press Stud Tool Table 15 Press Stud Parts List Description Repair MIS143 Hand Press Tool MIS142 FAS169 Die Set for Hand Press Tool Item 10 Stud Post Schaeffer Plastic FAS170 Stud Cap Schaeffer Plastic FAS171 Stud Socket Schaeffer Plastic FAS152 Snap Fastener Cap Metal FAS153 Snap Fastener Socket Metal FAS154 Snap Fastener Post Metal FAS155 Issue 2 January 2005 Snap Fastener Stud Metal SEROO05 Chap 3 Page 33 Repair Mattress and Seat Systems Service Manual Chap 3 Issue 2 Page 34 SERO005 January 2005 Mattress and Seat Systems Service Manual Troubleshooting CHAPTER 4 TROUBLESHOOTING 1 Troubleshooting Table Table 16 contains fault symptoms their possible causes and suggests steps to rectify the problem Where possible reference is made to the relevant repair chapter and section Table 16 Troubleshooting Table Fault Possible Cause Remedy Not Inflating Mattress CPR or Rapid Deflate stopper Check and replace not inserted Chapter 3 Page 28 Section 10 Leakages e Cells check welded seams amp grommets Replace cell s Chapter 3 Page 24 Section 6 Chapter 3 Page 25 Section 7 e Manifold rectify or replace Chapter 3 Page 26 Section 8 Chapter 3 Page 27 Section 9 Manifold tubes kinked or Clear blockage or replace blocked Chapter 3 Page 26 Section 8 Chapter 3 Page
24. Page 1 Testing Mattress and Seat Systems Service Manual Chap 5 Issue 2 Page 2 SERO005 January 2005 Mattress and Seat Systems Service Manual Technical Specification CHAPTER 6 TECHNICAL SPECIFICATION Table 18 Mattress Replacement Overlay and Seat System Dimensions Product Mattress Type Length Width Inflated Height Alpha Active MR 2090 82 2 866 34 1 Alpha Active German Alpha Relief OL 2090 82 2 866 34 1 860 33 9 Alpha Trancell II 2006 79 0 840 33 1 Alpha Trancell Il Ventilated 2090 82 2 2006 79 0 840 33 1 Alpha Trancell Il Without Cover 2006 79 0 840 33 1 Alpha Trancell ICC13 459 18 1 457 18 0 50 2 0 AlphaXcell Studded Zipped Cover 2040 80 3 860 33 9 114 4 5 AlphaXcell Double Mattress 2040 80 3 1350 53 1 114 4 5 Aura 470 18 5 455 17 9 50 2 0 Turbo Puls Turbo Puls 2040 80 3 2040 80 3 860 33 9 860 33 9 a Mattress Type MR Mattress Replacement OL Mattress Overlay b Dimensions are given in metric mm with imperial in parentheses inches Issue 2 January 2005 SEROO05 114 4 5 Chap 6 Page 1 Technical Specification Mattress and Seat Systems Service Manual Chap 6 Issue 2 Page 2 SERO005 January 2005 Mattress and Seat Systems Service M
25. Xcell Mattress Overlay OL Chap 3 Issue 2 Page 10 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Table 8 AlphaXcell Mattress Overlay OL Parts List Part Number Description IC087 AlphaXcell Mattress Overlay Studded Cover Euro 1C137 AlphaXcell Mattress Overlay Zipped Cover IC076 AlphaXcell Mattress Overlay Studded Cover USA IC088 Loop Base Sheet Assembly for IC087 and IC137 IC075 Loop Base Sheet Assembly for IC076 IC082 Head Cell Assembly ICO90 Body Cell Assembly Non Ventilated for IC087 and IC137 IC068 Body Cell Assembly Ventilated for IC076 IC036 Non Return Valve Assembly IC017 Manifold Tube Twin Bore End Plug IC016 Manifold Tube Twin Bore Non Return Valve Assemblies Manifold Tube Assembly Pump End for IC087 and IC137 IC091 comprises Items 80 90 and 100 Manifold Tube Assembly Pump End for IC076 IC054 comprises Items 80 and 110 BP432 Connector Female BP431 Connector Male ICO91UF Manifold Tube Twin Bore for IC091 ICO54UF Manifold Tube Twin Bore for I1C054 IC081 Top Cover Assembly for IC087 and IC076 1IC133 Top Cover Assembly for 1C137 Base Cover Assembly for 1C137 only a Different connectors are fitted to the two Manifold Tube Assemblies Item 70 as follows IC091 has 1 off BP432 Item 80 and 1 off BP431 Item 90 IC054 has 2 off BP432 Item 80 on
26. able 5 ICT18 Mattress Overlay OL Figure 14 Table 11 Issue 2 Chap 3 January 2005 SERO005 Page 1 Repair Mattress and Seat Systems Service Manual Ae DO RS Detail A 70 Note the orientation of the Non Return Valves Item 70 Cell Arrangement tra OO O QQOQQ00 OQQOOOO Tra Static Static Alternating Alternating Non ventilated Ventilated Ventilated Non ventilated Item 170 2 off Item 180 1 off Item 180 7 off Item 170 7 off Figure 6 Alpha Active Mattress Replacement MR Chap 3 Issue 2 Page 2 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Detail A Note the orientation of the Non Return Valves Item 70 Cell Arrangement en OO O QQOQQ00 OOQQO0O0O Ena a Static Static Alternating Alternating Non ventilated Ventilated Ventilated Non ventilated Item 170 2 off Item 180 1 off Item 180 7 off Item 170 7 off Figure 7 Alpha Active Mattress Overlay OL Issue 2 Chap 3 January 2005 SERO005 Page 3 Repair Mattress and Seat Systems Service Manual Table 4 Alpha Active Mattress Replacement MR and Overlay OL Parts List Part Number Description 400001DAR Alpha Active Mattress Replacement Dartex Cover USA 400002DAR Alpha Active Mattress Overlay Dartex Cover German 400003ADV Alpha Active Mattress Replacement Advantex Cover German 400003DAR Alpha Active Mattress Replacement Dartex Cover German 40
27. al 23 70 A R FAS154 Snap Fastener Post Metal 23 80 A R FAS155 Snap Fastener Stud Metal 23 90 A R Chap 7 Issue 2 Page 8 SER0005 January 2005 Mattress and Seat Systems Service Manual Service Contact Details CHAPTER 8 SERVICE CONTACT DETAILS Africa Huntleigh Africa Pty Ltd Willem Cruywagen Avenue Stand 120 Klerksoord Pretoria T 27 12 542 4680 F 27 12 542 4982 Belgium Huntleigh Healthcare 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 Huntleigh Healthcare 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 Huntleigh Healthcare Pte Limited Block 603 Elias Road 08 232 Singapore 510603 T 61 8 9 309 3083 F 60 8 9 309 4582 Issue 2 January 2005 Australia Huntleigh Healthcare Pty Limited PO Box 330 Hamilton Hill Western Australia 6963 T 61 8 9 337 4111 F 61 8 9 337 9077 Denmark Huntleigh Healthcare A S Vassinger dvej 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 Huntleigh Healthcare India Pvt Ltd 8 Shah
28. anual 1 Alpha Active Mattress Replacement and Overlay Part Number 400001DAR 400002DAR 400003ADV 400003DAR 400064 400061 402302 400050 400076 400062 400077 400058 400065 400065UF ICO36 BP432 197301 ICO67 IC033 FAS167 IC300 Issue 2 January 2005 Alpha Active Mattress Replacement Dartex Cover USA Alpha Active Mattress Overlay Dartex Cover German Alpha Active Mattress Replacement Advantex Cover CHAPTER 7 PARTS LIST Description German Alpha Active Mattress Replacement Dartex Cover German Base Cover Assy for 400001DAR 400003ADV amp DAR Base Cover Assy for 400002DAR Foam Base for 400001DAR 400003ADV amp 400003DAR only Loop Base Sheet Assembly for 400001DAR amp 400002DAR Loop Base Sheet Assembly for 400003ADV amp 400003DAR Top Cover Assembly for 400001 DAR Top Cover Assembly for 400003ADV Top Cover Assembly for 400002DAR amp 400003DAR Manifold Assembly Pump End Manifold Tube Twin Bore Non Return Valve Assembly Connector Female Connector Straight Male Male End Plug Assembly End Plug 2 way e Clevis Pin OD 3 16 x 5 8 Long e Swing Label and Web Assembly CPR Pull SEROO05 Parts List Fig item Qty 6 10 7 10 6 20 6 30 7 30 6 30 6 40 6 40 6 40 7 40 6 50 7 50 6 60 7 60 6 70 7 70 6 80 7 80 6 90 7 90 6 100 7 100 6 110 7 110 6 120 7 120 6 130 7 130 Chap 7
29. cells is slowly vented to atmosphere causing them to reduce pressure In some of the mattress replacements or overlays there is a third set of cells labelled C which are supplied from a static feed This static feed C is generated by two partial non return valves in the mattress manifold assembly from alternating feeds A and B and is therefore never at zero pressure Where fitted the C cells are normally in the head section of the mattress to provide a stable pillow section and prevent the patient s head from rising and falling Air Inputs Feet End Head End o Static where Alternating Cells Cells eau Alternating 1 oO v 00000000000000000 Ei v Alternating 3 4 v 0000000000000000 i O Manifold Assembly Partial Non return Valves N CPR where applicable where applicable Figure 4 Typical Mattress Pneumatic Diagram and Cell Inflation Cycle Chap 1 Issue 2 Page 6 SER0005 January 2005 Mattress and Seat Systems Service Manual Introduction 7 Rapid Deflation of the Overlay or Mattress Replacement Most but not all mattress replacement and overlay systems have a cardiopulmonary resuscitation CPR or Rapid Deflate plug to allow rapid deflation of the mattress replacement or overlay system None of the seat systems have a CPR or Rapid Deflate plug The CPR or Rapid Deflate plug is located at the
30. ction 4 Press Stud Replacement Depending on the particular mattress or seat system being repaired the press stud parts fitted to it are either plastic or metal Make sure that the new press stud parts are of the same material as the old press stud parts being removed Refer to Table 15 Note Do not mix metal and plastic press stud parts on the same mattress or seat system 18 1 Make sure that the two halves of the die set Fig 23 Item 20 are installed in the jaws of the hand press tool Fig 23 Item 10 18 2 Remove the old press stud parts from the mattress if necessary using side cutters taking care not to damage the mattress fabric 18 3 Place the new stud post Table 15 Item 30 in the location hole in the assembly where it is to be fitted Note Check with similar studs for the correct position 18 4 Position the stud post and assembly in the hand press tool 18 5 Depending on which is to be fitted fit a stud cap Table 15 Item 40 or stud socket Table 15 Item 50 onto the stud post and firmly squeeze the handles of the hand press tool together 18 6 Remove the secured press stud assembly from the hand press tool Note Make sure that the stud assembly comprising a stud post and stud cap or socket is installed correctly The stud assembly should grip the material and not rotate freely Chap 3 Issue 2 Page 32 SERO005 January 2005 Mattress and Seat Systems Service Manual Part
31. e 22 CPR Rapid Deflate End Plug Assembly Chap 3 Issue 2 Page 28 SER0005 January 2005 Mattress and Seat Systems Service Manual Repair 11 Removing the Loop Base Sheet Assembly Note On the Alpha Trancell II mattress overlay there is no loop base sheet assembly or individual replaceable cells Instead there is a one piece manufactured item the mattress overlay assembly which can only be replaced as a single complete item All Mattresses MR and OL and Seat Systems except Alpha Trancell Il 11 1 Remove the top cover Refer to Page 21 Section 3 11 2 Remove the manifold assembly and all the cells from the loop base sheet assembly as follows Note It is not necessary to remove the cells from the manifold assembly 11 2 1 Pull apart the press studs that secure each end of the cell to the loop base sheet assembly 11 2 2 Pull the cell out through the loops in the loop base sheet assembly towards the manifold side of the mattress 11 3 Move the cells and manifold assembly out of the way and remove the loop base sheet assembly from the mattress or seat Alpha Trancell Il Mattress Overlay only 11 4 Remove the top cover Refer to Page 21 Section 3 11 5 Carefully remove the 16 T connectors on the manifold assembly from the mattress overlay assembly Refer to Figure 10 Note The T connectors are part of the manifold assembly 11 6 Remove the mattress overlay assembly 12 Installing the Loop Base Sheet Assembly All Ma
32. eflate it After carrying out a service or any repairs on the mattress or seat system but before installing the top cover check the following 1 1 All press studs on the mattress overlay or seat system are connected 1 2 All cells are evenly positioned in their loop straps The repair will normally have disturbed the position of the cells and they should be re positioned evenly After carrying out a service or any repairs the mattress or seat system must be tested for serviceability by carrying out the Pressure and Function Test on the mattress or seat system in accordance with Chapter 5 Page 1 Section 1 2 Product Assembly Drawings and Parts Lists Refer to Table 3 for the assembly drawing and parts list for each mattress or seat system Table 3 Product Assemblies and Parts Lists Product Assembly Drawing Parts List Alpha Active Mattress Replacement MR Figure 6 Table 4 Alpha Active Mattress Overlay OL Figure 7 Table 4 Alpha Relief Mattress Replacement MR Figure 9 Table 6 Alpha Trancell Il Mattress Overlay OL Figure 10 Table 7 Alpha Trancell Seat Figure 15 Table 12 AlphaXcell Mattress Overlay OL Figure 11 Table 8 Alphaxcell Double Mattress Overlay OL Figure 12 Table 9 Aura Seat Figure 16 Table 13 Turbo Puls Mattress Replacement MR Figure 13 Table 10 Turbo Puls Mattress Overlay OL Figure 13 Table 10 Turbo Puls Seat Figure 17 Table 14 ICT 6R Mattress Overlay OL Figure 8 T
33. emoving a Cell Refer to Figure 20 for a typical view of the connections between the cell assembly and the manifold assembly Note The cells in the Alpha Trancell II mattress overlay are not individual replaceable cells but are a one piece manufactured item and can only be replaced as a single complete item the mattress overlay assembly All Mattress Replacement and Overlay Systems except Alpha Trancell Il 6 1 Remove the top cover Refer to Page 21 Section 3 6 2 Pull apart the press studs that secure each end of the cell to the loop base sheet assembly 6 3 Carefully remove the T connector on the end of the cell from the manifold tubes Note The T connector is part of the cell assembly 6 4 Pull the cell out through the loops in the loop base sheet assembly Alpha Trancell Il Mattress Overlay only 6 5 To remove the mattress overlay assembly Refer to Page 29 Section 11 All Seat Systems 6 6 Remove the top cover Refer to Page 21 Section 3 6 7 Pull apart the press studs that secure each end of the cell to the loop base sheet assembly 6 8 Carefully remove the T connector or elbow connector on the end cells on the manifold from the side entry grommet on the cell Note The T connector and elbow connector are part of the manifold assembly 6 9 Pull the cell out through the loops in the loop base sheet assembly Cell AA Sy ay Press Stud Manifold Tubes AF Side Entry Grommet T Connector Loop Base Sheet As
34. entilated Harada Mattress Overlay Loop Base Sheet Assembly for IC044 and IC120 Loop Base Sheet Assembly for IC109 Loop Base Sheet Assembly for 1C116 Cell Assembly for 1C044 and 1C120 Cell Assembly for IC109 and 1C116 Non Return Valve Assembly Manifold Tube Twin Bore End Plug Manifold Tube Twin Bore Non Return Valve Assemblies Manifold Tube Twin Bore Pump End for 1C044 IC109 amp 1IC120 Manifold Tube Twin Bore Pump End for 1C116 only Cell Assembly Ventilated for 1C120 only Top Cover Assembly for IC 116 only Parts List Fig item Qty 8 10 1 8 20 20 8 30 1 8 40 2 8 50 1 Fig Item Qty 14 10 1 14 10 1 14 10 1 14 20 18 148 14 20 188 14 30 2 14 40 1 14 50 1 14 60 1 14 60 1 14 70 4 a 14 80 1 a There are 18 off Cell Assemblies on the ICT18 Mattress Overlays as follows 1C044 has 18 off IC058 Item 20 IC109 and IC116 have 18 off IC090 Item 20 I1C120 has 14 off IC058 Item 20 and 4 off IC068 Item 70 Issue 2 January 2005 SEROO05 Chap 7 Page 7 Parts List Mattress and Seat Systems Service Manual 12 Hand Press Tool Part Number Description Fig Item Qty MIS143 Hand Press Tool 23 10 1 MIS142 Die Set for Hand Press Tool Item 10 23 20 1 FAS169 Stud Post Schaeffer Plastic 23 30 A R FAS170 Stud Cap Schaeffer Plastic 23 40 A R FAS171 Stud Socket Schaeffer Plastic 23 50 A R FAS152 Snap Fastener Cap Metal 23 60 A R FAS153 Snap Fastener Socket Met
35. fold tubes which simply push onto the pump connectors All mattresses and seats with manifold connectors have one male and one female connector except the Alpha Active mattresses MR and OL which both have two female connectors To replace the pump connectors on the end of the manifold tubes carry out the following procedure 16 1 Do not disassemble the mattress or seat 16 2 Remove the connectors from the ends of the manifold tubes 16 3 Install the new connectors onto the ends of the manifold tubes Make sure the correct connectors are fitted to the manifold tubes Note On all mattresses and seats with one male and one female manifold connector either connector type can be installed on either tube except on the Aura Seat where the female connector must be installed on the shorter of the two manifold tubes 17 Replacing the Turn Valves on the AlphaXcell Double Mattress Overlay The AlphaXcell Double Mattress is a double inflatable mattress overlay which provides static pressure to one side and alternating pressure relief to the other side The static and alternating sides of the mattress can be set up on either side of the bed depending on customer requirements There are three 90 turn valves on the AlphaXcell double mattress overlay e Two valves at the feet end of the mattress retain the air in the static side of the mattress One valve at the head end of the mattress is used to release air from the static side of the mattress
36. head end of the manifold assembly feed the CPR swing label and web assembly out between the top cover and the mattress before securing the top cover Note Make sure that CPR swing label and web assembly passes freely between the top cover and mattress or seat and does not get trapped Zipped Top Cover 4 3 Zip the sides of the top cover to the mattress or seat and connect the velcro strips at the head and foot end of the mattress Studded Top Cover 4 4 Connect the press studs together on all four sides of the top cover Strapped Top Cover 4 5 Carry out either of the following procedures depending on the strap configuration 4 5 1 Top covers secured with straps and buckles which pass under the mattress 4 5 1 1 Pass each strap underneath the mattress and fasten to the strap buckle on the opposite side of the cover 4 5 2 Top covers secured with elasticated corner straps 4 5 2 2 Pass the elasticated loops over the corners of the mattress Chap 3 Issue 2 Page 22 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair 5 Replacing the Non Return Valve Assemblies Not all of the mattress replacements and overlays detailed in this service manual have non return valve assemblies Only those mattress replacements and overlays which have static head cells have non return valve assemblies fitted in the manifold assembly None of the seat systems have static cells or non return valve assemblies Refer to Chapter 1 Page
37. head end of the overlay or mattress replacement on the same side as the tubeset refer to Figure 5 For rapid deflation of the overlay or mattress replacement in an emergency pull the CPR or Rapid Deflate tag to remove the CPR or Rapid Deflate plug from the manifold To re inflate the overlay or mattress replacement replace the CPR or Rapid Deflate plug securely reconnect the manifold tubes to the pump and switch on CPR Plug Figure 5 Cardiopulmonary Resuscitation CPR or Rapid Deflate Plug Issue 2 Chap 1 January 2005 SERO005 Page 7 Introduction Mattress and Seat Systems Service Manual Chap 1 Issue 2 Page 8 SERO005 January 2005 Mattress and Seat Systems Service Manual Maintenance CHAPTER 2 MAINTENANCE 1 Mattress Seat System Service To carry out a service on the mattress or seat system do the following 1 1 Carry out the Mattress Seat System Maintenance Checks Refer to Page 1 Section 2 1 2 Carry out the Pressure and Function Test on the mattress or seat system in accordance with Chapter 5 Page 1 Section 1 2 Mattress Seat System Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with the procedures detailed in Chapter 3 Repair Note Some of the items may not be applicable to a particular model of mattress or seat system 2 1 Visually inspect the following for damage wear and potential faults Issue 2 Base and top cover Base top cover zip Anti
38. ide entry grommet on the end of the cell adjacent to the T connector on the manifold assembly 7 7 Carefully insert the end of the T connector or elbow connector on the end cells into the side entry grommet on the cell 7 8 Connect the press studs that secure each end of the cell to the loop base sheet assembly 7 9 Install the top cover Refer to Page 22 Section 4 Cell Loop Cell Feet End Side Entry lt lt Grommet Cell Seam Manifold Tubes T Connector Figure 21 Cell Orientation Issue 2 Chap 3 January 2005 SER0005 Page 25 Repair Mattress and Seat Systems Service Manual 8 Removing a Manifold Assembly Refer to Figure 20 for a typical view of the connections between the cell assembly and the manifold assembly Note The cells in the Alpha Trancell II mattress overlay are not individual replaceable cells but are a one piece manufactured item the mattress overlay assembly All Mattress Replacement and Overlay Systems except Alpha Trancell Il 8 1 Remove the top cover Refer to Page 21 Section 3 8 2 Disconnect all the cells from the manifold assembly as follows 8 2 1 Pull apart the press studs that secure the end of the cell to the loop base sheet assembly on the manifold side only 8 2 2 Carefully remove the T connector on the end of the cell from the manifold tubes Note The T connector is part of the cell assembly 8 3 Onmattresses with a base cover assembly pull the ends of the manifold tubes which connect to the
39. ly Issue 2 Chap 3 January 2005 SERO005 Page 11 Repair Mattress and Seat Systems Service Manual Refer to Detail B Refer to Detail A Detail B Note the orientation of the Non Return Valves Item 130 Figure 12 AlphaXcell Double Mattress Overlay OL Chap 3 Issue 2 Page 12 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Table 9 AlphaXcell Double Mattress Overlay OL Parts List Part Number Description 632001 AlphaxXcell Double Mattress Overlay 6320052 Top Cover Assembly 632057 Loop Base Sheet Assembly 632050 Double Cell Assembly 632058 Manifold Tube End Assembly CPR comprises Items 50 70 197301 Connector Straight Male Male 1C017UF Manifold Tube Twin Bore IC128 End Plug Assembly comprises Items 80 100 IC033 End Plug 2 way FAS167 Clevis Pin OD 3 16 x 5 8 Long 401309 Swing Label and Web Assembly CPR Pull 632302 Valve 90 Turn 627415 Valve Stopcock IC016 Manifold Tube Twin Bore Short IC036 Non Return Valve Assembly 401300 T Connector 403305 Elbow Connector IC091 Manifold Tube Twin Bore without connectors BP431 Connector Male BP432 Connector Female Tube Blue ID6 OD10 Issue 2 Chap 3 January 2005 SERO005 Page 13 Repair Mattress and Seat Systems Service Manual Note Items 70 and 80 are only fitted on the Mattress Replacement Figure 13 Turbo P
40. overlay OL system is shown in Figure 1 It includes a base sheet alternating and static cells which are individually replaceable a cover air inlet tubes with connectors where applicable and a Cardiopulmonary Resuscitation CPR pull tag also referred to as a Rapid Deflate stopper The cell configurations are detailed in Table 2 The AlphaXcell Double Mattress system is a double inflatable mattress overlay which provides static pressure to one side and alternating pressure relief to the other side The static and alternating sides of the mattress can be set up on either side of the bed depending on customer requirements The Trancell system is an exception The cells for the Alpha Trancell system are not individual replaceable cells but are a one piece manufactured item and can only be replaced as a complete item Static Cells Head Section Cardiopulmonary Resuscitation CPR Pull Tag Cover Air Inlet Tubes Tube Connections lt P Lay Securing Apron Setting up Instructions Strap Strap Alternating Cells OD Base Sheet Cell Loops Figure 1 Typical Mattress Overlay OL System Issue 2 Chap 1 January 2005 SERO005 Page 3 Introduction Mattress and Seat Systems Service Manual 4 Mattress Replacement Systems MR A typical mattress replacement MR system is shown in Figure 2 The MR systems are basically the same configuration as the OL systems with the addition of a foam base which replaces
41. pump into the mattress through the hole in the base cover assembly 8 4 Lift the manifold assembly complete with the CPR end plug assembly where fitted out of the mattress Alpha Trancell Il Mattress Overlay 8 5 Remove the top cover Refer to Page 21 Section 3 8 6 Carefully remove the 16 T connectors on the manifold assembly from the mattress overlay assembly Refer to Figure 10 Note The T connectors are part of the manifold assembly 8 7 Remove the manifold assembly complete with the CPR end plug assembly from the mattress All Seat Systems 8 8 Remove the top cover Refer to Page 21 Section 3 8 9 Disconnect all the cells from the manifold assembly as follows 8 9 3 Pull apart the press studs that secure the end of the cell to the loop base sheet assembly on the manifold side only 8 9 4 Carefully remove the T connector or elbow connector on some end cells on the manifold from the side entry grommet on the cell Note The T connector and elbow connector are part of the manifold assembly 8 10 Onsome seat types pull the ends of the manifold tubes which connect to the pump into the seat through the hole in the loop base sheet assembly 8 11 Lift the manifold assembly out of the loop base sheet assembly Chap 3 Issue 2 Page 26 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair 9 Installing a Manifold Assembly Note Installing the T or elbow connectors into the manifold tubes or side
42. sembly Figure 20 Manifold Cell Connections Chap 3 Issue 2 Page 24 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Note Note Note Installing a Cell There are several different cell assemblies in the various mattress replacements overlays and seat systems detailed in this service manual Make sure the cell assembly is the correct type for the particular mattress or seat and also for the position within the mattress where applicable Make sure the orientation of the cell is correct Refer to Figure 21 The seams should be facing the feet of the mattress Installing the T or elbow connectors into the manifold tubes or side entry grommets on the cells is made easier if the parts are wetted with methylated spirit immediately prior to insertion All Mattress Replacement and Overlay Systems except Alpha Trancell Il 7 1 7 2 7 3 7 4 Feed the cell through the loops in the loop base sheet assembly with the cell T connector adjacent to the manifold assembly Carefully insert the two ends of the T connector into the manifold tubes Connect the press studs that secure each end of the cell to the loop base sheet assembly Install the top cover Refer to Page 22 Section 4 Alpha Trancell Il Mattress Overlay only 7 5 To install the mattress overlay assembly Refer to Page 29 Section 12 All Seat Systems 7 6 Feed the cell through the loops in the loop base sheet assembly with the s
43. slip pads Fixing straps Loop base sheet Foam block Connectors Cells Manifold Non return valves Turn valves Press studs CPR or Rapid Deflate plug January 2005 Check for tears staining clarity of printed labels Check the zip runs freely and condition of zip teeth Check for damage Check condition and security Check for broken torn loops Check condition Check for damage and security Check for damage and security Check for damage and security Check for condition Check operation Check condition Check condition and operation Chap 2 SEROO05 Page 1 Maintenance Mattress and Seat Systems Service Manual Chap 2 Issue 2 Page 2 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair CHAPTER 3 REPAIR 1 General This chapter details the repair procedures for the range of mattress and seat systems identified in Chapter 1 Page 2 Table 1 All repairs should be carried out by Huntleigh approved service personnel The repair procedures in this chapter are general and not unique to a product Refer to Table 3 first to identify the relevant assembly drawing and parts list for the product being repaired and then refer to them whilst carrying out the repair procedures detailed in Section 3 onwards of this chapter It is easier to carry out the repair procedures if the mattress or seat system is fully deflated first Disconnect the tubeset between the mattress or seat system and the pump to d
44. tion CPR or Rapid Deflate plug to allow rapid deflation of the mattress replacement or overlay system None of the seat systems have a CPR or Rapid Deflate plug The CPR or Rapid Deflate end plug assembly is located at the head end of the mattress replacement or overlay on the same side as the manifold 10 1 Remove the top cover Refer to Page 21 Section 3 10 2 Atthe head end of the mattress on the manifold side move the base cover assembly and loop base sheet assembly including cells out of the way to reveal the CPR end plug assembly 10 3 Replace the following parts on the CPR end plug assembly as necessary Refer to Figure 22 e End plug 2 way e Clevis pin e Swing label and web assembly Straight connector male male Note Make sure that the CPR end plug assembly fits tightly into the manifold tubes and that the clevis pin is securely fitted before inflation so that no air escapes Note Installing the end plug or straight connectors is made easier if the parts are wetted with methylated spirit immediately prior to insertion 10 4 Atthe head end of the mattress lay the base cover assembly and loop base sheet assembly including cells back in their correct positions 10 5 Install the top cover Refer to Page 22 Section 4 End Plug 2 way Clevis Pin Swing Label and Web Assembly Straight Connector rar Male Male aeaa a E Dn Manifold Tubes Figur
45. ts have a foam base between the loop base sheet assembly and the base cover Alpha Active MR and Alpha Relief MR 13 1 Remove the top cover Refer to Page 21 Section 3 13 2 Pull the ends of the manifold tubes which connect to the pump into the mattress through the hole in the base cover assembly 13 3 Lift the loop base sheet assembly complete with foam block cells manifold assembly and CPR end plug assembly out of the mattress 13 4 Pull out the flap of the foam base pocket at the end of the loop base sheet assembly and slide out the foam block Turbo Puls MR 13 5 Remove the top cover Refer to Page 21 Section 3 13 6 Pull the ends of the manifold tubes which connect to the pump into the mattress through the hole in the base cover assembly 13 7 Lift the loop base sheet assembly complete with cells manifold assembly and CPR end plug assembly out of the mattress 13 8 Remove the foam block from the base cover 14 Installing the Foam Base Alpha Active MR and Alpha Relief MR 14 1 Insert the foam block into foam block pocket at the end of the loop base sheet assembly 14 2 Install the loop base sheet assembly complete with foam block cells manifold assembly and CPR end plug assembly into the mattress 14 3 Feed the pump ends of the manifold tubes out of the mattress through the hole in the base cover assembly 14 4 Install the top cover Refer to Page 22 Section 4 Turbo Puls MR 14 5 Insert the
46. ttresses MR and OL and Seat Systems except Alpha Trancell Il 12 1 Lay the loop base sheet assembly onto the mattress or seat Note Refer to the relevant figure in this chapter to make sure the loop base sheet assembly and the cells and manifold assembly are in the correct positions 12 2 Install the manifold assembly and all of the cells onto the loop base sheet assembly as follows 12 2 1 Feed the cell through the loops in the loop base sheet assembly from the manifold side of the mattress 12 2 2 Connect the press studs that secure the ends of the cell to the loop base sheet assembly 12 3 Install the top cover Refer to Page 22 Section 4 Alpha Trancell Il Mattress Overlay only 12 4 Lay the mattress overlay assembly next to the manifold assembly with the CPR end plug assembly at the head end of the mattress Align the T connectors on the manifold assembly with the side entry grommets on the mattress overlay assembly Refer to Figure 10 12 5 Carefully insert the 16 T connectors on the manifold assembly into the side entry grommets on the mattress overlay assembly Note Installing the T connectors into the side entry grommets is made easier if the parts are wetted with methylated spirit immediately prior to insertion 12 6 Install the top cover Refer to Page 22 Section 4 Issue 2 Chap 3 January 2005 SERO005 Page 29 Repair Mattress and Seat Systems Service Manual 13 Removing the Foam Base All mattress replacemen
47. uls 9 Turbo Puls Turbo Puls ICT 6R Standard ICT18 ICT18 Ventilated Harada a Mattress Type MR Mattress Replacement OL Mattress Overlay b The Alpha Active system has 8 ventilated cells and 9 non ventilated cells c The AlphaXcell Double Mattress has 20 cells on each side On one side 17 cells are alternating and 3 are static and on the other side all 20 cells are static Issue 2 January 2005 SEROO05 Chap 1 Page 5 Introduction Mattress and Seat Systems Service Manual 6 Operating Principles Refer to Figure 4 for a typical pneumatic system diagram and cell inflation cycle and Table 2 for the actual cell configurations All pumps have two pressurised air outlets Air from the outlets is fed to separate cells or groups of cells in the mattress or seat cushion via a rotary valve The mattress or seat cushion support cells are continuously inflated and deflated during a ten minute cycle During the cycle air is pumped from one outlet to cells A or B for 4 minutes and 10 seconds This is followed by a period of 50 seconds when air is pumped from both outlets to cells A and B Subsequently air is pumped from the other outlet to cells B or A for 4 minutes and 10 seconds and then a further 50 seconds with air from both outlets to cells A and B During the period when air is pumped from an outlet to one group of cells the second set of
48. uls Mattress Replacement MR and Overlay OL Chap 3 Issue 2 Page 14 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Table 10 Turbo Puls Mattress Replacement MR and Overlay OL Parts List Part Number Description BB27001 Turbo Puls Mattress Overlay Standard Cover BB27002 Turbo Puls Mattress Replacement Standard Cover BB27004 Turbo Puls Mattress Overlay Luxury Cover BB27055 Top Cover Assembly Standard for BB27001 and BB27002 BB27064 Top Cover Assembly Luxury for BB27004 BB27052 Loop Base Sheet Assembly IC082 Cell Assembly BB27054 Manifold Assembly comprises Items 50 60 BP418 Stopper BB27054UF Manifold Tube Twin Bore BB27061 Base Cover Assembly for BB27002 only 402302 Foam Base for BB27002 only Issue 2 Chap 3 January 2005 SER0005 Page 15 Repair Mattress and Seat Systems Service Manual Note the orientation of the Non Return Valves Item 30 Cell Arrangement ma OOO OO 0000 OOOOQOO0000 Ena Static Alternating Alternating Non ventilated Non ventilated Non ventilated Item 20 3 off Item 20 2 off Item 20 9 off Alternating 4 off Non ventilated Item 20 all except IC 120 Ventilated Item 70 IC 120 only Figure 14 ICT18 Mattress Overlay OL Chap 3 Issue 2 Page 16 SERO005 January 2005 Mattress and Seat Systems Service Manual Repair Table 11 ICT18 Mattress Overlay OL Parts List

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