Hill-Rom The ZoneAire Sleep Surface System Service Manual
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Hill-Rom The ZoneAire Sleep Surface System Service Manual

Hill-Rom The ZoneAire Sleep Surface System Service Manual

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SERVICE MANUAL
For Parts Or Technical Assistance
USA 1-800-445-3720 Canada 1-800-267-2337
The ZoneAire
Sleep Surface
System
From Hill-Rom
Product No. P993-00
errata
man121-e1
®
man121

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  • Page 1 SERVICE MANUAL The ZoneAire Sleep Surface System errata From Hill-Rom man121-e1 ® Product No. P993-00 For Parts Or Technical Assistance man121 USA 1-800-445-3720 Canada 1-800-267-2337...
  • Page 2 ZoneAire Sleep Surface System Service Manual Revisions Revision Letter Pages Affected Date Original Issue May, 1996 man121 ZoneAire Sleep Surface System Service Manual Page i ®...
  • Page 3 Herculite Products, Inc. ® The information contained in this manual is subject to change without notice. Hill-Rom makes no commitment to update or keep current, the information contained in this manual. The only product warranty intended by Hill-Rom is the express, written warranty accompanying the bill of sale to the original purchaser.

  • Page 4: Table Of Contents

    Typographical Conventions Used in this Manual......1 - 5 Introduction to the ZoneAire Sleep Surface System ..... . . 1 - 6 Overview.
  • Page 5 Table of Contents Safety Tips ............1 - 14 Caution and Warning Labels .
  • Page 6 Table of Contents Auto Firm Mode ..........3 - 21 Mode Transition .
  • Page 7 Table of Contents EEPROM ..........3 - 32 Digital-to-Analog Converter.
  • Page 8 Table of Contents Power Supply Board Replacement ........4 - 15 Removal .
  • Page 9 Table of Contents Caregiver Pendant Control ......... . 5 - 12 Patient Pendant Control .
  • Page 10 Table of Contents Preventive Maintenance Checklist ....... . . 6 - 31 Tool and Supply Requirements.
  • Page 11 Table of Contents NOTES: Page x ZoneAire Sleep Surface System Service Manual ®...
  • Page 12 Typographical Conventions Used in this Manual......1 - 5 Introduction to the ZoneAire Sleep Surface System ..... . . 1 - 6 Overview.
  • Page 13 Chapter 1: Introduction Electrical Description ......... . . 1 - 12 CSA/UL Classification .

  • Page 14: Chapter 1: Introduction

    Chapter 1: Introduction Purpose of this Manual This manual provides the information required for Hill-Rom ZoneAire Sleep Surface System normal operation and maintenance. It also includes a complete parts list for ordering replacement components. The parts list is located in chapter 5.

  • Page 15: Chapter 4: Removal, Replacement, And Adjustment Procedures

    Chapter 4 includes removal, replacement, and adjustment procedures for the ZoneAire Sleep Surface System components. Chapter 5: Parts List Chapter 5 contains Hill-Rom’s warranty, replacement part ordering procedure, exchange policy, illustrated parts lists, and general service information. Chapter 6: General Procedures Chapter 6 contains cleaning and care, lubrication requirements, preventive maintenance, ZoneAire Sleep Surface System tool and supply requirements.

  • Page 16: Typographical Conventions Used In This Manual

    Typographical Conventions Used in this Manual Chapter 1: Introduction Typographical Conventions Used in this Manual This manual contains different typographical conventions designed to enhance readability and understanding of its content. Note the following examples: • Standard text—used for standard text throughout the manual. •...

  • Page 17: Introduction To The Zoneaire Sleep Surface System

    Introduction to the ZoneAire Sleep Surface System Overview The ZoneAire Sleep Surface System is a zoned mattress replacement product providing for the prevention and treatment of pressure ulcers in acute care. All necessary electronic and pneumatic components are packaged in a single control housing.
  • Page 18 Air Hoses The ZoneAire Sleep Surface System has one air hose that connects the air pump to the surface control module inside the mattress. This air hose both inflates and deflates the air bladder.

  • Page 19: Caregiver Pendant

    Chapter 1: Introduction Multiple Zone Bladders The sleep surface consists of multiple zone bladders to provide significant improvement in the reduction of patient interface pressure. Multiple zone bladders allow greater patient and/or nurse adjustment to particular parts of the patient’s body. The multiple zones consist of six different zones. The six zones are the head, seat, thigh, and heel zones 1, 2, and 3.

  • Page 20: Modes Of Operation

    Modes of Operation The ZoneAire Sleep Surface System has four patient care modes. They are pressure relief, heel relief, auto firm, and comfort. The choice of mode is best determined through an assessment of the patient as to his or her risk of pressure ulceration.

  • Page 21: Comfort Mode (Optional)

    The surface adjusts not only to patient’s weight distribution but to patient position and bed articulation. When the ZoneAire Sleep Surface System is placed in the pressure relief mode, the green LED light on the PRESSURE RELIEF button will illuminate, reminding caregivers that the surface is in the proper mode for the patient.

  • Page 22: Auto Firm Mode

    Specifications Chapter 1: Introduction Auto Firm Mode To facilitate patient handling, the caregiver can press the AUTO FIRM button within the caregiver pendant. The auto firm mode will fully inflate all the air bladders within the surface making the surface very firm. The patient’s body will no longer displace air from the air bladders but will be raised up by the surface.

  • Page 23: Patient Pendant (Optional)

    All ZoneAire Sleep Surface Systems are factory tested for complete operation and insulation integrity. The ZoneAire Sleep Surface System operates on 120 volts, 60 Hz, single phase power. The supply cord is #18 AWG, three conductor type STO, and extends 100"...

  • Page 24: Csa/Ul Classification

    Model Identification Chapter 1: Introduction CSA/UL Classification • Class grounded equipment per UL 544 • CSA risk class 2G per CA per CSA 22.2 Model Identification Table 1-1. Model Identification Model Description ZoneAire Sleep Surface System ZoneAire Sleep Surface System Service Manual Page 1 - 13 ®...

  • Page 25: Safety Tips

    Safety Tips Chapter 1: Introduction Safety Tips WARNING: Do not use the ZoneAire Sleep Surface System in the presence of flammable gas or vapors. A fire and explosion hazard in this environment exists as a result of equipment operation. WARNING: Do not use this product with an oxygen tent.
  • Page 26 Sleep Surface System. CAUTION: The EnhanceMate Voice Activated Control System is compatible with the ZoneAire Sleep Surface System and should be installed before installing the power unit assembly. CAUTION: Do not raise the convertible footboard on the critical care bed with the caregiver pendant attached.

  • Page 27: Caution And Warning Labels

    Caution and Warning Labels Chapter 1: Introduction Caution and Warning Labels Figure 1-5. Caution and Warning Labels m121_004 Page 1 - 16 ZoneAire Sleep Surface System Service Manual ®...
  • Page 28 Chapter 2 Troubleshooting Procedures Chapter Contents Getting Started ........... . 2 - 3 Initial Actions .

  • Page 29: Chapter 2: Troubleshooting Procedures

    Chapter 2: Troubleshooting Procedures NOTES: Page 2 - 2 ZoneAire Sleep Surface System Service Manual ®...

  • Page 30: Getting Started

    Technical Support at (800) 445-3720 for assistance. Initial Actions Initial Actions are used to gather information from operators concerning problems with the ZoneAire Sleep Surface System. Note symptoms or other information concerning the problem the operator identifies. This information helps identify the probable cause.

  • Page 31: Function Checks

    Surface System. These tests are the caregiver pendant diagnostic test, valve driver diagnostic test, and pneumatic components diagnostic test. During these diagnostic tests the ZoneAire Sleep Surface System automatically checks each component. The caregiver pendant will display a flashing LED indicating any improperly functioning area of the ZoneAire Sleep Surface System.
  • Page 32 Function Checks Chapter 2: Troubleshooting Procedures Figure 2-1. Caregiver Pendant m121_007 The service required LED is located on the caregiver pendant. Observe the dif- ferent flashes (signals) and count the number of times the LED flashes to deter- mine the area that requires service. 1.
  • Page 33 Function Checks Chapter 2: Troubleshooting Procedures Figure 2-2. Cable Connection AC power JP120 Power unit Caregiver JP119 pendant JP121 Patient pendant (Optional) Air tube Heel bottom zone JP131 Heel mid zone Heel top zone Knee zone Seat zone Head zone Pressure sense lines Sleep surface 4.

  • Page 34: Caregiver Pendant Diagnostic Test

    Function Checks Chapter 2: Troubleshooting Procedures Table 2-1. Service Required LED Fault Number of Name of Error Solution Flashes Slow leak Go to RAP 2.1 Continuous run Go to RAP 2.2 Triac short Go to RAP 2.3 Sensor EEPROM Go to RAP 2.4 Mattress disconnect Go to RAP 2.5 Triac open...

  • Page 35: Valve Driver Diagnostic Test

    Function Checks Chapter 2: Troubleshooting Procedures 5. Press the power switch again, or wait 1 minute to exit this test. The pendant diagnostic test ends after 1 minute, service required LED goes out, and the mains LED stays on. ↓ →...

  • Page 36: Pneumatic Components Diagnostic Test

    Function Checks Chapter 2: Troubleshooting Procedures Table 2-2. Valve LED Relationship Valve Driver Head manifold valve driver Pressure relief switch LED Seat manifold valve driver Heel 1 switch LED Knee manifold valve driver Heel 2 switch LED Heel top manifold valve driver Heel 3 switch LED Heel middle manifold valve Comfort switch LED driver...
  • Page 37 Function Checks Chapter 2: Troubleshooting Procedures Figure 2-3. Mattress Bladders m121_058 Table 2-4 on page 2-10 shows the correlation between the bladders, valves, and sensors. The valves are connected to the left patient hoses, and the sensors are connected to the right patient hoses. Table 2-4.
  • Page 38 Function Checks Chapter 2: Troubleshooting Procedures Figure 2-4. Valve\Sensor Identification Sensor control board Head Heel 3 Seat Knee Heel 2 Heel 1 Knee Seat Head Heel 1 Heel 2 Valve assembly Heel 3 m121_044 3. Release all switches. Press and hold the softer switch, and press the pressure relief switch.
  • Page 39 Function Checks Chapter 2: Troubleshooting Procedures 6. Release all switches. Press and hold the softer switch, and press the heel 1 switch. Observe that the seat bladder 2A inflates (see figure 2-3 on page 2-10). ↓ → Check the air hose connections on the seat bladder 2A and the valve and sensor connection at the foot end of the mattress (see figure 2-4 on page 2-11).
  • Page 40 Function Checks Chapter 2: Troubleshooting Procedures 12. Release all switches. Press and hold the softer switch, and press the heel 3 switch. Observe that the heel top bladder 4 inflates (see figure 2-3 on page 2-10). ↓ → Check the air hose connections on the heel top bladder 4 and the valve and sensor connections at the foot end of the mattress (see figure 2-4 on page 2-11).

  • Page 41: Final Actions

    Final Actions Chapter 2: Troubleshooting Procedures 17. Press and hold the softer switch, press and release the auto firm switch, and press and release the firmer switch. Observe that the heel bottom bladder 6 deflates and that all other bladders do not deflate (see figure 2-3 on page 2-10).

  • Page 42: Slow Leak

    2.1 Slow Leak Chapter 2: Troubleshooting Procedures Slow Leak Pneumatic Subsystem The pneumatic subsystem is comprised of the following five components: • Bladders, both top and lower • Hoses and hose fittings • Air P.C. board • Solenoid valves • Air pump When isolating the fault to one component in the pneumatic subsystem: •...
  • Page 43 2.1 Slow Leak Chapter 2: Troubleshooting Procedures 5. Replace leaking bladder. This solves the problem. ↓ → Go to step 7. 6. Go to “Final Actions” on page 2-14. 7. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.
  • Page 44 2.1 Slow Leak Chapter 2: Troubleshooting Procedures Figure 2-5. Power Unit m121_059 9. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power unit housing (G). 10. Connect the caregiver pendant connector (A), the mattress cable (B), the mattress air hose (C), and the patient pendant connector (D) (optional) to the power unit assembly.
  • Page 45 16. Go to “Final Actions” on page 2-14. 17. Replace the sensor control board (refer to procedure 4.2). This solves the problem. ↓ → Call Hill-Rom Technical Support at (800) 445-3720. 18. Go to “Final Actions” on page 2-14. Page 2 - 18 ZoneAire Sleep Surface System Service Manual ®...

  • Page 46: Continuous Run

    2.2 Continuous Run Chapter 2: Troubleshooting Procedures Continuous Run SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source. 1. Check the mattress for pinched or disconnected air hoses. Pinched or disconnected air hoses are found.
  • Page 47 11. Go to “Final Actions” on page 2-14. 12. Replace the sensor control board (refer to procedure 4.2). This solves the problem. ↓ → Call Hill-Rom Technical Support at (800) 445-3720. 13. Go to “Final Actions” on page 2-14. Page 2 - 20 ZoneAire Sleep Surface System Service Manual ®...

  • Page 48: Triac Short

    1. Replace the air control board (refer to procedure 4.7). This solves the problem. ↓ → Call Hill-Rom Technical Support at (800) 445-3720. 2. Go to “Final Actions” on page 2-14. ZoneAire Sleep Surface System Service Manual Page 2 - 21 ®...

  • Page 49: Sensor Eeprom

    2.4 Sensor EEPROM Chapter 2: Troubleshooting Procedures Sensor EEPROM SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source. CAUTION: Wear an appropriate static strap when working with electronics to prevent component damage.
  • Page 50 8. Go to “Final Actions” on page 2-14. 9. Replace the sensor board (refer to procedure 4.2). This solves the problem. ↓ → Call Hill-Rom Technical Support at (800) 445-3720. 10. Go to “Final Actions” on page 2-14. ZoneAire Sleep Surface System Service Manual Page 2 - 23 ®...

  • Page 51: Mattress Disconnect

    2.5 Mattress Disconnect Chapter 2: Troubleshooting Procedures Mattress Disconnect SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source. CAUTION: Wear an appropriate static strap when working with electronics to prevent component damage.
  • Page 52 2.5 Mattress Disconnect Chapter 2: Troubleshooting Procedures 6. Go to “Final Actions” on page 2-14. 7. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.
  • Page 53 2.5 Mattress Disconnect Chapter 2: Troubleshooting Procedures 10. Connect the caregiver pendant connector (A), the mattress cable (B), the mattress air hose (C), and the patient pendant connector (D) (optional) to the power unit assembly. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.
  • Page 54 2.5 Mattress Disconnect Chapter 2: Troubleshooting Procedures 14. Connect the negative lead of the voltmeter to the anode (end without line) of D16 (H) located on the air control board (see figure 2-9 on page 2-27). Prepare to take two voltage measurements quickly. Initiate self diagnostics “Caregiver Pendant Diagnostic Test”...
  • Page 55 2.5 Mattress Disconnect Chapter 2: Troubleshooting Procedures 15. Put the positive lead on pin 13, on P114 (I). The voltage is greater than 4V ↓ → Go to step 18. 16. Replace the air control board (refer to procedure 4.7). This solves the problem.
  • Page 56 2.5 Mattress Disconnect Chapter 2: Troubleshooting Procedures Figure 2-10. Sensor Control Board m121_030 19. Put the positive lead on pin 13, on P131 (L). The voltage is greater than 4V ↓ → Replace the mattress sensor control board (refer to procedure 4.2).
  • Page 57 → Replace the cable if required (refer to procedure 4.4). If this solves the problem, go to “Final Actions” on page 2-14. Otherwise, go to step 21. 21. Call Hill-Rom Technical Support at (800) 445-3720. Page 2 - 30 ZoneAire Sleep Surface System Service Manual ®...

  • Page 58: Triac Open

    2.6 Triac Open Chapter 2: Troubleshooting Procedures Triac Open 1. Disconnect the mattress cable (B) from the power unit (see figure 2-11 on page 2-32). 2. Perform “Valve Driver Diagnostic Test” on page 2-8. Only the first six LEDs are flashing. ↓...
  • Page 59 2.6 Triac Open Chapter 2: Troubleshooting Procedures Figure 2-11. Power Unit m121_059 5. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power unit housing (G). 6. Connect the caregiver pendant connector (A), the mattress air hose (C), and the patient pendant connector (D) (optional) to the power unit assembly.
  • Page 60 2.6 Triac Open Chapter 2: Troubleshooting Procedures Figure 2-12. Block Diagram Refer to fold-out 3-2 at the rear of this manual. ZoneAire Sleep Surface System Service Manual Page 2 - 33 ®...
  • Page 61 2.6 Triac Open Chapter 2: Troubleshooting Procedures 9. Measure the AC voltage between pins 3 and 12 on P118 (see figure 2-12 on page 2-33). The voltage is greater than 20V AC. ↓ → Go to step 11. 10. Replace the air control board (refer to procedure 4.7). This solves the problem.
  • Page 62 2.6 Triac Open Chapter 2: Troubleshooting Procedures ↓ → Replace the air control board (refer to procedure 4.7). If this solves the problem, go to “Final Actions” on page 2-14. Otherwise, go to step 28. 19. Disconnect and inspect the power supply/air board wiring assembly. Repair any broken or damaged wires.
  • Page 63 27. Replace the power supply board (refer to procedure 4.6). This solves the problem. ↓ → Go to step 28. 28. Go to “Final Actions” on page 2-14. 29. Call Hill-Rom Technical Support at (800) 445-3720. Page 2 - 36 ZoneAire Sleep Surface System Service Manual ®...

  • Page 64: Lon Communication Error

    2.7 LON Communication Error Chapter 2: Troubleshooting Procedures LON Communication Error 1. Inspect the caregiver pendant cable for cuts, pinched, or broken wires. Cuts, pinched, or broken wires are found. ↓ → Go to step 4. 2. Repair or replace the caregiver pendant cable (refer to procedure 4.13). This solves the problem.
  • Page 65 9. Go to “Final Actions” on page 2-14. 10. Replace the air control board (refer to procedure 4.7). This solves the problem. ↓ → Call Hill-Rom Technical Support at (800) 445-3720. 11. Go to “Final Actions” on page 2-14. Page 2 - 38 ZoneAire Sleep Surface System Service Manual ®...

  • Page 66: Key Stuck Closed

    Key Stuck Closed 1. Replace the caregiver pendant board (refer to procedure 4.13). This solves the problem. ↓ → Call Hill-Rom Technical Support at (800) 445-3720. 2. Go to “Final Actions” on page 2-14. ZoneAire Sleep Surface System Service Manual Page 2 - 39 ®...

  • Page 67: Zoneaire Sleep Surface System Does Not Work

    2.9 ZoneAire Sleep Surface System Does Not Work Chapter 2: Troubleshooting Procedures ZoneAire Sleep Surface System Does Not Work 1. Unplug the power unit from its power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.
  • Page 68 2.9 ZoneAire Sleep Surface System Does Not Work Chapter 2: Troubleshooting Procedures 4. Connect the caregiver pendant connector (A), the mattress cable (B), the mattress air hose (C), and the patient pendant connector (D) (optional) to the power unit assembly. 5.
  • Page 69 2.9 ZoneAire Sleep Surface System Does Not Work Chapter 2: Troubleshooting Procedures Figure 2-14. Air Control Board m121_031 8. Replace the air control board (refer to procedure 4.7). This solves the problem. ↓ → Go to step 9. 9. Go to “Final Actions” on page 2-14. 10.
  • Page 70 Final Actions Chapter 2: Troubleshooting Procedures 12. Go to “Final Actions” on page 2-14. 13. Measure the AC voltage at pins 1 and 2 on P28 (O) located on the power supply board (see figure 2-15 on page 2-43). The voltage is greater than 100V AC.
  • Page 71 → Replace the power supply board (refer to procedure 4.6). If this solves the problem, go to “Final Actions” on page 2-14. Otherwise, go to step 18. 18. Call Hill-Rom Technical Support at (800) 445-3720. Page 2 - 44 ZoneAire Sleep Surface System Service Manual ®...
  • Page 72 Chapter 3 Theory of Operation Chapter Contents Schematics ............3 - 5 Software Theory of Operation .

  • Page 73: Chapter 3: Theory Of Operation

    Chapter 3: Theory of Operation Diagnostic Routines ......... 3 - 26 Hardware Theory of Operation.
  • Page 74 Chapter 3: Theory of Operation Regulator..........3 - 36 Mattress Plumbing .
  • Page 75 Chapter 3: Theory of Operation NOTES: Page 3 - 4 ZoneAire Sleep Surface System Service Manual ®...
  • Page 76 Schematics Chapter 3: Theory of Operation Schematics Figure 3-1. ZoneAire Sleep Surface System Wiring Diagram Refer to fold-out FO3-1 at the rear of this manual. ZoneAire Sleep Surface System Service Manual Page 3 - 5 ®...

  • Page 77: Schematics

    Schematics Chapter 3: Theory of Operation Figure 3-2. Power Unit Block Diagram Refer to fold-out FO 3-2 at the rear of this manual. Page 3 - 6 ZoneAire Sleep Surface System Service Manual ®...
  • Page 78 Schematics Chapter 3: Theory of Operation Figure 3-3. Caregiver Pendant Schematic Diagram Refer to fold-out FO3-3 at the the rear of this manual. ZoneAire Sleep Surface System Service Manual Page 3 - 7 ®...
  • Page 79 Schematics Chapter 3: Theory of Operation Figure 3-4. Power Supply Schematic Diagram Refer to fold-out FO3-4 at the rear of this manual. Page 3 - 8 ZoneAire Sleep Surface System Service Manual ®...
  • Page 80 Schematics Chapter 3: Theory of Operation Figure 3-5. Air Control Board (Sheet 1 of 3) Refer to fold-out FO3-5.1 at the rear of this manual. ZoneAire Sleep Surface System Service Manual Page 3 - 9 ®...
  • Page 81 Schematics Chapter 3: Theory of Operation Figure 3-6. Air Control Board (Sheet 2 of 3) Refer to fold-out FO3-5.2 at the rear of this manual. Page 3 - 10 ZoneAire Sleep Surface System Service Manual ®...
  • Page 82 Schematics Chapter 3: Theory of Operation Figure 3-7. Air Control Board (Sheet 3 of 3) Refer to fold-out FO3-5.3 at the rear of this manual. ZoneAire Sleep Surface System Service Manual Page 3 - 11 ®...
  • Page 83 Schematics Chapter 3: Theory of Operation Figure 3-8. Sensor Board Schematic Diagram Refer to fold-out FO3-6 at the rear of this manual. Page 3 - 12 ZoneAire Sleep Surface System Service Manual ®...

  • Page 84: Software Theory Of Operation

    Software Theory of Operation Air Control Board General Description The ZoneAire Sleep Surface System is an air inflated, multi-functional, automatic and/or user controlled sleep surface used in conjunction with hospital patient beds. The system functions are separated into several modes of operation.

  • Page 85: Reset

    Software Theory of Operation Chapter 3: Theory of Operation Reset A reset can happen two ways. A reset is initiated when power is applied to the NEURON micro controller, and when a Neuron watchdog timer expires. Upon reset, the following sequence occurs: •...

  • Page 86: Off Mode

    Software Theory of Operation Chapter 3: Theory of Operation In all seven modes, the caregiver pendant is monitored for activity pertaining to the air system. In all modes, except the off mode, a main loop is executed at an approximate 25 Hz rate that performs the following functions: •...

  • Page 87: Pressure Relief Mode

    Software Theory of Operation Chapter 3: Theory of Operation The transition to the off mode can be initiated two ways: • Pressing the sleep surface power switch while in any of the other six modes. • An air system error occurs with exception of a communication error. Can occur while in any of the other six modes.

  • Page 88: Comfort Mode

    Software Theory of Operation Chapter 3: Theory of Operation Transition to a heel relief mode can be made by: • Pressing the respective heel relief switch (heel relief switch 1, 2, or 3) while in the pressure relief mode. • Pressing the respective heel relief switch (heel relief switch 1, 2, or 3) while in either of the other two heel relief modes.

  • Page 89: Auto Firm Mode

    Software Theory of Operation Chapter 3: Theory of Operation Transition to the comfort mode can be made by: • Pressing the comfort switch while in any other mode except off mode, if patient pendant is present. • Pressing the auto firm switch while in the auto firm mode provided the auto firm mode was initiated from the comfort mode (mode memory feature).

  • Page 90: Intermode Transitions

    Software Theory of Operation Chapter 3: Theory of Operation During transition from the off mode to the pressure relief mode, the following occurs: • The low voltage AC/mattress power relay is activated and all I/O is initialized. • Any and all errors are cleared. •...

  • Page 91: System Errors

    LED. For the ZoneAire Sleep Surface System, the code consists of a certain number, N, of short flashes which identifies which error has occurred on the system.

  • Page 92: Continuous Run Error

    Software Theory of Operation Chapter 3: Theory of Operation Continuous Run Error In all modes, except the off mode, the system is monitored for failure conditions that would cause the pump to be commanded, by the control algorithm, to run continuously. Examples of these are: •...

  • Page 93: Mattress Connection Error

    LON Communication Error In all modes, except the off mode, communications with the caregiver pendant is checked. The ZoneAire Sleep Surface System gets updates, via LON communications, from the caregiver pendant at most every 30 seconds. The ZoneAire Sleep Surface System refreshes a 5 minute timer whenever it gets this update.

  • Page 94: Diagnostic Routines

    Software Theory of Operation Chapter 3: Theory of Operation communications and should discover that communication was lost. It will then flash code 7. Diagnostic Routines Component Manual Activation While in the off mode, operation of the relay, air manifold valves, flow direction valve, and pump can be tested.

  • Page 95: Hardware Theory Of Operation

    Hardware Theory of Operation Power Supply This supply is provides logic power to the ZoneAire Sleep Surface System air control board (44760xx), sensor control board assembly (44740), caregiver pendant, and other future upgrades. One central supply allows several nodes or logic boards to power up at nearly the same time.

  • Page 96: Air Control Board

    For 230V AC power, a 0.125A, UL198G, or a 0.1A, IEC127-3, time-lag fuse should be used. Check assembly drawing or schematic for proper Hill-Rom fuse. The transformer full load output (as configured for this supply) is 9V rms at 2A rms.

  • Page 97: Valve/Sensor Module Digital Control Lines

    IC on the valve/sensor board will access the Neurowire bus. Other Signals The BDXT signal is not used on the ZoneAire Sleep Surface System. SGMIF and SGMDF are signals from the patient pendant inflate and deflate switches. The pendant switches connect Vcc (via R83) from the air control board to connector P111 pins 3 and 4.

  • Page 98: 24V Ac Solenoid Drivers

    Hardware Theory of Operation Chapter 3: Theory of Operation of the schmitt-trigger inverter LO which keeps U10-6 LO. U10 is a programmable timer with a 16 stage counter and internal oscillator. Upon power up the Q output goes HI. If MR, master reset, is constantly LO, the Q output will oscillate at 30 sec.

  • Page 99: Esd Protection

    Hardware Theory of Operation Chapter 3: Theory of Operation ESD Protection Some ICs have a 100 ohm resistor in series with its Vcc pin to limit Icc to 50 mA. This helps prevent latch-up. Switched inputs have RC protection for debounce and static.

  • Page 100: Input Protection

    Hardware Theory of Operation Chapter 3: Theory of Operation circuit gain, offset, and calibration parameters to remain on board thereby allowing characteristic independence from the mating control processor circuit. Input Protection Diodes D21-D26, D30 are transient voltage suppressors used to divert input electrostatic discharge (ESD) currents to ground.

  • Page 101: Digital-To-Analog Converter

    Hardware Theory of Operation Chapter 3: Theory of Operation Resistor R24 acts as a current limiter which protects U3 should a latchup condition occur. C11 provides decoupling. Digital-to-Analog Converter NAND gate U7 pin 1 acts as a D/A chip select pin. A logic level 0 at P131 pin 3 (A/D_D/A_CS) enables the CLK signal to the shift register U8.

  • Page 102: Analog-To-Digital Converter

    Hardware Theory of Operation Chapter 3: Theory of Operation This voltage is subtracted from that at U6 pin 7 and the result is amplified by G = 2. The voltage at U5 pin 7 is then applied to the A/D converter U4 pin 3. Resistor R3 acts as a current limiter which protects U6 should a latchup condition occur.

  • Page 103: Power Supply

    Hardware Theory of Operation Chapter 3: Theory of Operation Power Supply Voltage regulator U8 maintains Vcc at 5 + 0.25 volts. C6 and C7 maintain regulation stability. D2 provides a bleed off path for C6 during loss of power at P131 pin 1 (VBB2SW).

  • Page 104: Connector P1

    Hardware Theory of Operation Chapter 3: Theory of Operation The multi-character display driver is a Motorola MC14489 used in the no decode mode. See Motorola data book “CMOS Application-Specific Standard ICs”, DL130 Rev 1 for more details. Three sets of data must be sent to the driver to control the LEDs.
  • Page 105 Hardware Theory of Operation Chapter 3: Theory of Operation Figure 3-9. Mattress Bladders There is also a port on the right side of each bladder that connects the bladders to their pressure sensor located at the footend of the mattress and possibly to another bladder.
  • Page 106 Chapter 4 Removal, Replacement, and Adjustment Procedures Chapter Contents Mattress Replacement..........4 - 3 Removal .
  • Page 107 Chapter 4: Removal, Replacement, and Adjustment Procedures Switching Valve Assembly Replacement....... 4 - 20 Removal .

  • Page 108: Mattress Replacement

    4.1 Mattress Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Mattress Replacement Tools required: Wire tie cutter Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 109: Installation

    6. Remove the mattress. Installation 7. Perform the removal procedure in reverse order. After the new mattress is installed, refer to the ZoneAire Sleep Surface System installation procedures for the proper cable and air hose routing. • For retractable beds: Advance series bed, 840 and 850 series bed, and Centra beds, refer to procedure 6.1.

  • Page 110: Mattress Sensor Control Board Replacement

    4.2 Mattress Sensor Control Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Mattress Sensor Control Board Replacement Tools required: 3/16" Nut driver Standard head screwdriver Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 111: Installation

    4.2 Mattress Sensor Control Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-2. Mattress Sensor Control Board Replacement m121_044 5. Using the standard head screwdriver, disconnect the mattress cable connector (D) from the sensor control board (C). 6. Disconnect the surface valves connector (E) from the sensor control board (C).

  • Page 112: Sensor Control Valve Replacement

    4.3 Sensor Control Valve Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Sensor Control Valve Replacement Tools required: Standard head screwdriver Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 113: Installation

    4.3 Sensor Control Valve Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-3. Sensor Control Valve Replacement m121_045 6. Match mark each of the six air tubes (C) to the corresponding valve on the sensor control valve assembly (D). 7.

  • Page 114: Mattress Cable Replacement

    4.4 Mattress Cable Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Mattress Cable Replacement Tools required: Standard head screwdriver Wire tie cutters Removal 1. Unplug the bed and the power unit from their power source. 2. Remove the foot panel from the bed. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 115: Installation

    4.4 Mattress Cable Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-4. Mattress Cable Replacement m121_044 5. Using the standard head screwdriver, disconnect the mattress cable connector (D) from the sensor control board (C). 6. Cut all red wire ties that secure the mattress cable and mattress air hose to the frame.
  • Page 116 4.4 Mattress Cable Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 3. For retractable beds: Advance series bed, 840 and 850 series bed, and Centra beds: Measure 57" along the mattress cable connector and air hose from the power unit. Mark this point on the cable and hose. For non-retractable beds: Century series and 425, 426, 715, 720, 723, 820, 822, 8200, 8350 beds: Measure 60"...

  • Page 117: Mattress Air Tube Replacement

    4.5 Mattress Air Tube Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Mattress Air Tube Replacement Tools required: Wire tie cutters Standard head screwdriver Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 118: Installation

    4.5 Mattress Air Tube Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-5. Mattress Air Tube Replacement m121_044 4. Using the standard head screwdriver, remove the surface control cover (A) from the surface control frame (B). 5. Disconnect the air tube (C) from the surface control valve (D). 6.
  • Page 119 4.5 Mattress Air Tube Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 3. For retractable beds: Advance series bed, 840 and 850 series bed, and Centra beds: Measure 57" along the power cable connector and air hose. Mark this point on the cable and hose. For non-retractable beds: Century series and 425, 426, 715, 720, 723, 820, 822, 8200, 8350 beds: Measure 60"...

  • Page 120: Power Supply Board Replacement

    4.6 Power Supply Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Power Supply Board Replacement Tools required: Phillips head screwdriver Standard head screwdriver Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 121: Installation

    4.6 Power Supply Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-6. Power Supply Board Replacement m121_034 3. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power unit housing (J). 4.

  • Page 122: Air Control Board Replacement

    4.7 Air Control Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Air Control Board Replacement Tools required: Phillips head screwdriver Standard head screwdriver Needle nose pliers Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.
  • Page 123 4.7 Air Control Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-7. Air Control Board Replacement m121_024 3. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power unit housing (G). 4.

  • Page 124: Installation

    4.7 Air Control Board Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 10. Remove the transformer wiring assembly connector (P) from P118 on the air control board (K). 11. Using the phillips head screwdriver, remove the two phillips head screws (L) that secure the air control board (K) to the power unit assembly.

  • Page 125: Switching Valve Assembly Replacement

    4.8 Switching Valve Assembly Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Switching Valve Assembly Replacement Tools required: Phillips head screwdriver Standard head screwdriver Removal 1. Unplug the bed and the power unit from their power sources. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 126: Installation

    4.8 Switching Valve Assembly Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 3. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power unit housing (G). 4. Remove the quick coupling hose (H), the muffler hose (I), the air pump input hose (L), and the air pump output hose (M) connected to the switching valve assembly (J).

  • Page 127: Transformer Replacement

    4.9 Transformer Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Transformer Replacement Tools required: Phillips head screwdriver Needle nose pliers Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 128: Installation

    4.9 Transformer Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 3. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power supply housing (G). 4. Disconnect the transformer wiring assembly connector (I) from the air control board (M) P118.

  • Page 129: 4.10 Compressor Replacement

    4.10 Compressor Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 4.10 Compressor Replacement Tools required: Phillips head screwdriver Wire tie cutters Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 130: Installation

    4.10 Compressor Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 3. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power supply housing (G). 4. Remove the connector (J) from P116 on the air control board (N). 5.

  • Page 131: 4.11 Line Filter Replacement

    4.11 Line Filter Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 4.11 Line Filter Replacement Tools required: Phillips head screwdriver Needle nose pliers Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 132: Installation

    4.11 Line Filter Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 3. Using the phillips head screwdriver, remove the seven screws (E) that secure the power unit cover (F) to the power supply housing (I). 4. Using the needle nose pliers, remove the filter/power supply wiring assembly white wire (M) from the noise filter stud number 3.

  • Page 133: 4.12 Power Unit Power Cord Replacement

    4.12 Power Unit Power Cord Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures 4.12 Power Unit Power Cord Replacement Tools required: Phillips head screwdriver Needle nose pliers 1 1/4" open end wrench Removal 1. Unplug the bed and the power unit from their power source. SHOCK HAZARD: An electrical shock hazard exists if you do not unplug the ZoneAire Sleep Surface System from its power source.

  • Page 134: Installation

    4.12 Power Unit Power Cord Replacement Chapter 4: Removal, Replacement, and Adjustment Procedures Figure 4-12. Power Plug Replacement m121_049 3. Using the phillips head screwdriver, remove the seven phillips head screws (E) that secure the power unit cover (F) to the power supply housing (L). 4.

  • Page 135: 4.13 Caregiver Pendant Pc Board And Cable

    4.13 Caregiver Pendant PC Board And Cable Chapter 4: Removal, Replacement, and Adjustment Procedures 4.13 Caregiver Pendant PC Board And Cable Tools required: Phillips head screwdriver 1. Using the phillips head screwdriver, remove the six phillips head screws (A) that secure the back cover (B) to the front cover (E). Figure 4-13.

  • Page 136: Installation

    4.13 Caregiver Pendant PC Board And Cable Chapter 4: Removal, Replacement, and Adjustment Procedures 3. Disconnect the caregiver pendant cable connector (G) from P1(F) located on the board (D). Installation Perform the removal procedure in reverse order. ZoneAire Sleep Surface System Service Manual Page 4 - 31 ®...
  • Page 137 4.13 Caregiver Pendant PC Board And Cable Chapter 4: Removal, Replacement, and Adjustment Procedures NOTES: Page 4 - 32 ZoneAire Sleep Surface System Service Manual ®...
  • Page 138 Chapter 5 Parts List Chapter Contents Warranty ............5 - 3 Ordering Service Parts .
  • Page 139 Chapter 5: Parts List NOTES: Page 5 - 2 ZoneAire Sleep Surface System Service Manual ®...

  • Page 140: Warranty

    ® A Hillenbrand Industry LIMITED WARRANTY Hill-Rom has a long tradition of providing superior quality products and service to our customer. Our goal is “Total Customer Satisfaction.” In that spirit, Hill-Rom is proud to offer the following warranty. GENERAL WARRANTY: Hill-Rom warrants to the original purchaser that its products shall be free from defects in material and workmanship for a period of one (1) year after date of delivery.
  • Page 141 A Product Assurance and/or Preventive Maintenance contract will be offered at the time of installation for a pre-determined fee. This will act to advise the customer of the condition of Hill-Rom products being upgraded along with specific parts and PM recommendations.

  • Page 142: Ordering Service Parts

    Use the parts lists in this service manual to identify the part numbers you require. Call your Technical Customer Support Specialist at the Hill-Rom Technical Support Department—phone (800) 445-3720. To help expedite the processing of your parts order, please have your six-digit customer account number, purchase order number, product number, and serial number available for the Technical Customer Support Specialist when you call.
  • Page 143 Ordering Service Parts Chapter 5: Parts List For your convenience, Hill-Rom provides a telefax number to promptly order parts, request part prices and availability, or to follow up on a service order. The telefax number is (812) 934-8472. We suggest a minimum of $40.00 when placing orders for service parts. This will help prevent an increase in the cost of processing your service order.

  • Page 144: Exchange Policy

    In some cases, the invoice sent with the parts will show the full selling price of the parts. This is for Hill-Rom’s internal use only and should not be confused with the price you will actually pay.

  • Page 145: Power Unit Assembly

    Power Unit Assembly Chapter 5: Parts List Power Unit Assembly Figure 5-2. Power Unit Assembly m121_001 Page 5 - 8 ZoneAire Sleep Surface System Service Manual ®...
  • Page 146 Power Unit Assembly Chapter 5: Parts List Table 5-1. Power Unit Assembly Item Number Part Number Quantity Description 46922 (462) Power unit cover 9002712 (462) Screw 4476004 (462) Air control board assembly 9002506 (462) Screw 4921 (462) Screw 4692448 (462) Mounting bracket 48691 (462) Quick coupling...
  • Page 147 Power Unit Assembly Chapter 5: Parts List Item Number Part Number Quantity Description 46927 (462) AC power cord assembly 90058-04 (462) Screw 4471904 (462) Power supply board assembly 22247 (462) Caution label 48775 (462) Sound insulation 46933 (462) Pendant position label 46940 (462) Transformer cable assembly 90073-04 (462)
  • Page 148 Power Unit Assembly Chapter 5: Parts List NOTES: ZoneAire Sleep Surface System Service Manual Page 5 - 11 ®...
  • Page 149 Caregiver Pendant Chapter 5: Parts List Caregiver Pendant Figure 5-3. Caregiver Pendant—P/N 48358 m121_002 Page 5 - 12 ZoneAire Sleep Surface System Service Manual ®...
  • Page 150 Caregiver Pendant Chapter 5: Parts List Table 5-2. Caregiver Pendant—P/N 48358 Item Number Part Number Quantity Description 48690 (462) Caregiver pendant overlay 48749 (462) ZoneAire pendant label 48602 (462) Caregiver pendant front 48816 (462) Foam eprom retainer 48754 (462) Caregiver pendant cable assembly 14450 (462) Small cable tie 46943 (462)

  • Page 151: Patient Pendant Control

    Patient Pendant Control Chapter 5: Parts List Patient Pendant Control Figure 5-4. Patient Pendant Control—P72901 m121_003 Page 5 - 14 ZoneAire Sleep Surface System Service Manual ®...
  • Page 152 Patient Pendant Control Chapter 5: Parts List Table 5-3. Patient Pendant Control—P72901 Item Number Part Number Quantity Description P72901 (462) Patient pendant SA7341 (462) Cable tie 19124 (462) Large cable tie SA7346 (462) Pendant control—front SA7337 (462) Compression boot SA7338 (462) Pendant control—back SA7339 (462) Screw...

  • Page 153: Power Supply Board Assembly-P/N 4471904

    Power Supply Board Assembly—P/N 4471904 Chapter 5: Parts List Power Supply Board Assembly—P/N 4471904 Figure 5-5. Power Supply Board Assembly—P/N 4471904 m121_029 Page 5 - 16 ZoneAire Sleep Surface System Service Manual ®...
  • Page 154 Power Supply Board Assembly—P/N 4471904 Chapter 5: Parts List Table 5-4. Power Supply Board Assembly—P/N 4471904 Component Symbol Part Number Description 43669-478 (462) Capacitor D1, D2, D3, D4 30210-5401B (462) Diode 30214-180A (462) Tranzorb 44714-08 (462) Fuse 44715-18 (462) Fuse L1, R2, R3 30016 (462) Resistor...

  • Page 155: Air Control Board-P/N 4476004

    Air Control Board—P/N 4476004 Chapter 5: Parts List Air Control Board—P/N 4476004 Figure 5-6. Air Control Board—P/N 4476004 TOP VIEW m121_031 Page 5 - 18 ZoneAire Sleep Surface System Service Manual ®...
  • Page 156 Air Control Board—P/N 4476004 Chapter 5: Parts List Figure 5-7. Air Control Board—P/N 4476004 BOTTOM VIEW ZoneAire Sleep Surface System Service Manual Page 5 - 19 ®...
  • Page 157 Air Control Board—P/N 4476004 Chapter 5: Parts List Table 5-5. Air Control Board—P/N 4476004 Component Symbol Part Number Description C1-C17, C25, C31-C35 47642104K3C (462) Capacitor 47644334K3C (462) Capacitor C26,C27 47644474K3C (462) Capacitor 30125101M (462) Capacitor C18, C19 47641330J3A (462) Capacitor C39, C40 47643103K3A (462) Capacitor...
  • Page 158 Air Control Board—P/N 4476004 Chapter 5: Parts List Component Symbol Part Number Description R111 30007121 (462) Resistor 47618393 (462) Resistor R29-R36 47619151 (462) Resistor R66-R67 47618153 (462) Resistor R57-R63, R99 30024181 (462) Resistor R38, R39 47618222 (462) Resistor 47618753 (462) Resistor 47619271 (462) Resistor...

  • Page 159: Sensor Control Board Assembly-P/N 44740

    Sensor Control Board Assembly—P/N 44740 Chapter 5: Parts List Sensor Control Board Assembly—P/N 44740 Figure 5-8. Sensor Control Board Assembly—P/N 44740 m121_030 Page 5 - 22 ZoneAire Sleep Surface System Service Manual ®...
  • Page 160 Sensor Control Board Assembly—P/N 44740 Chapter 5: Parts List Table 5-6. Sensor Control Board Assembly—P/N 44740 Component Symbol Part Number Description C1, C3, C5, C9, C11-C14, 30109-473K (462) Capacitor 30108 (462) Capacitor formed C7, C21 30109-104K (462) Capacitor 30129-105K1 (462) Capacitor D1, D15, D21-D26, D30 30214-050A (462)
  • Page 161 Sensor Control Board Assembly—P/N 44740 Chapter 5: Parts List Component Symbol Part Number Description U7, U9 3040074HC14 (462) Integrated circuit 30312-2931 (462) Integrated circuit 44741 (462) Pressure sensor assembly Page 5 - 24 ZoneAire Sleep Surface System Service Manual ®...
  • Page 162 Sensor Control Board Assembly—P/N 44740 Chapter 5: Parts List NOTES: ZoneAire Sleep Surface System Service Manual Page 5 - 25 ®...

  • Page 163: Caregiver Pendant Board Assembly-P/N 46943

    Caregiver Pendant Board Assembly—P/N 46943 Chapter 5: Parts List Caregiver Pendant Board Assembly—P/N 46943 Figure 5-9. Caregiver Pendant Board Assembly—P/N 46943 m121_033 Page 5 - 26 ZoneAire Sleep Surface System Service Manual ®...
  • Page 164 Caregiver Pendant Board Assembly—P/N 46943 Chapter 5: Parts List Table 5-7. Caregiver Pendant Board Assembly—P/N 46943 Component Symbol Part Number Description C1-C4, C7-C22, C24, C25 47641104K3C (462) Capacitor C5, C6 47641330J3A (462) Capacitor 47662226M1 (462) Capacitor 305055 (462) LED—green 305056 (462) LED—yellow 30214-180A (462) Tranzorb...

  • Page 165: Sleep Surface Mattress Assembly-P1412Ca01,02 & P1412Ea01,02

    Sleep Surface Mattress Assembly—P1412CA01,02 & P1412EA01,02 Chapter 5: Parts List Sleep Surface Mattress Assembly—P1412CA01,02 & P1412EA01,02 Figure 5-10. Sleep Surface Mattress Assembly—P1412CA01,02 & P1412EA01,02 m121_006 Page 5 - 28 ZoneAire Sleep Surface System Service Manual ®...
  • Page 166 Sleep Surface Mattress Assembly—P1412CA01,02 & P1412EA01,02 Chapter 5: Parts List Table 5-8. Sleep Surface Mattress Assembly—P1412CA01,02 & P1412EA01,02 Item Number Part Number Quantity Description SA8651 (462) Comfort ticking—blue SA8652 (462) Ultron ticking—green SA4589 (462) Magnet SA7395 (462) Push rivet SA7397 (462) Strap with buckle insert SA7396 (462) Strap with buckle catch...

  • Page 167: Sleep Surface Mattress Assembly-P1414Ca01,02 & P1414Ea01,02

    Sleep Surface Mattress Assembly—P1414CA01,02 & P1414EA01,02 Chapter 5: Parts List Sleep Surface Mattress Assembly—P1414CA01,02 & P1414EA01,02 Figure 5-11. Sleep Surface Mattress Assembly—P1414CA01,02 & P1414EA01,02 m121_006 Page 5 - 30 ZoneAire Sleep Surface System Service Manual ®...
  • Page 168 Sleep Surface Mattress Assembly—P1414CA01,02 & P1414EA01,02 Chapter 5: Parts List Table 5-9. Sleep Surface Mattress Assembly—P1414CA01,02 & P1414EA01,02 Item Number Part Number Quantity Description SA8659 (462) Comfort ticking SA8660 (462) Ultron ticking SA4589 (462) Magnet SA7395 (462) Push rivet SA7397 (462) Strap with buckle insert SA7396 (462) Strap with buckle catch...

  • Page 169: Sleep Surface Mattress Assembly-P1416Ca01,02 & P1416Ea01,02

    Sleep Surface Mattress Assembly—P1416CA01,02 & P1416EA01,02 Chapter 5: Parts List Sleep Surface Mattress Assembly—P1416CA01,02 & P1416EA01,02 Figure 5-12. Sleep Surface Mattress Assembly—P1416CA01,02 & P1416EA01,02 m121_006 Page 5 - 32 ZoneAire Sleep Surface System Service Manual ®...
  • Page 170 Sleep Surface Mattress Assembly—P1416CA01,02 & P1416EA01,02 Chapter 5: Parts List Table 5-10. Sleep Surface Mattress Assembly—P1416CA01,02 & P1416EA01,02 Item Number Part Number Quantity Description SA8663 (462) Comfort ticking SA8664 (462) Ultron ticking SA4589 (462) Magnet SA7395 (462) Push rivet SA7397 (462) Strap with buckle insert SA7396 (462) Strap with buckle catch...

  • Page 171: Sleep Surface Control Module Assembly

    Sleep Surface Control Module Assembly Chapter 5: Parts List Sleep Surface Control Module Assembly Figure 5-13. Sleep Surface Control Module Assembly m121_036 Page 5 - 34 ZoneAire Sleep Surface System Service Manual ®...
  • Page 172 Sleep Surface Control Module Assembly Chapter 5: Parts List Table 5-11. Sleep Surface Control Module Assembly Item Number Part Number Quantity Description SA7404 (462) Locator plate SA7403 (462) Tubing clamp 47610pl (462) Surface control base 28968 (462) Screw lock 4875601 (462) Tube 45846 (462) Quick coupling—female...

  • Page 173: Trapeze Support Adapter-P844A02

    Trapeze Support Adapter—P844A02 Chapter 5: Parts List Trapeze Support Adapter—P844A02 Figure 5-14. Trapeze Support Adapter—P844A02 Reference frame assembly P/N 44795 m121_053 Table 5-12. Trapeze Support Adapter—P844A02 Item Number Part Number Quantity Description 4894848 (462) Trapeze adapter bracket 90017-20 (462) Hex head bolt 9013221 (462) Hex nut Page 5 - 36...
  • Page 174 Chapter 6 General Procedures Chapter Contents Installing on a Retractable Bed Frame ........6 - 3 Installation .
  • Page 175 Chapter 6: General Procedures NOTES: Page 6 - 2 ZoneAire Sleep Surface System Service Manual ®...

  • Page 176: Installing On A Retractable Bed Frame

    6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures Installing on a Retractable Bed Frame This procedure provides installation and removal instructions for the following bed frames: • Advance series bed (3 motor): 1100, 1110, 1120, 1130, 1140 •...

  • Page 177: Installation

    CAUTION: Hill-Rom does not recommend using the bed exit system in conjunction with the ZoneAire Sleep Surface System when the mattress is installed on beds with a spring fabric deck. 1. If the bed is equipped with a DynamicAire Sleep Surface System, make sure its air power switch is in the off position.
  • Page 178 6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures 6. Put the ZoneAire Sleep Surface System mattress on the bed with the white heel zone locator buttons at the foot end. 7. If your bed is equipped with a hard panel sleep surface, complete this step.
  • Page 179 6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures Figure 6-3. Bed Equipped With a Spring Fabric Sleep Surface m121_012 9. Unplug the bed from its power source. 10. Raise both right siderails and lock in the upright position. 11.
  • Page 180 6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures NOTE: Make sure you clean and dry the frame surface thoroughly for better wire tie holder adhesion. 12. Measure 8" from the foot rack pivot (F) toward the foot end of the bed, and put one wire tie holder on the retracting frame at location (E).
  • Page 181 6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures Figure 6-5. Retractable Bed Cable Routing m121_014 17. Complete this step for 840 and 850 bed frames only. From the base of the caregiver pendant (L), measure 40" along the pendant cable and with a permanent marker, mark the 40"...
  • Page 182 6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures CAUTION: The wire ties should be snug enough to hold the cables and the air tube in place but not so snug as to kink or compress the air tube and restrict airflow.
  • Page 183 6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures Figure 6-7. Cable Routing and Connection Foot end NOTE: The head section is shown in the up position for clarity. m121_010 21. Route the caregiver pendant cable, the mattress power cable, and the mattress air tube along the arm assembly (S).

  • Page 184: Removal

    6.1 Installing on a Retractable Bed Frame Chapter 6: General Procedures 29. Using the wire cutters, cut off all excess material from the wire ties. 30. Perform a functional check of the ZoneAire Sleep Surface System. Refer to the ZoneAire Sleep Surface System In-Service Manual. Removal To remove the system, cut all of the red cable ties that were installed during the installation procedure.

  • Page 185: Installing On A Non-Retractable Bed Frame

    CAUTION: Hill-Rom does not recommend using the bed exit system in conjunction with the ZoneAire Sleep Surface System when the mattress is installed on beds with a spring fabric deck. 1. If the bed is equipped with a DynamicAire Sleep Surface system, make sure its air power switch is in the off position.
  • Page 186 Use the clamping screws with the long threads on beds equipped with bayonet mounting posts. 7. Put the ZoneAire Sleep Surface System mattress on the bed with the white heel zone locator buttons at the foot end. 8. If your bed is equipped with a hard panel sleep surface, complete this step.
  • Page 187 6.2 Installing on a Non-Retractable Bed Frame Chapter 6: General Procedures seat sections of the bed (see figure 6-9 on page 6-14). Locate the cable and air hose approximately 8" from the surface edge on the patient’s right side. Figure 6-9. Bed Equipped With a Hard Panel Sleep Surface m121_011 9.
  • Page 188 6.2 Installing on a Non-Retractable Bed Frame Chapter 6: General Procedures 10. Put the caregiver pendant (E) on top of the footboard on the patient’s right side (see figure 6-11 on page 6-15). Figure 6-11. Caregiver Pendant Cable Routing m121_016 11.
  • Page 189 6.2 Installing on a Non-Retractable Bed Frame Chapter 6: General Procedures 16. Using the red cable ties, secure the caregiver pendant cable, mattress power cable, and mattress air tube to the bed frame at locations (J) and (K) (see figure 6-12 on page 6-16). Figure 6-12.

  • Page 190: Removal

    23. Plug the power unit into an appropriate power source. 24. Using the wire cutters, cut off all excess material from the wire ties. 25. Perform a functional check of the ZoneAire Sleep Surface System. Refer to the ZoneAire Sleep Surface System In-Service Manual.

  • Page 191: Installing On A Critical Care Bed

    6.3 Installing on a Critical Care Bed Chapter 6: General Procedures Installing on a Critical Care Bed This procedure provides installation and removal instructions for the Century CC bed: 892, 894, 895, 896 bed frames. Tools required: Phillips head screwdriver Wire cutters Tape measure Permanent marker...

  • Page 192: Installation

    DynamicAire Sleep Surface, disconnect the air tubes. 4. Remove the existing mattress and headboard from the bed. 5. Put the ZoneAire Sleep Surface System mattress on the bed with the white heel zone locator buttons at the foot end.
  • Page 193 6.3 Installing on a Critical Care Bed Chapter 6: General Procedures 10. Put the power unit on the bed in place of the headboard. Position the clamping screws, located on the front of the power unit, in the proper pair of threaded holes (see figure 6-13 on page 6-20).
  • Page 194 6.3 Installing on a Critical Care Bed Chapter 6: General Procedures Figure 6-14. Caregiver Pendant Cable Routing m121_022 15. From the base of the caregiver pendant (A), measure 40" along the pendant cable, and with a permanent marker, mark the 40" point. 16.
  • Page 195 6.3 Installing on a Critical Care Bed Chapter 6: General Procedures Figure 6-15. Cable Routing Head end Foot end m121_021 23. Remove the phillips head screw from the white plastic P-clamp (H) located near the foot end gas spring pivot. 24.
  • Page 196 6.3 Installing on a Critical Care Bed Chapter 6: General Procedures Figure 6-16. Mattress Cable Routing Foot end m121_025 30. Continue to route the mattress cable (O) and air hose (P) under the upper weight frame crossbar (Q) on the head end side, behind the Trendelenburg lever (S), under the cable (R), and over the pivot (L) (see figure 6-17 on page 6-23).
  • Page 197 6.3 Installing on a Critical Care Bed Chapter 6: General Procedures 31. Route the surface power cable and the air tube through the head end gas spring lever (N) along with the caregiver pendant cable (see figure 6-15 on page 6-22). 32.
  • Page 198 6.3 Installing on a Critical Care Bed Chapter 6: General Procedures Figure 6-19. Cable Connection m121_026 38. Connect the surface power cable connector (Z) to the 25 pin plug on the power unit assembly. 39. Connect the caregiver pendant cable connector (Y) to the gray ringed connector on the power unit assembly.
  • Page 199 (see figure 6-19 on page 6-25). 46. Cut off all excess wire tie material. 47. Perform a functional check of the ZoneAire Sleep Surface System. Refer to the ZoneAire Sleep Surface System In-Service Manual. Page 6 - 26...

  • Page 200: Post Installation For Beds With Scale Option Only

    ZoneAire Sleep Surface System cable routing for interference with the scale system. 9. Plug the power unit into an appropriate power source. 10. Perform a functional check of the ZoneAire Sleep Surface System. Refer to the ZoneAire Sleep Surface System In-Service Manual. Removal To remove the system, cut all of the red cable ties that were installed during the installation procedure.

  • Page 201: Cleaning And Care

    Clean the unit with a lightly dampened cloth and ordinary disinfectants. Do not subject any area to excessive amounts of liquid. Steam Cleaning Do not use any steam cleaning device on the ZoneAire Sleep Surface System. The excessive moisture involved can damage mechanisms and components in the unit.

  • Page 202: Preventive Maintenance

    Joint Commission on Accreditation of Healthcare Organizations (JCAHO) annually. This not only meets JCAHO requirements, but will help to ensure a long and productive life for the ZoneAire Sleep Surface System. This will help minimize downtime due to excessive wear failures.

  • Page 203: Preventive Maintenance Schedule

    Preventive Maintenance Chapter 6: General Procedures Preventive Maintenance Schedule Table 6-1. Preventive Maintenance Schedule Function Procedure Power unit assembly Check the mattress power cable for cuts, nicks, or breaks. Check all hose connections to the mattress for punctures, cuts, or tears Check the o-rings on hose connections for dried out condition.

  • Page 204: Preventive Maintenance Checklist

    Preventive Maintenance Chapter 6: General Procedures Preventive Maintenance Checklist Table 6-2. Preventive Maintenance Checklist Date Function Power unit assembly Air compressor Power cord Caregiver pendant Patient pendant Sleep surface Cable routing Function check Overall appearance Labor Time: Repair Cost: Inspected By: ZoneAire Sleep Surface System Service Manual Page 6 - 31...

  • Page 205: Tool And Supply Requirements

    Tool and Supply Requirements Chapter 6: General Procedures Tool and Supply Requirements The ZoneAire Sleep Surface System requires no special tools or supplies. Page 6 - 32 ZoneAire Sleep Surface System Service Manual ®...
  • Page 206 Chapter 7 Accessories Chapter Contents Accessories ............7 - 3 Trapeze Support Adapter Kit .
  • Page 207 Chapter 7: Accessories NOTES: Page 7 - 2 ZoneAire Sleep Surface System Service Manual ®...
  • Page 208 Accessories Chapter 7: Accessories Accessories Table 7-1. Accessories List Product Number Description P844A02 Trapeze support adapter kit ZoneAire Sleep Surface System Service Manual Page 7 - 3 ®...
  • Page 209 Trapeze Support Adapter Kit The trapeze support adapter kit must be used any time the trapeze support is used in conjunction with the ZoneAire Sleep Surface System. The trapeze support adapter kit provides the additional space necessary to attach the ZoneAire Sleep Surface System power unit assembly at the head end of the bed.
  • Page 210 7.1 Trapeze Support Adapter Kit Chapter 7: Accessories Figure 7-1. Trapeze Support Adapter Kit Head end of bed m121_052 Installation 1. Loosely attach both trapeze adapter brackets (A) to the bed frame with hex bolts (B) and hex nuts (C) (see figure 7-1 on page 7-5). 2.
  • Page 211 7.1 Trapeze Support Adapter Kit Chapter 7: Accessories NOTES: Page 7 - 6 ZoneAire Sleep Surface System Service Manual ®...
  • Page 212 Schematic Wiring Diagram— ZoneAire Sleep Surface System Back to Chapter 3...
  • Page 213 Power Unit Block Diagram Back to Chapter 2 Back to Chapter 3...
  • Page 214 Schematic Wiring Diagram— Caregiver Pendant Back to Chapter 3...
  • Page 215 Schematic Wiring Diagram— Power Supply Back to Chapter 3...
  • Page 216 Schematic Wiring Diagram— Air Control Board Sheet 1 of 3 Back to Chapter 3...
  • Page 217 Schematic Wiring Diagram— Air Control Board Sheet 2 of 3 Back to Chapter 3...
  • Page 218 Schematic Wiring Diagram— Air Control Board Sheet 3 of 3 Back to Chapter 3...
  • Page 219 Schematic Wiring Diagram— Sensor Board Back to Chapter 3...

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