Huntleigh Nimbus II Service Manual
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Huntleigh Nimbus II Service Manual

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Huntleigh
H E A LT H C A R E
Nimbus II, Nimbus 3,
DFS2 and DFS3
Service Manual
Issue 1
SER0001
Jun 2001

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  • Page 1 Huntleigh H E A LT H C A R E Nimbus II, Nimbus 3, DFS2 and DFS3 Service Manual Issue 1 SER0001 Jun 2001...
  • Page 3 Nimbus / DFS Service Manual Amendment Record AMENDMENT RECORD Amendment Incorporated by Date Issue 1 Amendment Record Jun 2001 SER0001 Page (i)
  • Page 4 Amendment Record Nimbus / DFS Service Manual Amendment Record Issue 1 Page (ii) SER0001 Jun 2001...

  • Page 5: Table Of Contents

    Nimbus / DFS Service Manual Contents Contents CHAPTER 1 Introduction ........1 About This Manual .
  • Page 6 Contents Nimbus / DFS Service Manual Replacing the Coil Assemblies ....... 15 Replacing the Manifold Gasket .
  • Page 7 Nimbus / DFS Service Manual Contents Removing the Base Cover ........3 Installing the Base Cover .
  • Page 8 Contents Nimbus / DFS Service Manual High/Low Pressure Setpoint and Mute Mode Checks ....2 Static and Dynamic Mode Pressure Tests ..... . . 2 High/Low Pressure Setpoint Checks and Mute Mode Check using the Psion Organiser .
  • Page 9 Nimbus / DFS Service Manual Contents Pump Assembly Parts List ........1 Mattress Assembly Parts List .
  • Page 10 Contents Nimbus / DFS Service Manual Issue 1 Page (vi) SER0001 Jun 2001...

  • Page 11: Introduction

    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.

  • Page 12: Dynamic Mode

    Introduction Nimbus / DFS Service Manual Small adjustments can be made to the mattress pressure, using the comfort control knob on the pump. This is a patient comfort feature to make small adjustments to the softness or firmness of the mattress.

  • Page 13: Static Mode

    Nimbus / DFS Service Manual Introduction In the mattress there is a third section of cells labelled as C. These are fed through partial non-return valves from cells A and B and are therefore never at zero pressure. These are positioned as shown in Fig 1 to prevent the torso section from ‘bottoming’...

  • Page 14: Auto-Matt

    Introduction Nimbus / DFS Service Manual Auto-Matt The Auto-Matt sensor consists of a flexible air sensor pad which is located underneath the mattress cells. This acts as a pressure regulator and accommodates changes in patient weight and position in the following manner: It is pneumatically connected in parallel to the mattress cells and when it is not occluded it channels the air supply away from the cells.

  • Page 15: Maintenance

    Nimbus / DFS Service Manual Maintenance CHAPTER 2 MAINTENANCE Pump Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with Chapter 3, Pump Repair. Visually inspect the following for damage, wear and potential faults: 1.1.1 Outer Casing Check for damage and security.

  • Page 16: Pump Soak Times

    Maintenance Nimbus / DFS Service Manual 1.3.4 Shuttle Valve Assemblies Pump Soak Times A pump must be soaked with its ports occluded for the following reasons: • To ensure that the pump is at normal running temperature prior to pneumatic performance tests being carried out.

  • Page 17: Mattress Maintenance Checks

    Nimbus / DFS Service Manual Maintenance Mattress Maintenance Checks If any parts are found to be damaged they must be replaced in accordance with Chapter 4, Mattress Repair. Visually inspect the following for damage, wear and potential faults: 4.1.1 Base and Top Cover Check for tears, staining, clarity of printed labels.
  • Page 18 Maintenance Nimbus / DFS Service Manual Chap 2 Issue 1 Page 4 SER0001 Jun 2001...

  • Page 19: Pump Repair

    This chapter details repair procedures for the Nimbus 2, Nimbus 3, DFS 2 and DFS 3 pumps. All repairs should be carried out by Huntleigh approved service personnel. After carrying out a service or any repairs, the pump must be soaked for the recommended time (Refer to Chapter 2, Page 2, Section 2) and tested for serviceability.
  • Page 20 Pump Repair Nimbus / DFS Service Manual 40 50 Figure 3 - Removing and installing the Hanging Bracket Table 2 - Hanging Bracket Part List Item Part Number Description 151123 Hanging Bracket Assembly 151427 Bracket 151428 Wire FAS046 Screw M3 x 10 CSK FAS216 Nut M3 x 0.5 Euro Series Chap 3...

  • Page 21: Removing The Hanging Bracket

    Nimbus / DFS Service Manual Pump Repair Removing the Hanging Bracket Ease the bottom of the hanging bracket off of the base of the pump. Rotate the hanging bracket (Fig 3) and remove it from the handle recess in the back of the pump.
  • Page 22 Pump Repair Nimbus / DFS Service Manual Ends of cord meet at this point Figure 4 - Rear Case Assembly Chap 3 Issue 1 Page 4 SER0001 Jun 2001...

  • Page 23: Disassembling The Rear Case

    Nimbus / DFS Service Manual Pump Repair Disassembling the Rear Case WARNING: BEFORE DISMANTLING THE PUMP UNIT , ENSURE THE UNIT HAS BEEN ISOLATED FROM THE POWER SUPPLY BY REMOVING THE MAINS/POWER PLUG FROM THE WALL SOCKET. Remove the hanging bracket from the pump (Refer to Page 3, Section 2). Place the pump unit on a flat surface with the front case (Fig 4, Item 20) face down.
  • Page 24 Pump Repair Nimbus / DFS Service Manual Slots Figure 5 - Pump Filter Assembly Chap 3 Issue 1 Page 6 SER0001 Jun 2001...

  • Page 25: Disassembling The Pump Filter

    Nimbus / DFS Service Manual Pump Repair Disassembling the Pump Filter Disassemble the Rear Case (Refer to Page 5, Section 4). Lay the Rear Case on a flat surface and remove the six screws (Fig 5, Item 40) and keep them in a safe place.
  • Page 26 Pump Repair Nimbus / DFS Service Manual Compressor Earth Wire Earth Wires PCB Board Front Panel Compressor Rotor Assembly Power Supply Figure 6 - Remove the Double Compressor Assembly and Disassemble the AV mounts Chap 3 Issue 1 Page 8 SER0001 Jun 2001...

  • Page 27: Removing The Double Compressor Assembly

    Nimbus / DFS Service Manual Pump Repair Removing the Double Compressor Assembly Disassemble the Rear Case (Refer to Page 5, Section 4). Remove the screws (Fig 6, Item 50) and the compressor lids (Fig 6, Item 20). Lift the four pairs of power cables, together with the rubber grommets, out from the side of each compressor casing.

  • Page 28: Removing The Av Mounts

    Pump Repair Nimbus / DFS Service Manual Make sure that the blanking grommets (Fig 6, Item 40) are installed in the compressor casings and install the compressor lids (Fig 6, Item 20). Secure the lids with screws (Fig 6, Item 50). Install cable ties where they were removed.
  • Page 29 Nimbus / DFS Service Manual Pump Repair Note : Do not install the screw, washers and ‘P’ clip to the left compressor bracket at this stage. 11.6 Install the double compressor assembly (Refer to Page 9, Section 9). Table 5 - Compressor Parts List Item Part Number Description...
  • Page 30 Pump Repair Nimbus / DFS Service Manual Figure 7 - Replacing the Compressor Bump Stops Table 6 - Compressor Bump Stops Parts List Item Part Number Description FAS051 Screw M4 6mm Pan Head FAS160 Washer M4 Plain 165310 Bump Stop 165324 Bump Stop Plate FAS177...

  • Page 31: Replacing The Compressor Filters

    Nimbus / DFS Service Manual Pump Repair 12 Replacing the Compressor Filters 12.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 12.2 For each compressor filter (8 in total): 12.2.1 Remove the screw and the compressor filter lid (Fig 7, Items 60 and 70). 12.2.2 Replace the compressor filter (Fig 7, Item 80).
  • Page 32 Pump Repair Nimbus / DFS Service Manual Slot Guide Coil Plate 50 60 Connector shown cut away for clarity Tube shown disconnected from connector 30 40 to gain access to the screw Figure 8 - Replacing the Shuttles and the Coils of the Compressor Table 7 - Shuttle and Coil Parts List and Special Tool Item Part Number...

  • Page 33: Replacing The Shuttle Assemblies

    Nimbus / DFS Service Manual Pump Repair 15 Replacing the Shuttle Assemblies 15.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 15.2 Remove the screws (Fig 6, Item 50) and the compressor lids (Fig 6, Item 20). Make sure the blanking grommets remain in the compressor casing.
  • Page 34 Pump Repair Nimbus / DFS Service Manual Note : The spacer saddle gauge set (Item 90) comprises 5 saddle gauges. The gauges provide adjustment in steps of 0.5 litres/minute with gauge A giving maximum air flow and gauge E giving minimum air flow. 16.10 Move the coils such that they rest against the setting tool.

  • Page 35: Replacing The Manifold Gasket

    Nimbus / DFS Service Manual Pump Repair 17 Replacing the Manifold Gasket 17.1 Remove the manifold screws (Fig 9, Item 40). 17.2 Remove the manifold outer (Fig 9, Item 30A or 30B) and the manifold gasket (Fig 9, Item 20). The manifold inner (Fig 9, Item 10) will remain connected to the tubes inside the pump.

  • Page 36: Removing The Rotary Valve Assembly

    Pump Repair Nimbus / DFS Service Manual 17.4.8 Install bolts (Fig 9, Item 55) into the 2 holes nearest to the pressure sensor unit and bolts (Fig 9, Item 50) into the other 2 holes. 17.4.9 Install the vibration grommets and the nuts (Fig 9, Items 60 and 70 ) and the domed nuts (Fig 9, Item 80).

  • Page 37: Installing The Rotary Valve Assembly

    Nimbus / DFS Service Manual Pump Repair 18.2 Using a small flat head screwdriver, carefully prise the hoses off the rotary valve assembly at connections A, B and C. 18.3 Disconnect the microswitch and timer cables from the PCB display board. 18.4 Carefully remove the cable tie (Fig 10, Item 50) holding the three cables.
  • Page 38 Pump Repair Nimbus / DFS Service Manual Sounder Pressure Control Brown Micro-switch Blue (Low Pressure) Display Board PCB Power Switch Pressure Switch (High Brown Pressure) Blue PCB Transformer Compressor Compressor Motor Blue Blue Brown Brown Micro-switch (Cycle) Figure 12 - Wiring Schematic for Nimbus 2/DFS 2 Pumps with 2 Circuit Boards Sounder Pressure Control Brown...

  • Page 39: Circuit Boards

    Nimbus / DFS Service Manual Pump Repair 20 Circuit Boards CAUTION : Electrostatic discharge can seriously damage the display panel PCB. Prior to replacement or handling, adequate earthing precautions must be taken. There are three different configurations of circuit boards fitted to Nimbus pumps. The following description will determine which configuration the pump has and therefore which repair procedure to follow.
  • Page 40 Pump Repair Nimbus / DFS Service Manual Front Panel Earth Wire Figure 14 - Removing the Old Style Display Board PCB and PCB Transformer Figure 13 - Removing the Old Style Front Panel Chap 3 Issue 1 Page 22 SER0001 Jun 2001...
  • Page 41 Nimbus / DFS Service Manual Pump Repair 21.3 Remove the Pressure Control Assembly (Refer to Page 29, Section 24). 21.4 Remove the screws (Fig 14, Item 20) and the PCB Transformer (Fig 14, Item 10) from the pump. 21.5 Remove the nuts and washers (Fig 14, Items 40, 50 and 60) from the Display Board PCB (Fig 14, Item 30).
  • Page 42 Pump Repair Nimbus / DFS Service Manual Brown Blue Pressure Control Micro-switch (LP) Power Switch Display Panel PCB Brown Blue HP Cycle Orange Brown Blue Pressure White Switch (HP) Grey Fuses Rotary Valve Assembly Compressor Compressor Mains Motor Filter Microswitch (Cycle) Figure 15 - Wiring Schematic for Nimbus 2/3 and DFS 2/3 Pumps with 1 Circuit Board Display PCB/Front Panel Earth Wire...

  • Page 43: Removing The New Style Display Panel Pcb

    Nimbus / DFS Service Manual Pump Repair 22 Removing the New Style Display Panel PCB 22.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 22.2 Cut and remove any cable ties as necessary and disconnect the wires as follows: •...

  • Page 44: Installing The New Style Display Panel Pcb

    Pump Repair Nimbus / DFS Service Manual Figure 17 - Replacing the New Style Front Panel 23 Installing the New Style Display Panel PCB 23.1 Install the correct Front Panel (Fig 17, Item 60) and secure with screws and fixing caps (Fig 17, Items 70 and 80).
  • Page 45 Nimbus / DFS Service Manual Pump Repair • Rotary Assembly Micro-switch (Cycle) • Compressor Power Cable • Power switch to Display Panel PCB (bottom) • Power switch to Display Panel PCB (top) • Power Supply Fuses to Power switch 23.8 Refer to Fig 15 and fit cable ties to the following groups of wires: •...
  • Page 46 Pump Repair Nimbus / DFS Service Manual Figure 18 - Replacing The Pressure Control Assembly Table 12 - Pressure Control Assembly Parts List Item Part Number Description 151059 Pressure Control Assembly FAS043 Screw M3 x 6 Pan Hd FAS002 Washer 6BA 151305 Control Knob 151327...

  • Page 47: Removing The Pressure Control Assembly

    Nimbus / DFS Service Manual Pump Repair 24 Removing the Pressure Control Assembly 24.1 Carefully prise the Control Knob (Fig 18, Item 40) off the front panel. 24.2 Disassemble the Rear Case (Refer to Page 5, Section 4). 24.3 Disconnect the Pressure Control Assembly cable (Fig 15, Cable 3). 24.4 Disconnect the following hoses at the Pressure Control Assembly end: •...
  • Page 48 Pump Repair Nimbus / DFS Service Manual Figure 19 - Replacing the High Pressure Switch Table 13 - High Pressure Switch Parts List Item Part Number Description 198394 High Pressure Switch FAS182 Screw 3 x 20 Pan Hd Pozi PT Chap 3 Issue 1 Page 30...

  • Page 49: Removing The High Pressure Switch

    Nimbus / DFS Service Manual Pump Repair 26 Removing the High Pressure Switch 26.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 26.2 Disconnect the hose attached to the High Pressure Switch (A). 26.3 Cut and remove any cable ties and disconnect the High Pressure Switch cable (Fig 15, Cable 4).
  • Page 50 Pump Repair Nimbus / DFS Service Manual Figure 20 - Replacing the Power Switch Table 14 - Power Switch Part List Item Part Number Description 151353 Power Switch Chap 3 Issue 1 Page 32 SER0001 Jun 2001...

  • Page 51: Replacing The Mains/Power Switch

    Nimbus / DFS Service Manual Pump Repair 28 Replacing the Mains/Power Switch 28.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 28.2 Disconnect the connectors from the back of the Power Switch (Refer to Fig 12, 11 or 15 - depending on the PCB fitted to the pump).
  • Page 52 Pump Repair Nimbus / DFS Service Manual Live (Brown) Earth (Green/Yellow) Neutral (Blue) Figure 21 - Replacing the Mains/Power Inlet Socket Table 15 - Mains/Power Inlet Socket and Cordset Parts List Item Part Number Description 151351 Mains/Power Inlet Socket FAS194 Screw 151348 Pillar...

  • Page 53: Replacing The Mains/Power Inlet Socket And Cordset (Moulded Cordset Versions Only)

    Nimbus / DFS Service Manual Pump Repair 29 Replacing the Mains/Power Inlet Socket and Cordset (Moulded Cordset Versions Only) 29.1 Disassemble the Rear Case (Refer to Page 5, Section 4). Note : For Nimbus 3 and DFS 3 pumps, the Bio Filter can be removed to gain easier access to the Fuse Holders (Refer to Page 49, Section 41).
  • Page 54 Pump Repair Nimbus / DFS Service Manual Fuse holder Cover Figure 22 - Replacing the Mains/Power Inlet Fuses and the Fuse Holders Table 16 - Mains/Power Inlet Fuses and Fuse Holders Part List Item Part Number Description Fuse Holder - Neutral (Blue) - (Pumps with mains/power inlet 151069 socket) 151118...

  • Page 55: Replacing The Mains/Power Fuses (All Versions)

    Nimbus / DFS Service Manual Pump Repair 30 Replacing the Mains/Power Fuses (All Versions) 30.1 Unscrew the Fuse Holder Inner and remove the Fuse (Fig 22, Item 30). 30.2 Install the Fuse (Fig 22, Item 30) into the Fuse Holder Inner and screw into the Fuse Holder. 31 Replacing the Mains/Power Inlet Fuse Holders (Moulded Cordset Versions Only) WARNING:...
  • Page 56 Pump Repair Nimbus / DFS Service Manual Earth - Green/Yellow (Green) Screws Neutral - Blue (White) Live - Brown (Black) Figure 23 - Replacing the Mains/Power Cable (Hard wired versions only) Table 17 - Mains/Power Cable (Hard wired versions only) Part List Item Part Number Description...

  • Page 57: Removing The Mains/Power Cable (Hard Wired Versions Only)

    Nimbus / DFS Service Manual Pump Repair 32 Removing the Mains/Power Cable (Hard wired versions only) WARNING: BEFORE REPLACING THE MAINS/POWER CABLE, ENSURE THE PUMP UNIT HAS BEEN ISOLATED FROM THE MAINS/POWER SUPPLY BY REMOVING THE MAINS/POWER PLUG FROM THE WALL SOCKET. 32.1 Disassemble the Rear Case (Refer to Page 5, Section 4).
  • Page 58 Pump Repair Nimbus / DFS Service Manual Earth Wires Compressor Front Panel/ Display PCB Rotary Valve Assembly Mains/Power Filter Mains/Power Input Earth Stud 2 Wires to Lower Fuseholder (Item 80) Side View of Pump Front View of Pump (in direction of arrow) Rear of Pump 5-way Connector Wiring (Item 40) Filter Output - Blue...

  • Page 59: Removing The Mains/Power Fuseholders (Hard Wired Versions Only)

    Nimbus / DFS Service Manual Pump Repair 34 Removing the Mains/Power Fuseholders (Hard wired versions only) WARNING: BEFORE REPLACING THE MAINS/POWER FUSEHOLDERS, ENSURE THE PUMP UNIT HAS BEEN ISOLATED FROM THE MAINS/POWER SUPPLY BY REMOVING THE MAINS/POWER PLUG FROM THE WALL SOCKET. 34.1 Disassemble the Rear Case (Refer to Page 5, Section 4).

  • Page 60: Installing The Mains/Power Fuseholders (Hard Wired Versons Only)

    Pump Repair Nimbus / DFS Service Manual 35 Installing the Mains/Power Fuseholders (Hard wired versons only) 35.1 Feed the wires of the new fuseholder assembly (Fig 22, Item 10 or 20) through the hole in pump casing from the outside. 35.2 Pull the fuseholder shroud off the back of the fuseholder, and ease it through the hole.

  • Page 61: Installing The Mains/Power Filter (Hard Wired Versions Only)

    Nimbus / DFS Service Manual Pump Repair 37 Installing the Mains/Power Filter (Hard wired versions only) 37.1 Place the new mains/power filter (Fig 24, Item 60) in position in the casing, and install the screw (Fig 24, Item 70) to secure it. Note: Make sure that the 5 wires from the mains/power filter are routed correctly, and are not trapped beneath the filter.
  • Page 62 Pump Repair Nimbus / DFS Service Manual Mains Cable Figure 25 - Replacing the 5-Way Connector and Support (Hard wired versions only) Chap 3 Issue 1 Page 44 SER0001 Jun 2001...

  • Page 63: Removing The 5-Way Connector And Support (Hard Wired Versions Only)

    Nimbus / DFS Service Manual Pump Repair 38 Removing the 5-Way Connector and Support (Hard wired versions only) WARNING: BEFORE REPLACING THE 5-WAY CONNECTOR AND SUPPORT, ENSURE THE PUMP UNIT HAS BEEN ISOLATED FROM THE MAINS/POWER SUPPLY BY REMOVING THE MAINS/POWER PLUG FROM THE WALL SOCKET. 38.1 Remove the mains/power fuseholders (Refer to Page 41, Section 34).
  • Page 64 Pump Repair Nimbus / DFS Service Manual Not Used 5-Way Connector Figure 26 - Replacing the Silencer Bag (5-Way Connector Configuration) Table 21 - Silencer Bag and 5-Way Connector Tube Parts List Part Number Description 151098 Silencer Bag 151090 Pressure Control Assembly Tube 151101 Rotary Valve - Pressure Control Assembly - Left (Nimbus 2, DFS 2) 151130...

  • Page 65: Replacing The Silencer Bag

    Nimbus / DFS Service Manual Pump Repair 40 Replacing the Silencer Bag 40.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 40.2 Disconnect and remove the Silencer bag (Fig 26, Item 10) from the Rotary Valve Hose (Fig 26, Item 50) and the Compressor Hose. 40.3 Install the new Silencer bag (Fig 26, Item 10) from the Rotary Valve Hose (Fig 26, Item 50) and the Compressor Hose.
  • Page 66 Pump Repair Nimbus / DFS Service Manual Power Switch to Fuse Holder Wires Corner Adaptor (Blue & Brown) Cable Ties Hose to Silencer Bag Figure 27 - Replacing the Bio Filter (Nimbus 3 and DFS 3 Pumps Only) Table 22 - Bio Filter Part List Item Part Number Description...

  • Page 67: Removing The Bio Filter (Nimbus 3 And Dfs 3 Pumps Only)

    Nimbus / DFS Service Manual Pump Repair 41 Removing the Bio Filter (Nimbus 3 and DFS 3 Pumps Only) 41.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 41.2 If it is necessary to replace the Bio Filter hoses as well as the Bio Filter, then cut and remove the cable ties as shown in Fig 27.
  • Page 68 Pump Repair Nimbus / DFS Service Manual Sounder Display Board PCB Battery Sounder Daughter Board Display Board PCB Battery Display Board PCB Battery Figure 28 - Changing the Battery and replacing the Sounder Table 23 - Battery and Sounder Parts List Item Part Number Description...

  • Page 69: Changing The Battery

    Nimbus / DFS Service Manual Pump Repair 43 Changing the Battery 43.1 There are four configurations of battery in Nimbus and DFS pumps. These are as follows: 43.1.1 A soldered round battery on the display board PCB (Early Nimbus 2 and DFS 2 pumps only).

  • Page 70: Replacing The Pump Case

    Pump Repair Nimbus / DFS Service Manual 45 Replacing the Pump Case 45.1 Remove the Pump Case as follows: 45.1.1 Disassemble the Rear Case (Refer to Page 5, Section 4). 45.1.2 Disassemble the Pump Filter (Refer to Page 7, Section 6). 45.1.3 Remove the Double Compressor Assembly (Refer to Page 9, Section 8).

  • Page 71: Pump Label Sets

    Nimbus / DFS Service Manual Pump Repair 46 Pump Label Sets The following table gives the part numbers for the pump label sets: Table 24 - Pump Label Sets Item Part Number Description 151382 Label Set Nimbus 2 (UK, EURO) 151397 Label Set Nimbus 2 (Germany) 151394...
  • Page 72 Pump Repair Nimbus / DFS Service Manual Chap 3 Issue 1 Page 54 SER0001 Jun 2001...

  • Page 73: Mattress Repair

    This chapter details repair procedures for the standard and narrow Nimbus and DFS mattresses. All repairs should be carried out by Huntleigh approved service personnel. After carrying out a service or any repairs, the mattress must be tested for serviceability. Carry out an inflation test on the mattress in accordance with Chapter 6, Page 15, Section 9.
  • Page 74 Mattress repair Nimbus / DFS Service Manual Figure 29 - Disconnect the Heel Protector FAST DEFLATE NORMAL TRANSPORT Figure 30 - Disconnect the 3 pop studs at the foot end of the mattress Chap 4 Issue 1 Page 2 SER0001 Jun 2001...

  • Page 75: Removing The Top Cover

    Nimbus / DFS Service Manual Mattress repair Removing the Top Cover Undo the two zips down the long sides of the top cover and pull the velcro end flaps off of the base cover. Installing the Top Cover Position the top cover over the mattress with the feet logo uppermost and at the foot end of the bed.
  • Page 76 Mattress repair Nimbus / DFS Service Manual Figure 31 - Disconnect the 6 pop studs at the head end of the mattress Figure 32 - Remove the soft and hard foam sheets from the pockets of the base cover Chap 4 Issue 1 Page 4 SER0001...
  • Page 77 Nimbus / DFS Service Manual Mattress repair Disconnect the six pop studs (Fig 31, Item 1) which connect the cell loop sheet to the base cover at the head end of the bed. Fold the mattress cell assembly back at the foot end of the bed and disconnect the sensor pad hoses (Fig 36, Item 1).
  • Page 78 Mattress repair Nimbus / DFS Service Manual Figure 33 - Small hard foam sheet in position Figure 34 - Large hard foam sheet in position together with the sensor pad Chap 4 Issue 1 Page 6 SER0001 Jun 2001...

  • Page 79: Installing The Base Cover

    Nimbus / DFS Service Manual Mattress repair Installing the Base Cover Install the small hard foam sheet (Fig 33, Item 1) into the pockets in the centre of the base cover. Install the large hard foam sheet (Fig 34, Item 1) into the pockets at each end of the base cover, with the sensor pad uppermost and sensor pad hoses towards the foot end of the base cover.
  • Page 80 Mattress repair Nimbus / DFS Service Manual Figure 36 - Connecting the Sensor Pad Hoses to the CPR Unit Figure 37 - Fitting the CPR Unit in the Base Cover Pocket Chap 4 Issue 1 Page 8 SER0001 Jun 2001...

  • Page 81: Replacing The Soft Foam Sheet

    Nimbus / DFS Service Manual Mattress repair Fold back the cell assembly at the foot end of the bed to reveal the sensor pad hoses (Fig 36, Item 1). Connect the sensor pad hoses to the hoses on the back of the CPR unit. Note : The sensor pad hoses for Nimbus 2/DFS 2 assemblies have to be routed through the hole in the base of the loop sheet and connected to the CPR Unit through the manifold assembly.
  • Page 82 Mattress repair Nimbus / DFS Service Manual Foot end Head end AST cells Foot cells Standard cells Standard cells Part No. 152059 Part No. 152140 Part No. 152057 Part No. 152057 Figure 38 - Cell Configuration and Part Numbers Figure 39 - Cell pop studs and connectors Chap 4 Issue 1 Page 10...

  • Page 83: Cell Replacement

    Nimbus / DFS Service Manual Mattress repair Cell Replacement There are 4 different types of cell (20 in total) in a Nimbus and DFS mattress. The cell configuration is shown in Fig 38. Always check that the replacement cell is of the same type as the cell to be changed. Removing a Cell Remove the top cover (Refer to Page 3, Section 2).

  • Page 84: Removing The Manifold Assembly

    Mattress repair Nimbus / DFS Service Manual Connect the lower pop stud, at the opposite end of the cell, to the mattress loop sheet. Push the cell connector(s) (Fig 39, Item 2) fully into the manifold assembly. Note : Fitting the connectors into the manifold assembly is made easier if the connector is wetted with methylated spirit immediately prior to insertion.
  • Page 85 Nimbus / DFS Service Manual Mattress repair Figure 41 - CPR and Heel Protector Connections to the Manifold Assembly 11.4 Connect all the lower pop studs (Fig 39, Item 3) on the cell corner flaps to the manifold assembly. 11.5 Push all the cell connector(s) (Fig 39, Item 2) fully into the manifold assembly. 11.6 Connect all the upper pop studs (Fig 39, Item 1) on the cell corner flaps to the manifold assembly.

  • Page 86: Removing The Partial Non-Return Valve Assemblies

    Mattress repair Nimbus / DFS Service Manual 12 Removing the Partial Non-Return Valve Assemblies 12.1 Unzip the top cover on the CPR side of the mattress and fold it back. 12.2 Locate the partial non-return valve assemblies (Fig 42, Item 1) at the head end of the manifold assembly.

  • Page 87: Removing The Loop Sheet Assembly

    Nimbus / DFS Service Manual Mattress repair 14 Removing the Loop Sheet Assembly 14.1 Remove the top cover (Refer to Page 3, Section 2). 14.2 Disconnect all the lower pop studs (Fig 39, Item 3) on the cell corner flaps from the manifold assembly.

  • Page 88: Replacing The Elastic Loops (Nimbus 3/Dfs 3 Only)

    Mattress repair Nimbus / DFS Service Manual 16 Replacing the Elastic Loops (Nimbus 3/DFS 3 Only) Note : On Nimbus 3/DFS 3 mattresses the five cells at the foot end of the bed are retained by elastic loops which are held in position by plastic supports located into pockets on the underside of the loop sheet.

  • Page 89: Removing The Sensor Pad Assembly

    Nimbus / DFS Service Manual Mattress repair 17 Removing the Sensor Pad Assembly 17.1 Remove the top cover (Refer to Page 3, Section 2). 17.2 Disconnect the six pop studs (Fig 31, Item 1) which connect the cell loop sheet to the base cover at the head end of the bed.

  • Page 90: Removing The Cpr Unit

    Mattress repair Nimbus / DFS Service Manual 19 Removing the CPR Unit 19.1 Remove the top cover (Refer to Page 3, Section 2). 19.2 Disconnect the three pop studs (Fig 30, Item 1) which connect the cell loop sheet to the base cover at the foot end of the bed.

  • Page 91: Replacing The Release Button

    Nimbus / DFS Service Manual Mattress repair 21 Replacing the Release Button 21.1 Press the release button and disconnect the tubeset from the manifolds on the mattress and the pump. 21.2 Refer to Fig 45. Press the release button down and insert the blade of a small flat head screwdriver in between the release button and the manifold body (A).

  • Page 92: Replacing The Tubeset

    Mattress repair Nimbus / DFS Service Manual 22 Replacing the Tubeset 22.1 Press the release button and disconnect the tubeset from the manifolds on the mattress and the pump. 22.2 Reconnect the new tubeset making sure that the connections are secure at each end. Note : The tubeset connectors of the Nimbus 3/DFS 3 have been colour coded blue so that the pump-mattress combination cannot be confused with the Nimbus 2/DFS 2.
  • Page 93 Nimbus / DFS Service Manual Mattress repair Table 21 - Mattress Parts List (Continued) Item Part Number Description 152059 Foot Cell - Standard 237059 Foot Cell - Narrow 152057 Standard Cell - Standard 237057 Standard Cell - Narrow 152140 AST Cell - Standard 237140 AST Cell - Narrow 152073...
  • Page 94 Mattress repair Nimbus / DFS Service Manual FAST DEFLATE NORMAL TRANSPORT Figure 46 - CPR Unit Components Chap 4 Issue 1 Page 22 SER0001 Jun 2001...

  • Page 95: Replacing The Cpr O-Rings

    Nimbus / DFS Service Manual Mattress repair 23 Replacing the CPR O-Rings 23.1 Remove the CPR Unit from the manifold mattress (Refer to Page 18, Section 19). 23.2 Remove the screws (Fig 46, Item 10) and the backplate (Fig 46, Item 20) from the CPR Unit . 23.3 Replace the O-Ring (Fig 46, Item 50) on each connector as follows: 23.3.1 Remove the connector (Fig 46, Item 30 or 40) from the hole in the front of the CPR...

  • Page 96: Repairing The Cpr Handle Sub-Assembly

    Mattress repair Nimbus / DFS Service Manual 24.12 Install the CPR Unit to the manifold of the mattress (Refer to Page 18, Section 20). 25 Repairing the CPR Handle Sub-Assembly 25.1 Remove the CPR Unit from the manifold mattress (Refer to Page 18, Section 19). 25.2 Remove the screws (Fig 46, Item 10) and the backplate (Fig 46, Item 20) from the CPR Unit .

  • Page 97: Replacing The Cpr Manifold Gasket

    Nimbus / DFS Service Manual Mattress repair 26 Replacing the CPR Manifold Gasket 26.1 Carefully remove the screws (Fig 47, Item 220). Note : Do not apply pressure on the screws when removing. If pressure is applied, the brass inserts can be pushed out of the case, inside the CPR Unit.
  • Page 98 Mattress repair Nimbus / DFS Service Manual Table 26 - CPR Unit Component Parts List Item Part Number Description 152077 CPR Module Asembly (Nimbus 2/DFS 2, except Germany) 152152 CPR Module Asembly (Nimbus 2 German Only) 152192 CPR Module Asembly (Nimbus 3/DFS 3, except Germany) 152202 CPR Module Asembly (Nimbus 3 German Only) FAS180...

  • Page 99: Alternating Head Cells

    Nimbus / DFS Service Manual Mattress repair 27 Alternating Head Cells The modification can be applied in two configurations: Configuration 1 All three head cells are converted from static pressure to alternating pressure. Configuration 2 The top head cell remains as a static pressure cell. The second and third cells are converted from static pressure to alternating pressure.
  • Page 100 Mattress repair Nimbus / DFS Service Manual 28.3 Remove the straight connectors from cell valves 1 to 5 (Fig 49). Cell Valves Manifold Outlets (Straight Connectors) Cell Valves Figure 49 - Remove the Straight Connectors (Configuration 1) 28.4 Fit the ‘T’ and elbow pieces to the cell valves 1 to 5 as shown in Fig 50. 'T' Connector Elbow Connector HEAD...
  • Page 101 Nimbus / DFS Service Manual Mattress repair 28.5 Connect the tubes to the valves as shown in Fig 51. Figure 51 - Connect the tubes (Configuration 1) 28.6 Remove the straight connectors from the manifold outlets that feed the top five cells of the mattress.

  • Page 102: Installing The Alternating Head Cell Modification - Configuration 2

    Mattress repair Nimbus / DFS Service Manual 29 Installing the Alternating Head Cell Modification - Configuration 2 Note: Not all parts of the kit are used if only two cells alternate as in Configuration 2. 29.1 Inflate the mattress. Unzip the top cover and lay it back, clear of the head end of the mattress. 29.2 Disconnect the top six manifold pop studs to reveal the six cell valves (Fig 48).
  • Page 103 Nimbus / DFS Service Manual Mattress repair 29.4 Fit the ‘T’ and elbow pieces to the cell valves 2 to 5 as shown in Fig 54. 'T' Connector Elbow Connector HEAD CELLS Figure 54 - Fit ‘T’ and Elbow Pieces (Configuration 2) 29.5 Connect the tubes to the valves as shown in Fig 55.
  • Page 104 Mattress repair Nimbus / DFS Service Manual 29.6 Remove the straight connectors from the manifold outlets that feed the 2nd to 5th cells of the bed from the top. Connect the two ‘T’ pieces to the manifold outlets. Fit blanking plugs to the 2nd and 3rd top manifold air outlets (Fig 56).

  • Page 105: Troubleshooting

    Nimbus / DFS Service Manual Troubleshooting CHAPTER 5 TROUBLESHOOTING Troubleshooting Table The following table contains fault symptoms, their possible causes and suggests steps to rectify the problem. Where possible, reference is made to the relevant repair Chapters. Fault Possible Cause Remedy High Pressure Mattress...
  • Page 106 Troubleshooting Nimbus / DFS Service Manual Fault Possible Cause Remedy Mattress Mattress in TRANSPORT Return to NORMAL mode. mode. CPR assembly not closed Reset the CPR. properly Cell leak. Trace and replace (Ch 4, Pg 11, Section 7) Leak in non-return Replace valves.
  • Page 107 Nimbus / DFS Service Manual Troubleshooting Fault Possible Cause Remedy Power Fail Alarm Pump Faulty Mains/Power Switch. Check and replace. With Unit Off (Only applies to early versions with more than one PCB) (Ch 3, Pg 33, Section 28 Poor connection between Check and repair.
  • Page 108 Troubleshooting Nimbus / DFS Service Manual Chap 5 Issue 1 Page 4 SER0001 Jun 2001...

  • Page 109: Testing

    Nimbus / DFS Service Manual Testing CHAPTER 6 TESTING Pump Flow, Pressure and Function Test This procedure must be carried out after a service or major repair of a pump. To test/calibrate the pump unit correctly, the following equipment is required: Table 28 - Pump Flow, Pressure and Function Test Equipment Equipment Part Number...

  • Page 110: Power Fail Alarm Check

    Testing Nimbus / DFS Service Manual Power Fail Alarm Check Switch the pump off at the mains/power socket, leaving the pump switched ON. The pump should respond by illuminating the flashing RED TRIANGLE and the POWER message while sounding an AUDIBLE ALARM. Push the MUTE button and the audible alarm should be silenced.

  • Page 111: High/Low Pressure Setpoint Checks And Mute Mode Check Using The Psion Organiser

    Nimbus / DFS Service Manual Testing High/Low Pressure Setpoint Checks and Mute Mode Check using the Psion Organiser Psion Organiser Setup Refer to Page 11, Section 6 to set up the Psion Organiser. High Pressure Switch Setpoint Check Select Inputs from the Psion menu. The Psion will now display: Reading HP switch Press any key for LP Slowly occlude the tubeset loop between ports 4 and 5 and record the pressure on the...

  • Page 112: Mute Mode Check

    Testing Nimbus / DFS Service Manual Mute Mode Check Press any key on the Psion, except for Q. The Psion will now display: Mute mode set to Mute mode set to Press key for Press key for valve microswitch valve microswitch Check the MUTE mode is set correctly for the country of use (0 for the UK and 1 for the rest of the world).

  • Page 113: High Pressure Switch Setpoint Check

    Nimbus / DFS Service Manual Testing High Pressure Switch Setpoint Check Click on Refresh at the bottom of the Sensor - Status column, and the High Pressure - Status should be set to OFF. Slowly occlude the tubeset loop between ports 4 and 5, and record the pressure on the manometer at which the High Pressure - Status changes to ON.

  • Page 114: Static Mode Pressure Tests

    Testing Nimbus / DFS Service Manual Static Mode Pressure Tests Select Test from the Psion menu. Wait (for up to 5 minutes) until the Psion display changes from: Please wait Rotor in crossover for crossover position. Coil 1 on. Go to next coil Y/N? Record the manometer reading for coil 1, with the comfort control set to minimum and maximum settings.

  • Page 115: Dynamic Mode Pressure Tests

    Nimbus / DFS Service Manual Testing 4.11 Press N again on the Psion. The Psion will display: Go to Dynamic Test Y/N? 4.12 Press Y on the Psion. Wait (up to 3 minutes) until the display changes to: Rotor in port 1 Position.

  • Page 116: Check Pump Serial Number

    Testing Nimbus / DFS Service Manual 4.23 Press any key, except Q on the Psion. The display will change to: Rotor in port 2 Position. Coils 2 & 4 on. Repeat Dyn. Test Y/N? 4.24 Close the restrictor. Record the manometer reading for Port 2, coils 2 & 4, with the comfort control set to minimum and maximum settings.

  • Page 117: Dynamic Mode Pressure Tests

    Nimbus / DFS Service Manual Testing Coil 1 is switched on, and the dialog box Rotor in crossover position. Coil 1 ON. Switch ON Coil 2? is displayed. Record the manometer reading for coil 1, with the comfort control on the pump set to minimum and maximum settings.

  • Page 118: Check Pump Serial Number

    Testing Nimbus / DFS Service Manual 5.29 Coils 1 and 3 are switched off, and then coils 2 and 4 are switched on. The dialog box Rotor in Port 1 position. Press OK for Port 2? is displayed. 5.30 Close the restrictor or reconnect to the pressure gauge. 5.31 Record the manometer reading for Port 1, Coils 2 &...

  • Page 119: Psion Organiser Setup

    Nimbus / DFS Service Manual Testing Psion Organiser Setup Switch the Psion on and select which type of pump is to be tested from the Psion menu. If at any time the Psion indicates the following message, then press the STATIC and MUTE buttons together on the pump.
  • Page 120 Passwords are not case sensitive. Note: The Production and Engineering tabs are for internal Huntleigh Healthcare use only. Should it be necessary to access either of these two tabs, please contact Huntleigh Healthcare who will supply the relevant passwords to access the tabs.

  • Page 121: Electrical Testing

    Nimbus / DFS Service Manual Testing Electrical Testing To test and calibrate the pump unit correctly, the following equipment is required: Table 30 - Electrical Test Equipment Equipment Insulation resistance tester (Megger) 500 Vdc Portable appliance tester Multimeter/Continuity tester Dielectric strength tester (Flash tester) 3.0 kVac with current limit Electrical Safety Checks - Class I There are several electrical safety checks that must be carried out after breakdown repairs and servicing.

  • Page 122: Dielectric Strength Test (Flash Test)

    Testing Nimbus / DFS Service Manual Dielectric Strength Test (Flash Test) This test shows the response of the insulation to high ac-voltage stress, indicates the effects of capacitive current, and gives an early warning of insulation problems which may develop in the appliance.

  • Page 123: Mattress Pressure And Function Test

    Nimbus / DFS Service Manual Testing Mattress Pressure and Function Test This procedure must be carried out after a service or major repair of a mattress. To test/calibrate the mattress correctly, the following equipment is required: Table 31 - Mattress Pressure and Function Test Equipment Equipment Pressure/Flow meter Portable inflation test unit...
  • Page 124 Testing Nimbus / DFS Service Manual Chap 6 Issue 1 Page 16 SER0001 Jun 2001...

  • Page 125: Technical Specification

    Nimbus / DFS Service Manual Technical specification CHAPTER 7 TECHNICAL SPECIFICATION Pump Size: Length 508mm (20") Height 220mm (8.7") Depth 100mm (4") Weight: 5.7kg (12.5lb) Case material: ABS or ABS/polycarbonate blend Supply Voltage: 240 Vac, 50 Hz (UK) 220 Vac, 50 Hz (Europe) 110 Vac, 50 Hz (USA) 100 Vac, 50 Hz (Japan) 100 Vac, 60 Hz (Japan)
  • Page 126 Technical specification Nimbus / DFS Service Manual Type BF Environmental Conditions Operating Temperature range: +10°C to +40°C Relative Humidity: 30% to 75% Atmospheric pressure: 700 hPa to 1060 hPa Storage Storage temperature -40°C to +70°C Relative Humidity 10% to 100% (non-condensing) Atmospheric pressure 500 hPa to 1060 hPa Environmental Protection...
  • Page 127 Nimbus / DFS Service Manual Parts List CHAPTER 8 PARTS LIST Pump Assembly Parts List Part Number Description Fig-Item 151001 Nimbus 2 Pump Assembly (UK) 151002 Nimbus 2 Pump Assembly (German) 151003 DFS 2 Pump Assembly (USA) 151004 Nimbus 2 Pump Assembly (Euro) 151005 Nimbus 2 Pump Assembly (French) 151006...

  • Page 128: Parts List

    Parts List Nimbus / DFS Service Manual Part Number Description Fig-Item FAS 188 Screw, M4 x 30mm Pan Head 4-30 151123 Hanging Bracket 3-10 • 151427 Bracket 3-20 • 151428 Wire 3-30 • Screw FAS046 3-40 • FAS216 3-50 Label Sets 151382 Nimbus 2 (UK, Euro) 151397...
  • Page 129 Nimbus / DFS Service Manual Parts List Part Number Description Fig-Item • 165054 Shuttle Assembly - 63 Shore (UK, EURO, Japan 8-10 50Hz) • Shuttle Assembly - 70 Shore (USA, Japan 60Hz) 165092 8-10 • 165058 Coil (pair) 240V (UK, EURO) 8-70 •...
  • Page 130 Parts List Nimbus / DFS Service Manual Part Number Description Fig-Item BP196 Cable Tie 6-180 Rotary Valve Assembly, Pressure Control Assembly and High Pressure Switch 151056 Rotary Valve Assembly (Nimbus 2 - UK, Euro) 10-10 151128 Rotary Valve Assembly (Nimbus 3 - UK, Euro) 10-10 151155 Rotary Valve Assembly (Nimbus 3 - Japan 60Hz &...
  • Page 131 Nimbus / DFS Service Manual Parts List Part Number Description Fig-Item 151500 Front Panel Assembly (Nimbus 3) - (French) 17-10 151501 Front Panel Assembly (Nimbus 3) - (Italian) 17-10 151502 Front Panel Assembly (Nimbus 3) - (Holland) 17-10 151495 Front Panel Assembly (DFS 2) - (USA) 17-10 151497 Front Panel Assembly (DFS 3) - (USA)
  • Page 132 Parts List Nimbus / DFS Service Manual Part Number Description Fig-Item 252317 Pillar, M3 x 11mm - (Hard wired pumps) 25-50 FAS145 Screw, 3 (dia) x 8mm Pan Head - (Hard wired pumps) 24-70 FAS194 Screw, M3 x 12mm Csk Head - (Hard wired pumps) 25-40 FAS144 Nut, M4 Full - (Hard wired pumps)
  • Page 133 Nimbus / DFS Service Manual Parts List Part Number Description Fig-Item Tools MIS155 Spacer saddle gauge set (5 gauges A to E) 8-90 Mattress Assembly Parts List Part Number Description Fig-Item 152001 Mattress Assembly Standard - Nimbus 2 152002 Mattress Assembly Standard - Nimbus 2 German 152003 Mattress Assembly Standard - DFS 2 152010...
  • Page 134 Parts List Nimbus / DFS Service Manual Part Number Description Fig-Item • 237059 Foot Cell - Narrow • 152057 Standard Cell - Standard • 237057 Standard Cell - Narrow • 152140 AST Cell - Standard • AST Cell - Narrow 237140 •...
  • Page 135 Nimbus / DFS Service Manual Parts List Part Number Description Fig-Item CPR Assembly 152077 CPR Module Assembly (Nimbus 2/DFS 2, except Germany) 152152 CPR Module Assembly (Nimbus 2 German Only) 152192 CPR Module Assembly (Nimbus 3/DFS 3, except Germany) 152202 CPR Module Assembly (Nimbus 3 German Only) •...
  • Page 136 Parts List Nimbus / DFS Service Manual Part Number Description Fig-Item • BP024 Brass Threaded Insert 44-260 Alternating Head Cells Modification Kit 152208 Alternating Head Cells Modification Kit • ‘T’ Pieces (polypropylene) 152418 • 152419 Elbow Pieces (polypropylene) • 152420 Blanking Plugs (acetyl) •...
  • Page 137 Nimbus / DFS Service Manual Service Contact Details CHAPTER 9 SERVICE CONTACT DETAILS Africa Middle East Huntleigh Africa (Pty) Limited Huntleigh Technology PLC 126 B Sarel Baard Crescent 307 Sh. Zayed Road Rooishuiskraal, Pretoria, South Africa Dubai, United Arab Emirates...
  • Page 138 Service Contact Details Nimbus / DFS Service Manual Chap 9 Issue 1 Page 2 SER0001 Jun 2001...

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