Huntleigh AlphaXcell Electric Service Manual
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Huntleigh AlphaXcell Electric Service Manual

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Huntleigh
H E A LT H C A R E
Mini Pump
Service Manual
Issue 2
SER0004
Nov 2001

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Summary of Contents for Huntleigh AlphaXcell Electric

  • Page 1 Huntleigh H E A LT H C A R E Mini Pump Service Manual Issue 2 SER0004 Nov 2001...
  • Page 3 Mini Pump Service Manual Contents AMENDMENT RECORD Amendment Incorporated by Date Issue 2 Contents Nov 2001 SER0004 Page (i)
  • Page 4 Contents Mini Pump Service Manual Contents Issue 2 Page (ii) SER0004 Nov 2001...

  • Page 5: Table Of Contents

    Mini Pump Service Manual Contents Contents CHAPTER 1 Introduction ........1 About This Manual .
  • Page 6 Contents Mini Pump Service Manual Installing the Old Style AV Mounts ......15 Removing the Compressor Mounting Bracket.
  • Page 7 Mini Pump Service Manual Contents Circuit Diagrams ........5 CHAPTER 5 Testing .
  • Page 8 Contents Mini Pump Service Manual Contents Issue 2 Page (iv) SER0004 Nov 2001...

  • Page 9: 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 10: Warnings, Cautions And Notes

    Introduction Mini Pump Service Manual Table 2- Country Codes/Power Supplies Mains Power Country Code Country Voltage (Volts AC) Frequency (Hz) 220 - 240 Germany 220 - 240 110 - 120 Euro 220 - 240 France 220 - 240 Japan 50/60 Italy 220 - 240 Australia...

  • Page 11: Technical Description

    Mini Pump Service Manual Introduction Technical Description The pressure regulated pump units listed in section 1 provide pressurised air for alternating pressure mattress systems which are used in aiding the prevention, treatment and management of pressure ulcers. Pressurised air is fed to a range of support systems, mattresses, seat cushions etc., which support patients at risk of developing pressure ulcers.
  • Page 12 Introduction Mini Pump Service Manual COMPRESSOR PRESSURE CONTROL OUTLET ROTOR/ PORTS STATOR PRESSURE CONTROL MODULE MICROSWITCH HEAD SECTION (STATIC) ALTERNATING CELLS = INFLATED = DEFLATED EXCEPTION: Aura has 9 alternating cells but no static cells. Figure 1 - Pneumatic Diagram and Pressure Variations For the Aura mini pump small adjustments can be made to cell pressure using the comfort control knob on the pump unit.

  • Page 13: System Start Up Sequence

    Mini Pump Service Manual Introduction Table 3 - Air Pressure/Flow Rates Minimum Flow Minimum Flow Minimum Maximum Adjustable Pump Rate at 20 mmHg Rate at 50 Pressure Pressure Pressure Model back pressure mmHg (mmHg) (mmHg) Range (litres/minute) (litres/minute) 20-24 57-73 20-24 72-92 83-87...

  • Page 14: Low Pressure Alarm (Electronic Units Only)

    Introduction Mini Pump Service Manual • The red ‘low pressure’ indicator will be illuminated. When operating pressure is achieved, the low pressure indicator will be extinguished automatically. After an electronic pump is switched to ‘Run’ the start up sequence is as follows: •...

  • Page 15: Battery Management (Electronic Units Only)

    Mini Pump Service Manual Introduction The power failure alarm is initiated by the removal of the mains/power supply from the unit for a period of more than 5 seconds, by a means other than operation of the ‘Run/Standby’ switch. A drop in the supply voltage below the minimum supply specification will be interpreted as a supply failure.
  • Page 16 Introduction Mini Pump Service Manual Chap 1 Issue 2 Page 8 SER0004 Nov 2001...

  • Page 17: Maintenance

    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: Note : If any parts require repairing or replacing then refer to the Huntleigh Healthcare service manual. 1.1.1 Check outer casings for damage.

  • Page 18: Pump Soak/Break-In Times

    Maintenance Mini Pump Service Manual Once the compressor has been visually inspected connect to a power supply and run, this is to ensure the compressor is working and that there is flow/pressure at the outlet port of the pump. Check for any excessive noise and vibration. Pump Soak/Break-in Times A pump must be soaked/broken-in for the following reasons: Note : Soaking/breaking-in consists of running the pump with the outlet ports blocked.
  • Page 19 Mini Pump Service Manual Maintenance Reassemble the pump and soak/break-in for the recommended time (Refer to Section 2). Carry out a flow, pressure and function test on the pump in accordance with Chapter 5. Carry out electrical tests on the pump in accordance with Chapter 5. Issue 2 Chap 2 Nov 2001...
  • Page 20 Maintenance Mini Pump Service Manual Chap 2 Issue 2 Page 4 SER0004 Nov 2001...

  • Page 21: Pump Repair

    This chapter details repair procedures for the range of pump units listed in Chapter 1, Page 1, Table 1. All repairs should be carried out by Huntleigh approved service personnel. After carrying out a service or any repairs, the pump must be soak tested/broken-in for the recommended time (Refer to Chapter 2) and tested for serviceability.
  • Page 22 Pump Repair Mini Pump Service Manual Pin (if fitted) Figure 2 - Removing the Control Knob Table 6 - Control Knob Part List Item Part Number Description 500484 Control Knob (MK2) 500304 Knob Arbour 500318 Pin (if fitted) 500316 Front Case Note : The obsolete MK1 control knobs are fully interchangeable with the MK2 control knobs.

  • Page 23: Removing The Pressure Control Knob

    Mini Pump Service Manual Pump Repair Removing the Pressure Control Knob Note : Removing the control knob avoids possible damage and allows the pump to sit on a flat surface without rocking. Locate the slot at the rear of knob (Fig 2, Item 10) and insert a 3 mm flatpoint screwdriver. Lever the screwdriver upward to lift the knob off the three retaining prongs.
  • Page 24 Pump Repair Mini Pump Service Manual Figure 3 - Removing and Replacing the Pump Filter Table 7 - Pump Filter Part List Item Part Number Description 500340 Felt Filter 500327 Filter Plate 500317 Rear Case FAS223 Pan Head Screw PT 3 Dia x 10 Pozi FAS225 Pan Head Screw PT 3 Dia.

  • Page 25: Disassembling The Pump Filter

    Mini Pump Service Manual Pump Repair Disassembling the Pump Filter Remove the centre screw (Fig 3, Item 40) retaining the filter plate (Fig 3, Item 20) in the rear case (Fig 3, Item 30). Carefully remove the filter plate and felt filter (Fig 3, Item 10) from the rear case. Discard the old filter.
  • Page 26 Pump Repair Mini Pump Service Manual Figure 4 - Replacing the New Style Bed Hook Table 8 - New Style Bed Hook Part List Item Part Number Description 500495 Bed Hook (New Style) 500496 Hook Plate (Left Hand) 500497 Hook Plate (Right Hand) FAS223 Pan Head screw PT 3 Dia.

  • Page 27: Disassembling The New Style Bed Hook

    Mini Pump Service Manual Pump Repair Disassembling the New Style Bed Hook Remove the pressure control knob from the pump (Refer to Page 3, Section 2). Remove the pump rear case (Refer to Page 5, Section 6). Note : The bed hook brackets are right and left handed. Hold a hook plate (Fig 4, Item 20 or 30) in position and remove the four securing screws (Fig 4, Item 40) from the inside of the pump rear case.
  • Page 28 Pump Repair Mini Pump Service Manual Figure 5 - Replacing the Old Style Bed Hooks Chap 3 Issue 2 Page 8 SER0004 Nov 2001...

  • Page 29: Removing The Old Style Bed Hook

    Mini Pump Service Manual Pump Repair Table 9 - Old Style Bed Hook Part List Item Part Number Description Bed Hook - Left Hand Bed Hook - Right Hand Hook Plate Pan Head screw PT 3 Dia. x 10 Pozi Note :The old bed hook bracket assemblies are left and right handed.
  • Page 30 Pump Repair Mini Pump Service Manual Figure 6 - Replacing the Compressor Filter Assembly Table 10 - Compressor Filter Assembly Part List Item Part Number Description 502003 Compressor Assy 230V 50Hz 11K/T 502002 Compressor Assy 110V 60Hz 5K/T (USA) 502007 Compressor Assy 100V 50/60Hz 4.5K/T (Japan) 500320 ‘F’...

  • Page 31: Removing The Compressor Inlet Filter

    Mini Pump Service Manual Pump Repair 12 Removing the Compressor Inlet Filter 12.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2). 12.2 Remove the rear case assembly (Refer to Page 5, Section 6). 12.3 Carefully pull the filter retaining clip (Fig 6, Item 30) from the ‘F’ tube connector (Fig 6, Item 20). 12.4 Remove and discard the old inlet filter (Fig 6, Item 40).
  • Page 32 Pump Repair Mini Pump Service Manual Figure 7 - Replacing the New Style AV Mounts Table 11 - New Style AV Mounts Part List Item Part Number Description 500124 Compressor Mounting Bracket 500416 AV Mount Mounting Pins Chap 3 Issue 2 Page 12 SER0004 Nov 2001...

  • Page 33: Removing The New Style Av Mounts

    Mini Pump Service Manual Pump Repair 14 Removing the New Style AV Mounts 14.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2). 14.2 Remove the rear case assembly (Refer to Page 5, Section 6). 14.3 Carefully lift the compressor, mounting bracket (Fig 7, Item 10) and AV mounts (Fig 7, Item 20) from the mounting pins (Fig 7, Item 30).
  • Page 34 Pump Repair Mini Pump Service Manual Figure 8 - Replacing the Old Style AV Mounts Table 12 - Old Style AV Mounts Part List Item Part Number Description AV Mounting Bracket 198375 AV Mount AV Mount Nut Washer Ref Table 14 Compressor Compressor Mounting Bracket (Part) Spacers...

  • Page 35: Removing The Old Style Av Mounts

    Mini Pump Service Manual Pump Repair 16 Removing the Old Style AV Mounts Note : Replacements are not available for the old style AV mounts. 16.1 Remove the pressure control knob from the pump (Refer to Page 3, Section 2). 16.2 Remove the rear case assembly (Refer to Page 5, Section 6).
  • Page 36 Pump Repair Mini Pump Service Manual Figure 9 - Replacing Mounting Brackets and Bump Stops Chap 3 Issue 2 Page 16 SER0004 Nov 2001...

  • Page 37: Removing The Compressor Mounting Bracket

    Mini Pump Service Manual Pump Repair Table 13 - Compressor Mounting Brackets and Bump Stops Part List Item Part Number Description 165310 Upper Bump Stop 165310 Lower Bump Stop 500124 Compressor Mounting Bracket (New Style) Compressor Mounting Bracket (Old Style) FAS160 Washer M4 Plain FAS051...

  • Page 38: Installing The Compressor Bump Stops

    Pump Repair Mini Pump Service Manual 20.3 Remove screw, washer and lower bump stop (Fig 9, Items 50, 40, 20) from the compressor mounting bracket. 21 Installing the Compressor Bump Stops 21.1 Fit screw, washer and replacement upper bump stop (Fig 9, Items 50, 40, 10) to the compressor lid.

  • Page 39: Replacing The Compressor Silencer Bag

    Mini Pump Service Manual Pump Repair Table 14 - Compressor Silencer Bag Part List Item Part Number Description 502003 Compressor Assy 230V 50Hz 11K/T 502002 Compressor Assy 110V 60Hz 5K/T (USA) 502007 Compressor Assy 100V 50/60Hz 4.5K/T (Japan) 502301 Compressor Lid FAS054 Screw Countersunk Pozi M4 x 12 mm BP032...
  • Page 40 Pump Repair Mini Pump Service Manual Figure 11 - Bellows Armature Assembly and Pivots Table 15- Bellows Armature Assembly Part List Item Part Number Description 502054 Bellows Armature Assembly Left-Hand 230V 50Hz BP215 Bellows Armature Assembly Left-Hand 110V 60Hz 502053 Bellows Armature Assembly Right-Hand 230V 50Hz BP214 Bellows Armature Assembly Right-Hand 110V 60Hz...

  • Page 41: Replacing The Bellows Armature Assemblies And Pivots

    Mini Pump Service Manual Pump Repair 23 Replacing the Bellows Armature Assemblies and Pivots 23.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2,22.3 and 22.4). 23.2 Using long nosed pliers, extract the armature blade, part of bellows armature assembly (Fig 11, Item 10 or 20) from the armature pivot (Fig 11, Item 30) 23.3 Unclip the bellows, part of bellows armature assembly from the valve body (Fig 11, Item 40) and lift the bellows armature assembly clear of the compressor.
  • Page 42 Pump Repair Mini Pump Service Manual Figure 12 - Compressor Valve Bodies Table 16 - Compressor Valve Bodies Part List Item Part Number Description BP554 Valve Body Assy, Blue (Each valve body contains items 20 to 70) BP351 Valve Body FAS027 Screw, Hex Head 4BA x 3/4 FAS013...

  • Page 43: Replacing The Compressor Valve Bodies

    Mini Pump Service Manual Pump Repair 25 Replacing the Compressor Valve Bodies 25.1 Remove/disassemble the compressor/AV bracket assembly and remove the silencer bag (Refer to Page 19, Section 22.1, 22.2, 22.3 and 22.4). 25.2 Unclip the bellows, part of bellows armature assembly from the valve body (Refer to Page 20, Fig 11, Items 10 or 20 and 40).
  • Page 44 Pump Repair Mini Pump Service Manual Figure 13 - ‘E’ Stack and Coil Assembly Table 17 - ‘E’ STACK and Coil Assembly Part List Item Part Number Description BP028 ‘E’ Stack FAS048 Pan Head Screw M3 x 25 mm Pozi FAS002 Washer - 6BA Anti-Vib.

  • Page 45: Replacing The 'E' Stack Assembly

    Mini Pump Service Manual Pump Repair 26 Replacing the ‘E’ Stack Assembly Note : After doing work in either Section 26 or 27 the pressure/flow characteristics can be altered by moving the coil assembly/’E’ stack nearer or further from the armature magnets. This can be done by adjusting screws (Fig 13, Item 20).
  • Page 46 Pump Repair Mini Pump Service Manual 28.2 Remove the compressor air inlet filter and clip from the ‘F’ tube connector, then disconnect the ‘F’ tube connector from the silencer bag outlet tubes (Refer to Page 11, Section 12.1, 12.2, 12.3 and 12.4). 28.3 Remove the compressor/AV bracket assembly from the pump case (Refer to Page 13, Section 14.1, 14.2 and 14.3 (new style AV mounts) or Page 15, Section 16.1, 16.2 and 16.3 (old style AV mounts)).

  • Page 47: Replacing The Pressure Control Module

    Mini Pump Service Manual Pump Repair Table 18 - Pressure Control Module Part List Item Part Number Description 500347 Terminal Block 5 way BP196 Cable Tie 500362 Tube Sil ID 3/16” 135 mm ± 5 mm LG FAS145 Screw 3 Dia. x 8 mm Pozi Pan Head PT FAS223 Screw 3 Dia.
  • Page 48 Pump Repair Mini Pump Service Manual Figure 15 - Removing the Alarm Monitoring PCB Table 19 - Removing the Alarm Monitoring PCB Part List Item Part Number Description FAS083 Screw No. 6 x 5/16” Pozi Pan Head PT 500346 PCB Alarm Monitoring 230 V 500345 PCB Alarm Monitoring 100/120 V Signal Connectors...

  • Page 49: Replacing The Alarm Monitoring Pcb

    Mini Pump Service Manual Pump Repair 30 Replacing the Alarm Monitoring PCB CAUTION : Electrostatic discharge can seriously damage the alarm monitoring PCB. Prior to replacing or handling, adequate earth/grounding precautions must be taken. Notes : 1 It is not necessary to remove the side panel in order to replace the alarm monitoring PCB. 2 The alarm monitoring PCB is only applicable to electronic versions of the mini pump.
  • Page 50 Pump Repair Mini Pump Service Manual Figure 16 - Replacing the Power Failure Alarm Battery Table 20 - Battery (Power Failure Alarm) Part List Item Part Number Description 151457 Battery Cable Tie Battery Plug to PCB Chap 3 Issue 2 Page 30 SER0004 Nov 2001...

  • Page 51: Changing The Battery

    Mini Pump Service Manual Pump Repair 31 Changing the Battery Caution : Electrostatic discharge can seriously damage the alarm monitoring PCB. Prior to replacing or handling, adequate earth/grounding precautions must be taken. Notes : 1 It is not necessary to remove the side panel in order to change the battery. 2 The battery (power failure alarm) is only applicable to electronic versions of the mini pump.
  • Page 52 Pump Repair Mini Pump Service Manual Figure 17 - Replacing the Neon Indicator Light Table 21 - Neon Indicator Part List Item Part Number Description FAS083 Screw No. 6 x 5/16” Pozi Pan Head PT 500324 Plate Neon Mounting 500373 Neon Assembly Red 230 V 500371 Neon Assembly Red 110 V...

  • Page 53: Replacing The Neon Indicator Light

    Mini Pump Service Manual Pump Repair 32 Replacing the Neon Indicator Light Note : The neon indicator light is only applicable to the mechanical versions of the pump. The electronic version of the pump has two red indicators, a green indicator and a yellow indicator. These are wired directly into the PCB and are replaced only by exchanging the complete PCB.
  • Page 54 Pump Repair Mini Pump Service Manual Figure 18 - Replacing the Micro switch and Terminal Block Table 22 - Micro switch and Terminal Block Part List Item Part Number Description 500338 Micro switch Sub Min 230 V/0.1A FAS224 Screw 2.2 Dia. x 14 mm Pozi Pan Head PT 500347 Terminal Block 5 Way FAS225...

  • Page 55: Replacing The Microswitch

    Mini Pump Service Manual Pump Repair 33 Replacing the Microswitch Note : It is not necessary to remove the pressure control module from the pump case. 33.1 Pull off connectors from the Micro switch terminals 1 and 3 (Fig 18, Item 10). 33.2 Release two screws (Fig 18, Item 20) and remove the Micro switch from the pressure control module.
  • Page 56 Pump Repair Mini Pump Service Manual (Aura Pumps Only) Figure 19 - Pressure Control Flaps, Air Bag, Control Knob Cam and Arbour Table 23 - Pressure Control Flaps, Air Bag, Control Knob Cam and Arbour Part List Item Part Number Description 500304 Knob Control Arbour...

  • Page 57: Replacing The Pressure Control Flaps And Air Bag

    Mini Pump Service Manual Pump Repair 35 Replacing the Pressure Control Flaps and Air Bag 35.1 Turn the control knob arbour fully counter-clockwise (Fig 19, Item 10). Hold the upper pressure control flap (Fig 19, Item 20) in position and withdraw the pivot pin (Fig 19, Item 30). Carefully remove the upper flap and the lower flap (Fig.19, Item 40) together with the low pressure operating spring and brass disc (Fig 19, Items 50 and 60).
  • Page 58 Pump Repair Mini Pump Service Manual Figure 20 - Control Knob Cam and Arbour Table 24 - Control Knob Cam and Arbour Part List Item Part Number Description FAS225 Control Adjustment Screw, 3 Dia x 16 mm Pozi Pan Head PT 500305 Knob Control Cam 500411...

  • Page 59: Replacing The Pressure Control Assembly

    Mini Pump Service Manual Pump Repair 36 Replacing the Pressure Control Assembly Note : It is not necessary to remove the side panel assembly from the pressure control module. 36.1 Remove the pressure control module from the pump case as described in Section 29. 36.2 Remove the pressure control flaps as described in Section 35.
  • Page 60 Pump Repair Mini Pump Service Manual Figure 21 - Synchronous Motor (Gearbox), Rotor/Stator Assembly Table 25 - Synchronous Motor (Gearbox), Rotor/Stator Assembly Part List Item Part Number Description FAS223 Screw 3 Dia x 10 mm Pozi Pan Head 500097 Gearbox 240V and Ferrule Assembly 500098 Gearbox 120V and Ferrule Assembly 500099...

  • Page 61: Replacing The Synchronous Motor (Gearbox), Rotor Stator Assembly

    Mini Pump Service Manual Pump Repair Table 25 - Synchronous Motor (Gearbox), Rotor/Stator Assembly Part List (continued) Item Part Number Description 500319 Stator Gasket 500418 Stator Gasket (Restricted) 500356 Rotor Drive Cup 500322 Pin Rotor Drive 500354 Washer Starlock O/D 21 mm 500358 Spring Comp 1.6 Diameter FL 22.36 TIM017...
  • Page 62 Pump Repair Mini Pump Service Manual Figure 22 - Replacement of the Side Panel On/Off Switch Table 26 - Side Panel On/Off Switch, Mains/Power Lead and Fuses Part List Item Part Number Description 500351 Switch Mains/Power Rocker 230 V Black (All electronic pumps) 500343 Switch Mains/Power Rocker 230 V Green (Illuminated) 500359...

  • Page 63: Replacing The Side Panel Mains/Power On/Off Switch

    Mini Pump Service Manual Pump Repair 38 Replacing the Side Panel Mains/Power On/Off Switch 38.1 Remove the pressure control module and remove the side panel as described in Section 29. 38.2 Pull off the electrical connections from the On/Off switch (Fig 22, Item 10). 38.3 Squeeze together the retaining flanges located on either side of the switch body and push the switch through the side panel.
  • Page 64 Pump Repair Mini Pump Service Manual Part Part Figure 23 - Snap-lock Connectors Table 27- Snap-lock Connectors Item Part Number Description 500350 Connector Panel, Female 1/4” Flow 504316 Connector Panel, Male 1/4” Flow 500361 Tube Sil Blue ID 6 OD 10 24 LG ± 1 500360 Tube Sil Blue ID 6 OD 10 15 LG ±...

  • Page 65: Replacing The Snap-Lock Connectors

    Mini Pump Service Manual Pump Repair 41 Replacing the Snap-lock Connectors Note : Older versions have a pump connectors moulded within the side panel and are not replaceable. 41.1 Remove pressure control module with side panel (Refer to Section 29.1 to 29.7) 41.2 Refer to Fig 15, disconnect the three signal connectors (Fig 15, Item 30 ) and the power wires from the PCB.

  • Page 66: Removing The Front Case

    Pump Repair Mini Pump Service Manual 42 Removing the Front Case 42.1 Remove the pressure control knob (Page 3, Section 2). 42.2 Disassemble the rear case (Page 5, Section 6). 42.3 Remove the screw and the fixing cap (Refer to Fig 14, Items 40 and 80) from the pressure control module.

  • Page 67: Pump Label Sets

    Mini Pump Service Manual Pump Repair 44 Pump Label Sets The following table gives the part numbers for the pump label sets: Table 28 - Pump Label Sets Part Number Description AlphaXcell Series 500386 Label set UK - AlphaXcell (ALX01) 500387 Label set Germany - AlphaXcell (ALX02) 500388...
  • Page 68 Pump Repair Mini Pump Service Manual Table 28 - Pump Label Sets (continued) Part Number Description Alpha Relief Series 500475 Label set UK - Alpha Relief (ALR01) 500478 Label set Germany - Alpha Relief (ALR02) 500470 Label set USA - Alpha Relief (ALR03) 500476 Label set Euro - Alpha Relief (ALR04) AlphaCare...

  • Page 69: Troubleshooting

    Mini Pump Service Manual Troubleshooting CHAPTER 4 TROUBLESHOOTING General This section details some problems which may occur after a long period of use and the appropriate procedures to correct them. The Alpha Relief, Aura and AlphaXcell (electronic) pump units are fitted with a visual and audible alarm for LOW PRESSURE and POWERFAIL alarm conditions.

  • Page 70: Low Pressure Fault Indicated (Checks Without Dismantling The Pump)

    Troubleshooting Mini Pump Service Manual Table 29 - Troubleshooting (continued) Problem Possible Cause Action Mains/Power Fail indicator There has been a mains/power Check if electrical plug is remains illuminated but failure but power has been restored. correctly fitted and if pump is there is no audible alarm.

  • Page 71: Loss Of Output Pressure (Checks By Dismantling The Pump)

    Mini Pump Service Manual Troubleshooting If the alarm still indicates, visually inspect tubing and mattress cells for punctures or tears and check they are fitted to the manifold correctly. Refer to the mattress service manual SER0005 for full details. WARNING: DANGER OF ELECTRIC SHOCK.

  • Page 72: Low Pressure Alarm Fault

    Troubleshooting Mini Pump Service Manual Low Pressure Alarm Fault If the low pressure alarm does not function correctly after recalibration as described in Chap. 5 (Testing), check: The electrical connections and leads between the low pressure micro-switch and the printed circuit board.

  • Page 73: Circuit Diagrams

    Mini Pump Service Manual Troubleshooting Circuit Diagrams The circuit diagram for the electronic models is given in Fig 24. The circuit diagram for mechanical models is given in Fig 25. Check for the above faults against the relevant circuit and repair as appropriate.
  • Page 74 Troubleshooting Mini Pump Service Manual Terminal Block Fuse Mains/Power Switch Live Mains/Power Lead Neutral Gearbox Microswitch Compressor Neon Figure 25 - Circuit diagram for AlphaXcell, AlphaBed, AlphaCare and Alpha TranCell (Mechanical) Mini Pumps Chap 4 Issue 2 Page 6 SER0004 Nov 2001...

  • Page 75: Testing

    Mini Pump Service Manual Testing CHAPTER 5 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 or equivalent is required: Table 30 - Pump Flow, Pressure and Function Test Equipment Equipment Part Number...
  • Page 76 Testing Mini Pump Service Manual PRESSURE ADJUSTMENT SCREW Stop Pin (If fitted) MINI PUMP MANOMETER (mmHg) DAMPER (FOR EVEN FLOW) BATTERY FLOW METER Figure 26 - Typical Test Rig setup for Mini Pumps Chap 5 Issue 2 Page 2 SER0004 Nov 2001...
  • Page 77 Mini Pump Service Manual Testing Table 32 - Pressure Range Pump Min. (mmHg) Max. (mmHg) AlphaBed 30 ± 5 90 ± 10 AlphaCare 30 ± 5 90 ± 10 Alpha Trancell ALT01-09 30 ± 5 73 ± 8 ALT10 30 ± 5 90 ±...
  • Page 78 Testing Mini Pump Service Manual Low Pressure Indicator Test (Mechanical Units Only) With the test equipment set up as in Section 1.1, set the pressure control knob in the mid position and use the flowmeter valve to adjust the pressure slowly up and down. Observe the LOW PRESSURE warning light to indicate the operation of the Micro switch.

  • Page 79: Electrical Testing

    Mini Pump Service Manual Testing Table 34 - Descending and Ascending Pressures Pump Pressure X Pressure Y AlphaBed 5 mmHg 17 mmHg AlphaCare 5 mmHg 17 mmHg Alpha Trancell 5 mmHg 17 mmHg Alpha Relief 5 mmHg 17 mmHg Aura 50 mmHg 82 mmHg AlphaXcell...

  • Page 80: Pcb Functional Tests (Electrical Units Only)

    Testing Mini Pump Service Manual WARNINGS: DANGER OF ELECTRIC SHOCK. DO NOT TOUCH ANY EXPOSED PARTS WHILE CONDUCTING THIS TEST. DO NOT TOUCH ANY PART OF YOUR BODY WITH THE CONTACTS OF THE PROBES. THIS EQUIPMENT SHOULD NOT BE USED IF YOU HAVE A HEARING AID OR PACEMAKER FITTED, DUE TO THE POSSIBILITY OF ELECTROMAGNETIC DISTURBANCE.

  • Page 81: Functional Tests (Mechanical Units Only)

    Mini Pump Service Manual Testing Functional Tests (Mechanical Units Only) Tests must be carried out using a 220-240 V, 50 Hz power supply. Test Setup and Initial Switch On Set the pressure control knob fully counter-clockwise and ensure that both outlet ports are open to atmosphere.
  • Page 82 Testing Mini Pump Service Manual Chap 5 Issue 2 Page 8 SER0004 Nov 2001...

  • Page 83: Technical Specification

    Mini Pump Service Manual Technical specification CHAPTER 6 TECHNICAL SPECIFICATION Pump Models The pump models covered in this series are:- • Alpha Relief • Aura • AlphaXcell (Electronic) • AlphaXcell (Mechanical) • AlphaBed • AlphaCare • Alpha Trancell Notes : Each model has a three letter code. For example, the Alpha Relief pump has the code ALR. Following the three letter code is a two digit code representing customer country’s power supply system.
  • Page 84 Technical specification Mini Pump Service Manual Cycle Time The cycle time for all pump models is 10 minutes. Rated Voltages The voltage ratings for each of the customer (two digit) codes is given in Chap. 1, Table 2. Rated Frequency The mains/power frequency ratings for each of the customer (two digit) codes is given in Chap.
  • Page 85 Mini Pump Service Manual Technical specification Environmental Conditions Operating conditions for all models: Temperature range: +10° C to +40° C Relative humidity: 30% to 75% Atmospheric pressure: 700 hPa to 1060 hPa Storage conditions for all pump models: Temperature range: -40°...
  • Page 86 Technical specification Mini Pump Service Manual Chap 6 Issue 2 Page 4 SER0004 Nov 2001...

  • Page 87: Parts List

    Mini Pump Service Manual Parts list CHAPTER 7 PARTS LIST Part Number Description Fig-Item Front and Rear Case 500316 Front Case 2 - 40 500318 Pin (if fitted) 2 - 30 500484 Control Knob (MK2) 2 - 10 500304 Knob Arbour 2 - 20 500317 Rear Case...
  • Page 88 Parts list Mini Pump Service Manual Part Number Description Fig-Item FAS027 • • Screw, Hex Head 4BA x 3/4 12 - 30 FAS013 • • 4BA Full Nut 12 - 40 BP039 • • Valve Body Washer 12 - 50 BP037 •...
  • Page 89 Mini Pump Service Manual Parts list Part Number Description Fig-Item BP196 Cable Tie 14 - 20 500362 Tube Sil ID 3/16” 135 mm ± 5 mm LG 14 - 30 FAS145 Screw 3 Dia. x 8 mm Pozi Pan Head PT 14 - 40 FAS223 Screw 3 Dia.
  • Page 90 Parts list Mini Pump Service Manual Part Number Description Fig-Item 500308 Rotor Module 21 - 30 500307 Stator Module 21 - 40 500332 Felt Rotor Silencer 21 - 50 500319 Stator Gasket 21 - 60 500418 Stator Gasket (Restricted) 500356 Rotor Drive Cup 21- 70 500322...
  • Page 91 Mini Pump Service Manual Parts list Part Number Description Fig-Item BP171 Mains/Power Cable - Australia 500344 Fuse Holder 22 - 40 CAS011 Fuselink 20 x 5 mm 500 mA QB 22 - 50 Snap-lock Connectors 500350 Connector Panel, Female 1/4” Flow 23 - 10 504316 Connector Panel, Male 1/4”...
  • Page 92 Parts list Mini Pump Service Manual Chap 7 Issue 2 Page 6 SER0004 Nov 2001...

  • Page 93: Service Contact Details

    Mini Pump Service Manual Service Contact Details CHAPTER 8 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 T +27 1266 10368...
  • Page 94 Service Contact Details Mini Pump Service Manual Chap 8 Issue 2 Page 2 SER0004 Nov 2001...

This manual is also suitable for:

Alphaxcell mechanicalAlphareliefAuraAlphatrancellAlphabedAlphacare

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