maintenance level service information manual...140124 solenoid valve w/plugin brass 140478 backflow...

MAINTENANCE

LEVEL

SERVICE

INFORMATION MANUAL

10/11/11

PENNER MANUFACTURING INC.

Penner Service Information

Typical Service replacement parts

140124 SOLENOID VALVE W/PLUGIN BRASS140478 BACKFLOW PREVENTOR 1/2" 9D-M3144105 VACUUM BREAKER WATTS 288A-3/8350112 CHECK VALVE ASSEMBLY SUPERIOR350151 RADA 320 CARTRIDGE ASSY COMP.350151 RADA 320 CARTRIDGE ASSY COMP.350195 SNAP CLAMP (OBSOLETE)350235 CHK VALVE- 3/8 BARB X 3/8 BARB350470 AIR TRANSMITTER - BLACK FLUSH350505 AIR SWITCH TBS 304350510 AIR SWITCH TBS 310350525 CIRCUIT BREAKER 20 AMP350526 CIRCUIT BREAKER 15 AMP350531 FUSE - 3AG 1/16 AMP SLO-BLO350532 FUSE - 3AG 6/10 AMP SLOBLO350533 FUSE - 1 AMP SLOBLO 1/4X1-1/4"350534 THERMOMETER DISPLAY CELSIUS350535 THERMOMETER 40/199F350536 THERMOMETER F W/POWER SUPPLY350545-09 TIMER-OFF-DELAY REPLACES ALL AFTER 09360402 BASE SHOE ASSY CASCA-SUPER360628 CHK VALVE 1 1/2" CASC SER REPL370505 AIR SWITCH TBS 302380345 BOOT CASTER MOUNTING SM GREY380350 BOOT CASTER MOUNTING LG GREY380355 CASTER FRONT SWIVEL NON-BRAKE380360 CASTER REAR TOTAL LOCK POLY381106 MOBILETTE CONTROLLER381107 BATTERY ELECTRIC TRANSFER381112 HAND CONTROL SW/2 COMPLETE381115 SEAT BLUE TRANSFER390302 DEMA INJECTOR 202CT SPECIAL390406 CHECK VALVE ASSY PACIFIC COMP.1404804 INJECTOR - DEMA COMPLETE3811060 EMERGENCY SW/RED BUTTON3811067 COMPARTMENT BATTERY COMPLETE3811068 SCALE PSC20 DISPLAY ONLY SERV381198 PCB/DISPLAY BRD TRANSFER SCALE3811072 BATTERY INTERNAL SINGLE TRANS3901764 KIT-BK FL, CK VALVE, DEMA PACI3911221 KIT BRAKE ACTUATOR PACIFIC350151MN CARTRIDGE RADA 222350535M THERMOMETER-Fahrenheit/Celsius350535M-SER THERMOMETER - SERV REPLACEMENT360125K KIT DOOR SEAL REMOVAL3911221 KIT BRAKE ACTUATOR PACIFIC

2

INDEX

2. TYPICAL SERVICE PARTS LIST3. INDEX4. GENERAL TRANSFER GENERAL TROUBLESHOOTING GUIDE5. TRANSFER LIFT TROUBLESHOOTING FLOW CHART6. TRANSFER LIFT HAND CONTROL7. ACTUATOR TESTING & PLUG REPLACEMENT8. SCALE CALIBRATION9. DISPLAY CONNECTING CABLE AND CONECTION PCB10. SCALE PRINTED CIRCUIT BOARD REPLACEMENT11. SCALE TROUBLE SHOOTING GUIDE PG 112. SCALE TROUBLE SHOOTING GUIDE PG 213. BATHING SYSTEMS IN GENERAL14. VIEW OF WATER PATH IN TYPICAL BATHING SYSTEM15. WATER DOOR LEAKING15. AIR BLOWER15. AIR JETS16. CHECK VALVES AND MIXING VALVE ISSUES17. MIXING VALVE BREAKDOWN18. MIXING VALVE ADJUSTMENT19. DISPENSER PUMP ISSUES19. THERMOMETER ISSUES19. DRAIN ISSUES20. RESERVOIR ISSUES21. INJECTORS ORIENTATION AND BREAKDOWN22. CASCADE GENERAL TROUBLESHOOTING FLOW CHART23 CASCADE TUB FILL TROUBLESHOOTING FLOW CHART24. CASCADE RINSE AND DISINFECT TROUBLESHOOTING FLOW CHART25. CASCADE SHOWER TROUBLESHOOTING FLOW CHART26. PACIFIC GENERAL TROUBLESHOOTING FLOW CHART27. PACIFIC TUB FILL TROUBLESHOOTING FLOW CHART28. PACIFIC SHOWER TROUBLESHOOTING FLOW CHART29. PENNER WARRANTY FORM30. PENNER WARRANTY STATEMENT31. SERIAL AND MODEL NUMBER IDENTIFICATION31. NOTEABLE CHANGES AND DATES APPLIED32. YOUR NOTES

3

TRANSFER INFORMATION

Helpful Hints:

(SECTION I) PENNER PATIENT TRANSFER LIFTS

GENERAL TROUBLSHOOTING GUIDES:

a. Always encourage having an extra battery on hand for transfers.

b. The AC adapter will plug in to both the wall charger and the mobilette, and batteries can be charged on both.

c. The AC adapter can be checked by measuring its’ DC output voltage with a volt meter. It should measure approximately 35 Volts DC

d. If the battery charges on a Mobilette and not on a wall charger, the wall charger is bad.

e. Most problems on transfers occur when the batteries are bad, defective AC adapter, or the cords not plugged into the mobilette correctly.

f. The plug for the connection of the pillar is a ¼” indexed plug, it must be pushed in and turned to lock.

k. The emergency lowering (orange button under mobilette) will not work with a poor battery. It is only used when the remote is defective.

l. The emergency stop button must be released to operate. Occasionally the push button is damaged causing the lift malfunction. The complete button must be replaced.

m. It is best if there is two Transfer systems, then you can interchanged components or roll one beside the other and connect the unit with a problem to the known good Transfer system.

n. If after confirming everything is ok and the lift goes up and won’t come down, it is possible the actuator is defective. Refer to you parts manual for directions on how to replace the actuator.

o. If the transfer tracks, or pushes crooked, the front casters can be aligned with the alignment pin above the casters. (pin pointing forward is normal. If it pulls to the right, turn the right pin inward. If It pulls to the left, turn the left pin inward).

p. For scale issues refer to Scale troubleshooting guide pages of this manual for steps to resolve the problems.

Penner Patient Care 102 Grant Street Aurora. NE 68818

For Service Please Call 1-800-732-0717 or 1-866-736-6377

Visit Our Web Site [email protected]

4




5

m. The mobilette can occasionally be repaired by replacing the emergency red button.

n. Occasionally the internal batteries may have a loose connection inside the battery pack causing it not to function or charge.

o. You can not tell a lot by trying to measure batteries because they must be measured under load. The best evaluation is to substitute a known good battery.

p. Often a facility has multiple systems which then allows you to interchange components to resolve the issue if you do not have the spare components required.

q. You may realize a savings by interchanging the internal defective batteries to create a good battery pack. Sometimes, if not usually, both internal batteries are not bad.

Use a Multimeter and measure the ohms across pins 7 & 9 as indicated below while depressing the DOWN button. If good you should measure approximately 3.25 m Ω. Do the same across pins 8 & 9 while depressing the UP button. This should also measure 3.25 m Ω. No reading on either would be defective.

DOWN ( 7 & 9)

CLOSED OR

3.25 MGΩ

UP ( 8 & 9)

CLOSED OR

3.25 MGΩ

1 2 3 4 5

6 7 8 9

TESTING THE HAND CONTROL OF THE PATIENT TRANSFER

This test is cumbersome to perform, you may need an assistant.

PINS 7 & 9

PINS 8 & 9

DOWN BUTTON

UP BUTTON

(SECTION I) PENNER PATIENT TRANSFER LIFTSCONTINUED

6

Penner Manufacturing, Inc.

TRANSFER & STRETCHER PARTS & ASSEMBLIES




3811075 CABLE JACK- PLUG REPLACEMENT

&

When the cable is cut, or a defective plug to actuator, order this number, cut to length so the cord is concealed under Transfer lift pillar clamp.

To test the actuator, touch the negative end to a battery output, and using a screw driver, touch the positive section to the other battery output. This will make the actuator go up or down by reversing. Note: the center section is not used.

Indexed plug

ACTUATOR TESTING ON THE TRANSFER LIFT

7

Standard 3-button calibration Instructions14. Should calibration be necessary, all that is

required is a 25 lb (50 lb for some models) precision weight*. Do not use packaged goods, fitness weights, or other items that say they weigh 25 lb (50 lb for some models). Failure to use a precision weight may cause the scale to display an inaccurate weight. A certified weight is the method preferred, NIST Class F or ANSI/ASTM Class 6 weights are recommended.

15. To enter the calibration mode, press the “ON/ZERO” pad. While holding the “ON/ZERO”pad, press and hold the “LB/KG” pad. After approximately 3 seconds the message on the display will change from “ZERO” to “CAL”. Release both and the display will show “C 0”.

TRANSFER SCALE CALIBRATION (only on Transfers with Scales)



CALIBRATION




Note:

When Calibrating a Bariatric (PSC20B), substitute 50 where 25 LB or (C25) is stated

16. Make sure the lift seat is empty and stabilized** prior to pressing the “ON/ZERO” pad. The display will count down from -16- to -0- or -8- to -0-. When finished the display will show the message “C 25” (C50 for some models).

17. Place a 25 lb (50 lb for some models) precision weight on the seat and permit it to stabilize*. Press the “ON/ZERO” pad once again. The indicator will count down from -16- to -0- or -8- to -0- as before. The indicator automatically returns to the weighing mode and displays the weight used. Calibration is now complete. Please remove the 25 lb (50 lb for some models) precision weight, stabilize* the lift, and press the “ON/ZERO” pad to zero the scale. The scale is ready to use.

*NIST Class F or ANSI/ASTM Class 6 weights are recommended. Please note that dumbbells are not precision weights.

**Failure to stabilize the unit may cause the scale to display an inaccurate weight or not permit calibration; here are some notes on how to stabilize the unit (empty or with weight). -weight must be centered directly below the hanging scale or middle of the weighing platform-do not side load the scale -permit the weight to stop bouncing or swinging (15-30 seconds is generally enough time for the weight to stabilize)

8






9



381198 Printed Circuit Board (PCB) Replacement for PSC20 Scale readout




10

Scale Troubleshooting Guide:The following is a very general overview of items to check for and has been compiled over the years. These procedures must be performed by trained / qualified individuals.

1. Check the battery voltage to ensure that the appropriate power requirements have been met. During the start up sequence of most scales the display will show “b X.X”, “X.X” is the voltage. 9 volt system should be close to 9.0 volts, 4 AA and 4 C cell systems should be close to 6.0 volts. If batteries need to be replaced we recommend alkaline batteries from Duracell or Energizer. Purchasing sub-standard batteries will result in lower battery life or other potential problems.

a). The indicator has a low battery icon in the upper left hand corner of the display. When the battery voltage is too low the icon will come on. If the battery is not replaced in a timely fashion the display will show “BATT” rendering the scale inoperable until the battery is replaced.

2. After checking the battery voltage remove the battery and check for corrosion on the battery itself and inside the battery compartment. If corrosion is found, clean and ensure proper contact is being made. If the contacts within the battery compartment appear flat (AA battery compartment) bend them out slightly for proper contact. Insert the battery.

3. Ensure that the lift is on a level surface and that all the wheels/points of contact are touching the floor and dispersing the weight evenly.

4. Membrane switches are very durable. Occasionally an operator will use a sharp object to depress the switch. This may cause a short in the switch and show up as a non-responsive pad, a locked up display or some erratic display. Visually check for cuts or indentations in the switch.

5. Calibrate the scale with precision weights – please reference the calibration instructions in this manual or the video. Both can be found on our website –www.pennerpatientcare.com






11






Scale Troubleshooting Guide: ContinuedIf the problem persists continue to step 6. At any time during the next steps if something is found and corrected calibrate the unit to see if that correction fixed the problem.

6. Verify that nothing is touching or interfering with the load cell(s). If any of the load cell(s) are bridged the scale will not operate correctly. Bridging is anything that can occur at any time throughout the weighing process to cause the load cells to contact the load cell carrier bracket, and it may occur at 10 lbs or at near capacity. Generally what is viewed is that as the weight is incremented, readings will be farther off until the display will not change. If bridging is found, repair the cause and calibrate the scale again and verify. If bridging is not found, the load cell may be damaged.

7. If the indicator has connector(s) that lead to load cell(s) in other areas of the lift make sure that the wires are not binding, have not been cut or frayed, and that any other junction boxes/connectors are not damaged. We need to have continuity between the load cell(s) and board.

An additional step can be done to further verify that good contact is being made; this is not a substitute for the previously mentioned check. Disconnect the connector(s) from the load cell and obtain the resistance reading between connections (1&2 and 3&4) or the (red/white and green/black) and compare to other load cells. Once the load cells have been checked, work your way back to the indicator, each time you connect a load cell in series divide your resistance by 2.

a). If one of the load cells has erratic readings you may have a bad load cell.b). Disconnect the potentially bad load cell from the indicator and calibrate the unit.

Depending on the lift the weight may be slightly off. Record your findings and repeat the same procedure only using the potentially bad load cell. If the load cell is displaying erratic weights we have now narrowed it down to that load cell and associated connections.

c). Check the connections on that side again and verify that everything is making good contact.

d). If a new load cell is needed please contact us.

8. If the above steps did not fix the problem please contact us. The readings recorded above will help expedite the process.

12

(SECTION II) Bathing Systems In General:

(Refer to the enclosed flowcharts to diagnosis problems)

a. Push a button (air transmitter) and nothing happens.

1. You should be able to hear the solenoid and the air switch engage (not a very loud sound). Look at which ever is not engaging. The Air switches are labeled inside the electrical kit to help isolate problem.

2. All solenoids are the same for all systems.

3. The solenoids have a pig tail on them that is approximately 9” long with a white connector. Occasionally that connection is not complete, or a pin inside is not secure in the connector. (Look at the color code for solenoid identification below, to help isolate which solenoid may be the problem).

Color coded solenoid ID

4. Often a facility has multiple systems which then allows you to interchange components to resolve the issue if you do not have the spare components required.

5. You can also switch solenoid connections to another solenoid to determine which components are not functioning.

TUB FILL GREEN

TUB SHOWER RED

PENNER BATHING SYSTEMS

TUB DISINFECT YELLOW BELOW IS ON PACIFIC SYSTEMS

TUN RINSE BLUE SHOWER DISINFECTANT WHITE

13

TOO MIXING VALVE

TEMP SENSOR

SHOWER

DISINFECTION

FILL

RINSE

MIXING VALVE

AIR FLOW

WATER FLOW

WATER AND AIR PATH ON THE PENNER CASCADE

FIGURE 1 14

Water door leaking:

a. Most causes of this is that a belt or an object has been pinched in the door when closed.

b. The water door must be left open when not in use so that the seal retrains its’ shape and thickness. The seal has a memory shape and will always return to original shape when open. If left closed continually, it will retain, or remember the depressed shape, thus not sealing as well.

c. The seal is not difficult to remove. Start with an end and pull as much off as possible. Then using your thumb to roll off the remainder, or scrape with a plastic tool being careful not to damage the gelcoat.

d. Water doors rarely become misaligned, but if this happens call Tech Support for advice.

(SECTION III) Aqua-Aire Blower:

a. Refer to Section II on Air switches

b. Refer to (Figure 1), the blower has a water trap as indicated. This is protection in the event the 1 ½” black check valve, (indicated) fails. In this event, water would go back into the blower and cause damage. The water trap allows water to drip out of the bottom drain hole in the cap (indicated) and not into the blower in the event the check valve fails.

(SECTION IV) Air Jets:

a. There is little maintenance required on these.

b. They can become clogged and not work. The cap snaps off of the jet, then using a needle nose pliers, remove the internal parts as shown in (figure 2). Once out, you may run the jets to clean it out, then reassemble.

Figure 2

PENNER BATHING SYSTEMS CONTINUED

15

(SECTION IV) Check valves, white, brass, and on the injectors:

a. The direction of white check valves is indicated on the ribs of each. The arrows are the full length of the check valve, and have the arrow head at one end.

b. Check valves can cause different problems. The normal is that if water is going in the wrong place a check valve is usually the reason. Problems related to liquids, may be due to the small check valves on the injectors, or the injector itself failed.

c. Referring to (Figure 1), find the check valve related to your symptom. (Example), if your getting water into the disinfection bottle, look for the check valve on that line. The plastic line from the bottle goes to a injector and connects to it’s check valve. In this case the check valve on the injector may be contaminated causing failure. You can remove it from the injector and clean it.

d. White check valves can also cause symptoms with backflow preventers, water seeping out of the top etc.

(SECTION V) Mixing Valve issues:

a. Most problems with water temperature are related to the mixing valve. Refer to (Mixing Valve Adjustments) for instructions on how to make this adjustment.

b. There are screens just after each inlet water connection, also a brass check valve just after it. These screens need to be cleaned frequently depending on the geographical location of the facility.

c. The screens being clogged can cause various effects to water temperature.

d. Most generally the problem is the mixing valve adjustment or cartridge failure internally on the mixing valve. The cartridge can be carefully removed and cleaned. Also the O-rings may be torn or cracked inside. You must lubricate the O-rings with a white grease or jelly, before re-inserting the cartridge, to prevent damage to the O-rings.


16

Penner Manufacturing, Inc.MIXING VALVE BREAKDOWN

17

Cascade Mixing Valve Adjustment

For Adjustable Temperature

1. Remove the temperature knob screw using a 3 mm hexagonal wrench (supplied). Remove the temperature knob.

2. Pull off the black polymer hub assembly which may inadvertently remain attached to the inside of the temperature control handle. This is a “push fit” and can be “levered” out using a thin blade screwdriver or pliers.

3. Rotate the spindle until required maximum blend temperature is obtained at outlet point (clockwise = decrease temperature, counterclockwise = increase temperature). When resistance is felt do not use force to turn any further, as this can damage the internal parts.

4. Once the desired maximum blend temperature is achieved, re-fit the hub without disturbing the spindle: Position the hub so that the hub stop comes up against the cartridge stop (refer to Figure 7-1) preventing any further rotation in a counterclockwise direction. Check that blend temperature has not altered.

5. Refit the temperature knob. Make sure that the indicator points to 9 o’clock.

18

(SECTION VI) Dispenser problems:a. When you have issues with these pumps it is often the pump itself.

However the red O-rings internally can be replaced and correct a lot of problems.

b. There can also be a kinked or disconnected clear hose behind the pumps.

c. At the bottle end of these clear hose there is a red check valve that again follows the rules of check valves. If liquids are going in the wrong direction, these are a likely cause.

d. It is good to note that caution must be taken when removing the stem from the pump. There is an internal spring and a ball that can be lost if not careful. The threads can be crossed on the pump mount nut if not carefully re-installed.

(SECTION VII) Thermometer problems:

a. There is no repair on these other than replacement, however they can be adjusted to some extend in the back with a eye-glass screw common driver.

b. On June 1, 2007, a new thermometer was implemented that is both Celsius and Fahrenheit. These no longer have the independent transformer, they are connected directly to the main transformer in the electrical box. Here again replacement will likely be the norm. The new thermometer can also be adjusted, but with a small cross-point screwdriver.

c. The new thermometer cannot replace the old one because of the power supplying it.

(SECTION VIII) Drain problems:

a. Typically the problem that occur here is cracking of the base shoe basket. These are currently made of a better material.

b. When cracking does occur, you can replace the base shoe basket or both shoe and basket. When replacing both, first disconnect the drain, then turn the assembly to free it from the tub. Then using the 2” removal tool from inside the tub, carefully unscrew the base shoe basket from the drain. Putty should be reapplied when installing the replacement.


19

(SECTION IX) Reservoir issues:

a. If you have a cracked base shoe basket, it is replaced the same as stated section VIII.

b. Most generally just the base shoe basket needs replacement. If the adapter is cracked then you need to order the Base Shoe Basket 105050, clear washer 370430, and 2” adapter 370315. There is a reservoir drain replacement kit 370307 for the older reservoirs without the brass gate valve.

c. When there is problems with the Transmitter and Switches those are diagnosed the same as stated in section II.

d. The float switch could also cause the reservoir not to fill, because it shuts off the solenoid.

e. Thermometer issues same as indicated in section VII.




20

DEMA INJECTOR 1404804

PARTS BREAKDOWN

DEMA INJECTOR

273.8

390302

ORIENTATION OF COMPONENTS IN INJECTORS




21




22




23




24




25




26




27




28

SERIAL NUMBER IDENTIFICATION AND CHANGE HISTORY

MONTH

YEAR

WORK ORDER

SEQUENCE OF WORK ORDER

NOTEABLE CHANGES AND DATES APPLIEDPENNER PATIENT TRANSFER LIFTS

BATHING SYSTEMS

ECR 456 Preventive Action. Eng Change to the air system on Pacific, Cascade, and Superior Air systems. Change is added water trap to prevent liquids getting into the air blower if there is a check valve failure. Same ECR replaced clear 1-1/2” check valve to current black because of availability. Date changed 08/30/04 starting work order 05903.

ECR 573 Started using compression fittings on the plumbing assemblies for ease of service part replacement . Date started in production 11/10/05.

ECR 588 Preventive Action for a field kit (3901762) for relocation the disinfect dema injector on Pacific systems to siphoning. Located just below Vacuum Breaker. Also ECR 458. Date of change 01/09/06. Change started after work order 06069

ECR 618 Added check valve 140474 above the backflow preventer in Pacific Systems to prevent disinfectant getting into backflow preventer. Also changed of angle, of 1-1/2” check valve 390406 assembly to allow internal ball to roll freely. Change date 04/14/06 starting at work order 10247.

ECR 734 Added number for black base shoe basket to be used on colored tubs for appearance. Along with the black, the white baskets were improved with better material to prevent being brittle and crack. Date of change 09/27/07. All work orders produced after this date.

ECR 720 Adding second thermometer 353535M for all tubs. Will be primary thermometer. Is in field tests of 06/21/07. UL evaluated on 10/04/07. Will be in all systems upon receipt of PO 16062. Also see

ECR 763. UL approval was received 02/09/08.This Thermometer is both “C” & “F”. It does not have it’s own transformer. It connects to the main transformer in the electrical kits. In production starting 6/21/07

ECR 476 Added service replacement kit for actuator brake on the Pacific Panel (3911221). This brake keeps the Pacific Height actuator from drifting down. Change date 11/10/04 starting work order 07100

ECR 311-312-509 Made changes to scale clamp hole patterns in 381175 and 381180. 381187 changed clamp to fit better. On Transfer built prior to 09/01/03 replacement clamps should include both front and back clamps.

ECR 643 Preventive Action to remove the two flat washers top of front casters on transfers and replace with an alignment washer to enable adjustment of tracking on all Transfer. Prevents pulling one direction. Date changed 06/19/06 starting after 10618 work order.

ECR 586 Preventive Action- Changed strength of push bar bolts as a result of breaking off of push bar. Bolt 381550 Date changed 01/06/06 after work order number 09396

ECR 595 Changed Specification on Powder Coating to included a Primer coat and better Powder Coating to better resist rust. Date changed 02/06/06 starting with work orders 09238 / 08359. Coating also changed on scales starting with serial number 604.

ECR 637 Changed from blue connector on transfers to PC type, also started conformal coating the Main PC boards starting at scale serial number 376 on 06/08/06. Starting work orders 10249 / 10496. S/N 380 First Stretcher

ECR 693A Corrective Action the vendor redesigned the Transfer hand control. to ensure that the solder joints are constant on all boards in the hand control thus eliminating the erratic hand control. Verification of action is the reduction of complaints since change. Date of change 05/04/07 all work order after this date.

ECR 678 Changed material on arm sockets for Pacific and End Opening Transfers to 1-1/2" instead of 1- 3/8". Shear strength on pin of 303 needs to remain the same for shear protection. Socket only change 3811851 Rev A. Change date 11/13/06 starting at work order 11656

31

NOTES

31

maintenance level service information manual...140124 solenoid valve w/plugin brass 140478 backflow...

Documents