Download wispa lite portable ceiling mounted electric hoist service manual

WISPA LITE PORTABLE
CEILING MOUNTED ELECTRIC HOIST
SERVICE MANUAL
Issue 1 September 2004
CONTENTS:
1.
Introduction.
2.
Operating Instructions
3.
Routine Maintenance.
4.
Servicing and Repair.
5.
Load testing.
6.
Spare Parts Listing
7.
Appendix
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Issue 1 September 2004
This manual is a controlled document loaned by Chiltern Invadex Ltd for the sole use of
approved personnel who have attended the Chiltern Invadex training course on this
product.
It must not be copied in whole or part and it remains the property of Chiltern Invadex Ltd.
Preface
Read and understand this manual before attempting to service or repair the hoist.
Warnings, Cautions and Notes
WARNINGS given in this manual identify possible hazards in procedures or conditions which, if
not correctly followed, could result in loss of life or severe personal injury.
Cautions given in this manual identify procedures or conditions which, if not correctly followed,
could result in equipment damage.
Notes given in this manual are used to explain or amplify a procedure or condition.
General Warnings
The installation must be carried out by a competent person and be in accordance with the relevant
requirements of local Building Regulations and Health and Safety at Work Act 1974 and
associated regulations
All electrical work must be carried out by a competent electrical engineer in accordance with the
current edition of IEE Wiring Regulations.
1.0 Introduction.
The Wispa Lite Portable hoist was designed to improve the independence of the disabled person,
with the help of a carer. It should be used in conjunction with a Wispa sling and other lifting
accessories from the Chiltern Invadex range, as assessed by a trained person.
Note: Not all slings and accessories are compatible with the hoist. If you are unsure please
contact your nearest Chiltern Invadex Office.
Using an appropriate sling, available from Chiltern Invadex, the overhead hoist will raise the user
from a bed or wheelchair and transfer them to the bath or toilet where the hoist will lower them
under total control.
The hoist has a Safe Working Load of 200Kgs (31 stones) (440lbs) and power is supplied by two
rechargeable 12 volt batteries which are contained within the hoist.
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Wispa Lite Portable: Powered Lifting - Manual Traversing
Wispa Lite
Introduced in 2004 with significant changes from previous portable:
Remote charger, emergency lowering, battery LED, dual controls, new handset
styling, improved electronics with fault diagnostic alarms
W
P
FEATURES
MANUAL TRAVERSING
CORDLESS BATTERY OPERATION
DUAL CONTROLS
EMERGENCY LOWERING
200kgs (440lb) SAFE WORKING LOAD
LOW BATTERY WARNING INDICATOR
SELF DIAGNOSTIC ALARMS
15 x 600mm (2ft) LIFTS @ 91 kgs ON FULLY
CHARGED BATTERY
2. Operating Instructions
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2.1
For Wispa Lite Portable
Ensure that the Emergency Stop – On/Off switch is in the on position by pressing in the red on/off
button on the side of the unit. Notice that the battery indicator shows a green light. If showing
Red, charge the batteries immediately.
Check the sling and lifting tape for fraying or broken stitching. Select the appropriate sling and
position it around the individual (refer to the sling instructions if this procedure is unfamiliar)
Pull the lifting tape to the required length by operating the hand control or the cover controls,
ensuring that the tape is kept tight. Attach the tape hook to the ceiling fixing. Caution: Check that
the tape hook is securely attached to the ceiling fixing before lifting commences.
To obtain the ideal position for the sling loops to the hoist; adjust the height of the Wispa Lite
Portable with the hand controls, using either the up or down functions. Maximum lifting travel
2.6mtrs (102 ins)
The hoist is equipped with limit switches on the lifting tape.
1
Maximum lift limit
2
Maximum lower limit
3
Slack lifting tape
Should any of the above limit switches be activated the hoist will stop.
After use, switch on the hoist by pressing the red on/off button, and put on charge if required.
2.2
EMERGENCY LOWERING
In the unlikely event of a component failure, the individual can be lowered using the emergency
lowering button as described below. The individual may be lowered, whilst suspended in the
sling.
Remove the grommet cover, push and hold the button, which is on one end of the case, until the
client is lowered safely.
The emergency lowering facility will only work if there is sufficient capacity in the batteries.
The emergency device should not be used for normal lowering except in an emergency
situation.
3. Routine Maintenance.
3.1 The Hoist Service Sheet
A typical hoist service sheet is shown in the appendix, this shows an example of the information
required forming a service record or database. The purpose of this sheet is to retrieve as much
information about the hoist installation with a quick reference checklist.
When servicing hoists in large numbers you may be asked to service all types and make of hoist,
this is why the hoist service sheet covers all aspects of hoist servicing. There are a number of
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Issue 1 September 2004
checks listed, however this report is used for overhead and mobile hoists, so some of the checks
do not apply to all overhead or mobile hoists which have to be carried out during a biannual or
annual hoist service. Each check has been abbreviated to keywords to jog the mind of the
experienced service engineer, if further instructions are required refer to "The Check List
Explained". This provides an in depth technical support relating to all servicing, repairs and
maintenance.
When carrying out any type of servicing to a hoist, the first action is a visual inspection of all
mechanical fixings to ensure that they are tight and secure. The outer casing must always be
removed for a closer inspection, and to bear in mind that any component part must last until the
next service.
The load test should be carried out using at least 100% of the maximum load. An example of a
hoist and lift test certificate is shown in the appendix.
3.2
An operator’s guide for checking the safety of the equipment.
a) Heavy Duty Areas: - Institutional / Hospital Utilisation
Above average activity.
Abnormal environment (E.g. Corrosive atmospheres such as hydrotherapy pools etc.)
Heavy weight patients.
In the above case the routine maintenance should be carried out at 6 monthly intervals.
b) Light to Standard Duty areas:Domiciliary Utilisation Light to standard activity environment and the patient's weight.
In the above case the routine maintenance should be carried out at 12 monthly intervals
Note: Lifting Operations & Lifting Equipment Regulations 1998. These regulations came into
force in December 1998. They apply to all types of lifting equipment used at work, including
patient hoists, irrespective of whether they are new, second-hand or existing items of equipment.
Further details can be obtained from the Health and Safety Executive in a booklet called ‘Simple
Guide to the Lifting Operations and Lifting Equipment Regulations 1998’.
Detailed records must also be maintained of all inspections and servicing especially if equipment
is moved about from location to location.
3.3
The Service Check List Explained
1. Carry Bar condition/cover must be tested under load with the rated capacity. Check welds
are secure and that the covers are complete and without any splits or tears. Check that
distance between carry handles and cover is equal.
2. Boom Condition - Mobile Hoists only
3. Mast Condition - Mobile Hoist only
4. Leg adjustment - Mobile Hoist only
5. Castor Security - Mobile Hoist only
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6. Ram/Actuator condition - Mobile Hoist only
7. Spline disengagement - Mobile Hoist only
8. On/Off switch operation check that it works and the terminals are not corroded.
9. Condition of Batteries - these should last for at least 3 years if correctly maintained,
however, this is often not the case due to deep discharging and infrequent re-charging. There
is no danger of over charging the batteries due to the electronic regulator circuit. It is the role
of the Installer and Service Engineer to educate the user or carer to always put the hoist on
charge when not in use. If you suspect a faulty battery, check the terminal voltage of each
battery independently and if one of the batteries is one volt or more lower, then it is faulty and
needs replacing.
10. Charger leads and plugs - involves inspecting to ensure that the leads and plugs are not
damaged. The transformer should be checked that it has the correct rating for load applied.
The minimum requirement is a 240VAC transformer with an output of 29v AC-output
charger.
11. Clean & lubricate the hoist taking care not to trap any wires when replacing the cover.
Always remove any greasy finger marks from hoist and track.
12. Carry bar fixing - not applicable to portable hoist
13. Brakes - Mobile Hoist only
14. Creep test pass - Mobile Hoist only
15. Correct range of travel - ensure that the hoist tape operates over its full range. Any
traversing should also be checked to ensure smoothness of travel.
16. Visual/Audio battery indicator - check operation if fitted.
17. All other indicators - ensure that the LED’s are working correctly.
18. Hand controls condition - Up & Down Control should be operated on and off load.
19. Boom alignment - Mobile Hoist only
20. Mast alignment - Mobile Hoist only
21. Bumpers - Mobile Hoist only
22. Oil seals may weep one or two drops of oil through their lifetime, but if oil can be seen on the
inside cover, the motor/gearbox should be replaced.
23. Correct descent rate - applicable to non portable overhead hoists only
24. Audible battery indicator - ensure that it is working correctly when the battery voltage is
low or faulty.
25. Limit Switches - All limit switches should be checked on and off load.
- ensure that the up limit switch operates as the magnet in the tape enters the hoist.
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If more tape is required due to high ceilings, a lanyard can be fitted from the track trolley to
the Handley bar, the hoist is then connected to the other side of the Handley bar as normal.
26. Max. Load labelled as - this should be entered onto the service label that is attached to the
cover of the hoist to indicate the rating of the hoist and when it was last serviced and next due.
Also check that the serial number is correct with the label inside the hoist.
27. Charging rate (v) to check that there is an output from the charger, test across the batteries to
see if there is any increase in voltage.
28. Overall hoist condition will vary depending on the environment; if installed over
hydro/swimming pools etc. the electrical components may require additional protection
against corrosion.
29. Track & Track fixing - check alignment of track, condition of moving parts (trolleys and
turntables), check all parts for corrosion especially if fitted in hydrotherapy pools and other
corrosive atmospheres. Track fittings should be inspected to see that they are tight and secure,
the track fixings may become loose if the timber strengthening beams have shrunk due to
seasoning. If studding is used, check that locking nuts are present. Coach screws may need a
quarter turn to close up any gaps between brackets and plasterboard. Always check the
installation has sufficient number of bracket fixings and the spacing is no more than one metre
or a minimum of three fixings. Where tracks are fixed between walls or on a gantry frame,
always check the deflection is not greater than the specified figure shown on chart. Finally,
check all the Allen cap screws that secure the fixing bracket to the track are tight to 10Nm
30. End stops are one of the most important safety aspects of any installation. If you need to
remove the hoist trolley from the track for repairs, and then refit, Never forget to replace the
stop end as someone's life could depend on it. Check the bolts are tight with a 13mm torque
spanner or wrench to 26Nm and traverse the hoist into both end stops.
31. Trolley bearings/nuts. Trolley Bearings rarely require lubrication as they are greased when
assembled from new. However, if a bearing becomes dry and starts to squeak then a few
drops of light oil applied in between the drive wheel and bearing housing will cure the
problem. The non-driven trolleys are sealed units and are maintenance free. Trolley Nuts
must be inspected to see that they are tight and that half nuts and lock nuts have been fitted.
32. Traverse motor/drive - Non portable overhead hoists only
33. Gear/chain lubrication - Lubricate all gears
34. Motor fixings should be checked for tightness, also pay attention to the motor and gearbox
casting as cracks may appear if fatigue is occurring. Check during load test.
35. Wiring internal/mains - All portable hoists are supplied with a charger with a moulded plug
attached. Check that the correct fuse is fitted in the plug top and the mains cable is free from
damage.
NOTE: - Consult the current IEEE wiring regulation for the correct protection.
35. Lifting tape wear can vary depending on application, but it is recommended that they should
be replaced every other service or every 2 years.
36. Condition of accessories - any accessories attached to the hoist must be checked for damage.
Slings, lanyards, etc. Check for pulled stitching where loops attached to the net and polyester
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fabric.
37. Emergency lowering must be tested with the load attached, raise the load pressing the up
button and lower by pulling the cord to its fullest extent.
38. Emergency stop not fitted to portable hoists
39. Weight tested to maximum load by lifting 100% of the maximum load. Raise the weight to
the up limit and lower to within 50mm (2”) of the floor, traverse the hoist along the track to
either end. If the hoist completes this test successfully a Hoist test certificate form must be
completed.
40. Date of last inspection/service - enter the date of the last inspection or service
41. Date of next inspection/service - enter the next due date for inspection or service
42. SWL labelled as - enter the maximum load of the hoist
43. Certificate No. - of the hoist weight test certificate
44. Safe to use - mark Yes or No if the hoist is safe to use
45. Lifting tape replacement due date - enter the date when the lifting tape is due to be replace.
Normally this is every two years or sooner if worn or damaged.
AFTER THE SERVICE HAS BEEN CARRIED OUT THE CUSTOMER OR
AUTHORITY MAY REQUIRE A SIGNATURE OF ACCEPTANCE FROM THE END
USER.
3.4
SERVICE RECORD LABEL
Apply a service record label to the case and complete the details as required
4. Servicing and Repair
4.1
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a)
This section gives information and procedures for the removal and installation of
replacement parts and sub-assemblies. Setting up procedures, which may be necessary
following component replacement, are included.
a)
Minor procedures, which may be deemed self-evident, have not been included.
b)
Do not dismantle more than necessary to replace a defective item
c)
Before removing any electric wire, make a note of its position and identification to assist reassembly.
4.2
Handset
The handset is removed from the hoist by unscrewing the two securing screws on the hand
control plug.
4.3
Cover Removal
Remove two screws from the side covers
The end covers are retained by moulded lugs so it may require easing with a small coin to
get them over the lugs.
Ease the covers off and disconnect the membrane leads from their plugs
Feed the carry bar levers through the aperture in the cover.
The top cover requires the handle to be unscrewed first and then the top screw can be
removed.
The bottom cover is retained by two screws each side with spacers.
Re-fitting is the reverse procedure as above.
When refitting ensure that there are no wires trapped between the covers
4.4
Lifting Tape Removal
1
2
Remove the covers as detailed in 4.3
Press the down button on the handset or side controls and pull the tape out from the hoist
to its maximum length or use the emergency lowering switch to activate the hoist.
Disconnect one lead from the battery
Slacken the battery clamp retaining nut and slide the battery to clear the lower limit switch
pin.
Remove the push on fix and remove the pin which releases the lover tape limit lever and
spring.
Unscrew the lower limit switch bracket from the chassis
Push the tape through the main shaft to allow you to remove the retaining pin
Pull the tape back through the shaft slot until it is clear
3
4
5
6
7
8
Re-fitting
1
Place the tape loop through the top slot and into spool recess ensuring the tape passes the
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6
7
8
slack tape pin
Push the tape through the shaft slot and fit the tape pin retainer
Pull the tape back through the slot ensuring that the tape pin is located correctly
Re-fit lead to battery
Rewind the tape back onto the spool, using the lift button on the handset to obtain the
correct rotation, otherwise when the emergency button is pressed the hoist will not come
down.
Refit the lower limit switch lever and adjust as required
Re-fit cover and test the hoist
Check the correct operation of the lower tape limit switch and slack tape switch
4.5
Battery replacement
2
3
4
5
1
2
3
4
5
Remove the covers as detailed in 4.3
Disconnect the leads from the battery terminals
Remove the nut from battery clamp
Disconnect the remaining leads from the terminals
Remove the foam packing from the bottom battery and refit to the new battery
Refitting is the reverse procedure of the above
Put hoist on charge
4.6
Motor/Gearbox removal
1
2
3
4
5
6
Remove all the covers as detailed in 4.3
Disconnect one lead from the battery
Remove the two wires from the motor connection plug
Remove three screws that hold the gearbox to the chassis
Remove collar from motor gearbox shaft
Swing the motor/gearbox down and slide sideways out of the chassis
Re-fitting is the reverse procedure of the above
3.2
Main PCB removal
1
2
3
4
Remove all the covers as detailed in 4.3
Disconnect one lead from the battery to isolate the supply
The PCB is retained by double sticky backed tape, replace as required
Disconnect the wires from the connector block on the main board noting their positions
Refitting is the reverse procedure of the above
3.3
1
2
3
4
Membrane Switches Replacement
Remove the end covers as detailed in 4.3
Disconnect one lead from the battery to isolate the supply
Remove two screws that retain board onto the side of the motor
Disconnect wires from connector block noting their location
Re-fitting is the reverse procedure of the above
3.4
Tape Limit Switches
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If the tape is wound in too far, the double thickness of the tape contains a magnet which operates a
reed switch. This breaks the motor circuit and stops the motor instantly.
There is also a lower limit switch to prevent the lifting tape to unwind too far, this is controlled by
a metal lever which rests on the wound tape until it reduced sufficiently to operate the switch
which stops the motor. This switch can be adjusted so that there is sufficient tape wound around
the shaft to hold the hoist correctly.
Also there is a slack tape switch which is operated should the hoist lower onto something and the
tape goes slack. This again turns off the motor until the tape is tight again.
3.5
Emergency Stop On/Off Switch
1
2
3
4
Remove the covers as detailed in 4.3
Disconnect one lead from the battery to isolate the supply
Unsolder the leads to the switch making a note of their positions
Press the sides of the switch locating lugs inwards to disengage from the side cover
Refitting is the reverse procedure of the above
3.6
Emergency Lowering Switch
1
2
3
4
Remove the top cover as detailed in 4.3
Disconnect one lead from the battery to isolate the supply
Disconnect the wires on the switch
Squeeze the switch locking arms in to allow the switch to pass through its holder
Refitting is the reverse procedure of the above
4.
Electrical Wiring
See the attached schematic drawing
5.
Load Testing
All installations/hoists should be proof load tested to at least 100% of its maximum load along the
entire track length to ensure that the installation is safe.
To carry out this test, a weight of 200kg (440lbs) is attached to the sling support arms. Raise the
weight to the up limit and lower to within 50mm (2”) of the floor, traverse the hoist along the
track to either end. If the hoist completes this test successfully a Hoist test certificate form should
be completed.
6. Spare Parts
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Wispa Lite Spare Parts
ITEM
PART No.
QTY
DESCRIPTION
1
350-00006
1
Chassis
2
350-00019
1
Tape Shaft
3
350-00003
2
Bush – 15mm Internal Diameter
4
350-00004
2
Bush – 20mm Internal Diameter
5
350-00008
1
Worm Shaft
6
350-00017
2
Pin – 4mm diameter x 90.5mm long
7
350-00018
2
Push-On Fixing – 4mm diameter
8
350-00021
1
Gear Wheel
9
350-00022
1
Spool Guide Disc - 20 Internal Diameter
10
350-00023
1
Spool Guide Disc – 26 Internal Diameter
11
350-00027
1
Lanyard & Handle Bracket
12
350-00011
1
Governor Arm
13
350-00026
2
Pin
14
306-00100
1
Motor
15
MHWMES27
2
Battery - 12V, 2A
16
350-00012
1
Stop Block Arm
17
COM0075
2
M5 Nylon Pillar
18
OH0034
1
Micro Switch
19
COM0066
2
Circlip – 20mm diameter
20
COM0067
4
Circlip – 8mm diameter
21
350-00036
1
Main PCB
22
350-00020
1
Wheel Pin
23
350-00024
1
Governor Arm Pin
24
350-00031
1
Hanger Arm Left
25
350-00032
1
Hanger Arm Right
26
350-00033
2
Strap Retainer
27
0H0008
1
Reed Switch (Part of loom)
28
350-00035
1
Membrane Panel LH
29
350-00034
1
Membrane Panel RH
30
COM0058
1
Thrust Bearing
31
350-00025
1
Slack tape shaft
32
COM1015
1
Spring
32A
OH0088
1
Governor Arm Spring
33
350-00028
1
Carry Handle
34
OH0011
1
On / Off Switch
35
OH0017
1
Emergency Lower Switch
36
COM1137
2
Covered Push –On Fixing
37
N/A
1
Hand Control Connector
38
OH0034
1
Micro switch with lever
39
300-00042-CI
1
Hand Control
40
COM1470
1
R Clip
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ITEM
PART No.
QTY
DESCRIPTION
41
350-00030
1
Lifting Tape
42
COM0071
4
Push-On Fixing M4
43
COM1178
1
Nylon Washer
44
COM0073
2
Ball Spring Plunger
45
COM0070
1
M6 Hex Head Screw x 55mm
46
COM1175
1
M6 Nylok
47
COM0028
1
Tape Securing Pin
48
OH0090
2
Battery Cushion Pad – self adhesive foam
49
350-00018
1
Micro switch Plate
50
350-00016
2
Cover Retaining Bar
51
350-00015
1
Battery Bracket
52
350-00040
1
Top Cover
53
350-00041
1
Bottom Cover
54
350-00038
1
LH Side Cover
55
350-00039
1
RH Side Cover
56
N/A
1
Charger Socket – Part of loom
57
COM1560
3
M6 Countersunk Head Screw x 12mm long
58
COM1628
3
M5 Button Head Screw x 10mm long
59
COM1124
1
M4 Switch adjust Screw x 12mm long
60
COM1170
2
M6 Governor arm washer Washer
61
COM0072
4
M3 Pozi Driv Button Head Screw x 14mm long
62
COM1105
4
M3 Plain Washer
5
Cover screws
63
64
COM0076
1
M4 Bolt x 18mm long
65
N/A
N/A
Not Available
66
COM1110
2
M3 Reed switch screw x 12mm long
67
COM1105
2
Reed switch plain washer
68
350-00013
1
Emergency Lowering Switch Bracket
69
COM1124
2
M4 EL screws x 12mm long
Not Shown
300-00207-CI
1
Charger Unit
Not Shown
300-00207-BF
1
Charger Unit – USA 110 volt
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7.
Appendix
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OHWLP01 WIRING DIAGRAM
Top Limit
Switch
Low Limit
Switch
Battery
Connections
On / Off
Switch
Slack Tape
Switch
PCB-Loom
Connections
Membrane
Connections
Charge
Socket
Motor
Connections
Emergency
Lowering
18
D. MILNER
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