WISPA LITE PORTABLE CEILING MOUNTED ELECTRIC HOIST SERVICE MANUAL

CONTENTS: 1. Introduction. 2. Operating Instructions 3. Routine Maintenance. 4. Servicing and Repair. 5. Load testing. 6. Spare Parts Listing 7. Appendix 2

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. 3

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 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 W P 2. Operating Instructions 4

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 5

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 6

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. 7

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 8

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 9

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 Remove the covers as detailed in 4.3 2 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. 3 Disconnect one lead from the battery 4 Slacken the battery clamp retaining nut and slide the battery to clear the lower limit switch pin. 5 Remove the push on fix and remove the pin which releases the lover tape limit lever and spring. 6 Unscrew the lower limit switch bracket from the chassis 7 Push the tape through the main shaft to allow you to remove the retaining pin 8 Pull the tape back through the shaft slot until it is clear Re-fitting 1 Place the tape loop through the top slot and into spool recess ensuring the tape passes the 10

slack tape pin 2 Push the tape through the shaft slot and fit the tape pin retainer 3 Pull the tape back through the slot ensuring that the tape pin is located correctly 4 Re-fit lead to battery 5 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. 6 Refit the lower limit switch lever and adjust as required 7 Re-fit cover and test the hoist 8 Check the correct operation of the lower tape limit switch and slack tape switch 4.5 Battery replacement 1 Remove the covers as detailed in 4.3 2 Disconnect the leads from the battery terminals 3 Remove the nut from battery clamp 4 Disconnect the remaining leads from the terminals 5 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 Remove all the covers as detailed in 4.3 2 Disconnect one lead from the battery 3 Remove the two wires from the motor connection plug 4 Remove three screws that hold the gearbox to the chassis 5 Remove collar from motor gearbox shaft 6 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 Remove all the covers as detailed in 4.3 2 Disconnect one lead from the battery to isolate the supply 3 The PCB is retained by double sticky backed tape, replace as required 4 Disconnect the wires from the connector block on the main board noting their positions Refitting is the reverse procedure of the above 3.3 Membrane Switches Replacement 1 Remove the end covers as detailed in 4.3 2 Disconnect one lead from the battery to isolate the supply 3 Remove two screws that retain board onto the side of the motor 4 Disconnect wires from connector block noting their location Re-fitting is the reverse procedure of the above 3.4 Tape Limit Switches 11

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 Remove the covers as detailed in 4.3 2 Disconnect one lead from the battery to isolate the supply 3 Unsolder the leads to the switch making a note of their positions 4 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 Remove the top cover as detailed in 4.3 2 Disconnect one lead from the battery to isolate the supply 3 Disconnect the wires on the switch 4 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 12

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 15

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 63 5 Cover screws 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 16

7. Appendix 17

OHWLP01 WIRING DIAGRAM Slack Tape Switch Top Limit Switch Battery Connections Low Limit Switch On / Off Switch PCB-Loom Connections Membrane Connections Charge Socket Emergency Lowering Motor Connections 18 D. MILNER