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FLIGHT MEDICAL INNOVATIONS Ltd.

FLIGHT 60 VENTILATOR

Service Manual

V60-00002-18 Rev. A

May 2011

Legal Notice

Legal Notice Disclaimer FLIGHT MEDICAL INNOVATIONS Ltd. (FLIGHT MEDICAL) provides this Service Manual in its commitment to help reduce patient risk and injury. However, this manual is not intended to in any way replace or substitute duty of care to a patient, professional responsibility, or professional judgment, nor is it intended to provide any warranty, promise, guarantee, assumption of risk or duty, release, or indemnity. Physicians shall at all times maintain responsibility for patient treatment and outcomes, and FLIGHT MEDICAL further assumes no liability for patient treatment or outcome or for physician's negligence, breach of duty of care, or malpractice. The FLIGHT 60 Ventilator operator is solely responsible for selecting the appropriate level and method of patient monitoring. Product modification or misuse can be dangerous. FLIGHT MEDICAL disclaims all liability for the consequences of product alterations or modifications, as well as for the consequences which might result from the combination of this ventilator with other products, whether supplied by FLIGHT MEDICAL or by other manufacturers, unless such a combination has been specifically endorsed by FLIGHT MEDICAL. The design of FLIGHT 60 Ventilator, the Operator’s and Service Manuals, and the labeling on the ventilator, take into consideration that the purchase and use of the equipment is restricted to trained professionals, and that certain inherent characteristics of the ventilator are known to the operator. Instructions, warnings, and caution statements are therefore limited to the specifics of the FLIGHT 60 Ventilator. Federal law (US) restricts this device to sale by or on the order of a physician. This Operator’s Manual excludes references to various hazards which are obvious to medical professionals and operators of this equipment, to the consequences of product misuse, and to potential adverse effects in patients with abnormal conditions. When the FLIGHT 60 Ventilator is used in homecare and subacute environments, only properly trained personnel should operate the ventilator. The FLIGHT 60 Ventilator is a restricted medical device designed for use by respiratory therapists or other properly trained and qualified personnel under the direction of a physician and in accordance with applicable state laws and regulations. Transport of patients with the FLIGHT 60 Ventilator requires that medical staff have a good working knowledge of the ventilator’s use and problem resolution. Proper emergency backup equipment must be immediately available during transport.

ii | FLIGHT 60

Legal Notice

FLIGHT 60 Ventilator operators must recognize their responsibility for implementing safety monitoring mechanisms which supply appropriate information on equipment performance and patient condition. Patient safety may be achieved through a wide variety of means, such as electronic surveillance of equipment performance and patient condition. However, equipment surveillance should not replace direct observation of clinical signs. The liability of FLIGHT MEDICAL is subject to and limited to the exclusive terms and conditions as set forth herein. Said liability is limited whether arising out of, or related to, the manufacture and sale of goods, their installation, demonstration, sales representation, use, performance, or otherwise. Any liability based upon product warranty is limited regardless of any fault attributable to FLIGHT MEDICAL and the nature of the action (including breach of warranty, negligence, and strict liability). The written warranties are in lieu of all other warranties, expressed or implied, including, without limitation, warranties of merchantability, fitness for any purpose, or non-infringement. FLIGHT MEDICAL shall not be liable for any special incidental or consequential damages incurred by the buyer to a third party. The buyer shall not be entitled to make liability recoveries from FLIGHT MEDICAL due to such situations.

Warranty The FLIGHT 60 Ventilator warranty does not apply for/ in case of:
Defects caused by misuse, mishandling, tampering, or by modifications not authorized by FLIGHT MEDICAL or its representatives.
Rubber and plastic components and materials, which are guaranteed to be free of defects at time of delivery. Any product which proves during the warranty period to be defective in workmanship or material, will be replaced, credited, or repaired. FLIGHT MEDICAL retains the discretion to select the most suitable of these options. FLIGHT MEDICAL is not responsible for deterioration, wear, or abuse. In all cases, FLIGHT MEDICAL will not be liable beyond the original selling price. Application of this warranty is subject to the following conditions:
FLIGHT MEDICAL or its authorized representatives must be promptly notified upon detection of the defective material or equipment.
Defective material or equipment must be returned to FLIGHT MEDICAL or its authorized representative.
Examination by FLIGHT MEDICAL or its authorized representatives must confirm that the defect is covered by the terms of this warranty. To ensure complete protection under this warranty, the Warranty Registration Card must be returned to a FLIGHT MEDICAL authorized representative within ten (10) days of equipment receipt.

Service Manual | iii

Legal Notice

The above is the sole warranty provided by FLIGHT MEDICAL. No other warranty, expressed or implied, is intended. Representatives of FLIGHT MEDICAL are not authorized to modify the terms of this warranty. In no way does this or any of FLIGHT MEDICAL policies, training materials, guidelines, or instructions create an obligation for FLIGHT MEDICAL to perform any services.

iv | FLIGHT 60

About this Document

About this Document This document is a service manual for the FLIGHT 60 and F60 Dual Limb Ventilators, ventilators that provide continuous or intermittent mechanical ventilation support for the care of individuals who require mechanical ventilation. It is intended for technicians who are responsible for maintaining, servicing, and providing troubleshooting assistance for the FLIGHT 60 and F60 Dual Limb Ventilators. For information on how to use the FLIGHT 60 Ventilator, see the FLIGHT 60 Ventilator Operator's Manual.

Chapters and Their Contents 1

Introduction

Product overview

Pg. 10

2

Safety Instructions

Warnings and cautions to be aware of when using the

Pg. 12

ventilator 3

Functional Description

Description of features and modules, including

Pg. 17

diagrams and specification tables 4

Removing and

Procedures for servicing the various device modules

Pg. 28

Calibration and testing procedures

Pg. 75

Reinstalling 5

Operation Verification Procedure (OVP)

7

Maintenance

Regular maintenance of the various device modules

Pg. 95

8

Troubleshooting

Problems and suggested actions; Contact information

Pg. 96

9

Repackaging and

Instructions for returning a device to FLIGHT MEDICAL

Pg. 99

Shipping

Style Conventions Convention

Used for

Verdana

Regular text.

Arial Bold

Names of labels, buttons, and other elements of the user interface.

Arial Italics

Special terms, the first time they appear. Notes, which offer an additional explanation or a hint on how to overcome a common problem. Warnings, which indicate potentially damaging user operations and explain how to avoid them.

Service Manual | v

Table of Contents

Table of Contents LEGAL NOTICE ........................................................................................... II DISCLAIMER .............................................................................................. II WARRANTY ............................................................................................... III ABOUT THIS DOCUMENT............................................................................. V TABLE OF CONTENTS .................................................................................VI 1

2

3

INTRODUCTION .................................................................................. 10 1.1

INTENDED USE ..................................................................................10

1.2

SYMBOLS .........................................................................................10

SAFETY INSTRUCTIONS ...................................................................... 12 2.1

GENERAL WARNINGS ...........................................................................12

2.2

CAUTIONS ........................................................................................15

FUNCTIONAL DESCRIPTION................................................................ 17 3.1

VENTILATOR DESCRIPTION ....................................................................17 3.1.1 Front Panel ..........................................................................17 LED Indicators ......................................................................................... 18

3.1.2 Left Side Panel .....................................................................19 3.1.3 Right Side Panel ...................................................................20 3.1.4 Back Panel ...........................................................................21 3.1.5 Optional Accessories..............................................................22 Air/Oxygen Entrainment Mixer .................................................................... 22 Oxygen Blending Bag Kit ........................................................................... 23 Patient Circuits......................................................................................... 23

4

3.2

VENTILATOR MODULES .........................................................................24

3.3

PNEUMATIC DIAGRAM ..........................................................................25

3.4

ELECTRICAL DIAGRAM ..........................................................................27

REMOVING AND REINSTALLING MODULES ......................................... 28 4.1

INTRODUCTION ..................................................................................28

4.2

REQUIRED EQUIPMENT .........................................................................28

vi | FLIGHT 60

Table of Contents

4.3

REPLACING THE DETACHABLE BATTERY ......................................................29 4.3.1 Removing the Detachable Battery ...........................................29 4.3.2 Installing the Detachable Battery ............................................29

4.4

REPLACING THE INTERNAL BATTERY ..........................................................29 4.4.1 Removing the Internal Battery................................................29 4.4.2 Installing the Internal Battery.................................................30

4.5

REMOVING THE VENTILATOR COVER ..........................................................30 4.5.1 Removing the Ventilator Cover ...............................................30 4.5.2 Installing the Ventilator Cover ................................................33

4.6

REPLACING THE POWER BOARD .............................................................33 4.6.1 Removing the Power Board ....................................................33 4.6.2 Installing the Power Board .....................................................36

4.7

REPLACING THE POWER SUPPLY ...............................................................38 4.7.1 Removing the Power Supply ...................................................38 4.7.2 Installing the Power Supply ....................................................40

4.8

REPLACING THE FRONT PANEL ASSEMBLY....................................................42 4.8.1 Removing the Front Panel Assembly ........................................42 4.8.2 Connecting the Front Panel Assembly ......................................43

4.9

REPLACING THE MAIN BOARD .................................................................44 4.9.1 Removing the Main Board ......................................................44 4.9.2 Installing the Main Board .......................................................48

4.10 REPLACING THE TOUCH SCREEN ..............................................................48 4.11 REPLACING THE MANIFOLD ASSEMBLY .......................................................48 4.11.1 Removing the Manifold Assembly ............................................48 4.11.2 Installing a Manifold Assembly ................................................52 4.12 REPLACING THE OXYGEN SENSOR ............................................................53 4.12.1 Removing the Oxygen Sensor .................................................53 4.12.2 Installing the Oxygen Sensor..................................................54 4.13 REPLACING THE PURGE BOARD ASSEMBLY...................................................54 4.13.1 Removing the Purge Board Assembly.......................................54 4.13.2 Installing the Purge Board Assembly .......................................55 4.14 REPLACING THE SOLENOID BOARD ASSEMBLY ..............................................55 4.14.1 Removing the Solenoid Board Assembly...................................55

Service Manual | vii

Table of Contents

4.14.2 Installing the Solenoid Board Assembly....................................56 4.15 REPLACING THE SOLENOID ASSEMBLY .......................................................57 4.15.1 Removing the Solenoid Assembly............................................57 4.15.2 Installing the Solenoid Assembly.............................................59 4.16 REPLACING THE LOWER BOARD AND D-TYPE BOARD ......................................59 4.16.1 Removing the Lower Board and D-type Board...........................59 4.16.2 Installing the Lower Board and D-type Board............................62 4.17 REPLACING THE FUSE ...........................................................................62 4.17.1 Removing the Fuse ...............................................................62 4.17.2 Installing the Fuse ................................................................63 4.18 REPLACING THE RUBBER BUMPERS ...........................................................64 4.18.1 Removing the Rubber Bumpers...............................................64 4.18.2 Installing the Rubber Bumpers................................................64 5

SOFTWARE MANAGEMENT .................................................................. 65 5.1

DOWNLOADING SYSTEM LOG FILES ..........................................................65

5.2

LOADING SOFTWARE ...........................................................................65 5.2.1 PCS.....................................................................................65 5.2.1.1 Update the Manifold S/N and Reset the Hours Meter ...............67 5.2.2 Main CPU .............................................................................71 5.2.3 Panel CPU ............................................................................73

6

OPERATION VERIFICATION PROCEDURE (OVP) ................................. 75 6.1

REQUIRED EQUIPMENT .........................................................................76

6.2

STANDARD VENTILATOR SETTINGS (STS) ..................................................76

6.3

FRONT PANEL SELF TEST ......................................................................77

6.4

PRESSURE SENSORS CALIBRATION ...........................................................78

6.5

PRESSURE RELIEF CALIBRATION ..............................................................80

6.6

VOLUME FACTOR CALIBRATION ...............................................................81

6.7

CIRCUIT TEST ...................................................................................82

6.8

PRESSURE GAUGE VERIFICATION ..............................................................83

6.9

PRESSURE VERIFICATION ......................................................................84

6.10 PEEP .............................................................................................85

viii | FLIGHT 60

Table of Contents

6.11 PRESSURE TRIGGER.............................................................................86 6.12 EXHALATION VALVE LEAK ......................................................................87 6.13 HIGH PRESSURE ALARM ........................................................................88 6.14 BATTERY /CHARGER /POWER SUPPLY ........................................................89 6.15 INLET LEAK.......................................................................................90 6.16 BUZZER TEST ....................................................................................91 6.16.1 High-level Alarm ...................................................................91 6.16.2 Low-level Alarm ....................................................................91 6.17 OXYGEN SENSOR ................................................................................92 6.17.1 Oxygen Sensor Calibration .....................................................92 6.17.2 Oxygen Sensor Test ..............................................................92 6.18 TEST TABLE ......................................................................................93 7

MAINTENANCE.................................................................................... 95

8

TROUBLESHOOTING GUIDE ................................................................ 96

9

8.1

INTRODUCTION ..................................................................................96

8.2

ERROR MESSAGES ..............................................................................96

REPACKAGING AND SHIPPING ........................................................... 99 9.1

PACKAGING ......................................................................................99

9.2

SHIPPING .........................................................................................99

INDEX..................................................................................................... 100

Service Manual | ix

Introduction Intended Use

1 Introduction This Service Manual (V60-00002-18 Rev. A) provides information for servicing the FLIGHT 60 Ventilator. It is for use by authorized service personnel while installing, servicing, and repairing the ventilator.

1.1

Intended Use

The FLIGHT 60 Ventilator is intended to provide continuous or intermittent mechanical ventilation support for the care of individuals who require mechanical ventilation. Specifically, the FLIGHT 60 Ventilator is applicable for adult and pediatric patients, greater than or equal to 10 kg (22 lbs).

1.2

Symbols

Symbol

Description

Front Panel On/Off button

Audio Paused

Rear Panel

Caution; consult accompanying documents

Type BF applied part

Temperature limitation

Humidity limitation

Atmospheric pressure limitation DC – Direct Current AC – Alternating Current

10 | FLIGHT 60

Introduction Symbols

Symbol

Description

USB – Universal Serial Bus LAN – Local Area Network

Service Manual | 11

Safety Instructions General Warnings

2 Safety Instructions At all times, strictly follow this manual. The safe use of the FLIGHT 60 Ventilator requires full understanding of its operation, and adherence to the manual's instructions. The equipment is only to be used for the purpose specified in section 1.1. Observe all of the WARNINGS and CAUTIONS posted in this manual, and on buttons found on the FLIGHT 60 Ventilator and associated accessories.

2.1

General Warnings

External power connection: To maintain grounding integrity when using AC power, only connect to grounded receptacles. Always disconnect the external power prior to servicing. There is a risk of explosion if used in the presence of flammable anesthetics.

All settings and adjustments in the different ventilation modes must be made in accordance with a physician's prescribed therapy.

Do not use electrically conductive patient circuits.

Always use a clean, disinfected patient circuit.

Always use an outlet filter or equivalent at the Airway Pressure Connector, to protect the internal sensors from moisture and other contaminants.

The ventilator is ready for operation only when: 1. It is completely assembled. 2. The OVP has been successfully completed.

12 | FLIGHT 60

Safety Instructions General Warnings

Failure to identify and correct alarm violations may result in patient injury.

Ensure that the oxygen source is not empty before and during the use of the optional Air/Oxygen Entrainment Mixer or Oxygen Blending Bag Kit.

As Li-Ion batteries are charged and discharged over time, their ability to hold a charge is decreased with use. This can shorten the amount of time the ventilator can function while on battery power.

The batteries should be replaced when the batteries no longer meet the needs of the user. This depends on a number of factors including settings and usage patterns.

Charge the batteries for a minimum of three hours before powering the ventilator from the batteries. This provides fully charged batteries.

During storage, charge the batteries for a minimum of three hours every 30 days. This provides charged batteries.

Always ensure that the green Ext. Power LED is illuminated after connecting the FLIGHT 60 Ventilator to an external AC or DC power source. If the LED is not illuminated, check all power connections and resolve any problems.

Always plug the FLIGHT 60 Ventilator into an AC power supply source when not in use, to ensure best battery performance.

Service Manual | 13

Safety Instructions General Warnings

The flow resistance of the air inlet filter, located on the right side of the ventilator, is likely to increase with repeated use. Ensure that the filter is changed regularly.

Only a FLIGHT MEDICAL approved patient circuit can be used with the FLIGHT 60 Ventilator.

Only a FLIGHT MEDICAL approved exhalation valve can be used with the FLIGHT 60 Ventilator.

Perform an exhalation valve calibration each time a clean circuit/exhalation valve is installed.

This FLIGHT 60 Ventilator has been tested and found to comply with the EMC limits according to the EN60601-1-1-2 standard class B. These limits are designed to provide reasonable protection against harmful interference in a typical medical installation. The equipment generates uses and can radiate radio frequency energy and, if not installed and used in accordance with these instructions, may cause harmful interference to other devices in the vicinity. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference with other devices, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving device. Increase the distance between the equipment. Connect the equipment into an outlet on a circuit different from that to which the device (s) is connected. Consult the manufacturer for help.

14 | FLIGHT 60

Safety Instructions Cautions

2.2

Cautions

Only use medical grade oxygen with the Air/Oxygen Entrainment Mixer or Oxygen Blending Bag Kit.

Do not place liquid containers in the immediate vicinity or on top of the FLIGHT 60 Ventilator. Liquids that get into the ventilator can cause equipment malfunction and damage.

After the FLIGHT 60 Ventilator is serviced, it must completely pass an Operational Verification Procedure (OVP) before being returned to patient use.

An authorized FLIGHT MEDICAL factory-trained technician must do all service or repairs performed on the FLIGHT 60 Ventilator.

Do not open the ventilator or perform service on an open unit while connected to external power.

Use standard antistatic techniques while working inside the ventilator or handling any electronic parts.

Clean all external accessories of the ventilator prior to servicing.

Water in the oxygen supply can cause equipment malfunction and damage.

Service Manual | 15

Safety Instructions Cautions

Batteries contain Li-Ion. Do not discard them in an incinerator or force them open. Batteries should not be disposed of with normal waste.

Use the tools and equipment specified in this manual to perform specific procedures.

16 | FLIGHT 60

Functional Description Ventilator Description

3 Functional Description 3.1 3.1.1

Ventilator Description Front Panel

The front panel contains the control buttons, visual indicators, display screen, and patient circuit connection.

Figure 1 – Front Panel Label

Name

Description

1

Patient Circuit Connector

Composed of a gas outlet and quick connector.

2

Up/Down button

Enables the user to scroll up and down the display controls.

3

Panel Lock button

Enables the user to lock the ventilator’s control, preventing accidental changes. Pressing the button of a locked panel, unlocks the panel.

4

On/Off button

Turns the ventilator on or off, to start or stop ventilation.

5

Manual Breath button

Delivers a user initiated manual inflation.

Service Manual | 17

Functional Description Ventilator Description

Label

Name

Description

6

Audio Paused / Alarm Reset

Toggle button. Pressing Audio Paused temporarily silences the

button

audible alarm; pressing Alarm Reset clears latched alarm LEDs.

7

Pressure Gauge

The pressure gauge is a visual indicator of breath activity, which shows the dynamic movements of the breath pressures. When a breath is being delivered, the user can see the relative pressure and phase of the breath (inspiration or expiration). The pressure gauge is comprised of 29 LEDs. From -10 to +20 cmH2O, each notch equals 2 cmH2O; from 20 to 50 cmH2O, each notch equals 5 cmH2O; above 50 cmH2O, each notch equals 10 cmH2O.

8

Display touch screen

Enables the user to modify the ventilation, alarm, and technical settings, and to view real time patient data, alarms, and logs.

9

LED Indicators

Inform the user of various events as detailed below.

10

Primary Alarm LED

Flashes red to indicate that there is a high priority alarm.

LED Indicators The LED indicators on the front panel inform the user of various events. The following table describes the available LED indicators. LED Indicator

Description

TRIG

Green LED indicates a patient’s breathing effort.

EXT PWR

Yellow LED indicates that an external power source is being applied to the ventilator.

LOW BAT

Red LED indicates that a 20% charge of detachable battery power remains.

BAT

Orange LED indicates that the ventilator is powered on batteries.

FAULT

Red LED indicates a ventilator malfunction.

APNEA

Red LED indicates that no breaths have been delivered for the preset APNEA interval.

BUV

Red LED indicates that backup ventilation is active.

HIGH MV

Red LED indicates that the high inspiratory minute volume alarm limit is being violated.

LOW MV

Red LED indicates that the low inspiratory minute volume alarm limit is being violated.

HIGH P

Red LED indicates that the high peak airway pressure alarm limit is being violated.

LOW P

Red LED indicates low peak airway pressure.

18 | FLIGHT 60

Functional Description Ventilator Description

3.1.2

Left Side Panel

Figure 2 – Left Side Panel Label

Name

1

Emergency Air Intake

Description Enables the patient to pull ambient air into the patient circuit in the event of a complete system failure. The Air Intake opening pressure is approximately -3 cmH2O (-3 mbar).

Service Manual | 19

Functional Description Ventilator Description

3.1.3

Right Side Panel

Figure 3 - Right Side Panel Label

Name

Description

1

Fresh Gas Intake and

Environmental air enters through this 30 mm ID Fresh Gas Intake.

Filter Cover

The air inlet particle filter is placed behind the Filter Cover to protect the patient as well as the ventilator’s piston system from dirt and particles. The Fresh Gas Intake also serves as the attachment socket for the optional FLIGHT 60 Ventilator Air/Oxygen Entrainment Mixer or Oxygen Blending Bag.

20 | FLIGHT 60

Functional Description Ventilator Description

3.1.4

Back Panel

Figure 4 – Back Panel

To ensure proper grounding and prevent possible shock hazards, this device should only be connected to grounded power receptacles.

Label

Name

Description

1

Detachable Battery

2

AC Connector with Fuses

100 – 240 V AC, 50 – 60 Hz; Fuses 2x8A (time lag)

3

DC Connector

12 – 15 V DC

4

RS-232 Serial Port (COM2)

Remote alarm connector (Normally Open and Normally Closed options).

5

RS-232 Serial Port (COM1)

Online output of the events and error messages to the PC, using a dedicated PCS2 protocol; for authorized and qualified service technicians only.

6

USB B type

PC connector: USB port for downloading the main application from the PC using a dedicated PCS2 protocol; for authorized and qualified service technicians only.

Service Manual | 21

Functional Description Ventilator Description

Label

Name

7

USB A type

Description USB port for uploading LOG files to an external memory stick; for authorized and qualified service technicians only.

8

LAN (RJ45)

LAN for network logging (currently not available).

9

Mini RS-485 (COM3)

For connecting FLIGHT MEDICAL peripherals. For future use.

3.1.5

Optional Accessories

Air/Oxygen Entrainment Mixer The Air/Oxygen Entrainment Mixer is used to blend atmospheric air with medical grade oxygen at a precise ratio. A control knob allows for incremental adjustment from 0.21 to 1.00 FIO2. The high pressure oxygen hose has a standard female DISS 1240 connection. The Mixer attaches to the Fresh Gas Intake of the FLIGHT 60 Ventilator on the Filter Cover, located on the left side of the ventilator. Pneumatic Requirements: Oxygen 35-90 psig (2.4 to 6.2 Bar)

Figure 5 - High Pressure Oxygen Mixer

22 | FLIGHT 60

Functional Description Ventilator Description

Oxygen Blending Bag Kit The Oxygen Blending Bag Kit is used to blend atmospheric air with a low flow (0 to 10 L/min) medical grade Oxygen source. The Oxygen Blending Bag Kit attaches to the Fresh Gas Intake on the Filter Cover, located on the left side of the ventilator. This system allows the user to ventilate patients with Oxygen enriched gas of up to 100% Oxygen. Pneumatic Requirements: Oxygen 0-10 L/min

Figure 6 - Low Pressure Oxygen Blending Bag

Patient Circuits Reusable (Single Patient) 22 mm ID 180 cm. length adult/pediatric circuit with 2.75 mm ID proximal pressure sensing line, 2.75 mm ID exhalation valve control drive line, 2.75 mm I.D. flow sensing line, exhalation valve, and flow sensing orifice. Single Use 22 mm ID 180 cm. length adult/pediatric circuit with 2.75 mm ID proximal pressure sensing line, 2.75 mm ID exhalation valve control drive line, 2.75 mm I.D. flow sensing line, exhalation valve, and flow sensing orifice.

Service Manual | 23

Functional Description Ventilator Modules

3.2

Ventilator Modules G

A

D B

E

H C

F

Figure 7 – Ventilator Modules

Component

P/N

A

Main board (MB)

V60-60002-65

B

Power board (PB)

V60-21000-65

C

Power supply (PS)

V60-13000-65

D

Manifold assembly

V60-21000-60

E

Solenoid board assembly

V60-26000-65

F

Solenoid assembly

V60-21400-69

G

Oxygen (O2) Sensor

V60-25000-29

H

Purge board

V60-23000-65

24 | FLIGHT 60

Functional Description Pneumatic Diagram

3.3

Pneumatic Diagram

Service Manual | 25

Functional Description Pneumatic Diagram

26 | FLIGHT 60

Functional Description Electrical Diagram

3.4

Electrical Diagram

Service Manual | 27

Removing and Reinstalling Modules Introduction

4 Removing and Reinstalling Modules 4.1

Introduction

This chapter provides detailed procedures on how to remove FLIGHT 60 Ventilator modules and assemblies that you suspect are worn, damaged, or performing improperly, and how to install new or repaired modules and assemblies. Make sure you are familiar with the FLIGHT 60 Ventilator's operation before attempting any service or maintenance. Ventilator log files must be downloaded prior to any service attempt. Refer to Chapter 5 for instructions.

Hazardous voltages are present inside the ventilator. Disconnect electrical power and oxygen sources before attempting any disassembly. Remove watch and any jewelry. Failure to do so may result in injury to service personnel or damage to the ventilator.

4.2

Required Equipment

The following equipment is required to remove and replace FLIGHT 60 ventilator modules:
Antistatic wrist strap
Phillips screwdriver PH1
Flat screwdriver 0.8x4
Torx screwdriver BT10x200
Cutter
Cable ties: PLT1M-M69; PLT4S-M69

To protect external parts and the touch screen from any damage while in contact with the working surface, place the ventilator on a cushioned surface while it is being serviced.

After servicing the ventilator modules, refer to the Test Table, section 6.18 (page 92) and perform the necessary Operation Verification Tests.

28 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Detachable Battery (P/N V60-19000-63)

4.3 4.3.1

Replacing the Detachable Battery (P/N V60-19000-63) Removing the Detachable Battery To remove the detachable battery:

1. Turn the lock dial counterclockwise, in the direction of the OPEN arrow.

Figure 7 – Removing the Detachable (Main) Battery 2. Pull the battery out of the ventilator.

4.3.2

Installing the Detachable Battery To install the detachable battery:

1. Insert the detachable battery into the ventilator. 2. Turn the lock dial clockwise, in the direction of the CLOSE arrow, until it is firmly locked.

4.4 Replacing the Internal Battery (P/N V60-19100-63) 4.4.1

Removing the Internal Battery To remove the internal battery:

1. Remove the four Phillips screws that secure the battery panel to the bottom panel.

Service Manual | 29

Removing and Reinstalling Modules Removing the Ventilator Cover (P/N V60-40000-60)

Figure 8 – Removing the Internal Battery Panel 2. Remove the internal batteries from the battery compartment.

4.4.2

Installing the Internal Battery To install the internal battery:


Follow the above procedure in reverse order.

4.5 4.5.1

Removing the Ventilator Cover (P/N V60-40000-60) Removing the Ventilator Cover

The following procedure describes how to remove the ventilator cover. In most cases the cover must be removed in order to access the ventilator modules. To remove the ventilator cover: 1. Remove the two Torx screws inside the ventilator handle.

30 | FLIGHT 60

Removing and Reinstalling Modules Removing the Ventilator Cover (P/N V60-40000-60)

Figure 9 – Removing Screws Inside Handle 2. Remove the two Torx screws connecting the ventilator cover to the back panel.

Figure 10 – Removing Back Screws 3. Remove the two Torx screws from the bottom panel.

Service Manual | 31

Removing and Reinstalling Modules Removing the Ventilator Cover (P/N V60-40000-60)

Figure 11 – Removing the Bottom Panel Screws 4. Remove the ventilator cover. The modules of the ventilator are now exposed and accessible.

Figure 12 – Removing the Ventilator Cover

Cover screws are longer than the rest of the screws used in the ventilator

32 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Power Board (P/N V60-21000-65)

4.5.2

Installing the Ventilator Cover To reattach the ventilator cover:


Follow the above procedure in reverse order.

4.6 4.6.1

Replacing the Power Board

(P/N V60-21000-65)

Removing the Power Board To remove the power board:

1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Disconnect the flat flex cable P3 from the power board.

Figure 13 – Disconnecting Flat Flex Cable from Power Board 4. Disconnect the 8-pin P2 manifold cable connector from the power board, by pressing the release tab on the connector.

Service Manual | 33

Removing and Reinstalling Modules Replacing the Power Board (P/N V60-21000-65)

. Figure 14 – Disconnecting Manifold Cable Connector P2 from Power Board 5. Disconnect the 4-pin P6 power supply connector from the power board, by pressing the release tab on the connector.

Figure 15 – Removing Power Supply Connector P6 from Power Board 6. Remove the Torx screw connecting the power board to its bracket.

34 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Power Board (P/N V60-21000-65)

Figure 16 – Removing Screw Connecting Power Board to Power Board Bracket

Do not hold the power board by its components. To pull the board out, hold the grooves. Refer to the figure below for correct positioning.

Figure 17 – Lifting Power Board from Ventilator Base

Service Manual | 35

Removing and Reinstalling Modules Replacing the Power Board (P/N V60-21000-65)

7. Holding the board by the grooves, carefully pull the board out by lifting up slightly on one side and then the other, continuing to alternate sides until the board is released from the socket.

4.6.2

Installing the Power Board To install the power board:

1. Check that the power board sockets do not have any bent pins. 2. Slide the power board through the right and left guide tracks, positioning the power board connectors over the sockets.

Right Track Right Slot Left Track

Left Slot

Figure 18 – Power Board Slots and Tracks

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Removing and Reinstalling Modules Replacing the Power Board (P/N V60-21000-65)

Figure 19 – Inserting Power Board into Ventilator Base 3. Firmly push down the power board, making sure that the power board connectors fit well into the sockets (pin headers) in the base of the ventilator.

Figure 20 – Pushing Power Board into Ventilator Base 4. Perform steps 1 to 6 of the removal procedure in the reverse order.

Service Manual | 37

Removing and Reinstalling Modules Replacing the Power Supply (P/N V60-13000-65)

4.7 4.7.1

Replacing the Power Supply (P/N V60-13000-65) Removing the Power Supply To remove the power supply:

1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Reposition the manifold motor cable towards the front and left so that it is out of the way.

Figure 21 – Repositioning the Motor Cable 4. Disconnect the power wiring (total of seven wires) by loosening the Phillips screws.

Figure 22 – Disconnecting the Wiring

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Removing and Reinstalling Modules Replacing the Power Supply (P/N V60-13000-65)

5. Remove the four Torx screws that are securing the power supply bracket (two on each end).

Figure 23 – Detaching the Power-Supply Bracket 6. Remove the power supply.

Figure 24 – Removing the Power Supply

Service Manual | 39

Removing and Reinstalling Modules Replacing the Power Supply (P/N V60-13000-65)

7. Detach the power supply from its bracket by unscrewing the three Phillips screws securing the bracket.

Figure 25 – Detaching the Power Supply from Its Bracket

4.7.2

Installing the Power Supply To install the power supply:


Follow the above procedure in reverse order, paying attention to the following:
The Power-Supply bracket fits under the power board bracket

Figure 26 – Bracket Positioning
Be sure not to apply pressure to the solenoid assembly during this procedure

40 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Power Supply (P/N V60-13000-65)


Connect the wires according to the following diagram: Connection Wire Color -

{unused}

Red

DC Output +V

Black

DC Output

-

{unused}

Yellow; Green; Yellow/green (3 wires)

GND (chassis)

Brown

AC Input

L

Blue

AC Input

N

-V


After reconnecting the power wiring, firmly tighten all 7 Phillips screws in the terminal block, including the unused ones.

Figure 27 – Securing the Power-Supply Screws

Service Manual | 41

Removing and Reinstalling Modules Replacing the Front Panel Assembly

4.8 4.8.1 •

Replacing the Front Panel Assembly Removing the Front Panel Assembly To remove the front panel assembly:

1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Disconnect the flat flex cable P16 from the Main Board.

Figure 29 – Flat Flex Cable going to P16 4. On the underside of the ventilator, unscrew the three Torx screws securing the bottom of the front panel.

Figure 30 – Loosening the Torx Screws Under the Front Panel

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Removing and Reinstalling Modules Replacing the Front Panel Assembly

5. There are 5 silicon tubes going to the main board:


2 connected to the pressure sensors




2 connected to the Solenoid control




1 going to the relief valve Do not disconnect the silicon tubes from the main board (Red and Blue colored connectors).

Mark each tube connection point to the Y connectors so to be able to connect it back to the correct position on assembly. Disconnect the silicon tubes from the Y connectors. 6. Disconnect the flat cable from connector P15 (the flat cable coming from the solenoid board) 7. Remove the Torx screws from the front panel brackets (one on each side). 8. Detach the front panel from the ventilator. 9. Disconnect the cable from the O2 sensor.

Figure 31 – Removing Torx Screws from Front Panel Bracket

4.8.2

Connecting the Front Panel Assembly To connect the front panel assembly:


Follow the above procedure in reverse order.

Service Manual | 43

Removing and Reinstalling Modules Replacing the Main Board (P/N V60-60002-65)

4.9 Replacing the Main Board (P/N V60-60002-65)

When servicing the main board, note that there are LEDs on the outer side of the board.

4.9.1

Removing the Main Board To remove the main board:

1. Follow the procedures for removing the front panel assembly (see section 4.8) 2. Remove the 6 Torx screws holding the board to the front panel 3. On the bottom side of the main board, disconnect buzzer connectors LS1 and LS2. 4. Disconnect the back light cable from connector P5. Do not pull the wires. Press the locker and then remove.

Figure 28 – Figure 29 - Figure 30 – Caption

LS1

P5

LS2

Figure 32 – LS1; LS2; P5 connectors

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Removing and Reinstalling Modules Replacing the Main Board (P/N V60-60002-65)

Figure 33 – Disconnecting LS2 connector 5. Disconnect the P13 flat cable by pressing hard on the locker and then pulling it out.

Figure 34 – Disconnecting the P13 Flat Cable 6. Remove the six Philips screws securing the main board to the front panel.

Service Manual | 45

Removing and Reinstalling Modules Replacing the Main Board (P/N V60-60002-65)

Figure 35 – Detaching the Main Board from the Front Panel 7. Remove the grounding screw at the top left of the board.

Figure 36 – Detaching the Grounding Screw 8. Lift the main board. Carefully detach the narrow and wide flat cables (J4) from their connectors on the main board.

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Removing and Reinstalling Modules Replacing the Main Board (P/N V60-60002-65)

Figure 37 – Removing the J4 Flat Cables 9. Remove the J3 flat cable by clicking the locker on the main board and then pulling out the cable.

Figure 38 – Removing the J3 Flat Cable 10. Remove the main board.

Do not remove the silicon tubes from the main board when it is sent for repair.

Service Manual | 47

Removing and Reinstalling Modules Replacing the Touch Screen (P/N V60-70010-60)

4.9.2

Installing the Main Board To install the main board:

1. Check that the main board sockets do not have any bent pins. 2. Perform the removal procedure in the reverse order.

4.10 Replacing the Touch Screen (P/N V60-70010-60) The touch screen cannot be detached from the front panel; When the touch screen needs replacement , the Front Subassembly (P/N V60-70010-60) is to be replaced 1. Follow the procedures for removing the:
front panel assembly (see section 4.8)
Main Board (see section 4.9) 2. Replace the front Subassembly To reassemble the touch screen:
Perform the above procedure in reverse order.

4.11 Replacing the Manifold Assembly (P/N V60-21000-60) 4.11.1 Removing the Manifold Assembly To remove the maniford assembly: 1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Remove the front panel assembly (see section 4.8) 4. Remove the Power board (see section 4.6) 5. Remove the two Torx screws securing the brackets of the inlet assembly.

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Removing and Reinstalling Modules Replacing the Manifold Assembly (P/N V60-21000-60)

Figure 39 – Detaching the Brackets 6. Disconnect the inlet assembly from the flex tube by pulling out the tube.

Figure 40 – Pulling out the Flex Tube 7. Disconnect the muffler assembly by cutting the two cable ties

Service Manual | 49

Removing and Reinstalling Modules Replacing the Manifold Assembly (P/N V60-21000-60)

Figure 41 – Cutting the Cable Ties 8. Gently pull the muffler out of the short flex tube, and put it aside.

Figure 42 – Removing the Muffler 9. Disconnect the flex tube going to the outlet assembly from the manifold assembly’s "L"-shaped white connector.

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Removing and Reinstalling Modules Replacing the Manifold Assembly (P/N V60-21000-60)

10. Disconnect the silicon tubes from the solenoid.

Figure 43 – Disconnecting the Flex Tubes 11. Release the Manifold power cord from the wire saddles. 12. Remove the six Torx screws from the manifold base (three on each side).

Figure 44 – Detaching the Manifold Base 13. Carefully lift out the manifold assembly.

Service Manual | 51

Removing and Reinstalling Modules Replacing the Manifold Assembly (P/N V60-21000-60)

Figure 45 – Removing the Manifold Assembly

Before sending the manifold assembly to FLIGHT MEDICAL, remove the short and long flex tubing.

4.11.2 Installing a Manifold Assembly To install a manifold assembly:
Perform the removal procedure in the reverse order, with the following additional step after inserting the muffler assembly, which is helpful for getting the cable ties through their slots:
Insert the detachable battery until it is almost completely in, and then assemble the cable ties through the slots under the muffler.
If a new manifold was installed, run PCS downloader to update the manifold serial number and reset working hours. See section 5.2.

52 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Oxygen Sensor (P/N V60-25000-29)

Figure 46 – Assembling Cable Ties

4.12 Replacing the Oxygen Sensor (P/N V60-25000-29) 4.12.1 Removing the Oxygen Sensor To remove the oxygen sensor: 1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Remove the front panel (see section 4.8). 4. Disconnect the electrical cable from the oxygen sensor.

Figure 47 – Removing the Oxygen Sensor

Service Manual | 53

Removing and Reinstalling Modules Replacing the Purge Board Assembly (P/N V60-23000-65)

5. Turn the oxygen sensor until it comes out.

4.12.2 Installing the Oxygen Sensor To install the oxygen sensor:
Follow the above procedure in reverse order.

4.13 Replacing the Purge Board Assembly (P/N V60-23000-65) 4.13.1 Removing the Purge Board Assembly To remove the purge board assembly: 1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Remove the front panel (see section 4.8). 4. Disconnect the two check valves at the ends of the silicon tubes from the purge board.

Figure 48 – Disconnecting the Check Valves 5. Remove the four Philips screws (star washers and flat washers) from the purge board. Carefully remove the stand-offs between the purge board and the solenoid board. 6. Carefully separate (pull out) the purge board from the connector on the solenoid board.

54 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Solenoid Board Assembly (P/N V60-26000-65)

4.13.2 Installing the Purge Board Assembly To install the purge board assembly:
Follow the above procedure in reverse order.

4.14 Replacing the Solenoid Board Assembly (P/N V60-26000-65) 4.14.1 Removing the Solenoid Board Assembly To remove the solenoid board assembly: 1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Remove the front panel (see section 4.8). 4. Remove the purge board (see section 4.13). 5.

Disconnect connector P1 and the flat cable from the solenoid board.

Figure 49 – Solenoid board connectors 6. Remove the silicon tubes from the fittings on the redundancy solenoid.

Service Manual | 55

Removing and Reinstalling Modules Replacing the Solenoid Board Assembly (P/N V60-26000-65)

Figure 50 – Removing the Silicon Tubes 7. Remove the solenoid board assembly.

4.14.2 Installing the Solenoid Board Assembly To install the solenoid board assembly: 1. Insert the solenoid assembly. 2. Insert the purge board assembly. 3. Connect the silicon tube attached to the female connector to the inner fitting on the redundancy solenoid. 4. Using the other silicon tube, connect the Solenoid assembly to the outer fitting on the redundancy solenoid.

Figure 51 – Connecting the Silicon Tubes

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Removing and Reinstalling Modules Replacing the Solenoid Assembly (P/N V60-21400-69)

4.15 Replacing the Solenoid Assembly (P/N V60-21400-69) 4.15.1 Removing the Solenoid Assembly To remove the solenoid assembly: 1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Follow the first three steps of the procedure for removing the front panel (see section 4.8), and pull the cover towards you as far as possible. (There is no need to remove the cover/panel completely.)

Figure 52 – Pulling the Cover/Panel Towards You 3. Disconnect the solenoid cable from the solenoid board (P1). Check that it is hanging freely and not tangled with other device components.

Figure 53 – Disconnecting the Solenoid Cable

Service Manual | 57

Removing and Reinstalling Modules Replacing the Solenoid Assembly (P/N V60-21400-69)

4. Disconnect the 3 silicon tubes from the solenoid assembly.

Figure 54 – Disconnecting Silicon Tubes 5. Unscrew the two adjacent Torx screws on the solenoid bracket.

Figure 55 – Detaching the Solenoid Bracket 6. Pull out the solenoid assembly.

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Removing and Reinstalling Modules Replacing the Lower Board (P/N V60-22000-65) and D-type Board (P/N V60-24000-65)

Figure 56 – Removing the Solenoid Assembly

4.15.2 Installing the Solenoid Assembly To install the solenoid assembly:
Follow the above procedure in reverse order.

4.16 Replacing the Lower Board (P/N V60-22000-65) and D-type Board (P/N V60-24000-65) 4.16.1 Removing the Lower Board and D-type Board To remove the Lower and D-type boards: 1. Remove the detachable battery (see section 4.3) and the internal battery (see section 4.4). 2. Remove the ventilator cover (see section 4.5). 3. Remove the front panel assembly (see section 4.8). 4. Remove the Power board (see section 4.6) 5. Remove the Power Supply (see section 4.7) 6. Remove the Manifold assembly (see section 4.11)

Service Manual | 59

Removing and Reinstalling Modules Replacing the Lower Board (P/N V60-22000-65) and D-type Board (P/N V60-24000-65)

7. Unscrew the 4 Torx screws securing the Power Supply base plate. Remove the Power Supply base plate.

Figure 57 – Removing the Power-Supply base plate 8. Unscrew the 2 Torx screws (plastic washers) securing the Outlet assembly. Remove the Outlet assembly.

Figure 58 – Removing the Outlet assembly

60 | FLIGHT 60

Removing and Reinstalling Modules Replacing the Lower Board (P/N V60-22000-65) and D-type Board (P/N V60-24000-65)

9. Disconnect connectors P5, P6 and P7 from the lower board

Figure 59 – Disconnecting P7 connector 10. Unscrew the 6 Philips screws securing the lower board and 2 Philips screws securing the D-type board 11. Gently lift the back side of the lower board and pull the lower board with D-type board out of the ventilator base

Figure 60 – Removing the Lower Board and D-type Board

Service Manual | 61

Removing and Reinstalling Modules Replacing the Fuse

12. Disconnect the D-type board from the Lower board

D-type Board

Lower Board

Figure 61 – D-type and Lower boards

4.16.2 Installing the Lower Board and D-type Board To install the Lower and D-type boards:
Follow the above procedure in reverse order.

4.17 Replacing the Fuse The fuse does not need regularly-scheduled servicing. Servicing is required only in case of a problem.

4.17.1 Removing the Fuse To remove the fuse: 1. Pull out the plastic fuse housing at the back of the device with the aid of a flat screwdriver.

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Removing and Reinstalling Modules Replacing the Fuse

Figure 62 – Removing the Fuse

4.17.2 Installing the Fuse To install the fuse: Reposition the fuse housing (flat edge on the left) and press firmly to make sure that it is inserted completely.

Figure 63 – Connecting the Fuse

Service Manual | 63

Removing and Reinstalling Modules Replacing the Rubber Bumpers (P/N G01-00001-67)

4.18 Replacing the Rubber Bumpers (P/N G01-00001-67) The six bumpers on the underside of the device do not need regularly-scheduled servicing. Servicing is required only in case of a problem.

4.18.1 Removing the Rubber Bumpers To remove bumpers: 1.

Use a Torx screwdriver to remove bumpers as needed.

Figure 64 – Removing a Rubber Bumper

4.18.2 Installing the Rubber Bumpers To install a bumper: Use a Torx screwdriver to attach the bumper and verify that it is fastened securely.

64 | FLIGHT 60

Software Management Downloading System Log Files

5 Software Management This chapter provides instructions on storing system log files and loading the software required for operating the device.

5.1

Downloading System Log Files

Log files can be saved on a FAT formatted USB mass storage device. 1. Press Technical and then press Go to More. 2. Enter the code 5844, and confirm by pressing




3. Insert the USB mass storage device to the USB connector on the back of the ventilator. Log files will download automatically.

5.2

Loading Software

Three types of software can be loaded into the ventilator:
PCS
Main CPU
Panel CPU Loading of PCS software is done through the USB B-type connector, located on the back of the ventilator. The Main CPU and Panel CPU software is loaded directly to the Main Board; the ventilator's cover should be removed for this purpose.

5.2.1

PCS

Required equipment:
USB cable with A-type and B-type connectors
Computer (WinXP SP3 Operating system) with PCS download application installed PCS is loaded in two cases:
After manifold replacement, to update the serial number and reset working hours
To update PCS version Service Manual | 65

Software Management Loading Software

• To load PCS 1. Go to Technical, press Show Info and write the number showing in Unit serial number, Compressor serial number and Hour Meter 2. Use the USB cable to connect the computer to the ventilator. 3. Copy the version to be uploaded to the folder C:\Program Files\PCS2Downloader\Dbase. 4. Launch the PCS2downloader application.

5. Click the folder icon

.

Choose the folder in C:\Program Files\PCS2Downloader\Dbase .

6.

Choose the *.dwn file from the folder.

66 | FLIGHT 60

Software Management Loading Software

7.

Highlight the version to be loaded, click the

icon.

The Program Card window opens. •

To update Manifold S/N and reset the Hour Meter continue to 5.2.1.1.

•

To Update PCS version go to 5.2.1.2.

5.2.1.1 Update the Manifold S/N and Reset the Hours Meter 1. Perform steps 1-7 of load PCS above. Verify that the boxes Upload Grid First, Download Grid and Download NV on the Program Card are NOT checked. 2. To reset Hours Meter - change the Values column of lPumpHours to 0.

Service Manual | 67

Software Management Loading Software

3. Place the cursor on the Values column in the szPumpSN row.

4. Click the left mouse button. A new window opens:

5. Type the serial number of the manifold in the right. Verify the numbers in "Value" on the left are updated accordingly. 6. Click the

icon.

7. Repeat steps 3-6 for the szSystemSN. Type the Unit Serial Number copied from the show info screen

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Software Management Loading Software

8. click the icon (see print-screen below). Verify Done downloading values Message at the bottom left of the application.

9. Check the show info window and verify that Unit serial number, Compressor serial number are correct and Hour Meter is zero.

5.2.1.2

Update the PCS version Updating PCS version overrides all calibration values. A complete OVP must be performed after the update

1. Perform steps 1-7 of load PCS. Check the Download Grid and Download NV checkboxes in the Program Card.

Service Manual | 69

Software Management Loading Software

2. Perform steps 3-7 of paragraph 5.2.1.1 to input the szSystemSN and szPumpSN with the numbers obtained from the show info screen 3. Update lPumpHours with the Hour Meter reading obtained from the show info screen

4. click the icon (see print-screen below). Verify File Download Complete! Message at the bottom left of the application.

5. The ventilator buzzer will start to alarm. Restart the ventilator 6. Check the show info window and verify that PCS in S/W Version is updated and Unit serial number, Compressor serial number and Hour Meter are correct. 7. Perform all OVP tests and calibrate the ventilator.

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Software Management Loading Software

5.2.2

Main CPU

Required equipment:
Jlink JFlash programmer (By Segger)
Computer with J-Flash application To load the Main CPU Software: 1. Power off the ventilator. 2. Remove the ventilator cover (see section 4.5). 3. Power up the ventilator. 4. Connect the programmer to the computer's USB connector. 5. Connect the programmer to connector P18 on the Main Board. 6. Launch the J-flash application on the computer. 7. Choose File

Open project. Highlight the file name and click Open.

8. Choose File

Open data file.

The Open data file window opens.

Service Manual | 71

Software Management Loading Software

9. Choose MainCPU. Then click Open. The following window opens:

10. Click OK. 11. Press F7. The following message appears:

12. Click Yes. Updates are loaded.

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Software Management Loading Software

A status message appears to let you know that the update is complete. 13. Click OK, and press F9.

5.2.3

Panel CPU

Required equipment:
Jlink programmer
Computer with the J-Flash application installed To load the Panel CPU Software: 1. Power off the ventilator. 2. Remove the ventilator cover (see section 4.5). 3. Power up the ventilator. 4. Connect the programmer to the computer's USB connector. 5. Connect the programmer to connector P9 on MB. 6. Launch the J-flash application on the computer.

Service Manual | 73

Software Management Loading Software

7. Choose File

Open project.

8. Highlight the file name and click Open. 9. Choose File

Open data file.

The Open data file window opens.

10. Select PanelCPU. 11. Proceed as instructed in steps 9-13 of the procedure for Main CPU, above.

74 | FLIGHT 60

Operation Verification Procedure (OVP) Loading Software

6 Operation Verification Procedure (OVP) The following verification procedure is to insure that the ventilator is calibrated and performing as per the specifications.
Front Panel Self Test
Pressure Sensors Calibration
Pressure Relief Calibration
Volume Factor Calibration
Circuit Test
Pressure Verification
Pressure verification
PEEP
Pressure Trigger
Exhalation Valve Leak
High Pressure Alarm
Battery / Charger / Power Supply
Inlet Leak
Buzzer Test
Oxygen Sensor

Service Manual | 75

Operation Verification Procedure (OVP) Required Equipment

6.1

Required Equipment

Required equipment includes:


Adult test lung specified up to 90cm H2O with adjustable lung compliance




Pressure meter, range to 120cm H2O, accuracy of 0.1 cmH2O (Note that this is not required if the adult test lung has autonomous pressure-measuring capability)




Syringe, 20-50ml




Screwdrivers: Phillips screwdriver PH1 Flat screwdriver 0.8x4 Torx screwdriver BT10x200




Reusable patient circuit (P/N V60-50000-60)




Vacuum gauge, range to -1bar




Oxygen Analyzer




Parabolic resistors: Rp5, Rp20 and Rp50




Medical-grade Oxygen source (pressure over 50PSI)

6.2

Standard Ventilator Settings (STS)

Refer to the following specifications whenever STS settings are called for:


ACMV




VCV = 500 mL




PEEP = 0




P trig = -1.0




f = 15




Ti = 1




Waveform = Square

For test lung:


Rp=5




C = 50 mL / cmH2O

76 | FLIGHT 60

Operation Verification Procedure (OVP) Front Panel Self Test

6.3

Front Panel Self Test To run the self test:

1.

Connect the ventilator to AC power.

2. Press the On/Off button on the front panel. 3. During the self test that begins automatically, check for the following:
Short audible beep
All LEDs on the LED indicator light up with the same intensity, with the following colors: Description

Colour

TRIG (Pressure trigger)

Green

EXT PWR (External power)

Yellow

LOW BAT (Low battery)

Red

BAT (Battery power)

Orange

FAULT (Device malfunction)

Red

APNEA

Red

BUV (Back up ventilation)

Red

HIGH MV (High minute ventilation)

Red

LOW MV (Low minute ventilation)

Red

High P (High pressure)

Red

LOW P (Low pressure)

Red

Audio Paused/Alarm Reset

Orange

On/Off

Green

Panel Lock

Orange


All LEDs between 60 – 100 on the pressure gauge light up.

If the test fails: No LEDs are on - Check the internal connectors to the front panel. Some LEDs are on - Replace the Main Board (see section4.9)

Service Manual | 77

Operation Verification Procedure (OVP) Pressure Sensors Calibration

6.4

Pressure Sensors Calibration To calibrate the pressure sensors:

STAGE 1 1.

Connect the reusable patient circuit to the test lung

2. Use the following settings for the test lung:
C = 10
Rp = 5

3. If a test lung with analysis software is used, configure the analysis software program to the same settings STAGE 2 1. Press Technical and then press Go to More. 2. Enter the code 5844, and confirm by pressing


.

3. Press Calibrate Pressure and then Enter to start the motor. 4. Follow the instructions which appear on the display. The values of the two Pressure Sensors appear on the screen:

5. Use the UP and DOWN buttons to match the External measurement value measured either by the pressure meter or the test lung External measurement should be between 50 and 75 cmH2O. 6. Press Enter to confirm this reading and to complete the calibration.

STAGE 3 1. Repeat the steps in STAGE 2, recording the Patient Pressure and Outlet Pressure readings 78 | FLIGHT 60

Operation Verification Procedure (OVP) Pressure Sensors Calibration

The two values should not differ by more than 0.1 cmH2O. If the difference is 0.1 cmH2O or less, press Cancel to complete the process of verifying the calibration precision.

If the test fails: 1. Replace patient circuit and redo calibration. 2. Do one of the following:
If the external measurement lower than 50: Check internal tubing connections for air leaks. Replace the solenoid and redo calibration.
If the external measurement higher than 75: Check internal tubing connections for blocking. Replace the solenoid and redo calibration.
If the patient pressure / outlet pressure difference is more than 0.1cmH2O: Repeat the calibration up to 3 times. If the desired results are not obtained after three attempts: 

Examine the silicon tube connections and try to locate a leak.



Verify that the relief valve is not activated.



Replace the solenoid (see section 14). Perform the required calibrations (see section 6.18).



Replace the Main Board (see section4.9). Perform the required calibrations (see section 6.18).

Service Manual | 79

Operation Verification Procedure (OVP) Pressure Relief Calibration

6.5

Pressure Relief Calibration To calibrate the pressure-relief mechanism:

1. Connect the ventilator to the test lung 2. Set the test lung to minimum compliance 3.

Press Technical and then press Go to More.

4. Enter the code 5844, and confirm by pressing


.

5. Press Calibrate Relief and then Enter to start the motor and increase pressure. 6. Follow the instructions which appear on the display. The pressure measurements are displayed. 7. Verify that there is no air leakage from the exhalation valve. Air should only be coming out via the pressure-relief valve. 8. Verify that the displayed pressure reading is between 105 and 115 cmH2O. 9. If the pressure is not within this range, need to adjust the Relief valve. The relief valve adjustment needs to be done when the ventilator is in a working position on a horizontal surface.
Place the ventilator on a table, close to the edge.
Rotate the ventilator in a way that the front left rubber pad deviates from the table, the ventilator only rests upon 3 bumpers, and the calibration screw is accessible from below (Refer to figure 31 below).
Break the RTV that secures the calibration screw.
Use a Philips screwdriver to adjust the relief valve by tightening or loosening the calibration screw located on the underside of the outlet fitting.

Figure 31 –Adjusting the Pressure Relief Valve

80 | FLIGHT 60

Operation Verification Procedure (OVP) Volume Factor Calibration

10. Press Enter to confirm the reading and to complete the calibration. Press Cancel to discontinue the calibration.

If the calibration screw on the pressure-relief valve was adjusted, repeat the calibration of the pressure sensors (section 5.4).

If the test fails:
Check internal tubing connections.

6.6

Volume Factor Calibration

To calibrate the volume factor: 1. Press Technical and then press Go to More. 2. Enter the code 5844, and confirm by pressing


.

3. Press Volume Factor and follow the instructions which appear on the display. Note: Connect the RP50 resistor to the edge of the flow orifice (nostril) and leave the other end of the resistor exposed to the open air, verifying that it is not blocked in any way. 4. After pressing "Enter" the ventilator will run volume factor calibration and display the volume factor value on the screen. The volume factor value should be between 0.9 and 1.1. If value is out of range, return to step 1. The test can be repeated up to a total of three times. 5. Repeat the test again and verify that the volume factor values of both tests are the same. If not repeat the test until 2 consecutive matching volume factor values are achieved. The test may be repeated up to 10 times. 6. Set the ventilator to STS. 7. Activate the ventilator and verify that the volume is between 450 and 550ml. If not, recalibrate the volume factor and check again. 8. Press Enter to exit from Volume Factor Calibration mode.

If the test fails: 1.

Check internal tubing connections for air leaks.

2. Run the following tests:

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Operation Verification Procedure (OVP) Circuit Test


Pressure sensor calibration
Solenoid / valve calibration
Pressure relief calibration
Volume factor calibration If Volume Factor is still out of spec, Replace the manifold (see section 4.10). Perform the required calibrations (see section 6.18).

6.7

Circuit Test Each time the Exhalation Valve or patient circuit is replaced or serviced, it must be tested.

To test the patient circuit / exhalation valve: 1.

Connect the patient circuit to the test lung. Set the lung to:
Rp=5
C=20

2. Press Technical, and then press Circuit TEST.

3. Press Enter.

4. The test is done automatically. It includes the following 3 steps:

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Testing the motor



Finding Test Points: six calibration points displayed. Check that the first (leftmost) value is 30 ±3.



Verifying

Operation Verification Procedure (OVP) Pressure gauge verification

If the results are acceptable, the display reads Test completed

If the test fails: 1. Press Cancel. 2. Replace the patient circuit. 3. Perform the calibration again. 4. Check internal tubing connections for air leaks. 5. Replace the solenoid (see section 4.14), and perform the required calibrations (see section 6.18).

6.8

Pressure gauge verification To test the pressure gauge:

1. Connect the ventilator to the test lung 2. Navigate to the Parameters screen. 3. Press High P Alarm. 4. Set the pressure to the maximum value of 99 cmH2O. 5. Adjust the ventilator settings to the following values:
PEEP = 0
f = 15
Ti = 2
ACMV
PCV = 20 6. Start ventilation 7. Check that 16 green LEDs in the -10 to 20 range are lit. 8. Check that the pressure readings on the ventilator and on the test lung are 20 cmH2O (± 1). 9. Press PCV, and adjust the pressure to 40 cmH2O. 10. Check that 16 green LEDs and 4 orange LEDs in the -10 to 40 range are lit. 11. Check that the pressure readings on the ventilator and on the test lung are 40 cmH2O (± 4). 12. Press PCV, and adjust the pressure to 60 cmH2O. 13. Check that 16 green LEDs, 4 orange LEDs and 3 red LEDs in the -10 to 60 range are lit.

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Operation Verification Procedure (OVP) Pressure Verification

14. Check that the pressure readings on the ventilator and on the test lung are 60 cmH2O (± 6). 15. Set the test lung to C = 10, and connect an RP5 resistor. 16. Start ventilating using the following settings:
PEEP = 0
f = 15
Ti = 1.2
ACMV
VCV = 1.20 17. The High Pressure alarm will sound. 18. Check that 16 green LEDs, 4 orange LEDs and 7 red LEDs in the -10 to 100 range are lit. 19. Check that the pressure readings on the ventilator and on the test lung are 100 cmH2O (± 10).

If the test fails: If the pressure reading is below target:
Redo pressure relief calibration. If the pressure reading is correct but LED doesn't light up: 1. Replace the Main Board (see section 4.9). 2. Perform the required calibrations (see section 6.18).

6.9

Pressure Verification To test the device for pressure:

1. Set the ventilator to STS settings. 2. Connect the ventilator to the test lung. 3. Use the following settings for the test lung:
C = 50
Rp = 5
If a test lung with analysis software is used, configure the analysis software program to the same settings

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Operation Verification Procedure (OVP) PEEP

4. Activate ventilation. 5. Set Ti = 2. 6. Check that the Pressure reading, measured either by the pressure meter or the analysis software, and the ventilator differ by no more than 2 cmH2O or 10%. (The higher of the two can be used for this determination.)

If the test fails: Repeat the following:
Pressure sensors calibration
Pressure relief calibration
Volume factor calibration
Solenoid / valve calibratio

6.10 PEEP To test the PEEP: 1. Use the following settings for the test lung:
C = 50
Rp = 5
If a test lung with analysis software is used, configure the analysis software program to the same settings 2. Connect the ventilator to the test lung. 3. Set the ventilator to STS settings. 4. Set PEEP to 5. 5. Activate ventilation. 6. After 5 breaths, check that the basic pressure levels in the lung and in the ventilator display are 5 ±1 cmH2O. 7. Raise the P trig level as needed, until no auto-triggering is observed. 8. Verify that the P trig level is not lower than -1.5 cmH2O, and that the ventilator is not performing an auto-trigger. 9. Set PEEP to 10.

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Operation Verification Procedure (OVP) Pressure Trigger

10. After five breaths, check that the basic pressure levels in the lung and in the ventilator display are 10 ±2 cmH2O. 11. Raise the P trig level as needed, until no auto-triggering is observed. 12. Verify that the P trig level is not lower than -2 cmH2O 13. Set PEEP to 20. 14. After five breaths, check that the basic pressure levels in the lung and in the ventilator display are 20 ±2 cmH2O. 15. Raise the P trig level as needed, until no auto-triggering is observed. 16. Verify that the P trig level is not lower than -3 cmH2O.

If the test fails: 1. Replace the patient circuit. 2. Repeat Solenoid / valve calibration. 3. Replace the solenoid (see section 4.14), and run the required calibrations (see (see section 6.18).

6.11 Pressure Trigger To test the pressure trigger: 1.

Set the ventilator to STS

2. Connect the ventilator to the test lung. Use the following settings for the test lung:
C = 50
Rp = 5 3. Activate ventilation. 4. Initiate inhalation by slightly raising the edge (shoulder) of the test lung to create negative pressure of at least 1.0 cmH2O. 5. Verify that the green P trig LED flashes and a mandatory breath is forced each time the edge (shoulder) is raised. 6. Change settings to:
SIMV
PSV = 20
f = 5.

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Operation Verification Procedure (OVP) Exhalation Valve Leak

7. Initiate inhalation by slightly raising the edge (shoulder) of the test lung to create negative pressure 8. Verify that the green P trig LED flashes and that the ventilator provides a mandatory breath followed by pressure-supporting ventilations (PSV) for 12 seconds. 9. Set the P trig level to 0.2 cmH2O, and verify that no auto-triggering occurs.

If the test fails: 1. Replace the patient circuit. 2. Repeat the following:
Pressure sensors calibration
Pressure relief calibration
Volume factor calibration
Solenoid / valve calibration 3. Replace the solenoid (see section 4.15), and perform the required calibrations (see section 6.18).

6.12 Exhalation Valve Leak To test the exhalation valve:

Use a single-use patient circuit for this test.

1. Set the ventilator to the following settings:
f = 10
Ti = 1.4
ACMV
VCV = 1.4L 2. Set the High-Pressure alarm to 99 cmH2O. 3. Connect the ventilator to a test lung. Use the following settings for the lung:
C = 20
Rp = 20

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Operation Verification Procedure (OVP) High Pressure Alarm

4. When the ventilator is in this state, a pressure level of 90 cmH2O should be observed. 5. Activate ventilation and continue for 15 breaths. 6. Verify that the pressure level is over 72 cmH2O. 7. Check for air flow from the underside of the Exhalation Valve during inhalation; If air flow is noticed (check either by hearing or by feeling air flow on your palm) there is a leak and the test fails.

If the test fails: 1. Replace the patient circuit. 2. Repeat the following:
Pressure sensors calibration
Pressure relief calibration
Volume factor calibration
Solenoid / valve calibration 3. Replace the solenoid (see section 4.15), and perform the required calibrations (see section 6.18)

6.13 High Pressure Alarm To test the high-pressure alarm: 1.

Set the ventilator to STS settings

2.

Connect the ventilator to a test lung. Use the following settings for the lung:
C = 20
Rp = 5

3. Activate ventilation. 4. Set HIGH P to 10 cmH2O. 5. Check that when the pressure reaches 10 cmH2O, the following occurs:
the audible alarm is triggered
the visual alarm is triggered
inhalation is interrupted.

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Operation Verification Procedure (OVP) Battery /Charger /Power Supply

6. Set HIGH P to 60 cmH2O. 7. Check that the following occurs:
the audible alarm is silenced automatically
the visual alarm is displayed until the Alarm Reset button is pressed.

If the test fails: 1. Replace the Main Board (see section 4.9). 2. Perform the required calibrations (see section 6.18).

6.14 Battery /Charger /Power Supply •

To test the power supply:

Verify that both batteries are at 100% on the display. If not, connect to external power for charging for at least 3 hours.

1. Disconnect the ventilator from AC power 2. Verify that the following occur:
the Power Switchover indicator is displayed
an audible beep is heard
the EXT PWR indicator is not lit (external power)
the battery (BAT) LED indicator is lit

3. Verify that the ventilator functions normally with no further alarms. 4. After at least 90 seconds have passed, reconnect to AC power. 5. Verify that within 30 seconds of the connection time the ventilator indicates switching back to AC power.

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Operation Verification Procedure (OVP) Inlet Leak

6. Verify that the following occur:
the battery (BAT) LED indicator is off
the green EXT PWR is lit

6.15 Inlet Leak To test the inlet leak: 1.

Set the ventilator to STS settings.

2.

Connect the ventilator to a test lung. Use the following settings for the lung:


C = 20




Rp = 5

3. Verify that the three screws securing the filter cover are tight, to insure that air leakage is prevented. 4. Connect a vacuum meter to the air inlet. 5. Activate ventilation. The vacuum reading should be no greater than -0.16 (negative 0.16) Bar at the end of expirium. If it is greater, this indicates a leak.

During expiration, a decrease in the vacuum meter’s negative pressure is normal.

If the test fails: 1. Tighten the screws locking the filter cover. 2. Replace the filter. 3. Remove the filter cover and check the O-ring. 4. Check the Inlet-to-muffler connection for a leak.

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Operation Verification Procedure (OVP) Buzzer Test

6.16 Buzzer Test To test the buzzer:
Check the buzzer mechanism by comparing the Low and High states, to verify that a louder sound is heard for the high alarm state than for the low one.

6.16.1 High-level Alarm 1.

Press Extended and then press Buzzer.

2. Select High. 3. Connect the ventilator to an AC source. Press On and verify that a beep is audible during startup. 4. Activate ventilation. 5. Disconnect the AC cable during ventilation, and check for the following:
there should be an audible beep
the display should read Power Switchover. 6. Press Alarm Reset to turn off the alarm. The ventilator should continue running on battery power. 7. Turn the ventilator off. 8. Verify that you hear 2 beeps followed by a constant alarm. Press Alarm Reset to turn the alarm off.

6.16.2

Low-level Alarm

1. Connect the ventilator to an AC source. 2. Connect the ventilator to a test lung 3. Begin ventilation. 4. Press Extended and then press Buzzer. 5. Select High. 6. Disconnect the patient circuit from the Airway Pressure connector on the Outlet, and check for an audible beep. 7. Reconnect the tube; the beep should no longer be heard. 8. Press Extended and then press Buzzer. 9. Select Low. 10. Disconnect the Patient circuit from the Airway Pressure connector on the Outlet, and check that the audible beep is softer (lower) than when it was set to High.

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Operation Verification Procedure (OVP) Oxygen Sensor

11. Reconnect the tube; the beep should no longer be heard.

If the test fails:
Replace the Main Board (see section 4.9), and perform the required calibrations (see section 6.18).

6.17 Oxygen Sensor 6.17.1 Oxygen Sensor Calibration •

To calibrate the O2 sensor:

1.

Connect the Air/Oxygen Entrainment Mixer to an Oxygen source. Install the Air/Oxygen Entrainment Mixer on the ventilator’s air inlet.

2.

Set the regulator on the oxygen source to 50 PSI.

3.

Connect a calibrated Oxygen Analyzer to the ventilator's outlet.

4.

Set the Oxygen mixer dial to Air.

5. Press Technical, and then press Go to More. 6.

Enter the code 5844, and confirm by pressing
.

7.

Press Calibrate FiO2.

Follow the instructions that appear on the display.

6.17.2 Oxygen Sensor Test •

1.

To test the O2 sensor:

Press Extended and then press FiO2.

2. Select ON. 3. Set the Low FiO2 and the High FiO2 alarm to OFF. 4. Connect the patient circuit via a calibrated Oxygen Analyzer to the test lung.

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Operation Verification Procedure (OVP) Test Table

5. Connect the Air/Oxygen Entrainment Mixer to an Oxygen source. Install the Air/Oxygen Entrainment Mixer on the ventilator’s air inlet. 6. Set the regulator on the oxygen source to 50 PSI. 7. Set the ventilator to the following settings:
ACMV
Volume Control = 1.0
f = 20
Ti = 1
Rp = 20 8. Set the Oxygen mixer dial to Air, and check that the display of FiO2 percent ranges between 20.9% and 29%. 9. Set the Oxygen mixer dial to 40, and check that the display of FiO2 percent ranges between 32% and 48%. 10. Set the Oxygen mixer dial to 60, and check that the display of FiO2 percent ranges between 52% and 68%. 11. Set the Oxygen mixer dial to 80, and check that the display of FiO2 percent ranges between 72% and 88%. 12. Set the Oxygen mixer dial to 100, and check that the display of FiO2 percent ranges between 92% and 100%.

If the test fails: 1. Check for an inlet leak (see section 6.15). 2. Replace the sensor cable. 3. Replace the sensor. 4. Replace the Main Board (see section4.9) and perform the required calibrations (see section 6.18).

6.18 Test Table The following table summarizes tests associated with each device module. When a module is replaced, All tests associated with the replacement must be performed before the ventilator is used again.

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Operation Verification Procedure (OVP) Test Table

Test

Module Front panel Pressure sensor Pressure relief valve






















Detachable Internal Power Power Front Main Manifold Oxygen Purge Solenoid Solenoid Fuse battery battery board supply panel board sensor board board








































Pressure gauge verification




Volume Factor











Solenoid exhalation valve














































Pressure verification PEPP




























Pressure trigger
































































Pressure support Exhalation valve leak High pressure alarm Power supply & battery charge Inlet leak test Alarm buzzer Oxygen sensor

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Maintenance Test Table

7 Maintenance MANIFOLD – The manifold should be replaced after every 15,000 hours of operation. For instructions on changing the manifold, see section 4.11. FILTER – Check the filter's condition whenever servicing the ventilator. OXYGEN (O2) SENSOR – Replace once a year

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Troubleshooting Guide Introduction

8 Troubleshooting Guide 8.1

Introduction

The FLIGHT 60 Ventilator is used in life-support situations. As such, it is essential that all individuals using the FLIGHT 60 Ventilator, including clinicians and support staff, have a thorough understanding of its operation. This should include a working knowledge of the ventilator's pneumatic and electronic systems. The following practical troubleshooting section is provided as a training resource for individuals learning how to use the FLIGHT 60 Ventilator, and as a reference tool for those already familiar with its use and operation. It should be noted that this outline is not all inclusive, and is intended only as a guide.

Only properly trained personnel should operate the ventilator. The FLIGHT 60 Ventilator is a restricted medical device designed for use by Respiratory Therapists or other properly trained and qualified personnel under the direction of a physician and in accordance with applicable state laws and regulations.

8.2

Error Messages

Displayed error

Potential Cause

Suggested Action

FIO2 HIGH / LOW

Oxygen sensor bad reading

Run Oxygen sensor calibration

Oxygen sensor defective

Replace Oxygen sensor

Problem in the proximal line.

Check internal hoses connections

Pressure sensors is improperly

Pressure Sensors Calibration

PROX LINE

calibrated or defective.

FLOW SENSOR ERROR

Processor defective

Replace Main Board

Replace Main Board

Processor communication problem EMPTY BAT

Main battery is less than 20%

Connect to AC (charging) for 3 hours

Secondary battery is less than

Replace Power Board

50%

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Troubleshooting Guide Error Messages

Displayed error

Potential Cause

Suggested Action

HIGH MV INS

Air leakage

Check internal hoses connections

HIGH MV EXH

Calibration problem

Check internal hoses connections

Hardware problem

Perform Volume factor calibration Replace Main Board Replace manifold

HIGH / LOW P BASE

Solenoid malfunction

Check solenoid Perform Exhalation Valve calibration Replace solenoid

PCV NOT REACHED

LOW MV EXH

MOTOR FAULT

PRESS SENSOR

Calibration problem

Perform Volume Factor calibration

Hardware problem

Replace manifold

Air leak

Check internal hoses connections

Hardware problem

Replace Main Board

Motor control

Replace Power Board

Motor

Replace manifold

Patient pressure sensor higher than outlet

POWER FAULT

Perform Pressure sensors calibration Replace Main Board

Check log file to identify failed power:

3.3V POWER FAULT

Replace Main Board

MAIN BOARD 10V POWER FAULT

Check cables Replace Power Board Replace Main Board

POWER BOARD 10V POWER FAULT

MEMORY FAULT

Check cables Replace Power Board

5V POWER FAULT

Replace Main Board

Parameters mismatch

Perform OVP Replace Main Board

MAIN BAT CHARGER

Charger malfunction

Replace battery Replace Power Board

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Troubleshooting Guide Error Messages

Displayed error

Potential Cause

Suggested Action

MAIN BAT V HIGH / LOW

Out of range

Replace battery Replace Power Board

MAIN BAT VOLTAGE

Mismatch in Battery voltage reading

MAIN BAT TEMP HIGH

Battery overheating

Replace battery Replace Main Board Replace battery Replace Power Board

MAIN BAT GAUGE

Battery control

Replace battery

SEC BAT CHARGER

Charger malfunction

Replace battery Replace Power Board

SEC BAT V HIGH / LOW

Out of range

Replace battery Replace Power Board

SEC BAT VOLTAGE

Mismatch in Battery voltage reading

SEC BAT TEMP HIGH

Battery overheating

Replace battery Replace Main Board Replace battery Replace Power Board

SEC BAT GAUGE

98 | FLIGHT 60

Battery control

Replace battery

Repackaging and Shipping Packaging

9 Repackaging and Shipping All returned items must have a Return Goods Authorization (RGA) number, assigned by FLIGHT MEDICAL. To obtain an RGA number, email a completed RGA form (filled in its entirely) to [email protected]. Also include the ventilator's log files and a detailed description of the failure analysis and the repair efforts undertaken. Items can be returned only after an RGA number was provided by FLIGHT MEDICAL. Copies of the RGA form and the Service Call should be included with the returned item.

9.1

Packaging

Use the following guidelines when you return a FLIGHT 60 ventilator:
The original box and packaging must be used.
Remove all accessories from the ventilator.
Do not ship any accessories unless they are requested by FLIGHT MEDICAL.
When returning a module, place it in the original box and packaging. If not available, place it in a box large enough to allow for it to be wrapped in a sufficient amount of packaging material.
Write the RGA number on the shipping label.

9.2

Shipping

Ship RGA items to: FLIGHT MEDICAL INNOVATIONS Ltd. 13 Hamelacha St Lod 71520, ISRAEL Tel: +972-8-923-5111 Address any technical questions or problems to FLIGHT MEDICAL: FLIGHT MEDICAL INNOVATIONS Ltd. Address: 13 Hamelacha St., Lod 71520, ISRAEL Tel: +972-8-923-5111 Fax: +972-8-923-6111 Email: [email protected] Website: www.flight-medical.com

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Repackaging and Shipping Shipping

Index A AC Connector with Fuses, 21 ACMV, 76, 83, 84, 87, 93 Air/Oxygen Entrainment Mixer, 13, 15, 20, 22, 92, 93 Antistatic wrist strap, 28 APNEA, 18 LED Indicator, 18 LED Indicator, 77 Audio Paused / Alarm Reset button, 18 Audio Paused/Alarm Reset LED Indicator, 77

B BAT LED Indicator, 18, 89, 90, 96, 97, 98 LED Indicator (Battery power), 77 Battery, 29, 75, 89, 98 BUV LED Indicator, 18 LED Indicator (Back up ventilation), 77 Buzzer Test, 75, 91

C Cable ties, 28 Charger, 75, 89, 97, 98 Ventilator Cover, 30, 32, 33 Cutter, 28

D DC Connector, 21 Detachable Battery, 21, 29 Display touch screen, 18 D-type Board, 59

E Electrical Diagram, 27 Emergency Air Intake, 19 Error Messages, 96 Exhalation Valve Leak, 75 EXT PWR LED Indicator, 18 LED Indicator (External power), 77

F FAULT LED Indicator, 18, 97 LED Indicator (Device malfunction, 77 FILTER, 95

100 | FLIGHT 60

Filter Cover, 20, 22, 23 Flat screwdriver, 28, 76 Fresh Gas Intake, 20, 22, 23 Front Panel, 10, 17, 42, 43, 46, 75, 77 Front Panel Assembly, 42, 43 Front Panel Self Test, 75, 77 Fuse, 62, 63

H HIGH MV LED Indicator, 18, 97 LED Indicator (High minute ventilation), 77 High P LED Indicator (High pressure), 77 HIGH P LED Indicator, 18, 88, 89 High Pressure Alarm, 75, 88

I Inlet Leak, 75, 90 Internal Battery, 29, 30

L LAN (RJ45), 22 LED Indicators, 18 Loading Software, 65 LOW MV LED Indicator (Low minute ventilation), 77 LOW BAT LED Indicator, 18 LED Indicator (Low battery), 77 LOW MV LED Indicator, 18, 97 LOW P LED Indicator, 18, 97 LED Indicator (Low pressure), 77 Lower Board, 59

M Main board, 24 Main Board, 42, 44, 46, 48, 65, 71, 77, 79, 84, 89, 92, 93, 96, 97, 98 Maintenance, v, 95 MANIFOLD, 95 Manifold Assembly, 48, 52 Manual Breath button, 17 Mini RS-485 (COM3), 22

O On/Off, 10, 17, 77

Repackaging and Shipping Shipping LED Indicator, 77 On/Off button, 10, 17, 77 Oxygen (O2) Sensor, 24 Oxygen Blending Bag Kit, 13, 15, 23 Oxygen Sensor, 53, 54, 75, 92

P Panel Lock, 17 LED Indicator, 77 Panel Lock button, 17 Patient Circuit Reusable, 23, 76 Single Use, 23 Patient Circuit Connector, 17 PEEP, 75, 76, 83, 84, 85, 86 Phillips screwdriver PH1, 28, 76 PLT1M-M69, 28 PLT4S-M69, 28 Pneumatic Diagram, 25 Power Board, 33, 34, 35, 36, 37, 96, 97, 98 Power board (PB), 24 Power Supply, 34, 38, 39, 40, 75, 89 Power supply (PS), 24 Pressure Gauge, 18 Pressure Gauge Verification, 75 Pressure Relief Calibration, 75, 80 Pressure Sensors Calibration, 75, 78, 96 Pressure Trigger, 75, 86 Pressure Verification, 75, 84 Primary Alarm LED, 18 Purge board, 24 Purge Board Assembly, 54, 55

R Removing and Reinstalling Modules, 28 Repackaging, v, 99 RGA number, 99 RS-232 Serial Port (COM1), 21 RS-232 Serial Port (COM2), 21 Rubber Bumpers, 64

S OXYGEN SENSOR Oxygen, 95 Shipping, v, 99 Solenoid / Valve Calibration, 75, 82 Solenoid Assembly, 57, 59 Solenoid Board Assembly, 55, 56 Standard Ventilator Settings (STS), 76, 81, 84, 85, 86, 88, 90 System Log Files, 65

T Test Table, 93 Torx screwdriver BT10x200, 28, 76 Touch Screen, 48 TRIG LED Indicator, 18 LED Indicator (Pressure trigger), 77 Troubleshooting Guide, 96

U Up/Down button, 17 USB A type, 22 USB B type, 21

V V60-13000-65, 24, 38 V60-21000-60, 24, 48 V60-21000-65, 24, 33 V60-21400-69, 24, 57 V60-23000-65, 24, 54 V60-25000-29, 24, 53 V60-26000-65, 24, 55 V60-60002-65, 24, 44 Verification, v, 15, 75 Volume Factor Calibration, 75, 81

W WinXP SP3, 65

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