840

V e n t i l a t o r Sy s t em
Service M anual

4-070496-00 Rev A
August, 2003

anual 4-070089-00 Rev. B (10/ 02)

Copyright informat ion
Copyrigh t 2003 Puritan -Ben n ett Corporation . All righ ts reserved. Th e 840TM Ven tilator System is m an ufactured in
accordan ce with Puritan Ben n ett proprietary in form ation , covered by one or m ore of th e foll owin g U.S. Paten ts an d
foreign equivalen ts: 4,954,799; 5,161,525; 5,271,389; 5,301,921; 5,319,540; 5,339,807; 5,368,019; an d 5,390,666.
840, 800 Series, DualView, SandBox, SmartAlert, Flow-by, an d are tradem arks of Puritan -Benn ett Corporati on .
Th e in form ation con tain ed in th is m an ual is th e sole property of Puritan -Ben n ett Corporation an d m ay n ot be
duplicated with out perm ission. Th is m an ual m ay be revised or replaced by Puritan Ben n ett at an y tim e an d with out
n otice. You sh ould en sure th at you h ave th e m ost curren t applicable version of th is m an ual; if in doubt, con tact th e
Tech n ical Support Departm en t of Puritan -Ben n ett Corp. or your local represen tative. W h ile th e in form ation set forth
h erei n is believed to be accurate, it is n ot a substitute for th e exercise of profession al judgm en t.
Th e ven tilator sh ould be operated an d serviced on ly by train ed professi onals. Puritan Ben n ett’s sole respon sibility
with respect to th e ven tilator, an d its use, is as stated in th e lim ited warran ty provided.
Noth in g in th is m an ual sh all li m it or restrict in an y way Puri tan Ben n ett’s righ t to revi se or oth erwise ch an ge or
m odify th e equi pm en t (in cludin g its software) described h erein , with out n otice. In th e absen ce of an express, written
agreem en t to the con trary, Puritan Ben n ett h as n o obligation to furn ish an y such revision s, ch an ges, or
m odification s to th e own er or user of th e equipm en t (in cl udin g its software) described h erein .

M anufacturer: Authorized Representative:

Puritan-Bennett Corporation Tyco Healthcare UK Limited
4280 Hacienda Drive 154 Fareham Road
Pleasanton, CA 94588-2719 Gosport
USA PO13 0AS
UK
Phone: +800.255.6774
 Preface

Definit ions
This m anual uses three special i ndicators to convey i nform ation of a specifi c nature.
They include:

Warning
Indicates a condition that can endanger the patient or the ventilator operator.

Caut ion
Indicates a condition that can damage the equipment.

NOTE:
Indicates points of particular interest that make operation of the ventilator more efficient or
convenient.

Warnings, caut ions, and not es

Please take the tim e to fam i liari ze yourself with the fol lowi ng caveats as they cover safety
considerati on s, special handling requi rem ents, and regulations th at govern the use of the 840
Ven til ator System .
• To en sure proper servi ci ng an d avoid the possibil ity of physical i nj ury, on ly qual ified
person nel shoul d attempt to servi ce or m ake authori zed m odifi cati ons to the ventil ator.
The user of thi s product shal l have sol e responsibi li ty for an y ventil ator malfunction
due to operation or mai ntenan ce perform ed by an yon e n ot trai ned by Puritan Ben nett
staff.
• To avoid an el ectri cal shock hazard whi le servici ng the ventil ator, be sure to rem ove all
power to th e venti lator by discon necti ng the power source and turning off all ven ti lator
power swi tches.
• To avoi d a fire h azard, keep m atches, l ighted cigarettes, an d all other sources of i gn ition
(e.g., flam mable anesthetics and/or h eaters) away from the 840 Ventil ator System and
oxygen hoses.
Do n ot use oxygen hoses that are worn , frayed, or contam i nated by com bustibl e m aterials
such as grease or oil s. (Textil es, oil s, an d other combusti bl es are easi ly ign ited and burn
wi th great i ntensity in air enrich ed with oxygen .)
In case of fire or a burn in g sm ell , im m ediatel y disconn ect th e ven til ator from the oxygen
supply, facil ity power, an d BPS.
• W hen handl ing any part of th e 840 Ven ti lator System , always fol low your hospi tal
infecti on con trol guidel ines for handl ing i nfecti ous m ateri al.
Puritan Benn ett recognizes that cl eani ng, steri lizati on, sanitati on, an d disi nfecti on
practices vary w idely am ong h ealth care i nstituti ons. It is n ot possible for Puri tan Benn ett
to specify or requi re specific practices th at wil l m eet all n eeds, or to be responsi ble for the
effectiveness of cleani ng, steril izati on , and other practi ces carried out i n th e pati ent care
settin g.

i 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual Rev. A (08/ 03)
Preface

Puritan Ben nett does recom m end that users of its products that require cleaning and
sterili zation /di si nfection consider the National Standards and Recommended Practices for
Sterilization publi sh ed by th e Associati on for the Advan cem ent of M edi cal
Instrum entati on (AAM I), as well as th e foll owi ng Cen ter for Di sease Con trol (CDC)
publi cati ons: Guidelines for Maintenance of In-use Respiratory Therapy Equipment and
Guidelines for Prevention of Nosocomial Pneumonia.
• Pati en ts on li fe-support equipm ent should be appropri ately m oni tored by competen t
m edical personnel an d sui tabl e m oni torin g devices.
• The 840 Ventil ator System i s not in tended to be a com prehensive m on itori ng device an d
does n ot acti vate alarm s for all types of dan gerous con diti on s for pati ents on li fe-support
equipm en t.
• For a thorough un derstan din g of ventil ator operati on s, be sure to th orough ly read the 840
Ventilator System Operator's and Technical Reference Manual before attem pti ng to use the
system .
• Before activating any part of th e venti lator, be sure to check the equipm ent for proper
operati on and, i f appropri ate, run SST (Short Sel f Test).
• Do n ot use sh arp obj ects to m ake sel ections on the graphical user interface (GUI) display
or keyboard.
• Federal law (U.S.) restricts the sale of thi s device to, or by th e order of, an y ph ysi cian.
• Check the ven tilator peri odical ly as outlin ed in this m anual; do n ot use i f defective.
Im m ediatel y replace parts th at are broken , missi ng, obviously worn, distorted, or
contam in ated.
• An altern ative source of ven tilation shoul d al ways be availabl e when usin g th e 840
Ventil ator System .
• The 840 Venti lator System is a m em ber of the 800 Series™ fam ily of products. An y
accessory whose m odel n um ber i s 80x (for exampl e, th e 802 Backup Power Source or 806
Com pressor Un it) operates with al l 800 Series ven ti lators. An accessory whose m odel
num ber is 84x operates onl y wi th a m odel 840 Ven ti lator System .

Year of manufact ure

The year of m anufacture for ven tilators wh ose serial numbers begin wi th 4200 is i ndi cated on
the rear pan el of th e BDU as shown here. The two di git num ber foll owi ng th e year in dicates
the m onth of m anufacture.

2003 – 10

For venti lators whose seri al num bers begi n wi th 3510, the year of m anufacture is in dicated by
the seri al num ber’s 5th and 6th digits. In the exam ple below, a ventil ator with seri al num ber
3510021223 was the 1223rd uni t buil t i n 2002.
3510 02 1223
Sequential number

Year of manufacture

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) ii

 Preface

Elect romagnet ic suscept ibilit y

The 840 Venti lator System com pl ies with the requirem ents of IEC 601-1-2 (EM C Coll ateral
Standard), i ncl uding the E-fi eld susceptibili ty requirements at a l evel of 10 vol ts per m eter, at
frequencies from 26 M Hz to 1 GHz, and the ESD requirements of this standard. However, even at
thi s l evel of devi ce im m un ity, certai n transm itting devi ces (cellular phones, walki e-tal kies,
cordl ess phones, paging transm itters, etc.) em i t radio frequen ci es th at could in terrupt
venti lator operation if located i n a range too cl ose to the venti lator. It i s diffi cul t to determ in e
when the fiel d stren gth of these devices becom es excessive. Practitioners sh ould be aware th at
radio frequency em i ssion s are additive, and that th e venti lator m ust be l ocated a suffici ent
di stan ce from transm ittin g devi ces to avoid i nterrupti on . Do not operate the ven til ator i n a
m agnetic reson an ce im agi ng (M RI) environ ment. Section 7 describes possible ven tilator
al arm s an d what to do i f they occur. Consult wi th your i nstituti on’s biom edi cal engin eerin g
departm ent in case of i nterrupted ven tilator operation and before relocating an y life support
equipm en t.

Cust omer assist ance

For furth er assistance contact Puri tan-Benn ett Corporati on at 1.800.255.6774 or your local
Puritan Benn ett representative.

About t his manual

This m an ual provides information n eeded to service the Puritan Bennett 840 Venti lator
System . This m anual is inten ded for use by certifi ed biom edical en gin eering tech ni cians or
personnel with equi valen t experience and trai nin g in servici ng thi s type of equipment. It is
recom mended that th e user complete the Puri tan Benn ett train ing class geared speci ficall y to
the 840 Ventil ator System .
W h ile this m anual covers the ventilator confi gurati on s curren tl y supported by Puritan
Ben nett, i t may not be al l-inclusive and m ay not be appl icabl e to your venti lator. Wi thi n the
USA, contact Puri tan Ben nett at 1.800.255.6774 for question s regardi ng the appli cabil ity of
the inform ati on.

iii 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual Rev. A (08/ 03)
 SECTION

C ONTENTS

1 General information
1.1 How to use this manual ............................................................................................... 1-1
1.2 General product description ........................................................................................ 1-1
1.3 Configuration information ...........................................................................................1-2
1.4 Accessories.................................................................................................................. 1-2
1.5 Specifications .............................................................................................................. 1-3
1.6 Compliance and approvals .......................................................................................... 1-7
1.7 Technical information..................................................................................................1-8
1.8 Range, resolution, accuracy, and new patient/ default settings .................................. 1-10
1.9 Tools, equipment, and service materials ....................................................................1-19
1.10 Periodic maintenance .............................................................................................. 1-22
1.11 Service kits ..............................................................................................................1-24
1.12 Controls and indicators ......................................................................................... 1-24
1.13 Onscreen symbols and abbreviations....................................................................... 1-41
1.14 Ventilator serial numbers and software version ........................................................ 1-41
1.15 Service philosophy...................................................................................................1-41

2 Theory of operation
2.1 Major ventilator subassemblies....................................................................................2-1
2.1.1 Breath delivery unit (BDU) ...................................................................................2-2
2.1.2 Graphic user interface (GUI) ................................................................................2-2
2.1.3 806 Compressor Unit .......................................................................................... 2-3
2.1.4 802 Backup Power Source (BPS) .......................................................................... 2-4
2.1.5 Cart ..................................................................................................................... 2-4
2.1.6 Patient system ..................................................................................................... 2-5
2.2 Operational overview .................................................................................................. 2-6
2.3 Pneumatic system ....................................................................................................... 2-9
2.3.1 Inspiratory module ............................................................................................ 2-14
2.3.1.1 Gas supply conditioning subsystem .........................................................2-15
2.3.1.2 Flow control subsystem ...........................................................................2-20
2.3.1.3 Safety valve and inspiration monitoring subsystem .................................. 2-23
2.3.1.4 Inspiratory module operation .................................................................. 2-28
2.3.2 Patient System ................................................................................................... 2-31
2.3.2.1 Patient system components.....................................................................2-32
2.3.2.2 Patient system operation ......................................................................... 2-33
2.3.3 Exhalation module............................................................................................. 2-33
2.3.3.1 Exhalation module components ..............................................................2-34
2.3.3.2 Exhalation module operation ................................................................... 2-35

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Cont ent s
2.3.4 806 Compressor Unit ........................................................................................ 2-38
2.3.4.1 806 Compressor unit components.......................................................... 2-38
2.3.4.2 806 Compressor unit operation............................................................... 2-41
2.4.1 Summary of electrical components ................................................................... 2-42
2.4.2 Overview of electrical system operation ............................................................ 2-47
2.4.3 ac distribution components............................................................................... 2-50
2.4.3.1 Power cord ............................................................................................. 2-50
2.4.3.2 ac panel .................................................................................................. 2-50
2.4.3.3 Power switch........................................................................................... 2-53
2.4.4 Power supply .................................................................................................... 2-54
2.4.5 BPS................................................................................................................... 2-56
2.4.6 Card Cage ........................................................................................................ 2-58
2.4.6.1 Motherboard PCB................................................................................... 2-60
2.4.6.2 BDU CPU PCB......................................................................................... 2-63
2.4.6.3 Analog interface (AI) PCB........................................................................ 2-67
2.4.7 Data key subsystem .......................................................................................... 2-69
2.4.8 GUI................................................................................................................... 2-69
2.4.8.1 GUI CPU PCB ......................................................................................... 2-69
2.4.8.2 Touch frame PCB .................................................................................... 2-75
2.4.8.3 Keyboard assembly with knob ................................................................. 2-76
2.4.8.4 GUI LED PCB........................................................................................... 2-78
2.4.8.5Backlight inverter PCB and LCD lamps ........................................................ 2-79
2.4.8.6 GUI alarm assembly ................................................................................ 2-80
2.4.9 BDU LED PCB ................................................................................................... 2-81
2.4.10 Inspiratory electronics PCB.............................................................................. 2-81
2.4.11 Exhalation transducer PCB .............................................................................. 2-83
2.4.11.1BD (continuous-tone) alarm assembly ....................................................... 2-85
2.4.12 806 Compressor unit ...................................................................................... 2-85
2.4.12.1806 compressor unit ac power distribution components and motor.......... 2-86
2.4.12.2 806 compressor PCB............................................................................... 2-86
2.4.12.3806 Compressor unit operation ................................................................ 2-90
2.5 Breath delivery .......................................................................................................... 2-92
2.5.1 Inspiration......................................................................................................... 2-92
2.5.1.1Pressure triggering ...................................................................................... 2-94
2.5.1.2 Flow triggering ....................................................................................... 2-94
2.5.1.3 Time-cycling method .............................................................................. 2-94
2.5.1.4 Operator triggering................................................................................. 2-94
2.5.2 Exhalation ......................................................................................................... 2-94
2.5.2.1Time-cycling method .................................................................................. 2-95
2.5.2.2 End-inspiratory flow method ................................................................... 2-95
2.5.2.3 Airway pressure method.......................................................................... 2-95
2.5.2.4 Time limit................................................................................................ 2-95
2.5.2.5 High circuit pressure limit........................................................................ 2-95
2.5.2.6 High ventilator pressure limit .................................................................. 2-95

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 Cont ent s
2.6 Other hardware operations .......................................................................................2-97
2.6.1 Gas supply and control...................................................................................... 2-97
2.6.2 Data monitoring................................................................................................ 2-97
2.6.3 Pressure transducer autozero ............................................................................. 2-98
2.6.4 Power monitoring and power fail handling......................................................2-100
2.6.4.1 Loss of power source .............................................................................2-100
2.6.4.2 Supply voltage monitoring .................................................................... 2-101
2.7.1 Safety valve open (SVO) state.......................................................................... 2-101
2.7.2 Occlusion handling ......................................................................................... 2-103
2.7.2.1 When the ventilator declares an occlusion .............................................2-103
2.7.2.2 Occlusion detection and handling ......................................................... 2-103

3 Self t est s
3.1 Introduction ................................................................................................................3-1
3.2 How to enter Service Mode ......................................................................................... 3-1
3.3 Self tests and background checks ................................................................................ 3-1
3.3.1 POST................................................................................................................... 3-1
3.3.2 SST...................................................................................................................... 3-1
3.3.3 EST ..................................................................................................................... 3-2
3.3.4 Background checks.............................................................................................. 3-2
3.3.5 When self tests are run ........................................................................................ 3-2
3.4 Power on self test (POST) ............................................................................................3-3
3.4.1 Safety ................................................................................................................. 3-7
3.4.2 POST characteristics ............................................................................................3-7
3.4.3 POST following power interruptions.................................................................... 3-8
3.4.4 POST user interface ............................................................................................. 3-8
3.4.5 Structure of POST................................................................................................ 3-9
3.5 SST (short self test) ....................................................................................................3-11
3.5.1 When to run ......................................................................................................3-11
3.5.2 Hardware requirements..................................................................................... 3-12
3.5.3 Running SST......................................................................................................3-13
3.6 EST (extended self test) ............................................................................................. 3-17
3.6.1 Description........................................................................................................3-17
3.6.2 When to run ......................................................................................................3-17
3.6.3 Hardware requirements..................................................................................... 3-18
3.6.4 Running EST...................................................................................................... 3-18

4 Service mode
4.1 Accessing service mode ............................................................................................... 4-1
4.2 Service mode functions ............................................................................................... 4-3
4.2.1 SST RESULT: Displaying SST results......................................................................4-5
4.2.2 DIAG LOG: Displaying error and status logs......................................................... 4-5
4.2.3 Alarm log: Displaying the alarm history ............................................................... 4-7
4.2.4 VENT CONFIG: Displaying software revisions and serial numbers ........................4-7
4.2.5 OPERATION TIME: Displaying ventilator and compressor elapsed hours.............. 4-7
4.2.6 TEST SUMMARY: Displaying results from EST and SST ......................................... 4-7
4.2.7 EST: Extended self test ......................................................................................... 4-7
4.2.8 DATE/ TIME: Adjusting date and time................................................................... 4-7
4.2.9 EXIT: Exiting service mode................................................................................... 4-7

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Cont ent s
4.2.10 Other screens.................................................................................................... 4-8
4.2.11 Service M ode Setup .......................................................................................... 4-8
4.2.12 External Test Control: Performing remote ventilator testing .............................. 4-8
4.2.13 Exp Valve Calibration ........................................................................................ 4-9
4.2.13.1 Running Exp Valve Calibration .................................................................. 4-9
4.2.14 Vent Inop Test ............................................................................................... 4-11
4.2.14.1 Running the Vent Inop Test ..................................................................... 4-11
4.2.14.2 Flow Sensor Calibration........................................................................... 4-12
4.2.15 Running Flow Sensor Calibration .................................................................... 4-13
4.2.15.1 Atmospheric Pressure Transducer ............................................................ 4-13
4.2.16 Automatically executed service mode functions .............................................. 4-14
4.2.16.1 Initialize Flow Sensor ............................................................................... 4-14
4.2.16.2 Cal Info Duplication ................................................................................ 4-14
4.2.17 Serial number setup ....................................................................................... 4-15
4.2.17.1 Running Serial Number Setup ................................................................. 4-15
4.2.18 Datakey Update .............................................................................................. 4-16
4.2.19 Serial Loopback Test ....................................................................................... 4-17

5 Performance verification
5.1 Tools, test equipment, and service materials ............................................................... 5-1
5.2 When to run ............................................................................................................... 5-1
5.3 Preliminary ventilator cleaning and inspection ............................................................ 5-4
5.4 Preliminary ventilator setup ......................................................................................... 5-5
5.5 Preliminary calibrations and tests ................................................................................ 5-5
5.6 Performance verification guidelines............................................................................. 5-7
5.7 Performance verification tests...................................................................................... 5-7
5.7.1 Electrical safety test ............................................................................................ 5-8
5.7.2 Ground isolation check ....................................................................................... 5-8
5.7.3 Extended self test (EST) ....................................................................................... 5-9
5.7.4 Regulator setting verification............................................................................... 5-9
5.7.5 Serial loopback test (10.4-inch GUI only) .......................................................... 5-10
5.7.6 Performance verification using PTS 2000 Performance
Test System and BreathLab 840 VTS software ................................................... 5-10
5.7.7 Manual ventilator check using equipment other than
PTS 2000 Performance Test System ................................................................... 5-10

6 Diagnostic codes
6.1 Introduction................................................................................................................ 6-1
6.2 Reference Tables ......................................................................................................... 6-1
6.3 Troubleshooting.......................................................................................................... 6-2
6.4 POST fault handling ................................................................................................... 6-2
6.5 Diagnostic CPU LED arrays.......................................................................................... 6-3
6.6 Diagnostic codes......................................................................................................... 6-4
6.6.1 How to interpret diagnostic codes ...................................................................... 6-4
6.7 Organization of diagnostic codes table ....................................................................... 6-5
6.8 System Diagnostic Log and BDU POST analog devices test ....................................... 6-54

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 Cont ent s
6.9 Diagnostic codes for POST faults ...............................................................................6-55
6.9.1 POST interrupt errors and test failures ...............................................................6-64
6.10 SST and EST test sequences and diagnostic codes....................................................6-66
6.10.1 How to troubleshoot LCD inverter PCB faults (UT0002).................................6-102

7 Alarm handling
7.1 Alarm classifications..................................................................................................... 7-1
7.2 Responding to alarms..................................................................................................7-2

8 Service and repair

8.1 How to use this section................................................................................................ 8-1
8.2 General repair safety.................................................................................................... 8-1
8.3 General repair guidelines............................................................................................. 8-2
8.4 Repair-related cleaning ................................................................................................8-2
8.5 Electrical cables and pneumatic tubing ........................................................................ 8-3
8.6 Adhesive use................................................................................................................8-3
8.7 Leak testing .................................................................................................................8-3
8.8 Electrostatic discharge control ..................................................................................... 8-4
8.8.1 ESD procedures and precautions ......................................................................... 8-4
8.9 Replacement part ordering ..........................................................................................8-4
8.10 Testing, calibration, and other post-service procedures.............................................. 8-4
8.11 Patient system and accessories................................................................................... 8-6
8.12 Graphic user interface (GUI) ...................................................................................... 8-6
8.13 Repairing the 10.4-inch GUI ...................................................................................... 8-8
8.13.1 Removing or installing the 10.4-inch GUI .......................................................... 8-8
8.13.2 Removing the 10.4-inch GUI cable assembly ..................................................... 8-9
8.13.3 Replacing the 10.4-inch GUI cable assembly...................................................... 8-9
8.13.4 Removing 10.4-inch GUI rear housing ............................................................... 8-9
8.13.5 Replacing 10.4-inch GUI rear housing ............................................................. 8-10
8.13.6 Removing the 10.4-inch CPU shield ................................................................ 8-11
8.13.7 Removing the 10.4-inch GUI backlight inverter PCBs.......................................8-11
8.13.8 Removing the 10.4-inch GUI CPU PCB ............................................................ 8-12
8.13.9 10.4-inch GUI support bracket ........................................................................8-14
8.13.9.1 Removing the 10.4-inch GUI support bracket ..........................................8-14
8.13.10 10.4-inch LCD panels ................................................................................... 8-15
8.13.10.1Removing the 10.4-inch LCD panels........................................................ 8-15
8.13.11 10.4-inch touchframe PCB (MKG Touch)...................................................... 8-15
8.13.11.1Removing the 10.4-inch touchframe PCB................................................ 8-15
8.13.12 Replacing the 10.4-inch touchframe PCB.......................................................8-16
8.13.13 10.4-inch GUI LED PCB ................................................................................. 8-16
8.13.13.1Removing the 10.4-inch GUI LED PCB..................................................... 8-16
8.13.13.2Replacing the 10.4-inch GUI LED PCB ..................................................... 8-16
8.13.14 10.4-inch GUI alarm assembly ....................................................................... 8-17
8.13.14.1Removing the 10.4-inch GUI alarm assembly...........................................8-17
8.13.14.2Replacing the 10.4-inch GUI alarm assembly ........................................... 8-17
8.13.15 10.4-inch GUI keyboard assembly ................................................................. 8-18
8.13.15.1Replacing the 10.4-inch GUI keyboard assembly .....................................8-18

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Cont ent s
8.13.16 10.4-inch GUI front housing ......................................................................... 8-18
8.13.16.1Replacing the 10.4-inch front housing .................................................... 8-18
8.13.17 10.4-inch rotor housing ................................................................................ 8-19
8.13.17.1Replacing the 10.4-inch rotor housing .................................................... 8-19
8.14 Repairing the 9.4-inch GUI...................................................................................... 8-20
8.14.1 Removing the 9.4-inch GUI touch screen bezel ............................................... 8-20
8.14.2 9.4-inch GUI window ...................................................................................... 8-21
8.14.3 Installing the 9.4-inch bezel ............................................................................ 8-22
8.14.4 The 9.4-inch keyboard assembly ..................................................................... 8-22
8.14.4.1 Removing 9.4-inch keyboard assembly.................................................... 8-22
8.14.4.2 Installing the 9.4-inch keyboard assembly ............................................... 8-24
8.14.5 Removing or installing the 9.4-inch GUI.......................................................... 8-24
8.14.6 9.4-inch GUI rear housing ............................................................................... 8-25
8.14.6.1 Removing 9.4-inch GUI rear housing....................................................... 8-25
8.14.6.2 Installing 9.4-inch GUI rear housing ........................................................ 8-26
8.14.7 9.4-inch GUI alarm assembly .......................................................................... 8-27
8.14.7.1 Removing 9.4-inch GUI alarm assembly .................................................. 8-27
8.14.7.2 Installing 9.4-inch GUI alarm assembly .................................................... 8-28
8.14.8 9.4-inch GUI backlight inverter PCB and GUI LED PCB.................................... 8-28
8.14.8.1 Removing 9.4-inch GUI backlight inverter PCB........................................ 8-28
8.14.8.2Installing 9.4-inch GUI backlight inverter PCB ........................................... 8-29
8.14.8.3 Removing 9.4-inch GUI LED PCB............................................................. 8-29
8.14.8.4 Installing 9.4-inch GUI LED PCB .............................................................. 8-29
8.14.9 GUI EMI shield ................................................................................................ 8-30
8.14.9.1 Removing the GUI EMI shield .................................................................. 8-30
8.14.9.2 Installing the 9.4-inch GUI EMI shield...................................................... 8-30
8.14.10 9.4-inch video controller and VGA LCD controller PCBs ................................ 8-30
8.14.10.1Removing 9.4-inch VGA LCD controller PCBs (older CPU PCB)................ 8-31
8.14.10.2Installing 9.4-inch VGA LCD controller PCBs (older CPU PCB) ................. 8-31
8.14.11 9.4-inch GUI CPU PCB .................................................................................. 8-32
8.14.11.1Removing the 9.4-inch GUI CPU PCB...................................................... 8-32
8.14.11.2Installing the 9.4-inch GUI CPU PCB ....................................................... 8-32
8.14.12 9.4-inch touchframe PCB (Carroll Touch)...................................................... 8-33
8.14.12.1Removing the 9.4-inch touchframe PCB.................................................. 8-33
8.14.12.2Reinstalling the 9.4-inch touchframe PCB................................................ 8-34
8.14.13 9.4-inch backlight panels and LCD panels .................................................... 8-36
8.14.13.1Removing a 9.4-inch backlight panel and LCD pane ............................... 8-36
8.14.13.2Reinstalling a backlight panel and LCD panel .......................................... 8-36
8.14.14 9.4-inch GUI cooling vent filters.................................................................... 8-38
8.14.15 9.4-inch rotor housing .................................................................................. 8-39
8.14.15.1Removing the 9.4-inch rotor housing...................................................... 8-39
8.14.15.2Installing the 9.4-inch rotor housing ....................................................... 8-39
8.15 Breath delivery unit (BDU) ...................................................................................... 8-40
8.15.1 Removing BDU ............................................................................................... 8-43
8.15.2 BDU power cord and retainer.......................................................................... 8-44
8.15.3 Installing BDU ................................................................................................. 8-44
8.15.4 Analog interface (AI) PCB and breath delivery (BD) CPU PCB .......................... 8-45
8.15.4.1 Removing AI PCB or BD CPU PCB ........................................................... 8-46
8.15.4.2 Installing AI PCB or BD CPU PCB............................................................. 8-47

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 Cont ent s
8.15.5 Power supply assembly.................................................................................... 8-48
8.15.5.1 Removing power supply assembly ........................................................... 8-48
8.15.5.2 Installing power supply assembly............................................................. 8-48
8.15.6 Power switch (S1)............................................................................................ 8-49
8.15.6.1 Removing power switch (S1) ...................................................................8-49
8.15.6.2 Installing power switch (S1).....................................................................8-49
8.15.7 Humidifier receptacle (100 – 120 V models only) ............................................ 8-50
8.15.7.1 Removing humidifier receptacle............................................................... 8-50
8.15.7.2 Installing humidifier receptacle ................................................................ 8-50
8.15.7.3 ac panel................................................................................................... 8-51
8.15.8 Inspiratory module ..........................................................................................8-52
8.15.8.1 Inspiratory module modifications............................................................. 8-52
8.15.8.2 Additional noise suppression (ferrite cores) .............................................. 8-52
8.15.8.3 Inspiratory module O-rings......................................................................8-53
8.15.8.4 Air inlet filter (F2)..................................................................................... 8-53
8.15.8.5 Fascia panel ............................................................................................. 8-54
8.15.8.6 Oxygen and air pressure switches (PS1 and PS2) .....................................8-56
8.15.8.7 PSOL cartridge ........................................................................................8-57
8.15.8.8 Removing inspiratory module..................................................................8-58
8.15.8.9 Leak testing inspiratory module ............................................................... 8-58
8.15.8.10Installing inspiratory module ................................................................... 8-59
8.15.8.11Oxygen sensor (OS) ................................................................................8-59
8.15.8.12Inspiratory check valve (CV3) ..................................................................8-62
8.15.8.13Right-side plate ....................................................................................... 8-62
8.15.8.14Inspiratory electronics PCB ...................................................................... 8-64
8.15.8.15Left-side plate..........................................................................................8-64
8.15.8.16PSOL manifold ........................................................................................ 8-65
8.15.8.17Oxygen and air flow sensors (Q1 and Q2) ............................................... 8-67
8.15.8.18Safety valve ............................................................................................. 8-68
8.15.8.19Check valve assembly, regulator assembly, and flow sensor manifold ......8-70
8.15.8.20Oxygen and air regulators (REG1 and REG2) ........................................... 8-72
8.15.8.21Inspiratory pressure transducer autozero solenoid (SOL1) ........................8-73
8.15.8.22Inspiratory floor assembly ........................................................................ 8-73
8.15.9 Exhalation module........................................................................................... 8-74
8.15.9.1 Exhalation collector vial (ECV) and expiratory filter (F9) ........................... 8-74
8.15.9.2 Removing exhalation module cover ......................................................... 8-74
8.15.9.3 Removing exhalation module .................................................................. 8-76
8.15.9.4 Installing exhalation module....................................................................8-76
8.15.9.5 Exhalation valve (EV) ............................................................................... 8-77
8.15.9.6 Exhalation flow sensor (Q3) ..................................................................... 8-80
8.15.9.7 Exhalation transducer PCB....................................................................... 8-81
8.15.9.8 Expiratory pressure transducer autozero solenoid (SOL2) ......................... 8-82
8.15.9.9 Exhalation heater (EXH HTR) and check valve (CV5) ................................ 8-83
8.15.10 BDU housing ................................................................................................. 8-84
8.15.10.1Removing BDU housing........................................................................... 8-84
8.15.10.2Installing BDU housing ............................................................................ 8-86
8.15.10.3M otherboard PCB ...................................................................................8-86
8.15.10.4BDU alarm assembly................................................................................ 8-87

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Cont ent s
8.15.11 Power indicator............................................................................................. 8-88
8.15.11.1Removing power indicator ...................................................................... 8-88
8.15.11.2Installing power indicator........................................................................ 8-89
8.15.11.3Alarm blindmate cable............................................................................ 8-89
8.15.11.4Inspiratory blindmate cable..................................................................... 8-90
8.15.11.5dc power supply blindmate cable ........................................................... 8-91
8.15.11.6ac power supply blindmate harness ........................................................ 8-92
8.15.12 Release handle .............................................................................................. 8-94
8.15.12.1Removing release handle ........................................................................ 8-94
8.15.12.2Installing release handle.......................................................................... 8-94
8.16 806 compressor unit ............................................................................................... 8-94
8.17 Servicing the 806 compressor ................................................................................. 8-95
8.17.1 Compressor inlet filter..................................................................................... 8-95
8.17.2 Removing and installing the compressor inlet filter ......................................... 8-95
8.17.3 Removing compressor from cart ..................................................................... 8-95
8.17.3.1 Disconnecting compressor from BDU...................................................... 8-95
8.17.3.2 Removing compressor from cart.............................................................. 8-96
8.17.4 Removing top cover........................................................................................ 8-96
8.17.5 Installing top cover ......................................................................................... 8-97
8.17.6 Cooling fans.................................................................................................... 8-97
8.17.6.1 Removing a cooling fan........................................................................... 8-97
8.17.6.2 Installing a fan......................................................................................... 8-98
8.17.7 Removing the back panel................................................................................ 8-98
8.17.8 Reinstalling the back panel.............................................................................. 8-98
8.17.9 Replacing an accumulator fitting and O-ring ................................................... 8-99
8.17.10 Pneumatic hoses........................................................................................... 8-99
8.17.11 Plenum assembly ........................................................................................ 8-100
8.17.11.1Removing the plenum assembly............................................................ 8-101
8.17.12 Heat exchanger (HE) ................................................................................... 8-102
8.17.12.1Replacing the heat exchanger ............................................................... 8-102
8.17.13 Removing and replacing the ac power cord ................................................ 8-102
8.17.14 Removing and replacing the data cable ...................................................... 8-102
8.17.15 Compressor PCB......................................................................................... 8-103
8.17.15.1Removing and replacing the compressor PCB....................................... 8-103
8.17.16 Air dryer (dryer) and solenoid valve assembly.............................................. 8-103
8.17.16.1Removing and reinstalling the air dryer
and solenoid valve assembly and replacing filters8-104
8.17.17 Compressor assembly ................................................................................. 8-105
8.17.17.1Removing the compressor assembly...................................................... 8-105
8.17.17.2Replacing the coalescing filter element ................................................. 8-106
8.17.18 Replacing the compressor panels................................................................ 8-107
8.17.19 Reinstalling the plenum assembly................................................................ 8-108
8.17.20 Reconnecting electrical cables.................................................................... 8-108
8.17.21 Replacing the Tinnerman clips .................................................................... 8-108
8.17.22 Reinstalling the back panel/accumulator assembly ...................................... 8-108
8.17.23 Replacing the main inlet filter and reinstalling the top................................. 8-109
8.17.24 Reinstalling the compressor module............................................................ 8-109
8.17.25 Running performance verification test ......................................................... 8-109

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 Cont ent s
8.18 Backup power source (BPS) ................................................................................... 8-110
8.18.1 Removing BPS............................................................................................... 8-110
8.18.2 Installing BPS................................................................................................. 8-111
8.18.3 Battery pack ..................................................................................................8-111
8.18.3.1 Removing battery pack..........................................................................8-111
8.18.3.2 Installing battery pack ...........................................................................8-112
8.18.4 BPS PCB ........................................................................................................ 8-113
8.18.4.1 Removing BPS PCB................................................................................ 8-113
8.18.4.2 Installing BPS PCB.................................................................................. 8-113
8.19 Cart .......................................................................................................................8-113
8.19.1 Casters ..........................................................................................................8-113
8.19.1.1 Removing casters...................................................................................8-113
8.19.1.2 Installing casters....................................................................................8-114
8.19.2 Removing/ installing GUI mount ....................................................................8-114
8.19.3 Removing/ installing flex arm inserts ..............................................................8-115

9 Part s list
9.1 How to use this parts list.............................................................................................. 9-1
9.2 840 Ventilator System patient system and accessories ................................................ 9-3
9.2.1 840 Ventilator System NeoMode patient system and accessories ........................ 9-6
9.3 Flex arm assembly ..................................................................................................... 9-8
9.3.1 Oxygen hose assemblies ................................................................................... 9-10
9.3.2 Air hose assemblies ........................................................................................... 9-12
9.3.3 Power cords ..................................................................................................... 9-14
9.4 Ventilator major assemblies ......................................................................................9-16
9.4.1 Label kits .......................................................................................................... 9-18
9.4.2 10.4-inch GUI (graphic user interface) assembly ...............................................9-26
9.4.3 10.4-inch GUI (graphic user interface) handle .................................................. 9-28
9.4.4 10.4-inch graphic user interface (GUI) rotor assembly ...................................... 9-30
9.4.5 10.4-inch GUI keyboards and speaker assembly ................................................9-32
9.4.6 9.4-inch graphic user interface (GUI) ................................................................ 9-35
9.4.6.19.4-inch GUI front housing assembly ........................................................... 9-38
9.4.6.29.4-inch GUI rear housing assembly ............................................................ 9-40
9.4.7 Breath delivery unit (BDU) ................................................................................ 9-42
9.4.7.1Exhalation module....................................................................................... 9-46
9.4.7.2Inspiratory module ...................................................................................... 9-49
9.4.7.3BDU cover ...................................................................................................9-58
9.4.7.4BDU chassis assembly ..................................................................................9-60
9.4.7.5BDU chassis kit ............................................................................................9-62
9.4.8 806 compressor unit ........................................................................................9-64
9.4.8.1806 compressor base assembly.................................................................... 9-66
9.4.8.2806 compressor unit enclosure assembly ..................................................... 9-68
9.4.8.3806 compressor unit plenum assembly........................................................9-70
9.4.9 Backup power source (BPS) .............................................................................. 9-72
9.4.10 Cart assembly ................................................................................................. 9-74

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xvi 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
 SECTION

FIGURES

Figure 1-1. Remote alarm (nurse’s call) port pinout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Figure 1-2. 840 Ventilator System RS-232 serial port pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-3. Monochrome GUI front view (showing all keys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Figure 1-4. 10.4-inch GUI rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Figure 1-5. BDU front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Figure 1-6. BDU I/ O panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Figure 1-7. BDU right-side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Figure 1-8. BDU rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Figure 1-9. GUI rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Figure 1-10. BPS controls and indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

Figure 2-1. 840 Ventilator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Figure 2-2. BDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-3. 10.4-inch GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4. Compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-5. BPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-6. Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7. Patient system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-8. NeoMode patient system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-9. 840 Ventilator System block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-10. Pneumatic system block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-11. Pneumatic system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-12. Inspiratory module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-13. Inspiratory module in ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-14. Inspiratory module gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-15. Gas supply conditioning subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-16. Gas supply conditioning subsystem gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2-17. Gas supply conditioning subsystem components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-18. Flow control subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Figure 2-19. Flow control subsystem gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Figure 2-20. Hot film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Figure 2-21. Flow control subsystem components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Figure 2-22. Safety valve and inspiration monitoring subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Figure 2-23. Inspiration monitoring subsystem gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Figure 2-24. Safety valve and inspiration monitoring subsystem components . . . . . . . . . . . . . . . . . . . 2-25
Figure 2-25. Safety valve open gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Figure 2-26. Air flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Figure 2-27. Oxygen flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Figure 2-28. Patient system (minus exhalation collector vial and expiratory filter) . . . . . . . . . . . . . . . . 2-31
Figure 2-29. Patient system flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Figure 2-30. Exhalation module (removed from BDU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Figure 2-31. Exhalation module flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

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Figures
Figure 2-32. Exhalation module components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Figure 2-33. 806 compressor on cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Figure 2-34. 806 Compressor Pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Figure 2-35. 806 components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Figure 2-36. Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Figure 2-37. 806 water trap assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Figure 2-38. Air dryer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Figure 2-39. 806 back panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Figure 2-40. 806 cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Figure 2-41. Electrical system block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Figure 2-42. ac panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Figure 2-43. 840 Ventilator System interconnect diagram – ac panel . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Figure 2-44. Power switch (S1) and indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Figure 2-45. Power supply assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Figure 2-46. 840 Ventilator System interconnect diagram – Power distribution . . . . . . . . . . . . . . . . . 2-55
Figure 2-47. BPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Figure 2-48. BPS battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Figure 2-49. BPS PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Figure 2-50. Card cage with all PCBs installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Figure 2-51. 840 Ventilator System interconnect diagram – Card cage . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Figure 2-52. Motherboard PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Figure 2-53. Motherboard PCB in place. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Figure 2-54. Motherboard PCB block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Figure 2-55. BD CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Figure 2-56. AI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Figure 2-57. Data key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Figure 2-58. 10.4” GUI CPU PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Figure 2-59. 9.4” GUI CPU PCB and backlight inverter PCB in place . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Figure 2-60. 840 Ventilator System interconnect diagram – GUI 10.4-inch LCD panels . . . . . . . . . . . . 2-72
Figure 2-61. 840 Ventilator System interconnect diagram – GUI 9.4-inch LCD panels . . . . . . . . . . . . . 2-74
Figure 2-62. Touch Frame PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Figure 2-63. Keyboard assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Figure 2-64. GUI LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
Figure 2-65. 10.4” GUI LCD panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Figure 2-66. 9.4-inch LCD panels and backlight tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Figure 2-67. GUI alarm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Figure 2-68. BDU LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Figure 2-69. Inspiratory electronics PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Figure 2-70. 840 Ventilator System interconnect diagram – Inspiratory module . . . . . . . . . . . . . . . . . 2-82
Figure 2-71. Exhalation transducer PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Figure 2-72. 840 Ventilator System interconnect diagram – Exhalation module . . . . . . . . . . . . . . . . . 2-84
Figure 2-73. BD alarm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Figure 2-74. 806 compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Figure 2-75. 806 Compressor fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Figure 2-76. 806 compressor PCBA installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Figure 2-77. 806 compressor PCB block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Figure 2-78. 840 Ventilator System interconnect diagram – Compressor unit . . . . . . . . . . . . . . . . . . . 2-89
Figure 2-79. Compressor operational sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Figure 2-80. Compressor unit start-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

xviii 4-070496-00 Rev. A (08/ 03) 840 Ventilatory System Service Manual
 Figures
Figure 2-81. Inspiration gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Figure 2-82. Exhalation gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Figure 2-83. Pressure transducer autozero mode gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Figure 2-84. Power loss sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
Figure 2-85. Safety valve open diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Figure 2-86. Pressure release, patient circuit occluded diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Figure 3-1. Patient circuit setup for SST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-2. EST setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Figure 3-3. EST screens during testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Figure 4-1. SERVICE MODE screens ................................................ .. 4-2

Figure 4-2. Service mode functions ................................................ .. 4-4
Figure 4-3. System Information Log ................................................ .. 4-6
Figure 4-4. EST/ SST Diagnostic Log ................................................ .. 4-6

Figure 6-1. Location of BD LED array. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Figure 7-1. Alarm message format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Figure 7-2. Alarm log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Figure 8-1. GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Figure 8-2. 10.4-inch GUI front and back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Figure 8-3. 10.4-inch GUI mounting platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Figure 8-4. Removing and replacing 10.4-inch GUI cable assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Figure 8-5. Removing 10.4-inch GUI rear housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Figure 8-6. 10.4-inch GUI rear warning label and serial number tag . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Figure 8-7. Removing the 10.4-inch CPU shield and GUI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Figure 8-8. Removal of a 10.4-inch backlight inverter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Figure 8-9. RS-232 shield and flex circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Figure 8-10. GUI CPU PCB touch panel jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Figure 8-11. 10.4-inch LCD panels and LCD shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Figure 8-12. 10.4-inch GUI touchframe PCB and GUI LED PCB locations. . . . . . . . . . . . . . . . . . . . . . . 8-15
Figure 8-13. Removal of the 10.4" GUI LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Figure 8-14. Removing the 10.4-inch GUI alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Figure 8-15. 10.4-inch GUI rotor housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Figure 8-16. 9.4-inch touch screen bezel and window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Figure 8-17. 9.4-inch GUI tilt positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Figure 8-18. Replacing the 9.4-inch keyboard assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Figure 8-19. 9.4-inch GUI mounting platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Figure 8-20. Removing 9.4-inch GUI handle assembly and interface cable . . . . . . . . . . . . . . . . . . . . . 8-25
Figure 8-21. Replacing 9.4-inch GUI rear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Figure 8-22. 9.4" GUI interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Figure 8-23. Replacing the 9.4-inch GUI alarm assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Figure 8-24. Replacing 9.4-inch backlight inverter and GUI LED PCBs. . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Figure 8-25. Removing 9.4-inch GUI EMI shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Figure 8-26. Removing 9.4-inch video controller PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Figure 8-27. GUI CPU PCB touch panel jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Figure 8-28. Replacing the 9.4-inch touchframe PCB and LCD panel assembly . . . . . . . . . . . . . . . . . 8-34
Figure 8-29. Routing the backlight extender cable assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

840 Ventilatory System Service Manual 4-070496-00 Rev. A (08/ 03) xix
Figures
Figure 8-30. LCD panel and backlight panel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Figure 8-31. Replacing the 9.4-inch GUI cooling vent filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
Figure 8-32. 9.4-inch rotor housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
Figure 8-33. BDU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
Figure 8-34. BDU connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Figure 8-35. Sure-Lock™ retainer and power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Figure 8-36. BDU release handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Figure 8-37. BD CPU PCB and AI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
Figure 8-38. BD card cage and PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
Figure 8-39. BDU I/ O panel connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
Figure 8-40. Replacing power supply assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Figure 8-41. Replacing power switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Figure 8-42. Replacing humidifier receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Figure 8-43. ac panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
Figure 8-44. Adding ferrites to air and oxygen transducer harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Figure 8-45. Replacing F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Figure 8-46. Removing inspiratory module fascia panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
Figure 8-47. Oxygen filter assembly and pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
Figure 8-48. Pressure switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56
Figure 8-49. Replacing PSOL cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
Figure 8-50. Removing inspiratory module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Figure 8-51. Opening oxygen sensor access port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-59
Figure 8-52. Detail of oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60
Figure 8-53. Replacing oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61
Figure 8-54. Inspiratory check valve (CV3) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Figure 8-55. Removing inspiratory module right-side plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63
Figure 8-56. Replacing inspiratory module left-side plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Figure 8-57. PSOL manifold ready for removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66
Figure 8-58. Replacing oxygen and air flow sensors (Q1 and Q2) and safety valve. . . . . . . . . . . . . . . . 8-67
Figure 8-59. Oxygen and air flow sensors (Q1 and Q2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68
Figure 8-60. Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-69
Figure 8-61. Disassembling flow sensor manifold/regulator assembly/check valve assembly . . . . . . . . 8-71
Figure 8-62. Removing REG1 and REG2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-72
Figure 8-63. Removing exhalation module cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-74
Figure 8-64. Exhalation module disassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-75
Figure 8-65. Replacing exhalation module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-76
Figure 8-66. Exhalation sample port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-77
Figure 8-67. Replacing exhalation module components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Figure 8-68. Exhalation flow sensor (Q3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-81
Figure 8-69. Replacing exhalation transducer PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
Figure 8-70. Replacing exhalation heater (EXH HTR) and check valve (CV5) . . . . . . . . . . . . . . . . . . . . 8-83
Figure 8-71. Removing BDU housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-85
Figure 8-72. Removing motherboard PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-87
Figure 8-73. BDU alarm and motherboard PCB cable connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88
Figure 8-74. Replacing power indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-89
Figure 8-75. Cable connections to ac panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-90
Figure 8-76. Replacing inspiratory blindmate cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-91
Figure 8-77. Replacing dc power supply blindmate cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-92
Figure 8-78. Replacing ac power supply blindmate harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-93

xx 4-070496-00 Rev. A (08/ 03) 840 Ventilatory System Service Manual

 Figures
Figure 8-79. 806 compressor mounted on cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-95
Figure 8-80. Top cover removed from compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-96
Figure 8-81. Fans installed in compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-97
Figure 8-82. Removing the back panel of the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-98
Figure 8-83. Disconnecting filter outlet port from main supply hose . . . . . . . . . . . . . . . . . . . . . . . . . 8-100
Figure 8-84. Disconnecting heat exchanger inlet connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-100
Figure 8-85. 806 printed circuit board (PCB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-101
Figure 8-86. Air dryer/solenoid valve assemblies installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-104
Figure 8-87. Air dryer and solenoid valve assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-105
Figure 8-88. 806 compressor motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106
Figure 8-89. Water trap assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-106
Figure 8-90. BPS and cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-110
Figure 8-91. Connecting BPS to BDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-111
Figure 8-92. Replacing battery pack and BPS PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-112
Figure 8-93. Removing caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-113
Figure 8-94. Assembling GUI mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114
Figure 8-95. Flex arm insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-115

Figure 9-1. 840 Ventilator System patient system and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Figure 9-2. NeoMode patient circuit and accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Figure 9-3. Flex arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Figure 9-4. Oxygen hose assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Figure 9-5. Air hose assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Figure 9-6. Power cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Figure 9-7. Ventilator major assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Figure 9-8. Label kits (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Figure 9-9. 10.4-inch GUI assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
Figure 9-10. 10.4-inch GUI handle assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Figure 9-11. 10.4-inch GUI rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
Figure 9-12. 10.4-inch GUI keyboard and speaker assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Figure 9-13. 9.4-inch GUI assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Figure 9-14. 9.4-inch GUI front housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Figure 9-15. 9.4-inch GUI rear housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Figure 9-16. Breath delivery unit (BDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
Figure 9-17. Exhalation module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
Figure 9-18. Inspiratory module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
Figure 9-19. Proportional solenoid (PSOL) valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
Figure 9-20. Inspiratory module floor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-57
Figure 9-21. BDU cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-59
Figure 9-22. BDU chassis assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
Figure 9-23. BDU chassis kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-63
Figure 9-24. 806 compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
Figure 9-25. 806 compressor base assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
Figure 9-26. Compressor unit enclosure assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69
Figure 9-27. Compressor plenum assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
Figure 9-28. Backup power source (BPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-73
Figure 9-29. Cart assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-75

840 Ventilatory System Service Manual 4-070496-00 Rev. A (08/ 03) xxi
Figures

Thi s page i ntentionall y blank.

xxii 4-070496-00 Rev. A (08/ 03) 840 Ventilatory System Service Manual
 SECTION

TABLES

Table 1-1. Ventilator specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table 1-2. Compliance with standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Table 1-3. Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 1-4. Ventilator range, resolution, accuracy, new patient/ defaults . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Table 1-5. Tools, equipment, and service materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Table 1-6. Schedule of periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Table 1-7. Service kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Table 1-8. GUI front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Table 1-9. GUI rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Table 1-10. BDU front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Table 1-11. BDU I/O panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Table 1-12. BDU right-side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Table 1-13. BDU rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Table 1-14. GUI rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Table 1-15. BPS controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

Table 2-1. Pneumatic component descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Table 2-2. Electronic Component Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Table 2-3. NOVRAM contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Table 2-4. Monitored data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Table 2-5. Out-of-tolerance supply voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Table 3-1. Self tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Table 3-2. Components tested by self tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3-4. POST outcomes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Table 3-3. POST Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Table 3-5. Hardware requirements for SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Table 3-6. SST tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Table 3-7. SST individual test results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Table 3-8. Overall SST outcomes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Table 3-9. Hardware requirements for EST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Table 3-10. EST tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Table 3-11. EST individual test results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Table 3-12. Overall EST outcomes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Table 4-1. Service mode functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Table 4-2. Other screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Table 4-3. Service Mode Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Table 4-4. Exhalation valve calibration errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Table 4-5. Vent Inop Test phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Table 4-6. Vent Inop Test troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Table 4-7. Flow sensor calibration errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Table 4-8. Initialize Flow Sensor errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

840 Ventilatory System Service Manual 4-070496-00 Rev. A (08/ 03) xxiii
Tables
Table 4-9. Cal Info Duplication errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Table 4-10. Serial number setup errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Table 4-11. Datakey update error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Table 4-12. Serial Loopback Test error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Table 5-1. Tools, equipment, and service materials required for

performance verification 5-2
Table 5-2. Pre-performance verification testing and calibration requirements . . . . . . . . . . . . . . . . . . . . . 5-6
Table 5-3. Manual ventilator check target values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Table 6-1. Values of diagnostic code digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Table 6-2. 840 Ventilator diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Table 6-3. Address codes for BDU POST analog devices test errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Table 6-4. BDU and GUI—Phase 1 (kernal) POST diagnostic codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Table 6-5. BDU only—Phase 2 POST diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Table 6-7. BDU or GUI—Phase 3 POST diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Table 6-8. Interrupt errors and test failures – POST self tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Table 6-9. SST diagnostic codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Table 6-11. UT0002 Fault Addresses for LCD inverter PCB errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102

Table 7-1. How the ventilator responds to alarm conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Table 7-2. Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Table 8-1. Testing and calibration requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Table 8-2. Differences between 9.4-inch and 10.4-inch GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Table 8-3. GUI part replacement chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Table 8-4. BDU part replacement chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Table 9-1. Abbreviations used in parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

xxiv 4-070496-00 Rev. A (08/ 03) 840 Ventilatory System Service M anual
 SECTION
S EC T I O N

General information 1 1
This section provides i ntroductory in form ati on on the Puri tan Ben nett 840 Ven til ator
System. In cluded are a descripti on of th e venti lator, i ncl uding specifi cati ons, requi red tools
and test equipm ent, schedul e of m ai ntenance, and control s and in dicators.

1.1 How t o use t his manual

This m an ual describes h ow to service the 840 Venti lator System. Puritan Ben nett
recom mends th at you becom e fam ili ar with th is m anual and accom panyi ng l abels before
attem pti ng to operate or m ain tain the venti lator.
The 840 Ventilator System Service Manual is i ntended to be used in conj un ction with th e 840
Ventilator System Operator’s and Technical Reference Manual. Both m anual s are n eeded for field
repai r of the ventil ator.
In several cases, however, sim ilar in form ation is contained i n both m an uals:
• Refer to th e “ M ai ntenan ce and servi ce” section of the 840 Ventilator System Operator’s and
Technical Reference Manual for operator m ain ten ance of filters an d the patient system .
Refer to Secti on 8 of th is m an ual for com pl ete venti lator m aintenan ce information.
• Refer to the “ Part num bers” appen dix of the 840 Ventilator System Operator’s and Technical
Reference Manual for pati en t system part num bers. Refer to Section 9 of th is m anual for
com plete part orderin g inform ation.

1.2 General product descript ion

The Puritan Benn ett 840 Ven til ator System i s a cri tical care ventil ator intended for acute an d
subacute care of i nfan t, pediatri c, an d adul t pati ents.
Electroni cally con troll ed and pneum atical ly powered, the 840 Ven til ator System contain s a
breath del ivery uni t (BDU), graphi cal user i nterface (GUI), and backup power source (BPS). An
opti onal com pressor unit and cart are al so avai labl e.
The BDU i s the core of the ventil ator. It contai ns the pneum atics that del iver gas and
el ectroni c an d electrical system s that con trol pneum atics, m on itor al arm s, and di stribute
power. The ven ti lator in cludes two i ndepen den t cen tral processi ng units (CPUs): one for the
BDU that control s venti lati on , and one for the GUI that m on itors ventil ator an d pati ent data.
The GUI CPU veri fies th at th e BD CPU i s functioning properly an d prevents a si ngl e fault
from causi ng a sim ul taneous failure of control li ng and m oni torin g operati on s.
The GUI provides a comm unicati on s path between th e ventil ator and the operator. By usin g
the touch screen, keys, and knob on the GUI th e practi tioner gives in itial i nstructions an d
data to the ventilator. Th e GUI CPU processes thi s inform ati on and stores it in the ventil ator’s
m em ory. The BD CPU uses this stored i nform ati on to control and m on itor the flow of gas to
and from th e patient.
The 840 Ventil ator System suppl ies m an datory or spontan eous breaths with a preset oxygen
concen trati on . A m andatory breath can be pressure- or volum e-controlled. A spontan eous
breath all ows the pati ent peak i nspi ratory fl ows up to 200 L/m in with or wi thout pressure
support.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 1-1
1 General information

The BPS (Backup Power Supply) provi des dc power to th e BDU in the event th at ac power is
l ost. A n ew, full y charged BPS all ows the ventil ator to function (wi thout compressor or
h umi di fi er) for at l east 30 m in utes; thus, th e BPS can power th e venti lator for transport
purposes wi th in the respi ratory care faci li ty. The BPS sh ould al ways be conn ected to the
venti lator duri ng operation.
The optional com pressor uni t provides com pressed ai r to the BDU, and can be used in place
of wall or bottl ed air for norm al operati on. The compressor uni t is powered by an d
com m un icates wi th the BDU.

NOTE:
An external air source is required when performing service mode calibrations and
performance verification testing.

1.3 Configurat ion informat ion

The 840 Venti lator System is avai lable in a variety of versi on s, i nten ded to m eet differing
n eeds and regulations through out the world. Th e m aj or differences i n configuration am ong
ven tilators are listed below:
Elect rica l req u irem en ts: Avai lable in 100 V, 50/60 Hz; 120 V, 60 Hz; 220 – 240 V, 50 Hz;
220 – 240 V, 60 Hz.
La n gu a ges: Keyboard, labels, software, an d operator’s m anual avai labl e in a vari ety of
l anguages.
Co m p ressor : With or without com pressor un it.
Mo u n t in g: Cart- or shel f-m oun t avai labl e.
Po w er co rd : A vari ety of plug en ds are avai lable. Refer to the parts list in Secti on 9 of thi s
m an ual or the 840 Ventilator System Operator’s and Technical Reference Manual for speci fi c part
n um bers.
O x y gen a n d a ir fit t in gs: Ven til ator avai lable with diam eter i ndex safety stan dard (DISS)
m al e, DISS fem al e, nonin terchan geable screw thread (NIST) m al e, Ai r Liquide, and sleeve
i ndex system (SIS) m ale fitti ngs.
O x y gen a n d a ir h o ses: Versi on s avail abl e to connect to DISS m ale, Air Li qui de, SIS m ale,
Bri ti sh Oxygen Com pany (BOC) fem ale, NIST m al e, and Dräger femal e supply fittings. DISS
fem al e x DISS fem al e version s availabl e i n different colors to satisfy differen t coun tries’
requirem ents.
Accesso ries: Ventil ators may be equipped with accessories l isted in Section 1.4.

1.4 Accessories
The followi ng accessories are eith er required or can be used with th e venti lator.
Pa tien t c ircu it : A variety of reusable Puritan Bennett patient ci rcui ts, adult an d pedi atric,
with and wi thout w ater traps, an d wi th and without h eated wi re, i s avail abl e. Consult the
“ Part num bers” appendi x of th e 840 Ventilator System Operator’s and Technical ReferenceManual
for pati ent circui t orderi ng in form ation.
H u m id ifica t ion d ev ic e: Th e 840 Venti lator System supports th e use of an optional
h um idi fication devi ce, in cludin g a heated humi difier, h eat and moisture exchan ger (HM E),
or heated wire. A m oun ti ng bracket i s avail abl e for the Fi sher & Paykel M 480/ M 730
Hum i difier. An ac socket for the humi di fier is avail abl e on 100 and 120 V ventil ators.
Rem o t e n u rse ca ll u n it: An anal og output con nector permi ts connection to a rem ote nurse
call uni t. (Puri tan Ben nett does not supply nurse’s call un its or cabl es.) Refer to th e 840
Ventilator System Operator’s and Technical ReferenceManual for nurse cal l specifi cations.

1-2 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
General information 1
1.5 Specificat ions

Table 1-1: Vent ilat or specificat ions

Physical char act erist ics

Weight Breath delivery unit (BDU): 18.2 kg (40.1 lb)

Graphic user interface (GUI): 5.7 kg (12.6 lb)
Backup power source (BPS): 6.6 kg (14.6 lb)
Cart: 15.5 kg (34.2 lb)
804 Compressor unit: 31.6 kg (69.7 lb)
806 Compressor unit (100 V, 120 V): 23.6 kg (52 lb)
806 Compressor unit (220 V): 24.5 kg (54 lb)

Dimensions BDU: 330 mm high x 457 mm wide x 254 mm deep (13 in. high x 18 in. wide x 10 in. deep)
GUI: 460 mm high x 394 mm wide x 170 mm deep (18.1 in. high x 15.5 in. wide x 6.7 in. deep)
BPS: 83 mm high x 244 mm wide x 254 mm deep (3.25 in. high x 9.6 in. wide x 10 in. deep)
Cart: 998 mm high x 582 mm wide x 602 mm deep (39.3 in. high x 22.9 in. wide x 23.7 in. deep)
804 Compressor: 417 mm high x 458 mm wide x 362 mm deep (16.4 in. high x 18 in. wide x 14.25
in. deep)
806 Compressor: 425 mm high x 458 mm wide x 362 mm deep (17 in. high x 18 in. wide x 14.25
in. deep)

Connectors Inspiratory limb connector: ISO 22-mm conical male

Expiratory limb connector (on expiratory filter): ISO 22-mm conical male
Air and oxygen inlets: DISS male, DISS female, NIST, Air Liquide, or SISfitting (depending on country
and configuration)

Environm ent al requirement s

Temperature Operating: 10 to 40 °C (50 to 104 °F) at 10 to 95% relative humidity, noncondensing

Storage: -20 to 50 °C (-4 to 122 °F) at 10 to 95% relative humidity, noncondensing

Atmospheric Operating: 700 to 1060 hPa (10.2 to 15.4 psi)

pressure Storage: 500 to 1060 hPa (7.3 to 15.4 psi)

Altitude Operating: -443 to 3280 m (-1350 to 10,000 ft)

Storage: Up to 6560 m (20,000 ft)

Pneum at ic sp ecificat ions

Oxygen and air inlet Pressure: 241 to 690 kPa (35 to 100 psi)
supplies
Warning
Due to excessive restriction of the Air Liquide, SIS, and Dräger hose assemblies, reduced
ventilator performance levels may result when oxygen or air supply pressures < 50 psi
(345 kPa) are employed.

Flow: M aximum of 200 L/ min

Oxygen sensor life The oxygen sensor should be replaced two years after date of manufacture, or as often as necessary.
Actual sensor life depends on operating environment; operation at higher temperature or O2% levels
will shorten sensor life.

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1 General information

Table 1-1: Vent ilator specifications (cont inued)

Gas mixing system Range of flow from the mixing system: Can be set to 150 L/ min standard temperature and pressure,
dry (STPD). Additional flow is available (up to 80 L/ min for pediatric patients whose IBW ≤ 24 kg,
and up to 200 L/ min for adults whose IBW > 24 kg) for compliance compensation.
Leakage from one gas system to another: Meets standard EN 60601-2-12.
Operating pressure range: 35 to 100 psi (241 to 690 kPa)
Air/ oxygen regulator bleed: Up to 3 L/ min

Elect rical specif icat ions

Input power Ventilator operation without compressor:

100 V~, 50/ 60 Hz; 5.1 A; 510 VA
120 V~, 60 Hz; 4.5 A; 540 VA
220 – 240 V~, 50 Hz; 1.5 A; 330 - 360 VA
220 – 240 V~, 60 Hz; 1.5 A; 330 - 360 VA
Ventilator operation with compressor:
100 V~, 50/ 60 Hz; 10.7 A; 1070 VA
120 V~, 60 Hz; 10.1 A; 1212 VA
220 – 240 V~, 50 Hz; 4.1 A; 902 - 984 VA
220 – 230 V~, 60 Hz; 4.1 A; 902 - 943 VA
M ains overcurrent release:
Ventilator: 5 A, 100 – 120 V~; 5 A, 220 – 240 V~
Auxiliary mains: 10 A, 100 – 120 V~; 5 A, 220 – 240 V~
Ventilator operation without humidifier or compressor:
Approximately 1126 BTU
Ventilator operation with 806 compressor and without humidifier:
Approximately 3078 BTU

NOTE:
Above values obtained using the following ventilator settings at 22 °C ambient temperature: mode, A/ C; mandatory
type, PC; IBW, 85 kg; fTOT, 20/ min; PSUPP, 30 cmH2O; TI, 1 s; Rise Time Percent (was Flow Acceleration), 50%; O2%,
50%; PMEAN, 50 cmH2O; PSENS, 3 cmH2O. Input power specifications are for ventilators with Fisher & Paykel M R730
humidifiers. (Humidifier connection only available on 100 – 120 V ventilators.)

Leakage current Earth leakage current:

At 100 – 120 V~ operation: 300 µA
At 220 – 240 V~ operation: 500 µA
Enclosure/ patient leakage current:
100 – 120 V~ operation: 100 µA maximum
220 – 240 V~ operation: 100 µA maximum
Humidifier leakage current: 50 µA maximum
Patient auxiliary leakage current: Not applicable

Warning
In the event of a defective earth conductor, connecting equipment to the auxiliary mains
socket outlet(s) (that is, the humidifier or compressor connections) may increase patient
leakage current to values that exceed the allowable limits.

Alarm volume 45 dB(A) to 85 dB(A)

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General information 1
Table 1-1: Ventilat or specificat ions (cont inued)

802 Backup Power 24 V dc, 6.5 Ah

Source (BPS) Operating time (for a new, fully charged battery): at least 30 minutes. Actual duration depends on
ventilator settings, battery age, and level of battery charge.
Recharge time: Automatically recharges within 8 hours maximum while ventilator is connected to ac
power.
Shelf life: 24 months from date of manufacture.
Recharge requirements: Recharge every 6 months when storage temperature is -20 to 29 °C (-5 to
84 °F); every 3 months when storage temperature is 30 to 40 °C (86 to 104 °F); every 2 months
when storage temperature is 41 to 50 °C (105 to 122 °F).
Storage conditions: Store at -20 to 50 °C (-4 to 122 °F), 25 to 85% relative humidity; avoid direct
sunlight.

NOTE:
BPS battery life specifications are approximate. To ensure maximum battery life, maintain full
charge and minimize the number of complete discharges.

Communications Rem ot e alarm (nurse’s call) port (Figure 1-1). Allows medium- and high-urgency alarm conditions
capabilities to be annunciated at locations away from the ventilator (for example, when the ventilator is in an
isolation room). The ventilator signals an alarm using a normally open or a normally closed signal.
The ventilator asserts a remote alarm when there is an active medium- or high-urgency alarm
condition, unless the alarm silence function is active. The remote alarm port is a 4-pin female
connector. Allowable current is 500 mA at 30 V dc (maximum).

4 1
3 2
8-00020

Pin Signal

1 Normally closed (NC)

2 Relay common

3 Normally open (NO)

4 Not connected

Figure 1-1. Remote alarm (nurse’s call) port pinout

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 1-5

1 General information

Table 1-1: Vent ilator specifications (cont inued)

Communication RS-232 (serial) port (Figure 1-2). A 9-pin male connector configured as data terminal equipment
capabilities (cont) (DTE). Allowable current is 0.2 A at 10 V dc (maximum).
1 2 3 4 5

8-00019
6 7 8 9

Figure 1-2. 840 Vent ilat or System RS-232 serial port pinout

Pin Signal

1 Not connected
2 Receive data (RxD)
3 Transmit data (TxD
4 Data terminal ready (DTR), terminated high
5 Ground (GND)
6 Not connected
7 Request to send (RTS)
8 Clear to send (CTS)
9 Not connected

NOTE:
The connection of accessories or equipment to the ventilator’s RS-232 and remote alarm ports
requires electrical separation of conductive earth (ground) connections between different items of
equipment of a system. The system cable assembly shielding can interconnect the ventilator and
other equipment, increasing the risk of excessive enclosure leakage current from external
equipment. For safe connection and prevent a double earth ground, the shield conductor must have
separation of 4 mm between the equipment and ventilator conductors, as shown below:

Minimum shield
To 840 Ventilator RS-232 and Cable conductive separation
remote alarm input connectors shielding 4 mm

Cable signal lines To accessory equipment

connector
Cable shield earth to ventilator
enclosure protective earth

1-6 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
General information 1
1.6 Compliance and approvals
The 840 Ventil ator System was developed in accordance with perti nent FDA guidances and
North Am erican an d EN 46001/ISO 13485 i nternati onal standards (Table 1-2). Th e
m anufacturin g faci li ty for this product i s EN 46001 certifi ed.
The ven til ator’s IEC 60601-1/EN 60601-1 classi ficati on i s Protecti on cl ass I, Type B, internal ly
powered, IPX 1 drip-proof equi pm en t, continuous operation.

Table 1-2: Compliance w it h standards

St andards/ cert ificat ions Configurat ions Cert ificat ion agency

Nor t h Am erica

Authorized to bear the CSA certification mark, 120 V, 60 Hz Canadian Standards

signifying the product has been evaluated to 220 – 240 V, 50 Hz Association (CSA)
the applicable ANSI/ Underwriters 220 – 240 V, 60 Hz
Laboratories Inc. (UL) and CSA standards for
use in the US and Canada.
CSA C22.2 No. 601.1
CSA C22.2 No. 601.1 Supplement 1
IEC No. 60601-2-12
UL No. 2601-1

Wor ldw ide

CB scheme certification: 100 V, 50/ 60 Hz Canadian Standards

IEC 60601-1 120 V, 60 Hz Association (CSA)
IEC 60601-1-1 220 – 240 V, 50 Hz
IEC 60601-1-2 220 – 240 V, 60 Hz
IEC 60601-2-12

IEC 60601-1-4 220 – 240 V, 50 Hz --

ISO 10651-1 220 – 240 V, 60 Hz

Eur opean

Approved to the type test requirements of 220 – 240 V, 50 Hz TÜV Product Service
Annex III of the Medical Device Directive. 220 – 240 V, 60 Hz
EN 60601-1
EN 60601-1-1
EN 60601-1-2
EN 794-1

EN 60601-1-4 --

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1 General information
1.7 Technical informat ion
Refer to Tabl e 1-3 for 840 Ven til ator System m iscel lan eous techn ical information.
NOTE:
When pressure units are set to hPa, pressure delivery and spirometry are subject to an additional 2% error.
M aximum limited pressure
M aximum working pressure
M easuring and display devices
M easuring and display devices
(cont)
M inute volume
(VE TOT) capability
Results of ventilator patient
circuit testing (using circuits
identified for use with 840
Ventilator)
1-8 4-070496-00 Rev. A (08/ 03)
Table 1-3: Technical informat ion
127.5 cmH2O (130 hPa)
100 cmH2O (102 hPa), ensured by high pressure limit
90 cmH2O (pressure-based ventilation)
Pressure measurements:
Type: Silicon solid-state differential pressure transducer
Sensing position: Inspiratory and expiratory limbs (used to algorithmically
approximate circuit wye pressure)
M easurements: M ean circuit pressure (range: -20 to 120 cmH2O, -20.4 to 122 hPa);
peak circuit pressure (range: -20 to 130 cmH2O, -20.4 to 133 hPa)
Volume measurements:
Type: Hot film anemometer.
Sensing position: Exhalation compartment
M easurements: Exhaled tidal volume (range: 0 to 6,000 mL); total minute volume
(range: 0 to 99.9 L)
Oxygen measurement:
Type: Galvanic cell
Sensing position: Inspiratory manifold
M easurement: Delivered% O2 (range: 0 to 103%)
Display of settings, alarms, and monitored data:
Type: Two liquid crystal display (LCD) touch screens
25 to 75 L/ min
Inspiratory pressure drop from inlet of open safety valve to outlet port without
inspiratory filter:
At 5 standard liters per minute (SL/ min): 0.06 cmH2O
At 30 SL/ min: 0.28 cmH2O
At 60 SL/ min: 0.95 cmH2O
Inspiratory pressure drop across inspiratory filter:
At 5 SL/ min: 0.17 cmH2O
At 30 SL/ min: 0.56 cmH2O
At 60 SL/ min: 1.37 cmH2O
Inspiratory pressure drop from inlet of open safety valve with inspiratory filter:
At 5 SL/ min: 0.17 cmH2O
At 30 SL/ min: 0.84 cmH2O
At 60 SL/ min: 2.32 cmH2O
Pressure drop across 1.68 m (5.5 ft) inspiratory or expiratory limb with water trap, to
patient wye:
Neonatal patient circuit N/ A (no water trap)
Pediatric patient circuit at 30 SL/ min: 0.73 cmH2O
Adult patient circuit at 60 SL/ min: 1.05 cmH2O
840 Ventilator System Service Manual
General information
Results of ventilator patient
circuit testing (using circuits
identified for use with 840
Ventilator) (continued)
NOTE:
• Patient circuit testing specifications are with the ventilator powered off, and are based on the
recommended configurations shown in the 840 Ventilator System Operator’s and Technical Reference
Manual.
• To ensure that compliance compensation functions correctly, the user must run SST with the circuit
configured as intended for use on the patient.
Bacteria filter efficiency
840 Ventilator System Service Manual
1
Table 1-3: Technical inform at ion (continued)
Pressure drop across 1.22 m (4 ft) inspiratory or expiratory limb without water trap, to
patient wye:
Neonatal patient circuit at 5 SL/ min: 0.45 cmH2O (inspiratory limb)
Neonatal patient circuit at 5 SL/ min: 0.40 cmH2O (expiratory limb)
Pediatric patient circuit at 30 SL/ min: 0.56 cmH2O
Adult patient circuit at 60 SL/ min: 0.70 cmH2O
Pressure drop across Fisher & Paykel humidifier and lead-in tube:
Neonatal patient circuit at 5 SL/ min: 0.14 cmH2O
Pediatric patient circuit at 30 SL/ min: 0.28 cmH2O
Adult patient circuit at 60 SL/ min: 0.93 cmH2O
Expiratory pressure drop across exhalation compartment:
At 5 SL/ min: 0.21 cmH2O (with neonatal filter and vial)
At 30 SL/ min: 1.5 cmH2O
At 60 SL/ min: 3.40 cmH2O
Total inspiratory pressure drop:
Neonatal patient circuit with neonatal filter/ vial at 5 SL/ min: 0.76 cmH2O
Pediatric patient circuit with water traps at 30 SL/ min: 1.85 cmH2O
Pediatric patient circuit without water traps at 30 SL/ min: 1.68 cmH2O
Adult patient circuit with water traps at 60 SL/ min: 4.30 cmH2O
Adult patient circuit without water traps at 60 SL/ min: 3.95 cmH2O
Total expiratory pressure drop:
Neonatal patient circuit with neonatal filter and vial at 5 SL/ min: 0.61 cmH2O
Pediatric patient circuit with water traps at 30 SL/ min: 2.23 cmH2O
Pediatric patient circuit without water traps at 30 SL/ min: 2.06 cmH2O
Adult patient circuit with water traps at 60 SL/ min: 4.45 cmH2O
Adult patient circuit without water traps at 60 SL/ min: 4.10 cmH2O
Internal volume:
Inspiratory pneumatics: 50 mL ±5 mL
Expiratory pneumatics: 1000 mL ±25 mL (including expiratory filter and collector vial)
The 840 Ventilator automatically adjusts for volume losses due to gas compressibility
(that is, automatic compliance compensation), subject to a maximum delivered volume
of 2500 mL.
99.97% for nominal particle size of 0.3 µm (micron) at 100 L/ min
4-070496-00 Rev. A (08/03) 1-9
1 General information

1.8 Range, resolut ion, accuracy, and new pat ient / default set t ings
Ranges, resol utions, accuracies, and new pati en t defaults for ven til ator setti ngs, alarm
settin gs, and patient data are listed in Tabl e 1-4.

Table 1-4: Ventilat or range, resolut ion, accuracy, new pat ient/ default s

Set t ing Range, resolut ion, accuracy, new pat ient / default

Vent ilat or set t ings

Apnea vent ilat ion

Apnea expiratory time (TE) Range: TE ≥ 0.2 s

Resolution: 0.01 s
Accuracy: ± 0.01 s
New patient: Apnea TTOT - Apnea TI

Apnea flow pattern Range: Square or descending ramp

Resolution: Not applicable
Accuracy: Not applicable
New patient: Descending ramp with NEONATAL patient circuit
Square with PEDIATRIC or ADULT patient circuit

Apnea I:E ratio Range: ≤ 1.00:1

Resolution: 0.01
Accuracy: ± 0.01 s of the inspiratory time determined by the I:E ratio and respiratory rate
settings
New patient: 1: Apnea TE/ TI

Apnea inspiratory pressure Range: 5 to 90 cmH2O: PI + PEEP < 90 cmH2O

(PI) Resolution: 1.0 cmH2O
Accuracy: ± (3.0 + 2.5% of setting) cmH2O, measured at the patient wye, 1 second after
the beginning of inspiration when the Rise Time Percent (formerly Flow
Acceleration) is 100%
New patient: 15 cmH2O

Apnea inspiratory time (TI) Range: TI 0.2 s to 8.00 s

Thigh 0.2 s to 30 s in Bi-Level mode
Resolution: 0.01 s
Accuracy: ± 0.01 s
New patient: Based on VT , Peak Flow, Plateau time, and Waveform shape in VC

Apnea interval (TA) Range: 10 to 60 s

Resolution: 1 s
Accuracy: ± 0.01 s

Apnea mandatory type Range: VC or PC

Resolution: N/ A
Accuracy: N/ A
New patient: PC with NEONATAL patient circuit
VC with PEDIATRIC or ADULT patient circuit

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General information 1
Table 1-4: Ventilator range, resolut ion, accuracy, new pat ient / default s (continued)

Set t ing Range, resolut ion, accuracy, new pat ient / default

Apnea O2% Range: 21 to 100%

Resolution: 1%
Accuracy: ± 3% by volume over the entire breath, achieved at the ventilator's inspiratory
port in steady state when at least 8 breaths and a total volume of 1 liter has been
delivered, and 15 seconds have passed following a settings change affecting the
delivered flow trajectories.
New patient: 40% with NEONATAL patient circuit
100% with PEDIATRIC or ADULT patient circuit

Apnea peak inspiratory Range: 1.0 to 30 L/ min when patient circuit is neonate
flow (VMAX) 3.0 to 60 L/ min when patient circuit is pediatric
3.0 to 150 L/ min when patient circuit is adult
Resolution: 0.1 L/ min for peak flows from 3 to 20 L/ min
1 L/ min for peak flows above 20 L/ min
Accuracy: ± (0.5 + 10% of setting) L/ min of the flow command input to the flow controller,
at the end of each control interval, after the first 100 milliseconds of inspiration.
New patient: Maximum of 1.0 or (0.87 x IBW) L/ min with NEONATAL patient circuit
M aximum of 3.0 or (0.572 x IBW) L/ min with PEDIATRIC patient circuit
M aximum of 3.0 or (0.435 x IBW) L/ min with ADULT patient circuit

Apnea respiratory rate (f) Range: 2.0 to 40/ min

Resolution: 0.1/ min for 2.0 to 9.9/ min; 1/ min for 10 to 40/ min
Accuracy: ± (0.1 + 0.6% of setting)/ min averaged over 60 s or 5 breaths, whichever
occurs later
New patient: 20/ min with NEONATAL patient circuit
14/ min with PEDIATRIC patient circuit
10/ min with ADULT patient circuit

Apnea tidal volume rate Range: ≥ 5 mL with NEONATAL patient circuit

(VT) ≥ 25 mL with PEDIATRIC or ADULT patient circuit
≤ 2500 mL with ADULT patient circuit
IBW base range: 1.16 x IBW minimum, 45.7 x IBW maximum
Resolution: 1.0 mL for 25 to 100 mL
5 mL for 100 to 400 mL
10 mL for 400 to 2,500 mL (full scale)
Accuracy: For TI < 600ms, ± (10+10% x 600ms/ TIms of setting), mL
otherwise ± (10+10% of setting), mL with PEDIATRIC or ADULT patient circuit;
± (4+10% of setting), mL with NEONATAL patient circuit
Applicable during steady state when 3 consecutive breaths are within 1% of
each other, and only when the flow limit and compliance compensation limits
are not reached.
New patient: Maximum of 5 mL or (7.25 x IBW); with NEONATAL patient circuit
(7.25 x IBW); with PEDIATRIC or ADULT patient circuit

Norm al (non-apnea) vent ilat ion

Constant during rate change Range: Inspiratory time, I:E ratio, or expiratory time
Resolution: Not applicable
Accuracy: Not applicable
New patient: Inspiratory time

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1 General information
Table 1-4: Vent ilator range, resolut ion, accuracy, new pat ient/ defaults (cont inued)
Set t ing
Disconnect sensitivity (DSENS)
Expiratory sensitivity (ESENS)
Expiratory time (TE)
Rise Time Percent (formerly
Flow Acceleration)
Flow pattern
Flow sensitivity (VSENS)
Humidification type
Ideal body weight (IBW)
1-12 4-070496-00 Rev. A (08/ 03)
Range, resolut ion, accuracy, new pat ient / default
Range: 20 to 95%
Resolution: 1%
Accuracy: Not applicable
New patient: 75%
Range: 1 to 80%
Resolution: 1%
Accuracy: Not applicable
New patient: 25%
Range: TE ≥ 0.2 s
Resolution: 0.01 s
Accuracy: ±0.01 s
New patient: 60/ f(new patient) - TI (new patient), s
Range: 1 to 100%
Resolution: 1%
Accuracy: Not applicable
New patient: 50%
Range: Square or descending ramp
Resolution: Not applicable
Accuracy: Not applicable
New patient: Descending ramp with NEONATAL patient circuit
Square with PEDIATRIC or ADULT patient circuit
Range: 0.1 to 10.0 L/ min with NEONATAL patient circuit
0.2 to 20.0 L/ min with PEDIATRIC or ADULT patient circuit
Resolution: 0.1 L/ min
Accuracy: Not applicable
New patient: 1.0 L/ min with NEONATAL patient circuit
2.0 L/ min with PEDIATRIC patient circuit
3.0 L/ min with ADULT patient circuit
Range: HME, non-heated expiratory tube, or heated expiratory tube
Resolution: Not applicable
Accuracy: Not applicable
Default: non-heated expiratory tube
Range: 0.5 kg (1.1 lb) to 7 kg (15.4 lb) with NEONATAL patient circuit
3.5 kg (7.7 lb) to 35 kg (77 lb) with PEDIATRIC patient circuit
7.0 kg (15.4 lb) to 150 kg (330 lb) with ADULT patient circuit
Resolution: 0.1 kg for 0.5 kg to 3.5 kg
0.5 kg for 4.0 to 9.5 kg
1 kg for 10 to 50 kg
5 kg for 50 to 100 kg
10 for 100 to 150 kg
Accuracy: Not applicable
New patient: 3.0 kg with NEONATAL patient circuit
15 kg with PEDIATRIC patient circuit
50 kg with ADULT patient circuit
840 Ventilator System Service Manual
General information
Table 1-4: Ventilator range, resolut ion, accuracy, new pat ient / default s (continued)
Set t ing
I:E ratio
Inspiratory pressure (PI)
Inspiratory time (TI)
Mandatory type
Mode
O2%
Patient circuit type
Peak inspiratory flow (VMAX)
840 Ventilator System Service Manual
1
Range, resolut ion, accuracy, new pat ient / default
Range: ≤ 4.00:1
Resolution: 0.01 for 4.00:1 to 1:9.99
0.1 for 1:10.0 to 1:99.9
1 for 1:100 to 1:299
Accuracy: ±0.01 s of the inspiratory time determined by the I:E ratio and respiratory
rate settings
New patient: 1: TE / TI
Range: 5 to 90 cmH2O: PI + PEEP ≤ 90 cmH2O
Resolution: 1.0 cmH2O
Accuracy: ± (3.0 + 2.5% of setting) cmH2O, measured at patient wye (end inspiratory
pressure after 1 s when Rise Time Percent (was Flow Acceleration) is 100%)
New patient: 15 cmH2O
Range: TI 0.2 to 8.00 s
Thigh 0.2 to 30 s in Bi-Level mode
Resolution: 0.01 s
Accuracy: ± 0.01 s
New patient: Based on Vt, Peak Flow, Plateau time, and Waveform shape in VC
Range: VC or PC
Resolution: Not applicable
Accuracy: Not applicable
New patient: PC with NEONATAL patient circuit
VC with PEDIATRIC or ADULT patient circuit
Range: A/ C, SIMV, SPONT, or Bi-Level
Resolution: Not applicable
Accuracy: Not applicable
New patient: SIM V with NEONATAL patient circuit
A/ C with PEDIATRIC or ADULT patient circuit
Range: 21 to 100%
Resolution: 1% O2
Accuracy: ± 3% by volume over the entire breath, achieved at the ventilator's inspiratory
port in steady state when at least 8 breaths and a total volume of 1 liter has been
delivered, and 15 seconds have passed following a settings change affecting the
delivered flow trajectories.
Range: Neonatal (if Neo-mode option is active), Pediatric, or Adult
Resolution: Not applicable
Accuracy: Not applicable
Range: 1.0 to 30 L/ min with NEONATAL patient circuit
3.0 to 60 L/ min with PEDIATRIC patient circuit
3 to 150 L/ min with ADULT patient circuit
Resolution: 0.1 L/ min for flows of 3 to 20 L/ min; 1 L/ min for flows above 20 L/ min
Accuracy: ± (0.5 + 10% of setting) L/ min of the flow command input to the flow controller,
at the end of each control interval, after the first 100 milliseconds of inspiration.
4-070496-00 Rev. A (08/03) 1-13
1 General information

Table 1-4: Vent ilator range, resolut ion, accuracy, new pat ient/ defaults (cont inued)

Set t ing Range, resolut ion, accuracy, new pat ient / default

PEEP Range: 0 to 45 cmH2O

Resolution: 0.5 cmH2O for 0 to 19.5 cmH2O; 1 cm for 20 to 45 cmH2O
Accuracy: ± (2.0 + 4% of setting) cmH2O measured at patient wye. PEEP measured
with returned flow < 5 L/ min.
New patient: 3 cm H2O

Plateau time (TPL) Range: 0.0 to 2.0 s

Resolution: 0.1 s
Accuracy: ± 0.01 s
New patient: 0.0 s

Pressure sensitivity (PSENS) Range: 0.1 to 20 cmH2O below PEEP

Resolution: 0.1 cmH2O
Accuracy: Not applicable
New patient: 2 cm H2O

Pressure support (PSUPP) Range: 0 to 70 cmH2O: PSUPP + PEEP ≤ 90 cm H2O

Resolution: 1 cmH2O
Accuracy: ± (3.0 +2.5% of setting) cmH2O measured at the patient wye 1 second after the
beginning of inspiration when the Rise Time Percent (was Flow Acceleration) is
100%, provided that inspiration is not terminated prematurely.

Respiratory rate (f) Range: 1 to 100/ min

≤ 150 / min with NEONATAL patient circuit
≤ 100 / min with PEDIATRIC or ADULT patient circuit
Resolution: 0.1/ min for 1.0 to 9.9/ min; 1/ min for 10 to 100/ min
Accuracy: ± (0.1 + 0.6% of setting)/ min averaged over 60 seconds or 5 breaths,
whichever occurs last
New patient: 20/ min with NEONATAL patient circuit
14/ min with PEDIATRIC patient circuit
10/ min with ADULT patient circuit

Safety ventilation Settings are identical to new patient values, except: mode = A/ C, mandatory type = PC,
respiratory rate = 16/ min, inspiratory time = 1 s, inspiratory pressure = 10 cmH2O, PEEP =
3 cmH2O, trigger type = pressure, O2% = 100% (21% if O2 not available), patient circuit
type = last set value or ADULT if none available, humidification type = last set value or
NON-HEATED EXP TUBE if none available, humidifier volume = last set value or 480 mL if
none available.
Alarm settings in safety ventilation: high circuit pressure = 20 cmH2O, high exhaled minute
volume = OFF, high exhaled tidal volume = OFF, high respiratory rate = OFF, low exhaled
mandatory tidal volume = OFF, low exhaled minute volume = 0.05 L, low exhaled
spontaneous tidal volume = OFF

Support type Range: PS, TC, or NONE

Resolution: Not applicable
Accuracy: Not applicable
New patient: PS

1-14 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
General information 1
Table 1-4: Ventilator range, resolut ion, accuracy, new pat ient / default s (continued)

Set t ing Range, resolut ion, accuracy, new pat ient / default

Tidal volume (VT) Range: ≥ 5 mL with NEONATAL patient circuit

≥ 25 mL with PEDIATRIC or ADULT patient circuit
≤ 2500 mL with ADULT patient circuit
IBW based range: 1.16 x IBW minimum, 45.7 x IBW maximum
Resolution: 1.0 mL for 25 to 100 mL
5 mL for 100 to 400 mL
10 mL for 400 to 2,500 mL (full scale)
Accuracy: For TI < 600ms, ± (10+10% x 600ms/ TIms of setting), mL
otherwise ± (4+10% of setting), mL with NEONATAL patient circuit
± (10+10% of setting), mL with PEDIATRIC or ADULT patient circuit
Applicable during steady state when 3 consecutive breaths are within 1% of each
other, and only when the flow limit and compliance compensation limits are not
reached.
New patient: Maximum of 5 mL or (7.25 x IBW) with NEONATAL patient circuit
(7.25 x IBW) with PEDIATRIC or ADULT patient circuit

Trigger type Range: Flow with NEONATAL patient circuit

Pressure or Flow with PEDIATRIC or ADULT patient circuit
Resolution: Not applicable
Accuracy: Not applicable
New patient: Flow

Setting limits for volume
control (VC) mandatory
breaths
Tidal volume: 25 mL ≤ VT ≤ 2500 mL; 1.16 mL/ kg ≤ VT ≤ 45.7 mL/ kg (default 7.25 mL/ kg)
Inspiratory time: 0.2 s ≤ TI ≤ 8 s
Expiratory time: 0.2 s ≤ TE ≤ 59.8 s
I:E ratio: 1:299 ≤ I:E ≤ 1:4.00
Flow (at 1/ min ≤ f ≤ 100/ min):
3 L/ min ≤ V ≤ 60 L/ min for IBW ≤ 24 kg
150 L/ min ≤ V for IBW > 24 kg
M inute volume (using square flow pattern, I:E = 1:1, and f ≥ 30/ min):
30 L/ min ≤ VE for IBW < 24 kg
30 L/ min < VE < 75 L/ min for IBW 24 to 54 kg
M aximum VE = 75 L/ min for IBW 55 to 150 kg
TI is a function of VT, flow pattern, TPL, and VMAX
TE is a function of VT, flow pattern, TPL, and f
I:E is the result of TI and TE
Any combination of settings for VT, VMAX, TPL, f, and flow pattern that violates these
boundaries is rejected. Refer to the Technical Reference section of the 840 Ventilator System
Operator’s and Technical Reference Manual for more details.

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1 General information

Table 1-4: Vent ilator range, resolut ion, accuracy, new pat ient/ defaults (cont inued)

Set t ing Range, resolut ion, accuracy, new pat ient / default

Setting limits for pressure
control (PC) mandatory
breaths
Inspiratory pressure: PI = 5 to 90 cmH2O; PI + PEEP ≤ 90 cmH2O; PI + PEEP
+ 2 cmH2O ≤ 1PMEAN
Inspiratory time: 0.2 s ≤ TI ≤ 8 s
Expiratory time: 0.2 s ≤ TE ≤ 59.8 s
I:E ratio: 1:299 ≤ I:E ≤ 1:4.00
Respiratory rate: 1/ min ≤ f ≤ 100/ min
High circuit pressure limit: 7 cmH2O ≤ ↑ PMEAN ≤ 100 cmH2O
TI is a function of f (for I:E or TE constant during rate change) and TE. TE is a function of f
(for I:E or TI constant during rate change) and TI. I:E is a function of f (for TI or TE constant
during rate change), TI, and TE.
Any combination of settings for PI, PEEP, 1PMEAN, f, TI, I:E, or TE that violates these
boundaries is rejected. Refer to the Technical Reference section of the 840 Ventilator System
Operator’s and Technical Reference Manual for more details.

Setting limits when selected
support type is pressure
support (PS)
Support pressure: PSUPP = 0 to 70 cmH2O; PSUPP + PEEP ≤ 90 cmH2O
PEEP: PEEP = 0 to 45 cmH2O; PEEP + 7 cmH2O ≤ 1PMEAN
High circuit pressure limit: PSUPP + PEEP + 2 cmH2O ≤ 1PMEAN
Any combination of settings for PSUPP, PEEP, or 1PMEAN that violates the above boundaries
is rejected. Refer to the Technical Reference section of part of the 840 Ventilator System
Operator’s and Technical Reference Manual for more details.

Alarm set t ings

Apnea interval (TA) Range: 10 to 60 s

Resolution: 1 s

High circuit pressure limit Range: 7 to 100 cmH2O

(↑ PPEAK) Resolution: 1 cmH2O
New patient: 30 cmH2O with NEONATAL patient circuit
40 cmH2O with PEDIATRIC or ADULT patient circuit
NOTE: New symbol for peak circuit pressure (monitored) (was PCIRC MAX)

High exhaled minute volume Range: 0.1 to 100 L or OFF

limit (2V E TOT) Resolution: 0.005 L for 0.05 to 0.5 L; 0.05 L for 0.5 to 5 L; 0.5 for 5 to 99.5 L
New patient: ((20 x 7.25 x IBW x 1.30/ 1000) + 0.05) with NEONATAL patient circuit
((14 x 7.25 x IBW x 1.30/ 1000) + 0.05) with PEDIATRIC patient circuit
((10 x 7.25 x IBW x 1.30/ 1000) + 0.05) with ADULT patient circuit

High exhaled tidal volume Range: 5 to 3000 mL or OFF

limit (2 VTE) 5 to 500 mL with NEONATAL patient circuit
25 to 1500 mL with PEDIATRIC patient circuit
25 to 3000 mL with ADULT patient circuit
Resolution: 1 mL for 5 to 99 mL; 5 mL for 100 to 399 mL; 10 mL for 400 to 2500 mL
New patient: maximum of 5 mL or (7.25 x IBW x 1.30)

High respiratory rate limit Range: 10 to 170/ min or OFF

(2 fTOT ) ≤ 170/ min with NEONATAL patient circuit
≤ 110/ min with PEDIATRIC or ADULT patient circuit
Resolution: 1/ min
New patient: OFF

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General information 1
Table 1-4: Ventilator range, resolut ion, accuracy, new pat ient / default s (continued)

Set t ing Range, resolut ion, accuracy, new pat ient / default

Low exhaled mandatory tidal Range: 1 to 2500 mL or OFF

volume limit < High Exhaled Tidal Volume Limit
(4 TE MAND) ≤ 300 mL with NEONATAL patient circuit
≤ 1000 mL with PEDIATRIC patient circuit
≤ 2500 mL with ADULT patient circuit
Resolution: 1 mL for 25 to 99 mL; 5 mL for 100 to 399 mL; 10 mL for 400 to 2500 mL
New patient: 7.25 x IBW x 0.70

Low exhaled minute volume
limit (4VE TOT)
Range: < high exhaled minute volume limit
OFF (immediately following the soft limit of 0.01 L/ min) to 10 L/ min with
NEONATAL patient circuit
0.05 L/ min ≤ 4VE TOT ≤ 30 L/ min with PEDIATRIC patient circuit
0.05 L/ min ≤ 4VE TOT ≤ 60 L/ min with ADULT patient circuit
Resolution: 0.005 L for 0.01 to 0.50 L; 0.05 L for 0.50 to 5.0 L; 0.50 L for 5.0 to 60.0 L
New patient: maximum of 0.01 or ((20 x 7.25 x IBW x 0.70/ 1000) - 0.05) with NEONATAL
patient circuit
((14 x 7.25 x IBW x 0.70/ 1000) - 0.05) with PEDIATRIC patient circuit
((10 x 7.25 x IBW x 0.70/ 1000) - 0.05) with ADULT patient circuit

Low exhaled spontaneous Range: 1 to 2500 mL or OFF

tidal volume limit < high exhaled tidal volume limit
(4 VTE SPONT) ≤ 300 mL with NEONATAL patient circuit
≤ 1000 mL with PEDIATRIC patient circuit
≤ 2500 mL with ADULT patient circuit
Resolution: 1 mL for 1 to 100 mL; 5 mL for 100 to 400 mL; 10 mL for 400 to 2500 mL
New patient: 7.25 x IBW x 0.70

M onit ored dat a

Breath type Range:

Type: Control, assist, or spontaneous
Phase: Inspiration or exhalation
Resolution: Not applicable
Accuracy: Not applicable

Delivered O2% Range: 0 to 103%

(O2%) Resolution: 1% O2
Accuracy: ±3% O2 of full scale

End expiratory pressure New symbol for end expiratory pressure (monitored) (was PEEND)
(PEEP) Range: -20.0 to 130 cmH2O
Resolution: 0.1 cmH2O for -20.0 to 9.9 cmH2O; 1.0 cmH2O for 10 to 130 cmH2O
Accuracy: ± (2 + 4% of reading) cmH2O (relative to pressure measured at the exhalation
side of the patient wye when the end-expiratory flow is less than 60 lpm)

End inspiratory pressure Range: -20.0 to 130 cmH2O

(PI END) Resolution: 0.1 cmH2O for -20.0 to 9.9 cmH2O; 1.0 cmH2O for 10 to 130 cmH2O
Accuracy: ± (2 + 4% of reading) cmH2O (relative to the patient wye for pressure control
breaths with inspiratory times of 1 s or longer)

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1 General information

Table 1-4: Vent ilator range, resolut ion, accuracy, new pat ient/ defaults (cont inued)

Set t ing Range, resolut ion, accuracy, new pat ient / default

Exhaled minute volume Range: 0.00 to 99.9 L

(VETOT) Resolution: 0.01 L for 0.00 to 9.99 L; 0.1 L for 10.0 to 99.9 L
Accuracy: For TE < 600 ms: ± ((10 x respiratory rate) +10% x (600 ms/ TE) of reading) mL
± ((4 x respiratory rate) + 10% of reading) mL with NEONATAL patient circuit
± ((10 x respiratory rate)+10% of reading) mL with PEDIATRIC or ADULT patient
circuit
TE = time to exhale 90% of exhaled volume

Exhaled tidal volume (VTE) Range: 0 to 6000 mL

Resolution: 0.1 mL for 0 to 9.9 mL; 1 mL for 10 to 6000 mL
Accuracy: For TI < 600 ms: ±10 (+10% (600 ms/ TE) of setting) mL
± (4 + 10% of reading) mL with NEONATAL patient circuit
± (10 + 10% of reading) mL with PEDIATRIC or ADULT patient circuit
Compliance- and BTPS-compensated
TE = time to exhale 90% of exhaled volume

I:E ratio Range: 1:599 to 149:1

Resolution: 0.1 for 9.9:1 to 1:9.9; 1.0 for 149:1 to 10:1 and 1:10 to 1:599
Accuracy: ± 1%

M ean airway pressure New symbol for mean airway pressure (was PCIRC).
(PMEAN) Range: -20.0 to 120 cmH2O
Resolution: 0.1 cmH2O for -20.0 to 9.9 cmH2O; 1 cmH2O for 10 to 120 cmH2O
Accuracy: ± (3 + 4% of reading) cmH2O relative to pressure measured at the exhalation
side of the patient wye.

Peak circuit pressure Range: -20.0 to 130 cmH2O

(PPEAK) Resolution: 0.1 cmH2O for -20.0 to 9.9 cmH2O; 1.0 cmH2O for 10 to 130 cmH2O
Accuracy: N/ A
NOTE: New symbol for peak circuit pressure (monitored) (was PCIRC MAX)

Spontaneous minute volume Range: 0.00 to 99.9 L

.
(V ESPONT) Resolution: 0.01 L for 0.00 to 9.99 L; 0.1 L for 10.0 to 99.9 L
Accuracy: For TE < 600 ms: ± ((10 x respiratory rate) + 10% (600 ms/ TE) of reading) mL
For TE ≥ 600 ms: ± ((10 x respiratory rate) + 10% of reading) mL

Total respiratory rate (fTOT) Range: 0 to 200/ min

Resolution: 0.1/ min for 0.0 to 9.9/ min; 1/ min for 10 to 200/ min
Accuracy: ± 0.8/ min

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General information 1
1.9 Tools, equipment , and service mat erials
The tools, equi pm ent, and service m ateri al s listed in Tabl e 1-5 are used to servi ce th e 840
Ventil ator System . Refer to Secti on 5 for a l ist of required tool s, equipm ent, and servi ce
m aterials specific to perform an ce veri fi cati on.

Table 1-5: Tools, equipment , and service mat erials

M anufact urer/ model or Purit an

Descript ion Where used
Bennet t part number

Adapter, patient pressure 4-011521-00 Performance verification

("T" connector)

Barometer See under “ Pneumatic calibration Atmospheric pressure transducer

analyzer” calibration

Cable, trigger 4-075360-00 Performance verification

Cable, null modem 4-075361-00 Performance verification

Pentium 166 M hz computer, Local supplier Performance verification

equipped, at a minimum, with the
following:
• 32 M B RAM (64 M B for NT systems)
• 800x600 screen display resolution
with 256 colors
• Two available serial ports
• Windows® 95, 98, 2000, XP or NT
4.0 operating system
• M ouse or equivalent pointer device
• 2x or higher CD-ROM drive
• 1 Gigabyte available hard disk
space
• One available TCP/ IP network port
with BNC connector (if software
download desired)

Connector, barb 4-000845-00 Performance verification

Cotton swabs Local supplier General cleaning

Coupling, barb connector 4-003443-00 Performance verification

Digital multimeter (DMM) accurate to Fluke Model 87 or equivalent Performance verification, general
3 decimal places, with test leads troubleshooting

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1 General information

Table 1-5: Tools, equipment , and service mat erials (cont inued)

M anufact urer/ model or Purit an

Descript ion Where used
Bennet t part num ber

Disinfectant/ cleaner The following solutions are acceptable General cleaning

for disinfecting/ cleaning the 840
ventilator:
M ild dishwashing detergent
Isopropyl alcohol (70% solution)
Bleach (10% solution)
Window cleaning solution (with
isopropyl alcohol and ammonia)
Ammonia (15% solution)
Hydrogen peroxide (3% solution)
Formula 409® cleaner (Clorox
Company)
Amphyl disinfectant (National
Laboratories, Reckitt & Colman Inc.)
Cavicide® surface disinfectant (M etrex
Research Corporation)
Control III germicide (Meril Products
Inc.)
Glutaraldehyde (3.4% solution)

Electrical safety analyzer capable of Dale M odel 600, Dale Technology Inc., Performance verification
measuring ground resistance and P.O. Box 196, 401 Claremont Ave.,
leakage current Thornwood, NY 10594 USA,
800.544.3253
http:/ / www.daletech.com
or equivalent

Electrostatic shielding bags:

8 x 5 in. (20.3 x 12.7 cm) 4-009803-00 Backlight inverter, vent head LED,
GUI LED, and exhalation PCB storage
11 x14 in. (27.9 x 35.6 cm) 4-009800-00 Card cage PCBs, GUI LCD panels,
inspiratory PCB, motherboard PCB,
compressor PCB storage
18 x 14 in. (45.7 x 35.6 cm)
4-009801-00 GUI CPU PCB storage
26 x 4 in. (66.0 x 10.2 cm)
4-009804-00 Keyboard PCB storage

Filter, inspiratory, Re/ Flex (for use on 4-074600-00 Performance verification

PTS 2000 tester port)

Finger cots or gloves Local supplier Removing window from GUI,

performance verification

Flex tube, 21.0 in. (53.4 cm) (gold 4-018506-00 EST, performance verification
standard tube) (2 required)

Grease, Krytox 4-732130-00 Lubricating O-rings

Hose, regulator calibration 4-079050-00 (quick disconnect) Performance verification

4-079051-00 (female)

Isopropyl alcohol Local supplier General cleaning

Leak detector fluid 4-004489-00 Leak-testing

Exhalation port test hose assembly 4-076704-00 Performance verification

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General information 1
Table 1-5: Tools, equipment , and service materials (continued)

M anufact urer/ model or Purit an

Descript ion Where used
Bennet t part number

Patient circuit, adult (reusable, without N-4401008 SST, performance verification

water traps or heated wire)
(2 required)

Patient circuit, pediatric (reusable, G-061223-00 SST, performance verification

without water traps or heated wire)

Pneumatic calibration analyzer or Puritan Bennett PTS2000 Performance Performance verification, regulator
equivalent devices capable of Test System (4-074686-00) (includes adjustment. Barometer used for
measuring oxygen percent, flow, BTPS accessory kit with serial cable) atmospheric pressure transducer
volume, pressure, and barometric calibration.
pressure. Oxygen analyzer connector
tee. Required accuracies: NOTE:
• Flow: 2.75% of reading ±0.05 slpm If you use a device other than
the PTS 2000 Performance Test
• Volume: 2% of reading or ±1 digit System, refer to the “ Manual
• Low pressure (-150 to +150 ventilator check” in Section 5 of
cmH2O): 0.75% of reading ±0.04 this manual.
cmH2O
• High pressure (0 to 150 psig): 1.0%
of reading ±0.1 psi
• Oxygen percentage: ±2% oxygen
• Barometric pressure: Range: 10 to
16 psia; resolution: 0.0 to 1 psia;
operating temperature: 10 to
40 °C; measurement accuracy:
±0.75 of reading; response: ≤ 100
ms.

Software download device 4-075497-00 BDU and GUI software updates

Static-dissipative field service kit 4-018149-00 Various service procedures

(includes wrist strap, static dissipative
mat, and earth (ground) cord)

Stoppers, no. 1, 5, and 5.5 Local supplier SST, EST, performance verification
(with center bore and luer fitting:
4-071856-00)

Stopper, no. 5.5 with center bore and 4-076467-00 Performance verification
Fitting, luer, bulkhead 4-012470-00

Test lung, 0.5 L 4-000612-00 EST, performance verification

Test lung, 3 L N-3800006 Performance verification

Test lung, 4 L 4-075578-00 Performance verification

Tie wraps 4-000003-00 (small) Various places

4-000004-00 (large)

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1 General information

Table 1-5: Tools, equipment , and service mat erials (cont inued)

M anufact urer/ model or Purit an

Descript ion Where used
Bennet t part num ber

Tool kit, including the following: Local supplier

• Diagonal cutters General repair
• Needlenose pliers General repair
• Nutdriver, 3/ 16-in. General repair
• Nutdriver, 5/ 16-in. General repair
• Nutdriver, 11/ 32-in. General repair
• Screwdriver, #0 Phillips General repair
• Screwdriver, #1 Phillips General repair
• Screwdriver, #2 Phillips
General repair
• Screwdriver, 1/ 8-in. flat-blade
General repair
• Screwdriver, 1/ 4-in. flat-blade
General repair
• Wrench, 5/ 16-in. open-end
• Wrench, 7/ 16-in. open-end General repair
• Wrench, 9/ 16-in. open-end General repair
• Wrench, adjustable Replacing pressure switch
Removing oxygen filter

Tubing, silicone, 3/ 16 in. ID x 5/ 16 in. 4-008577-00 Performance verification

OD, 36 in. (91.4 cm)

Tubing, silicone, 1/ 8 in. ID x 1/ 4 in. 4-008578-00 Performance verification

OD, 4.75 in. (12.1 cm)

Vacuum cleaner, ESD-safe, with 0.2 µm Local supplier General cleaning

filter (rated for photocopiers and laser
printers)

Wrench, caster N-4800168 Replacing casters

Wye 4-000338-00 SST, performance verification

1.10 Periodic maint enance

Caut ion
• To prevent component damage due to excessive wear, perform preventive maintenance
and replace components at recommended intervals, as indicated in Table 1-6. You may
find it convenient to note anticipated replacement dates for all components based on
typical usage rates or recommended intervals.
• Puritan Bennett has determined the 840 Ventilator’s preventive maintenance schedule
based on the life expectancies of ventilator parts. Be aware that these parts, listed below,
could also require unscheduled corrective maintenance and that other parts, not listed,
could also require corrective maintenance during your ventilator’s lifetime.
Pru

Table 1-6 lists th e peri odic m ain tenance activities requi red for the 840 Ven tilator System . See
the Venti lator Inform ati on screen for total h ours of operation for th e venti lator and
com pressor. For detai ls on patient system m ai ntenan ce, refer to the 840 Ventilator System
Operator’s and Technical Reference Manual.

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General information
Frequency
Several times a day or as
required by your
institution’s policy
Daily or as necessary
Every 250 hours (or more
often, if required)
Every 6 months
Every year
Varies: Every year or 100
autoclave cycles. Consult
product Directions for
Use.
2 years or as necessary
Every 10,000 hours
Every 15,000 hours
840 Ventilator System Service Manual
1
Table 1-6: Schedule of periodic maintenance
Part M aint enance
Patient circuit: inspiratory and expiratory Check for water build-up, empty, and clean
limbs as necessary.
Inspiratory and expiratory bacteria filters Inspect and check resistance across
inspiratory and expiratory filters before every
use, after 15 days of continuous use in
expiratory limb, or if you suspect excess
resistance. SST checks the resistance of the
expiratory filter.
Collector vial, water traps, and drain bag Check and empty as needed.
Oxygen sensor Calibrate oxygen sensor by pressing
100% O2/ CAL 2 min key.
Air inlet filter bowl If cracked, replace bowl. If any sign of
moisture is visible, remove ventilator from
use and inspect.
Compressor inlet filter Either vacuum filter or wash filter in a warm
detergent solution, rinse, and dry well.
Replace filter when it shows signs of wear.
Entire ventilator Run EST.
Atmospheric pressure transducer, expiratory Perform calibration/ test.
valve, flow sensors, and vent inop test
Entire ventilator Perform electrical safety tests, and inspect
ventilator for mechanical damage and for
label illegibility.
Reusable expiratory or expiratory bacteria Replace. Sterilize between patients and
filters circuit changes, or according to your
institution’s policy. Sterilize before
nondestructive disposal.
Oxygen sensor Replace. Actual sensor life depends on
BPS battery pack operating environment; operation at higher
temperature or O2% levels will result in
shorter sensor life.
Actual BPS life depends on the history of use
and ambient conditions.
Various parts Use appropriate preventive maintenance kit
(see Table 1-7).
NOTE:
If any part found in a preventive
maintenance kit requires replacement
before the recommended interval
elapses, consider installing the entire
kit anyway.
4-070496-00 Rev. A (08/03) 1-23
1 General information

1.11 Service kit s

Table 1-7 l ists the 840 Ven tilator System servi ce kits. Section 9 li sts th e m oun ting kits
avai lable for th e ventil ator.

Table 1-7: Service kits

Int erval Descript ion Part no. Kit cont ent s

10,000 hours GUI and BDU 4-079056-00 Filter, air inlet (F2) with O-ring
Filter, oxygen (F1)
Filter, oxygen inlet (F3) with O-ring
Installation instructions
Label, preventive maintenance
Lamps, fluorescent backlight
(for 9.4“ color LCD displays)
Spring

Oxygen sensor 4-072214-00 Oxygen sensor

BPS (6 month shelf life) 4-070523-SP Battery pack

15,000 hours Compressor, 100 V ~, 50/ 60 Hz 4-076806-00 15 K PM label

(806 only)
Compressor, 120 V ~, 60 Hz
Compressor, 220 – 240 V ~, 50/ 60 Hz
Compressor assembly for
4-076805-00
appropriate voltage configuration
4-076807-00 Fans (qty. 2)
Filter element for water trap assembly
Main inlet filter
Outlet filter for solenoid assembly
Tie wrap, large, for air dryer assembly
Tie wraps, small for fan harnesses (qty. 2)
Tinnerman clips (qty. 6)

1.12 Cont rols and indicat ors

Refer to Fi gure 1-3 through Figure 1-10 and Table 1-8 th rough Table 1-15 for ven ti lator
con trol s and indi cators.

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General information 1

16

15

12
14
13

8-00189
1 2 3 4 5 6 7 8 9 10 11

Figure 1-3. M onochrome GUI front view (show ing all keys)

Table 1-8: GUI front view

Index
Labeling Funct ion
(Figure 1-3)

1 Screen lock key. When the yellow light on the screen lock key is lit, touching
the screen or off-screen controls (including the knob and ACCEPT key) has
no effect until you press the screen lock key again. New alarms (or when an
alarm’s urgency level escalates) automatically unlock the screen and controls.
8-00435
The screen lock allows you to clean the touch screen and prevents
inadvertent changes to settings and displays.
or

8-10001

(US version only)

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1 General information

Table 1-8: GUI front view (cont inued)

Index
Labeling Funct ion
(Figure 1-3)

2 Color GUI (10.4-inch screen):

No key
Color GUI (9.4-inch screen):
Key inactive
8-00429
M onochrome GUI:
Display contrast key. Allows you to adjust screen contrast when you hold
or down this key while turning the knob.

8-10002

(US version only)

3 Color GUI (10.4-inch screen):

No key
Color GUI (9.4 inch screen):
Key present but inactive
8-00444
M onochrome GUI:
Display brightness key. Allows you to adjust screen brightness when you hold
or down this key while turning the knob.

8-10003
(US version only)

4 Alarm volume key. Allows you to adjust the alarm volume when you hold
down this key while turning the knob. You cannot turn off alarm volume.

8-00407

or

8-10004

(US version only)

5 Alarm silence key. Turns off alarm sound for 2 minutes. The yellow light on
the alarm silence key lights during the silence period, and turns off if you
press the alarm reset key or the 2-minute interval times out. A new, high-
urgency alarm cancels the silence. Alarms that can be silenced (lockable)
include all Patient-Data Alarms and Circuit Disconnect (see Table 7-2 for
8-00402 details).
Each time you press the alarm silence key, the silence period resets to 2
minutes. Each time you press the alarm silence key (whether or not there is
an active alarm), the keypress is recorded in the alarm log.

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General information 1
Table 1-8: GUI front view (cont inued)

Index
Labeling Funct ion
(Figure 1-3)

6 Alarm reset key. Clears active alarms or autoreset high-urgency alarms,

cancels an active alarm silence, and is recorded in the alarm log. (Pressing
the alarm reset key is not recorded in the alarm log if no alarm is active.) You
cannot reset a DEVICE ALERT alarm.

8-00441

7 Displays basic operating information about the ventilator.

8-00411

or

8-10005
US version only

8 Delivers 100% oxygen (if available) for 2 minutes and calibrates the oxygen
sensor. The green light on this key lights to indicate that 100% O2 delivery is
active. Pressing this key again restarts the 2-minute delivery interval. You may
cancel the 2-minute interval by touching the CANCEL button on the GUI
touch screen.
8-00401
Oxygen sensor calibration can be tested using a procedure in the 840
Ventilator System Operator’s and Technical Reference Manual.

9 Delivers one manual breath to the patient according to the current

mandatory settings. To avoid breath stacking, a manual inspiration is not
delivered during inspiration or the restricted phase of exhalation.
You can use the MANUAL INSP key to supplement minute volume or to help
measure a patient data parameter, such as peak inspiratory pressure.
8-00436

10 Allows you to measure auto-PEEP. Hold this key down until the maneuver
begins (at the next ventilator-initiated inspiration), and release when the
measurement is stable, up to 20 s. The measured values for intrinsic and total
PEEP are displayed at the end of the expiratory pause. Displays and freezes
the most recently selected graphics, allowing you to see when expiratory
8-00419 pressure stabilizes.
EXP PAUSE is not functional in SPONT. It has no effect during the inspiratory
phase of a breath. The pause is canceled and inspiration begins if you release
the EXP PAUSEkey, the patient triggers an inspiration, an alarm occurs, or the
maximum 20-s pause interval elapses. If flow triggering is active, backup
pressure sensitivity is used to detect patient effort. Only one expiratory pause
is allowed during a breath. Expiratory pause requests are ignored in apnea
ventilation, safety ventilation, occlusion status cycling (OSC), and idle mode.
During an expiratory pause, occlusion alarm detection is suspended. During
expiratory pause, the apnea interval is extended by the amount of time the
pause is active. In SIMV, the cycle during which the pause becomes active
(and the next scheduled VIM will occur) is extended by the amount of time
the pause is active. For purposes of I:E ratio calculation, expiratory pause is
considered part of the exhalation phase.

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1 General information

Table 1-8: GUI front view (cont inued)

Index
Labeling Funct ion
(Figure 1-3)

11 Extends the inspiratory phase of the current or next mandatory breath

(depending upon when pressed) for the purpose of measuring plateau
pressure, compliance, and, if possible, resistance. Pressing and releasing this
key initiates an automatic inspiratory pause lasting between 0.5 and 2
seconds. Pressing and holding this key initiates a manual inspiratory pause
8-00431 extending inspiration up to 7 seconds.

12 Cancels a proposed setting.

8-00415

13 Applies new settings.

8-00406

14 Adjusts the value of a setting. A button that is highlighted means that the
knob is linked to that setting. Where applicable, turning the knob clockwise
increases the value, and turning the knob counterclockwise decreases the
value.

8-00433

15 System operation
indicators

Gray normal ventilator operation indicator. Indicator appears unilluminated

when no ventilator inoperative condition exists.

8-00448

non-US version
or

US version text is not visible when no ventilator inoperative condition exists.

8-10007

US version

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General information 1
Table 1-8: GUI front view (cont inued)

Index
Labeling Funct ion
(Figure 1-3)

15 Red ventilator inoperative indicator. Illuminates when the ventilator cannot

(cont) support ventilation and requires service. The ventilator enters the safe state
and discontinues detection of new patient data or alarm conditions. A
qualified service technician must repair the ventilator to correct the problem
and must execute EST successfully before normal ventilation is allowed. This
indicator is accompanied by an audio signal and cannot be reset.

8-00447

non-US version
or

8-10007

US version

15 Red safety valve open (SVO) indicator. Illuminates when the ventilator has
(cont) entered its safe state and opened its safety valve to allow the patient to
breathe unassisted from room air.

8-00459
non-US version
or

8-10008
US version

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1 General information

Table 1-8: GUI front view (cont inued)

Index
Labeling Funct ion
(Figure 1-3)

Green BPS ready indicator. The ventilator senses that the BPS is installed,
operational, and has at least 2 minutes of estimated run time.
8-00460

or
BATTERY
READY
US version only

On BPS power indicator. When yellow bar to the right of a lit BPS ready
indicator (battery symbol) is lit, ventilator is operating on BPS, and ac power
is insufficient to support ventilator operation. During BPS operation, power
to the compressor unit and the humidifier outlet (if available) is off.
8-00457

or
BATTERY
ON
US version only

Green compressor ready indicator. The compressor logic cable and air supply
hose are connected to the ventilator. The compressor is up to operating
pressure but not supplying gas to the ventilator. The compressor motor turns
on intermittently to keep the compressor chamber pressurized.
8-00461

or
COM PRESSOR
READY
US version only

15 Green compressor operating indicator. When symbol to the right of a lit

(cont) compressor unit ready indicator is lit, compressor is supplying air to the
ventilator. This indicator does not light unless the compressor is actually
supplying air to the ventilator.
8-00458

or
COM PRESSOR
ON
US version only

16 Red high-urgency alarm indicator ( ! ! ! ) blinks rapidly if active; it is steadily

lit if autoreset.
Yellow medium-urgency alarm indicator ( ! ! ) blinks slowly if active; it turns
off if autoreset.
Yellow low-urgency alarm indicator ( ! ) is steadily lit if active; it turns off if
autoreset.
Green normal ventilator operation indicator steadily lit. This indicator is off if
the ventilator is not in a ventilation mode, for example, during service mode
8-00446
or short self test (SST).

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General information 1

2 3

Figure 1-4. 10.4-inch GUI rear view

Table 1-9: GUI rear view

Index
Labeling Funct ion
(Figure 1-4)

1 Remot e alarm Remote alarm (nurse’s call) port

2 RS-232 10.4-inch GUI only: Two serial ports with 9-pin male connector configured as
data terminal equipment (DTE).

NOTE:
Allowable current is 0.2 A at 10 V dc (maximum).

3 RS-232 NULL Null modem port (9.4-inch and 10.4-inch GUI)

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 1-31

1 General information

2 3
5

4
1

7
8-00197

Figure 1-5. BDU front view

Table 1-10: BDU front view

Index
Labeling Function
(Figure 1-5)

1 EXHAUST port BDU exhaust port. Gas is vented to atmosphere.

2 Ventilator operation
indicators

Red ventilator inoperative indicator. (See Table 1-8, item 15.)

8-00447

non-US version
or

8-10007
US version

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General information 1
Table 1-10: BDU front view (cont inued)

Index
Labeling Funct ion
(Figure 1-5)

2 Red safety valve open (SVO) indicator. (See Table 1-8, item 15.)
(cont)

8-00459
non-US version
or

8-10008
US version

Gray normal GUI indicator. Indicator appears unilluminated when no loss

of GUI condition exists.

8-00454
non-US version

US version text is not visible when no loss of GUI condition exists.

8-10009
US version

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 1-33

1 General information

Table 1-10: BDU front view (cont inued)

Index
Labeling Function
(Figure 1-5)

2 Red loss of GUI indicator. The ventilator has detected a malfunction that
(cont) prevents the GUI from reliably displaying or receiving information.

8-00455

non-US version
or

8-10009
US version

3 Power switch. I or ON represents on position; represents off position

for only a part of the equipment. This switch turns off power to the BDU
and GUI, but still allows the BPSto be charged if ac power is present. The
ac indicator LED is lit when ac power is available to the ventilator.
8-00439

non-US version
or

8-10006

US version

4 (Humidifier outlet, shown North-American style electrical receptacle for humidifier. Receptacle
covered) available in 100 – 120 V ventilators only. Ventilator supports a humidifier
rated for up to 2.3 A (270 VA) with a maximum leakage current of 50 µA.

5 To patient port Ventilator outlet

6 From patient port Expiratory limb connector on exhalation filter

7 (Collector vial drain port) Collector vial drain port. Use to attach drainage bag.

1-34 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
General information 1

2
1

8-00196

Figure 1-6. BDU I/ O panel

Table 1-11: BDU I/ O panel

Index
Labeling Funct ion
(Figure 1-6)

1 TEST TEST (service) button. Enables service mode. When you turn on the
ventilator and press this button after the first beep from the BDU, the
ventilator is placed into service mode (for example, to run EST).

2 PTS 2000 Puritan Bennett PTS 2000 Performance Test System connection.

3 Data key connection

8-00418 Caut ion

Do not remove the data key. The data key cover can only be
or
removed with a screwdriver. The data key enables software
options, and stores ventilator operational hours and the serial
Dat a Key numbers for the BDU and GUI. The data key is for use by a
qualified service technician only.
US version

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 1-35

1 General information

Table 1-11: BDU I/ O panel (cont inued)

Index
Labeling Function
(Figure 1-6)

4 Compressor data cable connection

8-00461

or
Compressor
US version

5 GUI cable connection

8-00427

or
Display
(GUI)
US version

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General information 1

2 3

1
5 8-00161

Figure 1-7. BDU right-side panel

Table 1-12: BDU right-side panel

Index
Labeling Funct ion
(Figure 1-7)

1 Ventilator circuit breaker for compressor and humidifier

8-00430 NOTE:
A humidifier connection is only available on 100 – 120 V
or ventilators.
Compressor &
humidifier
circuit
breaker
US version

2 Circuit breaker for ventilator power supply

8-00416

or
Vent ilat or
circuit
breaker
US version

3 Alternating current (at ac inlet and ac power indicator)

8-00405

or

ac input
8-00405

US version

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1 General information

Table 1-12: BDU right -side panel (cont inued)

Index
Labeling Function
(Figure 1-7)

4 Potential equalization point (ground). Provides a means of connection

between equipment (such as electrical safety analyzer) and the potential
equalization busbar of the electrical connection. A common grounding
point for the entire ventilator.
8-00426

5 Maximum allowed output to auxiliary mains socket (compressor

electrical connection)
8-00437

or
Compressor out let :
5.6 A max
US version

2
1

8-01298

Figure 1-8. BDU rear view

Table 1-13: BDU rear view

Index
Labeling Funct ion
(Figure 1-8)

1 (High-pressure air fitting) DISS male, DISS female, NIST, Air Liquide, or SIS fitting

2 (High-pressure oxygen DISS male, DISS female, NIST, Air Liquide, or SIS fitting
fitting)

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General information 1

Figure 1-9. GUI rear view

Table 1-14: GUI rear view

Index
Labeling Funct ion
(Figure 1-8)

1 (Warning label) Warns user of hazards associated with the operation of the 840 ventilator and
GUI

2 (Serial number label) Unique assigned number. M ust be the same as the GUI serial number stored
on the data key.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 1-39

1 General information

8-00199

Figure 1-10. BPS cont rols and indicators

Table 1-15: BPS cont rols and indicat ors

Index
Labeling Function
(Figure 1-10)

1 BPS charging indicator. When the ventilator is operating on mains

power, the top symbol (green indicator next to gray battery icon)
indicates that the BPS is charged, and the bottom symbol (yellow
indicator next to gray battery icon) indicates that the BPS is charging.

8-00456

or

8-00462

US version

1-40 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
General information 1
1.13 Onscreen symbols and abbreviat ions
Consult th e 840 Ventilator System Operator’s and Technical Reference Manual to i nterpret these.

1.14 Vent ilat or serial numbers and soft ware version

The 840 Ventil ator System seri al num bers and software versions can be di spl ayed on the GUI
upper subscreen. On the GUI upper screen, sel ect th e VENT CONFIG button. The ventilator
configuration subscreen di splays the curren t software revi si on s for the BDU, GUI,
com pressor, an d audi bl e al arm subsystem .

1.15 Service philosophy

Fi eld servi ce of th e venti lator is l im ited to th e service activi ties described in this m anual. For
field servi ce, techn ical support, or in form ation on techni cal train in g, call 1.800.225.6774
(wi thin the USA) or contact your Puri tan Benn ett represen tative (outside th e USA).

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 1-41

1 General information

Thi s page i ntentionall y blank.

1-42 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
 SECTION
S EC T I O N

Theory of operation 2 2
This section detai ls th e operation al th eory of the 840 Ven tilator System an d con tain s the
fol lowin g i nform ati on :
• descri ption of m aj or ventilator assem bli es
• overview of venti lator operati on
• descri ption of the pneum ati c system
• descri ption of the electri cal system , i ncl udi ng prin ted ci rcui t boards (PCBs)
• detail ed description of the in teractions am ong all ven tilator com pon ents during breath
deli very and under certain other con ditions
• oth er h ardware operations
• em ergen cy m odes of operation

2.1 M ajor vent ilat or subassemblies

The 840 Ventil ator System is an el ectroni call y controll ed, pn eum aticall y powered ventil ator
consi sting of a breath del ivery un it (BDU), graphi c user i nterface (GUI), the 802 Backup
Power Source (BPS), and pati ent system . Optional com pon en ts i ncl ude the 806 Com pressor
Unit and a ven ti lator cart. Fi gure 2-1 shows the 840 Ventil ator System wi th the optional
compressor unit and cart.

8-01203

Figure 2-1. 840 Ventilat or System

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 2-1
2 Theory of operation

2.1.1 Breath delivery unit (BDU)

The BDU, sh own in Figure 2-2, is th e core of the 840 Ventil ator System . Its pn eum atic system ,
under control of the breath delivery (BD) central processin g uni t (CPU), m i xes oxygen an d air
and control s gas flow to the pati ent. Breath delivery proceeds accordi ng to operator-sel ected
parameters en tered through th e GUI. The patient’s exhaled gas i s routed th rough an opened
exh alati on valve. Oxygen is provided by an extern al suppl y, an d air is provi ded by eith er an
external supply or the opti onal com pressor unit.
In addition to the BD CPU and other electron ics th at control ventil ation, th e BDU al so
h ouses the ac main s com pon ents an d power suppl y.

8-00187

Figure 2-2. BDU

2.1.2 Graphic user int erface (GUI)

The GUI (Figure 2-3) provides the operator interface to and from the ventilator. Ven tilation
m ode, param eters, an d alarm settings are entered by the operator via the GUI. The GUI CPU
m oni tors BDU com m un ication s. In turn, th e GUI displ ays patient an d venti lator
perform ance i nform ati on .

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Theory of operation 2

8-01159

Figure 2-3. 10.4-inch GUI

2.1.3 806 Compressor Unit

The opti on al 806 Com pressor Uni t (Figure 2-4) provi des compressed room air (200 L/m i n
peak flow, 2.5 L BTPS breath vol um e) w hen ac power is avail able, provided extern al
com pressed air is unavai labl e. The com pressor charges an accum ul ator at start-up an d
m ain tains the ch arge (stand-by operati on ) for im mediate use when extern al compressed air i s
used. The com pressor uni t receives electrical power from an d com muni cates with the BDU.

8-8-01132

Figure 2-4. Compressor unit

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2 Theory of operation

2.1.4 802 Backup Power Source (BPS)

The BPS(Figure 2-5) suppli es power to the BDU power supply when faci li ty ac power is l ost or
when a 30 vol t drop i n ac is detected. The BPS autom ati call y ch arges whi le the ven ti lator i s
conn ected to ac power an d wil l operate th e system up to 30 m in utes wi th new, full y charged
batteri es. The BPS does not supply the com pressor uni t or the hum idi fier with el ectrical
power. The ventil ator autom atical ly swi tches back to ac power when facility power return s
withi n the required li mi ts.

8-00199

Figure 2-5. BPS

2.1.5 Cart
The opti on al cart, sh own i n Figure 2-6, m ounts system com ponents an d accessories,
i ncl udi ng th e compressor unit. It also provi des m obili ty for th e ven ti lator. Brakes on the front
casters prevent th e cart from rolli ng an d turn ing.

8-01119

Figure 2-6. Cart

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Theory of operation 2
2.1.6 Patient system
The patien t system (adul t, reusable versi on shown i n Fi gure 2-7) i ncl udes reusabl e or single-
patient use tubi ng plus an i nspiratory fil ter th at prevents gas-borne parti cles from exi tin g the
ventil ator. A hum i difi er or heat and m oi sture exch an ger (HM E), water traps, and other
accessori es can be added.

8-00276

Figure 2-7. Patient syst em

NeoM ode, a software option, requires the use of the n eonatal patient system . In addition to
the pati ent tubi ng an d i nspiratory fi lter, the neonatal patien t system i ncl udes a di sposabl e
expi ratory fi lter, a coll ector vial , an d a special m ounti ng pl ate, as shown in Fi gure 2-8.

(From patient)
Neonate
patient circuit
mounting plate

Expiratory (To patient)

Expiratory limb filter
of breathing circuit

Patient wye Inspiratory

Collector filter
vial
Inspiratory limb
of breathing circuit

Humidifier

8-01140

Figure 2-8. NeoM ode pat ient syst em

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2 Theory of operation

2.2 Operat ional overview

By usi ng the touch screen, keys, an d kn ob on the GUI, th e operator gives i nstructi on s and
data to th e ven tilator (see Figure 2-9). The GUI CPU processes thi s i nform ati on and stores it
i n the ven ti lator’s m em ory. The BDU CPU uses this stored in form ation to control and
m onitor the flow of gas to and from the patient. Any new settings i nform ati on is tran sferred
an d veri fied usin g a four-way tran saction between the BDU and GUI CPUs. Each CPU th en
perform s con tinuous background verifi cation of settings integri ty.
To al low the GUI to m oni tor BDU function , th e BDU samples and records the followin g raw
sign al data, then transmi ts it to the GUI: inspi ratory pressure, expiratory pressure, exhal ation
valve current, an d the air an d oxygen inspiratory val ves. Th e BDU al so sen ds the foll owi ng
settin g and breath in form ation to the GUI: hi gh ci rcui t pressure li m it, breath phase, breath
m ode, autozero offsets, inspiratory tim e, apnea in terval , target pressure for pressure
control led breath s, breath phase start, and ti m e stam p.

Graphic user
interface (GUI)

Exhalation Inspiratory
module: module:
Active exhalation valve PSOLs
Pressure transducer Safety valve
Flow sensor Oxygen sensor
Pressure transducers
Flow sensors

Air Oxygen
regulator regulator

Air
supply
Expiratory
filter Oxygen
supply

(Expiratory (Inspiratory
Collector limb) limb) Inspiratory
vial filter

8-00001
Patient
Humidification
circuit
device

Figure 2-9. 840 Ventilat or Syst em block diagram

2-6 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
The GUI logs an event in th e di agnostic log an d declares a ventil ator inoperative condition if:
• An y raw si gnal data from th ree BDU transmi ssions withi n 24 hours is corrupted.
• The GUI does n ot recei ve data from the BDU wi thin the time requi red.
• The GUI determ in es th at raw data is vali d, but settings or alarm li mi ts are not being
handl ed properl y.
The ventil ator uses fl ow or pressure tri ggeri ng to recogn ize patien t effort. W hen pressure
triggering (P-TRIG) is selected, the ventil ator moni tors pressure i n th e patient circui t. As th e
patient draws gas from the circuit and the airway pressure drops by at least the value sel ected
for pressure sensiti vity (VSENS), the ventil ator triggers a breath .
W hen flow triggering (V-TRIG) i s selected, the BDU m ai ntai ns a constant fl ow of gas th rough
the pati ent circuit (called base flow) during the later part of exhalati on . The venti lator
i ndirectly m easures pati ent flow (assum in g mi ni mal leaks) by m on itori ng the di fferen ce
between th e in spi ratory an d expiratory flow sensor measurem ents. If th e patient i s not
i nspiring, any difference between th e del ivered and the ex hal ed flow i s due to sen sor
i naccuracy or leaks in th e patient system . To com pensate for leaks i n the pati ent system , the
operator can i ncrease th e flow sen sitivi ty, which i deal ly equal s desired flow sen siti vity + l eak
fl ow.
As th e patient inspires from th e base flow, th e ventil ator m easures less exhaled fl ow whi le
del ivered fl ow rem ains con stant. As th e patient con ti nues to i nspire, th e di fference between
the two flows, m easured by the in spiratory and expi ratory tran sducers, i ncreases.
The ventil ator decl ares an i nspi ration when th e fl ow i nspired by the patient (that is, the
difference between th e m easured fl ows) is equal to or greater th an the operator-selected value
for fl ow sensi tivi ty (VSENS).
As a backup m ethod of tri ggering inspirati on , a pressure sen siti vity of 1 cm H 2O i s also in
effect. Thi s setti ng is the m ost sen sitive settin g that i s stil l large enough to avoid autocycl ing,
yet wil l trigger with acceptable patien t effort.
Air and oxygen from cyli nders, wall suppli es, or com pressor (ai r only) enter the ventilator
through h oses and fitti ngs (the fittings are avail abl e i n several versions). On ce insi de th e
ven til ator, ai r and oxygen are regulated to pressures appropriate for th e venti lator, th en
m ixed accordin g to the operator-sel ected O2 %.
The ventil ator delivers th e m i xed air an d oxygen through the inspiratory module, and out to
the pati ent. Th e oxygen concentrati on of the deli vered gas is m on itored here, using a
gal vanic oxygen sensor. The gal vani c sensor gen erates a voltage proportional to th e oxygen
concen trati on . The ventil ator al arm s i f the m oni tored oxygen concentrati on i s m ore than
seven percent above or below the O2 % setti ng, or bel ow 18%. A safety valve rel ieves pati ent
pressure if necessary (for exam ple, if the patient ci rcui t i s ki nked or occluded). Th e operator
selects the hum i difi cation type, wh ich th e venti lator uses to correct for gas tem perature and
h um idity.
Ventil ator in spi ratory pn eum atics consist of two parall el ci rcuits: one for oxygen an d on e for
air. The prim ary el em en ts of th e in spi ratory pneum atics are two proportional solenoid valves
(PSOLs), whi ch control the flow of gas deli vered to the patient. Air and oxygen flow sensors,
along wi th pressure signals from the inspiratory and exhalati on m odules, provide feedback
that is used by the BDU CPU to con trol the PSOLs. As a result, th e ven ti lator suppl ies m ixed
breath in g gas to the pati en t accordin g to operator-set variables. Th e m i xed air an d oxygen
passes through th e pati en t circui t external to th e ven tilator.

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2 Theory of operation

The patient circuit includes th e com pon ents external to the ventil ator th at route gas between
the ventil ator and the pati ent. These com pon ents incl ude the inspiratory filter (which protects
agai nst contam i nati on between the patient and venti lator), a hum idi fication devi ce, the
i nspi ratory an d expi ratory l im bs of the pati ent circuit (th e tubi ng through which the gas
travel s), a collector vial (whi ch protects the expiratory system from bulk m oi sture i n the
exhaled gas), an d an expiratory filter (whi ch l im its the bacteria in th e patient’s exhal ed gas
from escapin g to room air or contam i nati ng the ventil ator).
The ven ti lator activel y control s the exhal ation valve, wh ich i s accurately posi tioned by
software through out i nspiration and exhal ati on, and all ows the ven tilator to deliver
aggressive breath s whi le m in im i zi ng pressure overshoots, con troll ing PEEP, an d reli evi ng
excess pressures. The exhalation system m on itors the gas leaving the pati ent circuit for
spirom etry.
Throughout the respi ratory cycle, pressure tran sducers mon itor inspiratory, expiratory, and
atm ospheric pressures. Th e tem perature of th e exh aled gas i s heated to a tem perature above
i ts dew point to prevent con densation in the exh alation com partment.
Power to operate the ven ti lator com es from ac m ains (wall) power or th e BPS. The in tegral
power suppl y is desi gned to protect again st excessi ve vol tages, tem peratures, or current
draws. A power cord retai ner preven ts accidental disconn ection . A pow er swi tch cover
protects agai nst spil ls and accidental ac power-off.
The ven til ator i ncl udes th e BPS that suppl ies dc power to the ven til ator i f ac power is l ost. A
fully ch arged BPS operatin g under n om inal am bient con diti on s can power th e venti lator for
at least 30 m i nutes. Th e BPS rech arges duri ng operation from ac power. Th e GUI an d BPS
i ndi cate when th e ventil ator i s operati ng on the BPS. Th e BPSdoes n ot power th e compressor
unit or the hum idifi er pow er outl et.
In som e situati ons, the ven ti lator decl ares a ventilator inoperativecondi ti on. A hardware fai lure
or critical software error th at could com promi se safe ventil ation triggers thi s con dition.
W h en th is occurs, th e ven tilator i noperative in dicator lights an d the ven ti lator enters th e
safety valve open (SVO) state. To correct a ven tilator inoperative condi tion, th e ven tilator m ust
be turned off, then powered on again; at power on, a quali fied service tech nician must run
extended self test (EST). The ven tilator m ust pass EST before norm al ven til ation can resum e.
In the safety val ve open (SVO) state, the safety val ve allows th e patient to breathe room ai r
unassisted. The ventil ator rem ai ns i n the SVO state unti l the con dition that caused the SVO
state is corrected or, if the ven tilator decl ared a venti lator in operative con diti on , the power
on self test (POST) verifies that power l evel s to the venti lator are acceptable an d that th e
m aj or electron ics system s are functioni ng correctl y.
If the ven til ator enters the SVO state, the safety val ve open i ndi cator ligh ts and a hi gh-
urgen cy alarm sounds. The venti lator enters the SVO state if a h ardware or softw are fail ure
occurs th at coul d comprom ise safe ventil ation, both air and oxygen suppli es are lost, or an
occlusion is detected. In case of a m alfun ction that prevents software from openi ng the safety
valve, th ere is also an an alog circui t that opens th e safety val ve i f system pressure exceeds 100
to 120 cm H 2O.

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Theory of operation 2
2.3 Pneumat ic syst em
This subsection descri bes th e 840 Ven til ator pneum atics, as follows:
• Inspiratory m odule: Con tain s the fol lowin g pneum atic subsystem s:
– Gas supply con diti oning subsystem
– Fl ow control subsystem
– Safety val ve/ inspiration m onitorin g subsystem
• Pati ent system
• Exhalation m odule
• Compressor uni t (optional)
Fi gure 2-10 and Figure 2-11 are diagram s of the pneumatic system . Table 2-1 l ists th e
compon ents withi n the pn eum ati c system .

Inspirat ory module

Safety valve/inspiration Pat ient

monitoring subsystem syst em

Air flow Oxygen flow

control control

Exhalat ion
m odule

Air supply Oxygen supply

conditioning conditioning

Air Oxygen
Exhaled
supply supply
gas

Elect ronic
Com pressor Backup
modules
module pow er
(hardware
source
and software)

8-00141

Figure 2-10. Pneumat ic system block diagram

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2 Theory of operation

C NC
Patient Wye

SOL2
PE EXH
HTR NO
WT WT
CV5

F9
H P Oxygen, Wall
Q3 Reg Oxygen
H P Air, Wall/Comp
Humidifier
ECV Reg Air
Mixed Gas F8
Atmosphere
Vacuum
EV To Patient
Water

Vent PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS

CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2
WT1 F4

PA PI

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C
F12
Dryer
HB
8-01145
Figure 2-11. Pneumatic syst em diagram

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Theory of operation 2

Table 2-1: Pneumat ic component descript ions

Reference
Component Descript ion
designat or

Inspirat or y module

Fitting, inlet Connects external oxygen and air sources to ventilator via hoses.
Fittings include diameter index system standard (DISS) (male or
--
female), noninterchangeable screw thread (NIST), Air Liquide, and
Sleeved Index System (SIS).

Manifold, flow sensor Holds bases of flow sensors Q1 and Q2, and houses pressure valves
TP1 and TP2 and pneumatic noise filters F6 and F7.

Manifold, PSOL/ SV Houses proportional solenoid valves (PSOL1 AND PSOL2) and safety
--
valve (SV).

Orifice, inspiratory pressure Bypasses inspiratory check valve to relieve pressure when an occlusion
-- relief is present in exhalation circuit while safety valve is open. Minimizes
rebreathing of exhaled gas during SVO.

Check valve, air/ compressor CV2 opens to admit external compressed air and CV4 closes to isolate
CV2 compressor unit. When CV4 opens to allow compressor-supplied
CV4 compressed air, CV2 closes to prevent compressed air (compressor
source) from venting out the air (external source) inlet fitting.

Check valve, inspiratory Opens to supply inspiratory gas and restricts exhalation flow in reverse
CV3
direction.

F1 Filter, oxygen impact Traps particles larger than 65 to 110 µm (microns).

F3 Filter, inlet, oxygen/ air Filters matter greater than 0.3 µm (micron).
F2

F5 Filter, screen, oxygen/ air impact Filters large debris from REG1 and REG2. These filters are part of the
F4 regulator assemblies (one in each regulator).

Filter, pneumatic noise, oxygen/ Conditions gas flow by eliminating swirling of gas induced by elbows
F7
air and restrictions. These filters are part of the flow sensor manifold (two
F6
in each manifold).

Sensor, oxygen (percentage) Measures partial pressure of oxygen in inspired gas. Range is 21 to
OS
100% O2.

Pressure transducer, absolute Measures atmospheric pressure (psia). Located on inspiratory

PA
electronics PCB.

Pressure transducer, inspiratory Measures pressure (psig) at outlet manifold. Located on inspiratory
PI
electronics PCB.

PS1 Pressure switch, oxygen/ air Opens when pressure is less than 20.0 psig nominal.
PS2 Closes when pressure is greater than 31.5 psig nominal.

PSOL1 Proportional solenoid valve, 0 to 200 L/ min BTPS output (intermittent) or 0 to 180 L/ min BTPS
PSOL2 oxygen/ air output (steady state).

Q1 Sensor, flow, oxygen/ air Measures oxygen or air flow before PSOL.
Q2

REG1 Regulator, oxygen/ air Reduces input supply pressure (35 to 100 psig, flow up to 200 L/ min
REG2 BTPS) to output pressure (9 psig minimum to 12 psig maximum).

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2 Theory of operation

Table 2-1: Pneumat ic component descript ions (cont inued)

Reference
Component Descript ion
designat or

Solenoid, autozero, inspiratory +6 V, three-way solenoid. Energized (common to normally closed)

SOL1 pressure transducer when transducer is autozeroed. De-energized (common to normally
open) all other times.

Safety valve +12 V actuator. Commanded open (de-energized) at 100 cmH2O,

SV during power on self test (POST), loss of both source gases, or due to
ventilator inoperative condition. Energized (closed) all other times.

TP1 Pressure valve, oxygen/ air Allows measurement of REG1 and REG2 output.
TP2

WT1 Water trap, air Houses air inlet filter (F2) and includes a manual drain.

Pat ient syst em

-- Humidification device (optional) Humidifies inspired gas.

-- Wye Connects inspiration and expiration tubing forming a closed circuit.

Collector vial, exhalation Collects water (up to 250 mL with the full line at 200 mL) resulting
ECV from condensation in patient circuit. Neonatal collector vial collects up
to 25 mL water (with the full line at 15 mL) .

Filter, inspiratory (main flow) Filters matter greater than 0.3 µm (micron) (nominal) at 100 L/ min
F8
flow.

Filter, expiratory Filters matter greater than 0.3 µm (micron) (nominal) at 100 L/ min
F9
flow.

WT Trap, water Collects excessive water. Present only on certain patient circuits.

-- Mounting plate (neonatal only) Allows neonatal expiratory filter to be installed in place of adult filter.

Exhalat ion m odule

Check valve, exhalation Opens during exhalation to let exhaled gas into exhalation system.
CV5
Prevents rebreathing when safety valve is open.

Exhalation valve Electronically controlled, electrically operated valve that opens during
exhalation (as required to maintain positive end expiratory pressure
EV
(PEEP)/ continuous positive airway pressure (CPAP). Closed during
inspiration.

Heater, exhalation 16 W heater that maintains gas temperature above condensation

EXH HTR
level.

PE Pressure transducer, expiratory M easures pressure (psig) at a port on exhalation transducer PCB.

Q3 Sensor, exhalation flow M easures exhalation flow.

Solenoid, autozero, expiratory +6 V, three-way solenoid valve. Energized (common to normally

SOL2 pressure transducer closed) when transducer is autozeroed. De-energized (common to
normally open) all other times.

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Theory of operation 2
Table 2-1: Pneumat ic component descriptions (continued)

Reference
Component Descript ion
designat or

806 Com pressor Unit ( opt ional)

Accumulat or Accumulator Four 1-L cylinders store compressed air generated by the compressor.

Air dryer Removes water vapor from the compressed air to lower the dew point
Dryer
below ambient temperature.

F10 Filter 0.3 micron filter that filters gas going to the ventilator.

F11 Filter Filters air to the pressure transducer on the PCBA.

F12 Filter, intake silencer Filters and silences the compressor intake.

F13 Silencer Reduces noise from the air dryer.

Housing base Collects water emptied from the water trap where it evaporates using
HB
heat from the compressor motor and air flow from the fans.

HE Heat exchanger Cools the compressed air allowing water vapor to condense.

Motor/ compressor assembly Supplies compressed air to the ventilator. Includes starting capacitor,
M/ C
shock mounts, inlet filter, and relief valve.

PC Compressor pressure transducer Differential pressure transducer that measures accumulator pressure.

R1 Restrictor Reduces pressure pulsations to the pressure transducer on the PCBA.

Relief valve Prevents over-pressurization of the compressor system. Opens when

RV
pressure reaches 36 psig.

Unloading solenoid Opens to atmosphere upon compressor start-up to reduce start-up

load on the compressor. During continuous use, vents excess
SOL 3
accumulator pressure to the air dryer to assist in drying compressed
air.

Water trap Collects condensate as the compressed air cools in the heat
WT2 exchanger. Automatically drains collected water to the housing base
where it evaporates.

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2 Theory of operation

2.3.1 Inspirat ory module

The i nspi ratory m odul e, whi ch is part of th e BDU, i s shown in Fi gure 2-12 and Figure 2-13. It
i ncl udes the gas supply conditi on ing, flow control, and safety val ve/i nspiration m oni torin g
subsystem s. Figure 2-14 is a diagram of th e i nspi ratory m odul e gas flow.

8-01158

Figure 2-12. Inspiratory module

8-01293

Figure 2-13. Inspirat ory module in ventilat or

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Theory of operation 2

To Patient

Vent
PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS
OXYGEN
SUPPLY
CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2
AIR
SUPPLY WT1 F4

PA PI
8-01294

Figure 2-14. Inspirat ory module gas flow diagram

2.3.1.1 Gas supply condit ioning subsyst em

The gas suppl y condi tioni ng subsystem (Figure 2-15) receives air an d oxygen from external
supplies and regul ates the gases to usable pressures. Th is subsystem h as two paral lel, but not
i denti cal , pneumatic circuits for oxygen and ai r. The gas suppl y condi tion ing subsystem
supplies the patien t wi th the alternate gas when one gas source is lost. It does th is by sendi ng
signal s to the el ectronics when a gas source fal ls below a m in im um pressure. Figure 2-16
i ll ustrates the gas flow through gas supply con dition ing subsytem .

Air regulator Oxygen regulator (REG1)

(REG2) with with impact filter (F5)
impact
filter (F4)
Air pressure
switch (PS2)
Oxygen pressure
switch (PS1)

Oxygen
inlet filter
(F3)

Check valve
assembly
(CV2/ CV4) Water trap (WT1)
Air inlet
filter (F2)

8-00277

Figure 2-15. Gas supply conditioning subsyst em

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2 Theory of operation

Vent

PS1
F7
F3
REG1
TP1
F5
F1

OXYGEN CV2
SUPPLY PS2

Vent

CV4
F2 REG2
F6
TP2
AIR
SUPPLY WT1 F4

8-01287

Figure 2-16. Gas supply condit ioning subsyst em gas flow diagram

2.3.1.1.1 Gas supply condit ioning subsyst em component s

The oxygen side of the gas supply condition ing subsystem includes the followi ng
com pon en ts:
• The oxygen h ose a n d in let fit t in g con nect an external oxygen source to the ventil ator.
Inlet fi tti ngs are avai labl e in DISSm ale, DISSfem al e, NIST m ale, Ai r Li quide, and SISm al e.
• The oxygen pressu re swit ch (PS1 ) senses a l oss of suppl y pressure. Th is 12V, norm al ly
open switch closes wh en gas pressure reaches 31.5 psig nom in al and opens when gas
pressure reaches 20.0 psig nomi nal.
• The oxygen im pa ct filt er (F1 ) fil ters m atter larger than 65 to 110 µm (m icrons).
• The oxygen in let filt er (F3) protects the pneum atic systems from debris by trapping
particles dow n to 0.3 µm (micron ). Th e bowl and O-ri ng m ust be properly in stal led to
preven t oxygen leakage i nto the inspiratory m odule.
• The oxygen regu la t or (REG1 ) is a spri ng-loaded, ven ting li ne regul ator that m ai ntains 9 to
12 psig output throughout a 35 to 100 psig supply range, from less th an 1 L/ m in to 200 L/
m in. Its n om in al output is 10.5 psig at 2 L/ m in . REG1 vents outside the BDU. Th e REG1
FRU i ncl udes th e oxygen im pa ct screen filt er (F5), wh ich rem oves debris enteri ng REG1.
• The oxygen pressu re va lve (TP1) ch ecks the oxygen regul ator setti ng (REG1).
• The oxygen pn eu m a t ic n oise filt er (F7), housed i n the flow sensor m an ifold, con diti ons
gas flow by eli m inati ng swi rl ing of gas i nduced by elbows and restricti ons.

2-16 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
The air side of the gas supply conditionin g subsystem i ncl udes the fol lowin g com ponents:
• The a ir h ose a n d in let fit t in g connect an external high-pressure air source to th e
venti lator. Inlet fi tti ngs are avail able i n DISS m ale, DISS fem al e, NIST m ale, Ai r Liquide,
an d SIS m ale fittin gs.
• The a ir pressu re sw it ch (PS2) sen ses a loss of supply pressure. Thi s 12 V, norm all y open
swi tch closes when gas pressure reaches 31.5 psig n om i nal and opens when gas pressure
reach es 20.0 psig n om i nal .
• The a ir in let filt er (F2) protects th e pneumatic system s from debris by trappin g parti cles
down to 0.3 µm (m icron).
• The coalescin g a ir w a t er t ra p (W T1 ) removes con densati on from the hi gh-pressure ai r.
Th is conden sati on can be caused by pressure drops betw een the w all outlet an d water
trap. W T1 al so houses F2. It has a screw-type drai n valve.
• The a ir a n d com pressor ch eck va lves (CV2 a n d CV4 ), h oused i n the check valve
m ani fold, are h igh-pressure un idi recti on al valves th at prevent ventil ator backfl ow into
the air system . CV2 open s and CV4 closes wh en wall air pressure exceeds com pressor ai r
pressure (or n o com pressor is in stal led). CV4 open s and CV2 closes wh en com pressor air
exceeds wall air pressure (or w all ai r is not connected). W hen wal l air pressure is equal to
com pressor air pressure, both check val ves are open .
• The a ir regu la t or (REG2) is a sprin g-loaded, venti ng li ne regul ator that m ain tain s 9 to 12
psi g output th roughout a 35 to 100 psig suppl y range, from less th an 1 L/ mi n to 200 L/
m in. Its n om in al output i s 10.5 psi g at 2 L/ m in . REG2 vents in side the BDU. Th e a ir
im pa ct screen filt er (F4), h oused in REG2, removes debri s enteri ng REG2.
• The a ir pressu re va lve (TP2) checks the oxygen regulator settin g (REG2).
• The a ir pn eu m a t ic n oise filt er (F6), housed in the flow sensor m an ifold, con diti on s gas
flow by eli mi natin g swi rl ing of gas in duced by elbows an d restri ctions.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-17

2 Theory of operation
)

8-00222

Oxygen/ air pressure sw it ches (PS1/ PS2)

Oxygen
inlet filter
(F3)

Oxygen
impact
filter
(F1)

8-00278

Oxygen Filt ers (F1 and F3)

8-00278

Air inlet filt er (F2)

Figure 2-17. Gas supply condit ioning subsyst em component s

2-18 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2

Air regulator
(REG2)

Oxygen regulator
(REG1)
8-00280

Oxygen and air regulat ors (REG1 and REG2)

CV4 Seat
CV2 Seat Compressor
check valve
(CV4)

Oxygen seat

8-01231

Air and compressor check valves (CV2 and CV4)

Figure 2-17. Gas supply conditioning subsytem component s (cont inued)

2.3.1.1.2 Gas supply condit ioning subsyst em operat ion

Hi gh -pressure oxygen and ai r enter the ventilator. Norm ally-open pressure switches, PS1 and
PS2, moni tor oxygen and air supply pressures. W h en gas pressure reaches 31.5 psig nom inal,
the respective pressure switch cl oses, si gnalin g th e in spi ratory el ectron ics PCB th at the supply
i s adequate. W h en the oxygen or ai r pressure drops to 20.0 psig nom in al, the corresponding
pressure switch open s, causi ng a NO AIR SUPPLY or NO O2 SUPPLY al arm. (See Section 7 for
alarm h andl in g.) The patien t i s ventilated wi th the remain ing gas source. If both gas sources
are lost, the ven til ator alarm s an d open s th e safety valve, and the pati en t breathes ai r from
the room , un assisted by the ventilator.

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2 Theory of operation

On th e air side, th e air in let fil ter (F2) protects the pneum atic system from debris and W T1
protects the pn eum atic system from water condensation. Th e air transfer tube directs th e air
to the ch eck val ve m anifold, which contai ns th e air ch eck valve (CV2) and the com pressor
check valve (CV4). Th ese check val ves direct air from th e highest pressure to the next part of
the system .

NOTE:
Use an external (optional) water trap if there is condensation in the piping system.

On the oxygen si de, two fil ters protect the pneum ati c system from debris. The first fi lter, the
oxygen i m pact fil ter (F1), traps particles down to 65 µm (m icrons) an d th e subsequent fil ter,
the oxygen inl et fi lter (F3), traps particl es down to 0.3 µm (m icron ). Th e oxygen transfer tube
di rects oxygen to the ch eck val ve m ani fold. There is no ch eck val ve for oxygen .
On both th e oxygen and air sides, fi ltered gas passes th rough screen fil ters F5 an d F4, wh ich
are part of regul ators REG1 and REG2. The regulators maintain a stable nom inal output of
10.5 psi g. Pn eum atic noise filters F7 and F6, part of the fl ow sensor m anifol d, condition gas
fl ow by eli m inating swi rl ing of gas i nduced by elbows and restricti ons.
Pressure valves TP1 an d TP2 let you check the regul ator setti ngs. Th is i s don e as part of the
perform ance verifi cati on (see Secti on 5).

2.3.1.2 Flow cont rol subsyst em

The flow con trol subsystem , shown in Figure 2-19 and Figure 2-18, controls the m ixture an d
fl ow of oxygen an d air to the pati en t. It is m oun ted on the gas supply conditi onin g
subsystem .

PSOL1

PSOL2

Q1
Q2

8-00281

Figure 2-18. Flow cont rol subsystem

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Theory of operation 2

PSOL1
Q1

OXYGEN
SUPPLY
SV

Q2
PSOL2

AIR SUPPLY
8-01286

Figure 2-19. Flow cont rol subsystem gas flow diagram

Figure 2-20. Hot film

2.3.1.2.1 Flow cont rol subsyst em component s

The flow control subsystem includes two parall el pneumatic ci rcuits for oxygen and ai r; th e
components on eith er si de are i nterchan geabl e. The foll owin g com ponen ts, sh own in Figure
2-21, com pri se this subsystem :
• The oxygen a n d a ir flow sen sors (Q1 a n d Q2 ) m easure gas flow in th e oxygen and air
ci rcui ts. The sam e flow sensor works on either th e oxygen or ai r side. The fl ow sensors use
un ique h arnesses wh ich determi ne the iden tity of each flow sensor. Th e fl ow sensors have
an onboard EPROM preprogram m ed with th e sensor’s serial num ber. Any ti m e you i nstall
a new sensor or swap existing sensors, you must run the flow sensor cal ibrati on functi on
(part of the service m ode). At power-on, the BDU veri fies the serial n um ber, sensor
positi on (ai r or oxygen), and calibrati on data from both flow sensors.
• Q1 an d Q2 use a hot fil m (Fi gure 2-20) w ithi n each
Constant
sen sor to m easure gas vel oci ty (flow). Th e h ot film
current
consti tutes on e leg of a bridge ci rcui t. The bridge i s
suppl ied by a constan t curren t. Wi th no flow, all legs of
the bridge ci rcuit have equal resi stance. As flow
increases (velocity increases), hot fi lm tem perature
(and resi stance) decreases. Current th rough th e hot
film leg i ncreases, and the bridge circui t becom es
unbalan ced. Output vol tage V OUT i ncreases
proporti onally to gas flow. Hot film

• The oxygen a n d a ir proport ion a l solen oid va lves

V out
(PSOL1 a n d PSOL2) are software-dri ven an d
individuall y control led to deli ver the prescri bed air/
oxygen m ixture to th e patient. Each proporti on al Constant
solen oi d val ve i ncl udes a l inear m otor that con trols a current
poppet val ve. The poppet valves open in proportion to
the appl ied current. Figure 2-20. Hot film

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-21

2 Theory of operation

8-01184

Oxygen and air flow sensors (Q1 and Q2) wit h ferrit es inst alled

8-00282

Oxygen and air proport ional solenoid valves (PSOL1 and PSOL2)

Figure 2-21. Flow control subsystem component s

2.3.1.2.2 Flow cont rol subsyst em operat ion

The flow control subsystem con trols the fol lowin g venti lation param eters:
• Peak fl ow (up to 200 L/m i n for spontan eous breaths)
• Square an d descendi ng waveform s
• Ti dal vol um e (25 to 2500 mL)
• Oxygen percentage (21 to 100%)
• Breath rate (1 to 100/ m in )
The PSOL con trol loop operates in two m odes: PSOLs closed and PSOLs opened.

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Theory of operation 2
W hil e the ventil ator is in the PSOLs cl osed m ode, the followi ng are true:
• The flow requiremen t is determ ined by BDU software (lookup table or calculate). Required
curren t i s then cal cul ated and i s added to li ft-off curren t.
• Current i s sent to the PSOL. A reasonabl eness ch eck is performed on this current.
• Flow i s checked at flow sensors Q1 an d Q2.
• Target flow and fl ow at th e sensor are com pared (error determ in ed). The curren t needed to
reposition the PSOL i s calcul ated and sen t to th e appli cabl e PSOL.
• The PSOL current i s checked for reason abl eness.
W hil e the ventil ator is in the PSOLs opened m ode, the foll owi ng are true:
• Flow i s checked at flow sensors Q1 an d Q2.
• Target flow and fl ow at th e sensor is com pared (error determ ined). Current needed to
reposition the PSOL i s calcul ated and sen t to th e appli cabl e PSOL.
• The PSOL current i s checked for reason abl eness.
Target gas flow i s derived differentl y for each breath type (volum e-l im ited m an datory,
pressure-li mi ted m andatory, spontaneous, and spontan eous with pressure support). The flow
control algorith m com pensates for agin g com ponen ts. It also prevents oversh oot.

2.3.1.3 Safet y valve and inspirat ion monit oring subsyst em

The safety valve and in spiration mon itorin g subsystem , sh own i n Figure 2-22 and Figure
2-23, is m ounted on the gas suppl y conditioni ng subsystem . Thi s subsystem in cludes:
• A safety valve section th at, un der certain ci rcumstances, vents excessi ve ven til ator
pressure and lets th e patient breath e room ai r.
• An in spiration moni torin g secti on that m onitors the pressure and oxygen con centration
of the inspiratory gas.

Inspiratory check
Absolute pressure valve (CV3) housing
transducer (PA)

Inspiratory
pressure
transducer
(PI)

Oxygen Safety
sensor valve (SV)
(OS)

Inspiratory
pressure
transducer
autozero
solenoid
(SOL1)
8-00152

Figure 2-22. Safety valve and inspiration monitoring subsyst em

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2 Theory of operation

To Patient
PSOL1

CV3
SV
OS

NO

SOL1
PSOL2

NC C

PA PI
8-01291

Figure 2-23. Inspirat ion monit oring subsyst em gas flow diagram

2.3.1.3.1 Safet y valve and inspirat ion monit oring subsyst em component s
The safety val ve section in cludes th e foll ow ing com ponen ts, shown in Figure 2-23:
• The sa fet y va lve (SV) con si sts of a +12 V solen oid actuator th at i s norm al ly energi zed
(closed) wh ile th e venti lator operates. The closed valve prevents gas from escaping to the
room and thus al lows th e venti lator to del iver gas through the outl et m an ifold to the
patient.
SV has two im portan t safety functi on s. First, if outlet pressure exceeds the m axi mum
operati ng pressure or if pressure m easured at the expiratory pressure transducer (PE)
reaches 100 cm H 2O, th e valve passively rel ieves the excess pressure. The actual SV reli ef
pressure m ay vary dependi ng on the pati ent fl ow rate. Second, i f the control system
detects a catastroph ic fai lure, the valve i s open ed an d the pati ent can freely breath e room
air.
Under som e ci rcum stances, i ncl udi ng when a venti lator in operative condi tion i s declared,
SV is de-energi zed, open ing the patien t ci rcuit to atm osphere an d venting pressure.
Typi cally, i f patient pressure exceeds 100 cm H 2O (m easured at PE), th e BD CPU
com m an ds SV to de-energize. If pressure at SV exceeds 115 cm H 2O nomi nal , SV is
m echan ical ly forced open.
• The ou t let m a n ifold h ouses the oxygen sensor (OS), th e in spi ratory ch eck val ve (CV3),
and the pressure rel ief ori fice. (See Figure 2-24.)
• The in spira t ory ch eck va lve (CV3) opens to supply inspiratory gas. It also restricts
exhal ation flow in the reverse direction wh en SV is open .
The inspirati on moni tori ng section in cl udes the fol lowing com ponents:
• The oxygen sen sor (OS) m on itors the oxygen concentrati on of delivered gas. This gal van ic
sensor gen erates a voltage proporti onal to the oxygen con cen tration . The ventil ator
alarm s if the m onitored oxygen concen trati on i s n ot wi thi n ±7% of the oxygen
percentage settin g.

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Theory of operation 2
• Two soli d-state di fferential pressure transducers m oni tor th e pressure of th e in spi ratory
an d exh aled gases. The in spir a t or y pressu re t ra n sd u cer (PI), located on the in spiratory
electronics PCB at the inspiratory lim b, mon itors the pressure of the inspiratory gas. The
expira t ory pressu re t ra n sd u cer (PE), located in the exh al ation com partm en t, m on itors
the pressure of the exh al ed gas.
• The in spir a t ory pressu re t ra n sd u cer a u t ozero solen oid (SOL1) is a +6 V, three-way
solen oi d. It i s energized periodi call y to set a zero referen ce or offset voltage for the
inspi ratory pressure transducer (PI). During the autozero procedure, SOL1 conn ects PI to
atm osphere.
• The a b solu t e pressu re t ra n sd u cer (PA), l ocated on th e inspi ratory electroni cs PCB,
m easures atmospheri c pressure (psia). One port is open ed to the atm osphere an d one port
i s con nected to a sealed vacuum ch am ber.

8-00269

Safet y valve (SV)

Seat
Check valve
Leaf
housing

Oxygen
sensor
Oxygen
sensor
port
8-01122

Inspirat ory out let manifold

Figure 2-24. Safety valve and inspirat ion monitoring subsyst em component s

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-25

2 Theory of operation

8-00284

Oxygen sensor (OS)

PA

PI

8-00285

Absolut e and inspirat ory pressure t ransducers (PA and PI) on inspirat ory elect ronics PCB

8-00283

Inspirat ory pressure t ransducer aut ozero solenoid (SOL1)

Figure 2-24: Safet y valve and inspirat ion monit oring subsystem component s (continued)

2-26 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
2.3.1.3.2 Safet y valve sect ion operat ion
Durin g n orm al operation, the safety valve is energi zed closed so th at gas is deli vered to the
patient.
Sh ould the operating pressure of the patient system exceed 100 cm H 2O (m easured at PE),
compon ents in the safety val ve subsystem work together to relieve excess pressure.
If pressure at the safety valve reach es nomi nal 115 cm H 2O, th e valve is forced open.

To Patient
PSOL1

CV3
SV
OS

NO

SOL1
PSOL2

NC C

8-01131
PA PI

Figure 2-25. Safety valve open gas flow diagram

In case of a catastroph ic failure, such as a power fai lure, SV is de-energized. This acti on
perm its the patien t to breathe room air. CV3, whi ch i s bui lt i nto the outlet m an ifold,
preven ts rebreath in g from room air by en surin g th at exh alati on occurs onl y th rough the
exh alati on valve.

2.3.1.3.3 Inspirat ion monit oring sect ion operat ion

Pressure tran sducers PI, PE, an d PA moni tor i nspi ratory, expiratory, an d atmospheric
pressures through out the respi ratory cycl e.
A patient-triggered i nspiration is ini tiated when the patient pressure measured by the
expi ratory pressure tran sducer drops below the baseli ne (PEEP) by an am ount equal to or
greater than the pressure sensi tivi ty setti ng.
Although exhal ation can be tri ggered by tim e, pressure, or fl ow, expi ratory pressure is
m oni tored th roughout th e i nspiratory phase. Exh alation is in itiated when the system
determ i nes the expi ratory pressure equal s or exceeds PEEP pl us the effective working pressure
for spontan eous, pressure-supported breaths.
Ongoing di agnostics mon itor ven tilator pressures and ch eck for severe occlusi on s and circui t
disconnects by compari ng pressure at PE an d PI.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-27

2 Theory of operation

2.3.1.4 Inspirat ory module operat ion

The followi ng subsecti ons descri be the in teraction between th e pn eum atic subsystem s
com prising the inspiratory m odule.

2.3.1.4.1 Air flow summary

The air fl ow th roughout th e in spi ratory m odule an d the related com pon ents are show in
Figure 2-26 bel ow.
1 Inlet fi tting
2 Ai r pressure swi tch (PS2)
24
3 Ai r inl et filter (F2) 21
19
4 Ai r water trap (W T1)
16
22
18 20
5 Tran sfer tube
6 Check valve m an ifol d 23 15

7 Air check valve (CV2)

8 Com pressor ch eck val ve
10
(CV4) 17
14
26 25
9 Ai r im pact screen fil ter (F4)
10 Ai r regul ator (REG2) 13 12
11 Flow sensor m ani fol d 9 11
7&8 2
12 Ai r pressure valve (TP2)
6 5
13 Ai r pneumati c noise fi lter
(F6)
1
14 Ai r fl ow sen sor (Q2) 33

15 PSOL/ SV m an ifol d
4
16 Air proporti on al solenoid
8-01283
valve (PSOL2)
17 Safety val ve (SV)
Figure 2-26. Air flow diagram
18 Outl et m an ifold
19 Inspiratory ch eck val ve (CV3)
20 Pressure rel ief orifice
21 Oxygen sensor (OS)
22 Inspiratory outl et
23 Inspi ratory pressure tran sducer (PI)
24 Absolute pressure transducer (PA)
25 Inspi ratory pressure tran sducer autozero solenoi d (SOL1)
26 Inspiratory el ectronics PCB
Figure 2-26. Air flow diagram

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Theory of operation 2
Gas in. Wal l air en ters the ven ti lator at the air i nlet fitti ng. The ventil ator requires wall air
pressure m ain tained between 35 and 100 psi g wi th i nterm ittent fl ow up to 200 L/ mi n. If wal l
air fal ls below compressor pressure, an optional com pressor uni t suppli es air to the ventil ator
at the ch eck val ve m anifold.
Pressure monitoring. Wal l ai r is monitored by PS2 (norm al ly open). As air pressure increases
above 31.5 psig nom inal, PS2 closes, indicating sufficient wall air pressure to operate the
ven til ator.
Filtration. Th e ai r in let fil ter (F2) traps particl es down to 0.3 µm (m icron), protecting th e
pneum ati c system from debri s. Coalescing-type water trap W T1 coll ects condensation.
Wall or compressor air. Extern all y suppli ed air con tinues through a transfer tube to th e check
valve m ani fold, wh ich contain s the air ch eck val ve (CV2) an d th e com pressor ch eck val ve
(CV4). Depen din g on wal l air pressure, either wal l air or com pressor output is suppli ed. If wall
air pressure fal ls below 26 psig, com pressor air i s supplied to REG2.
Regulation. From th e check valve m an ifold, air enters REG2 vi a the air i mpact screen filter
(F4). F4 traps parti cl es. REG2 reduces air pressure from 35 – 100 psig to 9 – 12 psi g (10.5 psi g
n omi nal). It ven ts 2 L/m i n insi de th e BDU.
Turbulence smoothing. Low-pressure ai r enters th e flow sensor m ani fol d, whi ch houses the ai r
pressure valve (TP2) and the air pneum atic noise fil ter (F6). TP2 i s used to check REG2
settings. F6 conditi on s gas flow by eli m inating swi rl ing of gas i nduced by elbows and
restri cti on s.
Air and oxygen mixing. Air con ti nues on to the air flow sensor (Q2), wh ere air flow i s m easured.
Software calcul ates air flow at Q2 and target flow. Software-controll ed current is appli ed to
PSOL2, open ing i t to al low a predetermi ned ai r flow through PSOL2. The PSOL/SV m ani fol d
h ouses proportional solenoid valves PSOL1 and PSOL2, and th e safety valve (SV). M ixed gas
i s deli vered to the patien t ci rcui t through the inspiratory outl et.
Safety valve. Should the operatin g pressure of the patient circui t exceed 100 cm H 2O (m easured
at PE), the safety valve opens. The outlet m anifold houses the oxygen sen sor (OS), th e
i nspiratory check val ve (CV3), and th e pressure relief orifice. CV3 prevents rebreath in g from
the room by en suri ng that exhal ation occurs onl y th rough th e exhal ati on valve.
Inspiration monitoring. Th e oxygen concen trati on of the deli vered gas is m easured by the
oxygen sensor (OS). The ven til ator alarm s i f th e m onitored oxygen concentration is not
wi thin ±7% of the oxygen percentage setting. Pressure m easurem ents are made by two
differenti al pressure tran sducers.
The inspiratory pressure transducer autozero solenoid (SOL1) is energized periodicall y to set a
zero referen ce or offset voltage for the i nspiration pressure transducer.

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2 Theory of operation

2.3.1.4.2 Oxygen flow summary

The followi ng paragraphs describe oxygen flow throughout th e i nspiratory m odul e
(Figure 2-27).
1 Oxygen inl et fitti ng
19
2 Oxygen pressure switch (PS1) 16

3 Oxygen im pact fi lter (F1) 15

17
18 20
4 Oxygen inl et fil ter (F3)
14
5 Tran sfer tube
6 Check valve m an ifol d 13 9
7 Oxygen im pact screen fil ter (F5)
8
8 Oxygen regulator (REG1)
9 Regulator ven t 4 11 12
7
10 Flow sensor m ani fol d 10
2 6
11 Oxygen pressure valve (TP1) 3 5

12 Oxygen pn eum atic n oi se fi lter

(F7) 1

13 Oxygen flow sensor (Q1)

14 PSOL/ SV m an ifol d 8-01284

15 Oxygen proportional solenoid Figure 2-27. Oxygen flow diagram

(PSOL1)
16 Inspiratory ch eck val ve (CV3)
17 Pressure release orifi ce
18 Outl et m an ifold
19 Oxygen sensor (OS)
20 Inspiratory outl et
Figure 2-27. Oxygen flow diagram

Gas in. Oxygen en ters the ven ti lator at the oxygen in let fitti ng. The ven til ator requires
oxygen pressure m ai ntain ed between 35 an d 100 psi g wi th interm i tten t flow up to
200 L/m i n.
Pressure monitoring. Oxygen is m onitored by PS1 (normally open ). As oxygen pressure
i ncreases above 31.5 psi g nom inal, PS1 cl oses, indicatin g sufficien t oxygen pressure to
operate the ventil ator.
Filtration. The oxygen im pact fil ter (F1) traps particles down to 65 µm (m icrons). Th e oxygen
i nlet fi lter (F3) traps parti cles down to 0.3 µm . These fil ters act togeth er, protecti ng the
pn eum atic system from debri s. Oxygen contin ues through a transfer tube, the check valve
m an ifold, and on to REG1. PSOL1 provides prim ary, and REG1, secondary, cross-
contami nati on protection. Thus, no oxygen check valve i s requi red i n the check valve
m an ifold.
Regulation. Oxygen enters REG1 through the oxygen im pact screen fi lter (F5). Th is fi lter traps
l arge parti cles to prevent accel eration an d to reduce parti cle tem perature. REG1 reduces
oxygen pressure from 35 – 100 psi g to 9 – 12 psig (10.5 psi g nom inal). It vents at a m axim um
of 2 L/ m in (outside th e BDU to prevent oxygen bui ldup).

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Theory of operation 2
Turbulencesmoothing. Low-pressure oxygen enters th e flow sensor m ani fol d, wh ich h ouses the
oxygen pressure val ve (TP1) and the oxygen pneum ati c noise fi lter (F7). TP1 checks REG1
settings. F7 conditi on s gas flow by eli m inating swi rl ing of gas i nduced by elbows and
restri cti on s.
Oxygen and air mixing. Oxygen contin ues on to the oxygen flow sensor (Q1), where oxygen
fl ow is m easured. Software calculates oxygen flow at Q1 and target fl ow. Software-control led
current is appli ed to PSOL1, openi ng it and allowi ng a predeterm ined oxygen flow through
PSOL1. The PSOL/ SV m an ifold houses proporti onal solenoi d valves PSOL1 an d PSOL2 and
safety val ve SV. M i xed gas is deli vered to the pati ent ci rcuit through th e i nspi ratory outlet.
Safety valve. If the operati ng pressure of th e patient ci rcuit ex ceeds 100 cm H 2O (m easured at
PE), SV opens. Th e outlet m anifold houses th e galvan ic oxygen sensor (OS), the inspiratory
check val ve (CV3), and the pressure rel ief orifice. CV3 prevents rebreath in g from the room by
directi ng exhaled gas to th e exhalati on valve.
Inspiration monitoring. The oxygen concen trati on of th e delivered gas is m easured by OS. The
ven til ator alarm s i f the m on itored oxygen concentration i s n ot wi thin 7 percentage points of
the O 2 percentage settin g. Pressure m easurem en ts are made by two soli d-state differen tial
pressure transducers.
SOL1 i s energized peri odi cally to set a zero reference or offset voltage for the in spi ration
pressure transducer.

2.3.2 Patient System

The patien t system , shown in Fi gure 2-28 and Figure 2-29, in cludes ex ternal com pon en ts th at
del iver gas from th e ven ti lator to the pati en t, control certai n aspects (h eat, humi dity) of
patient ven til ati on , and isol ate th e ven tilator from the patient using bacteria fil ters. The
patient circuit can h eat an d hum i dify del ivered gas w hen a hum idi ficati on devi ce is i nstal led.
A variety of opti on al accessories can be used i n the pati ent ci rcui t. Figure 2-28 sh ows a typical
patient system con fi gurati on .

Inspiratory
filter
(F8)
Humidification
device

Water trap
(2 PL)

Wye

8-00276

Figure 2-28. Patient syst em (minus exhalat ion collect or vial and expiratory filt er)

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-31

2 Theory of operation

PATIENT WYE

WT WT

F9

FROM PATIENT HUMIDIFIER

ECV F8
TO PATIENT

8-01290

Figure 2-29. Patient system flow diagram

2.3.2.1 Pat ient system component s

The patient system incl udes the fol lowi ng com ponents:
• The in spir a t or y (m a in flow ) filt er (F8) (the Puri tan Ben nett D/Flex or Re/Flex Filter)
helps protect th e patient from con tam ination by suppli ed gas. It al so h elps protect the
ventil ator from con tam ination by the pati en t circuit. F8 captures particl es of 27
nan om eters n om i nal at a flow of 30 L/m i n w ith 99.99% effici ency. It h as 22-m m ISO
conical con necti ons.
• Wa t er t ra ps (W T) in the i nspiratory and exhal ation si des of th e patien t ci rcuit col lect
excessi ve water th at m ay conden se on the insi de wall s of th e tubing. (Not present on all
patient circui t m odels.)
• An optional h u m id ifica t ion d evice warm s and hum idi fies gas del ivered to the patient.
• A wye connects i nspi ration and exhalati on tubi ng, form i ng a cl osed ci rcuit.
• The exh a la t ion collect ion via l (ECV) collects up to 250 m L of fluid from th e exhal ed gas.
• The expir a t ory filt er (F9) (Puritan Ben nett D/X800 si ngle-patient use fil ter or Re/X800
reusable fi lter) h elps prevent bacteria i n ex hal ed gas from bei ng ven ted to room ai r and
reduces cross-contam in ation of the ventil ator. The fi lter captures particl es of 27
nan om eters n om i nal at a flow of 30 L/m i n w ith 99.99% effici ency. It h as 22-m m ISO
conical con necti ons.
The NeoM ode DAR (PN 351919005) disposable expiratory fil ter and the Puritan Ben nett
Neo Re/ x800 reusabl e expi ratory filter are desi gned specificall y for use with the NeoM ode
opti on.
• The m ou n t in g pla t e, used on ly with n eonatal pati ent system s, allows the ven tilator to
accom m odate the neonatal expiratory fil ter.

Caut ion
To protect the exhalation assembly, always use a Puritan Bennett expiratory filter or a
recommended DAR expiratory filter.

2-32 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
2.3.2.2 Pat ient syst em operat ion
A predeterm i ned oxygen/ ai r gas m ixture flows from the ven tilator, through F8, and the
opti onal hum idi fication devi ce. W T col lects excessive m oisture (due to conden sation ), and
i nspiration gas is deli vered to the patient through the wye. Exh aled gas flows th rough the
wye, to th e ECV, an d through F9.

2.3.3 Exhalat ion module

The exh alati on m odule, shown in Figure 2-31 and Fi gure 2-30, conditions exhaled patient gas
by heati ng gas/ water vapor m i xture to prevent con densation wi thi n th e exhal ati on m odul e.
The exhalati on valve open s an d closes for exhalation an d i nspi rati on. Durin g exhal ati on, the
exh alati on val ve control s the PEEP/ CPAP (basel in e) pressure. A flow sen sor m oni tors fl ow and
a pressure tran sducer m onitors pressure.

8-01175

Figure 2-30. Exhalation module (removed from BDU)

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2 Theory of operation

C NC
SOL2
PE
EXH
HTR NO

CV5

F9
Q3
FROM
PATIENT
ECV

EV

8-01295

Figure 2-31. Exhalat ion module flow diagram

2.3.3.1 Exhalat ion module component s

The exhalation module in cludes th e foll owi ng com pon en ts, shown in Figure 2-32:
• The exh a la t ion ch eck va lve (CV5 ) is a on e-way devi ce th at preven ts room air from
en terin g the exh alation system . Th e pressure of th e exh aled gas open s the valve, resulti ng
in exhal ed gas flowi ng in to the exhalati on system . W hen the patient stops exhalin g, the
valve closes.
• The 16 W exh a la t ion h ea t er (EXH H TR) h eats the gas as it reach es the exhal ation system.
The heater m aintai ns gas tem perature above condensation l evels to prevent con den sati on
in the exh alati on m odule.
• The exh a la t ion flow sen sor (Q3) provides flow inform ation on exhaled gas. Flow sen sor
m easurem en ts are used to determ i ne n et gas fl ow to the patien t an d spirom etry.

2-34 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
• The exh a la t ion va lve (EV) cl oses durin g i nspiration to
prevent del ivered gas from ven ti ng to the atm osphere.
It opens during exh alati on to m aintain th e operator-
sel ected PEEP/ CPAP. Th is active exhalation valve i s
acti vel y controll ed at al l tim es el ectron ically. Th e
exhal ation valve is activel y coordi nated w ith th e
PSOLs to all ow very fast rise ti m e and to m i nim ize
pressure spikes that woul d otherwise occur.
Using an active exh alati on val ve al so m i ni m izes
pressure rises during in spi rati on wh en a patien t
cough s; th e valve is open ed and excess pressure
vented.
• The expira t or y pressu re t ra n sd u cer a u t ozero solen oid
(SOL2) is a +12 V, th ree-way sol enoid that is opened
periodical ly to set a zero referen ce or offset voltage for
the expi ratory pressure tran sducer (PE). Both the
inspi rati on and expiratory pressure tran sducers are
zeroed togeth er. Duri ng the autozero procedure, both
solen oi ds are energi zed so th at am bi en t pressure i s
suppl ied to both ports of both transducers. An average
offset pressure vol tage for each pressure tran sducer is 8-00286

calcul ated and tested, an d stored in data m em ory. Exhalat ion valve
• The expira t or y p ressu re t ra n sdu cer (PE) (on th e
exhal ation transducer PCB) m easures th e exhalati on system pressure. Th e ventilator uses
exhal ation pressure readings in breath del ivery calcul ations. The tran sducer is autozeroed
vi a SOL2.
• A pressu re port all ows pressure m easurements i n th e exhalati on m odule.

2.3.3.2 Exhalat ion module operat ion

Durin g exhalation, pati ent gas en ters th e exhalation system from the patien t ci rcui t. Th e
ven til ator acti vely control s th e exhalation valve (EV), open ing an d cl osin g i t i n preci se
i ncrem ents th roughout in spi rati on an d exh al ation. Such preci se control of th e val ve allows
the ventil ator to del iver aggressive breaths whil e m i nim izi ng pressure overshoots, controll ing
PEEP, and rel ievi ng excess pressures. The exh alation module al so perform s spi rom etry of the
exh aled gas and m onitors fl ow sensitivity.
The exhal ation heater (EX H HTR) h eats th e exhaled gas to m i nim i ze m oi sture i n th e
exh alation m odule, wh ile therm istors provide the venti lator wi th tem perature feedback. The
expi ratory pressure tran sducer (PE), on the exhalation tran sducer PCB, and th e exhal ation
fl ow sensor (Q3) provide readin gs used in breath del ivery calculations.

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2 Theory of operation

8-01176

8-00236

Exhalat ion flow sensor (Q3)

Figure 2-32. Exhalation module component s

2-36 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2

8-00287

Expirat ory pressure t ransducer autozero solenoid (SOL2)

8-00240

Exhalat ion check valve (CV5)

8-00239

Exhalat ion heat er (EXH HTR)

Figure 2-32: Exhalation module component s (continued)

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-37

2 Theory of operation

2.3.4 806 Compressor Unit

The opti on al, cart-m ounted 806 com pressor un it, shown in Fi gure 2-34, is the l atest styl e
com pressor system avail abl e for use with the 840 ventil ator. W h en ac power is presen t, the
com pressor system suppl ies ai r to the ven ti lator i n the event th at a hospi tal air source i s
unavail able or the source pressure drops bel ow 26 psig.

8-01257

Figure 2-33. 806 compressor on cart

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C

F12
Dryer
HB
8-01133

Figure 2-34. 806 Compressor Pneumatic diagram

2.3.4.1 806 Compressor unit component s

The 806 com pressor in cludes th e foll ow ing com pon en ts, shown in Figures 2-35 – 2-40:
• The in t a ke filt er /silen cer (F12) fil ters th e com pressor in take air and reduces com pressor
sound.
• The m ot or/com pressor (M/C) is a dual-piston com pressor that pressurizes room ai r to
suppl y the ventil ator.

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Theory of operation 2
• An em ergency relief va lve (RV) protects the com pressor system agai nst overpressurizati on
by open ing at 36 psi g.
• Cool ing fa n s blow air across a h ea t exch a n ger (H E) wh ich rem oves h eat from the
com pressed ai r. The air flow from the fans al so hel ps to cool the m otor/ com pressor.
• A w a t er t ra p (W T2) col lects the conden sation form ed as th e com pressed air travels
through the heat exchan ger. Th e water trap automatical ly dispenses its contents in to th e
h ou sin g ba se (H B) wh ere i t evaporates.
• A membrane a ir d ryer l owers the dew poi nt below am bi ent tem perature by rem ovi ng
resi dual water vapor from the com pressed ai r prior to bei ng stored i n th e accumulator. An
attached silen cer (F1 3) reduces n oi se from the air drying process.
• The com pressor u n loa d in g solen oid (SOL3) opens at com pressor start-up to reduce the
l oad on th e com pressor. As a secondary function, excess fl ow is ven ted through SOL3 to
the air dryer durin g periods of low dem and to assi st in rem oving water vapor from the air
dryer.
• Com pressed air, sufficient to m eet the ventil ator’s ful l fl ow requi rem ents, is stored in the
a ccu m u la t or.
• The 0.3 m icron filt er (F10 ) screens particl es from com pressed air fl ow ing to the venti lator.
• The com pressor pressu re t r a n sd u cer (PC) m easures pressure in the accumulator an d th e
pressure si gn al i s used to control the operati on of th e solen oi d, com pressor m otor, and
fan s. Air goin g to the pressure tran sducer passes through a rest rict or (R1 ) to reduce
pressure pul sati on s and a filt er (F11 ) to prevent contam in ants from enteri ng the
transducer.

Pressure
relief valve
To heat exchanger

Silencer M otor/compressor

Cooling fans
0.3 micron
filter

Intake filter Silencer

Filter foam 8-01273

Figure 2-35. 806 components

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2 Theory of operation

8-01264

Figure 2-36. Heat exchanger

Water
trap

Filt er
element

8-01262

Figure 2-37. 806 w at er trap assembly

To accumulator
To pressure
Unloading transducer (PC)
solenoid (SOL3)
To solenoid Filter (F10)

From heat
exchanger
8-01266 Air dryer Silencer

Figure 2-38. Air dryer assembly

2-40 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2

Accumulator

Air dryer
assembly
M otor/
Silencer compressor

8-01270

Figure 2-39. 806 back panel

2.3.4.2 806 Compressor unit operat ion

The 806 com pressor i s powered by and com m uni cates wi th the 840 BDU. Th e BDU sends a
sign al to the com pressor after com pl eti ng POST, an d the com pressor enters either stand-by
m ode or run m ode dependi ng upon the state of th e air-side pressure switch , PS2. If PS2 is
closed, indicating sufficient wall ai r pressure, the com pressor charges the accumulator to
27 psig and en ters stan d-by mode, ready to suppl y ai r to the ven tilator in th e event of a loss
of wall ai r pressure. If PS2 is open , the com pressor enters run m ode, and acts as the
ventil ator’s ai r source.
W hen th e com pressor i s operating, two cooli ng fans (Fi gure 2-40) blow ai r downward over a
h eat exchan ger used to con dense water vapor from the com pressed ai r. After passing through
the heat exch anger, the com pressed air flows th rough a water trap an d m em brane air dryer
wh ich rem ove excess water vapor prior to bein g stored i n the accum ulator. The air dryer al so
l owers th e dew point to a tem perature below am bient, preventi ng condensati on from
en terin g th e venti lator.

8-01256

Figure 2-40. 806 cooling fans

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2 Theory of operation

Duri ng the start-up sequen ce, a solenoid valve (SOL3) opens 1 second prior to the tim e the
com pressor m otor starts, and rem ai ns open for 0.5 seconds afterwards, reducing the load on
the com pressor. A tran sducer on th e PCBA m easures the accum ulator pressure, an d the signal
i s used to control the compressor operation . If pressure in th e accum ul ator drops below 13
psig, the com pressor shuts down and the ventil ator delivers 100% O 2 to the pati ent.
In stand-by mode, th e com pressor sh uts off w hen th e pressure reaches 27 psi g i n the
accum ulator, an d turns on w hen th e pressure drops to 22.5 psig. (This pressure drop can
occur because of sm all leaks i n the com pressor system or because of cool in g of com pressed air
i n the accumulator.)
The com pressor PCBA contain s an hour m eter that records the elapsed run tim e of the
com pressor. This i nform ati on is stored in the EEPROM on the PCBA, as i s th e com pressor’s
serial number. If a replacem ent PCBA is required, th e EEPROM from th e existing PCBA can be
rem oved an d i nstalled on th e n ew board, preservin g th e com pressor elapsed tim e and seri al
n um ber.
For more in form ation regardin g the 806 com pressor operati on , see Section 2.4.12 and
Figure 2-76.

2.4 Elect rical syst em

2.4.1 Summary of elect rical component s

The 840 Venti lator electri cal system , shown in Figure 2-41, i ncl udes the fol lowin g:
• ac distri bution com ponents, in cl udi ng power cord, ac panel (circuit breakers, ac fi lter PCB,
power rel ay, and other com ponents), and pow er swi tch
• Power suppl y
• Rechargeabl e BPS, whi ch suppl ies power to operate th e ventilator if ac power i s
interrupted
• Opti onal com pressor uni t incl udi ng com pressor, com pressor PCB, an d other compon ents
• Card cage, i ncl uding m otherboard PCB, BD CPU PCB, an d AI PCB
• GUI, incl udi ng the GUI CPU PCB, keyboard, GUI LED PCB, backli gh t in verter PCB, kn ob,
two VGA l iquid crystal di splay (LCD) panels, a touch fram e PCB, an d alarm speaker

NOTE:
The 10.4-inch GUI features color LCD panels, updated GUI CPU, touch frame, and
backlight inverter PCBs, and three serial communications ports. There is a single
serial communications port on the older 9.4-inch monochrome GUI (no longer
available) and the 9.4-inch color GUI color LCD panels, and one serial
communications port.

• BDU LED PCB

• BD (contin uous-ton e) al arm
• Inspiratory el ectroni cs PCB
• Exh alation transducer PCB
• Data key subsystem

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Theory of operation 2
For a di scussi on of el ectropn eum ati c parts, or el ectrical parts used in cl ose conjunction with
pneum ati c parts, see Secti on 2.3. For wi ring detai l s, see Fi gure 2-41, Figure 2-43, Figure 2-46,
Fi gure 2-51, Figure 2-61, Figure 2-70, Fi gure 2-72, and Figure 2-78. Table 2-2 descri bes the
el ectronic parts.

Table 2-2: Elect ronic Component Descript ions

Reference
Component Descript ion
Designat or

-- Power cord Connects facility ac power to the ventilator.

AC Panel (Figure 2-43)

CB1 Main circuit breaker Provides over-current protection to the power supply.

CB2 Auxiliary circuit breaker Provides over-current protection to the humidifier and compressor.

-- ac filter PCB Filters electrical noise to and from the ventilator.

J1 ac receptacle Receives facility ac power via the power cord.

J2 Potential equalization Provides attachment point to equalize electrical potential between the
connector ventilator and other equipment (such as electrical safety analyzer).

J3 Humidifier receptacle Located at the front of the ventilator, receives ac power from power
relay K1 and provides ac power to the humidifier.

J4 Compressor receptacle Receives ac power from power relay K1 and provides ac power to the
compressor via the compressor ac power cord.

K1 Power relay Switches power to the humidifier and compressor receptacles when ac
power is present and ventilator power switch is ON.

Power Syst em (Fig ure 2-46)

-- Power supply Converts ac and dc (from BPS) inputs to supply dc power to ventilator
electronics. Outputs include GUI +5V, GUI +12V, VH +5V, VH +12V, VH
+15V, VH -15V, BPS +36V, and relay +12V.

-- Back-up power source (BPS) With new, fully charged batteries, provides at least 30 minutes of back-
up power in the event of an ac line failure or temporary disconnect.
Output signals from the BPS PCB include charging*, charged*, BPS
model, IBATT, VBATT, and E-BP.

NOTE:
When the ventilator is running on battery power, the
compressor and humidifier are non-operational.

* indicates signal is active low

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2 Theory of operation

Table 2-2: Electronic Component Descript ions (continued)

Reference
Component Descript ion
Designat or

Card Cag e (Figure 2-51 & Figure 2-54)

-- Motherboard PCB Provides the main electrical interconnect between the breath delivery
CPU PCB, analog interface PCB, breath delivery LED PCB, exhalation
module, inspiratory module, power supply, power switch, and BD
alarm.

-- Breath delivery (BD) CPU PCB Contains the electronics and software that control all breath delivery
functions in the 840 ventilator. Communicates with the GUI CPU to
respond to operator inputs and display ventilation parameters.

-- Analog interface (AI) PCB Provides the interface for all analog signals in the ventilator. The AI and
BD CPU PCBs together provide the main intelligence and drive for the
mechanical devices and electronic sensors used in ventilation.

Breat h Deliver y Unit (Fig ure 2-46)

-- BD LED PCB Contains visual alarm indicators and LED drivers to annunciate safety
valve open, loss of GUI, and ventilator inoperative conditions. All
indicators are powered by +12V.

S1 Power switch Switches power to the power relay (K1), and power supply, enabling
its secondary outputs used by ventilator electronics.

-- BD audio alarm A continuous-tone alarm sounds if one or more of the following events
occurs: a ventilator inoperative condition, loss of communication
between the BD and GUI CPU PCBs, detection of a GUI alarm fault,
power switch failure, or low voltage condition detected by the +5V
sentry on the AI PCB.

-- Data key Required for proper ventilator operation, the data key stores BDU and
GUI serial numbers, hours of ventilator operation, and enables
ventilator software options.

Exhalat ion M od ule ( Figur e 2-72)

-- Exhalation transducer PCB Produces a voltage signal proportional to pressure in the patient circuit
exhalation limb using the exhalation pressure transducer (PE). The
PCB uses a +10V reference.

PE Exhalation transducer M easures the pressure difference in the patient circuit exhalation limb
relative to atmospheric air pressure.

EXH HTR Exhalation heater Heats the patient’s exhaled gas, preventing condensation in the
exhalation module. The 16 W exhalation heater uses +12V.

Q3 Exhalation flow sensor Measures exhalation flow for use in determining net flow to the
patient and for spirometry. Flow sensor drivers use +12V and +5V.
Thermistor supply voltage is +12V.

EV Exhalation valve Closes on inspiration, preventing delivered gas from venting to

atmosphere. Opens upon exhalation, maintaining operator-selected
PEEP/ CPAP level. Electronically controlled throughout the breath cycle,
the exhalation valve uses a maximum of 6V.

SOL2 Exhalation pressure transducer This +12V, 3-way solenoid periodically exposes the exhalation pressure
autozero solenoid transducer to atmospheric pressure for setting a zero-reference offset
voltage.

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Theory of operation 2
Table 2-2: Elect ronic Component Descriptions (cont inued)

Reference
Component Descript ion
Designat or

Inspirat or y M odule (Fig ure 2-70)

-- Inspiratory electronics PCB Produces voltage signals proportional to the pressure in the patient
circuit inspiratory limb and atmospheric pressure using the inspiratory
pressure transducer (PI) and absolute pressure transducer (PA),
respectively. Also provides an interface for the oxygen sensor. The PCB
uses a +10V reference.

PA Absolute pressure transducer Measures atmospheric pressure for use in volume delivery calculations.

PI Inspiratory pressure transducer Measures pressure in the patient circuit inspiratory limb relative to
atmospheric pressure.

SV Safety valve This +12V valve opens when de-energized (during POST, at pressures
> 100 cm H2O, during ventilator inoperative conditions, or when both
source gases are lost). Energized closed all other times.

PSOL2 Air PSOL A +12V proportional solenoid valve. Regulates the flow of air in the
inspiratory circuit by adjusting flow proportionally to the supplied
current which is under feed-back control from the Q2 flow sensor
signal and the inspiratory pressure transducers.

PSOL1 Oxygen PSOL A +12V proportional solenoid valve. Regulates the flow of oxygen in
the inspiratory circuit by adjusting flow proportionally to the supplied
current which is under feed-back control from the Q1 flow sensor
signal and the inspiratory pressure transducers.

SOL1 Inspiratory pressure transducer This +12V, 3-way solenoid periodically exposes the inspiratory pressure
autozero solenoid transducer to atmospheric pressure for setting a zero-reference offset
voltage.

Q1 Oxygen flow sensor Measures inspiratory oxygen flow. M easurements are used to control
PSOL1. Flow sensor drivers use +12V and +5V. Thermistor supply
voltage is +12V.

Q2 Air flow sensor Measures inspiratory air flow. M easurements are used to control
PSOL2. Flow sensor drivers use +12V and +5V. Thermistor supply
voltage is +12V.

PS1 Oxygen pressure switch Senses inlet oxygen pressure and opens if pressure drops below 20.0
psig nominal. Closes when pressure is greater than 31.5 psig nominal.

PS2 Air pressure switch Senses inlet air pressure and opens if pressure drops below 20.0 psig
nominal. Closes when pressure is greater than 31.5 psig nominal.

-- Oxygen sensor Senses inlet oxygen pressure and opens if pressure drops below 20.0
psig nominal. Closes when pressure is greater than 31.5 psig nominal.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-45

2 Theory of operation

Table 2-2: Electronic Component Descript ions (continued)

Reference
Component Descript ion
Designat or

GUI (Figure 2-60 & Figure 2-61)

-- Graphical user interface (GUI) Provides microprocessor control and monitoring of the display and
CPU PCB user interface system. Communicates with the BD CPU PCB via an
Ethernet connection.

Backlight inverter PCB
Converts +12V input into high-voltage ac that powers the fluorescent
lamps that backlight the LCD display panels. Pulse width modulation
from the GUI CPU board determines the magnitude of the ac voltage
which determines the brightness of the displays. Two backlight
inverter PCBs individually control the upper and lower LCD panels on
the 10.4-inch GUI. On the 9.4-inch GUI, one PCB performs the
backlight functions for both displays.

Touch frame PCB Contains the electronics and firmware to detect inputs to the GUI
touchscreen by means of locating the logical X/ Y coordinate position
of an operator's touch.

LCD displays Two variable voltage, 9.4-inch (older version) or 10.4-inch (current
version) color LCD flat panels display ventilator settings and patient
information.

GUI LED PCB Contains LED drivers and light bars that illuminate visual alarm and
status indicators on the GUI LED panel.

Keyboard/ knob PCB
A membrane keyboard assembly containing the multiposition rotary
encoder knob is used to change selected ventilator settings, accept or
clear settings changes, provide alarm silence, reset, and volume adjust
functions, actuate screen lock and information functions, and deliver
manual inspiration, inspiratory and expiratory pause, and 100% O2.

RS-232 connectors Three (10.4-inch GUI) or one (9.4-inch GUI) RS-232 connectors
provide for serial communications with external devices such as
printers or ventilator monitors.

Remote alarm connector Enables/disables an external alarm device (such as a nurse’s call). Relay
contacts are closed during normal ventilation, and open during an
alarm condition or when unit is off.

VGA controllers Plug-in modules (on some versions of the GUI CPU board) that
provide a video interface between the GUI CPU PCB and the LCD flat
panels. The VGA controllers are integrated into the current version of
the GUI CPU PCB.

GUI alarm assembly The ventilator’s primary alarm, emits multiple frequency alarm sounds
under control of the GUI CPU PCB.

806 Compr essor (opt ional; Figure 2-78)

-- Compressor PCB Controls the functions of the compressor motor, cooling fans, and
unloading solenoid.

SOL3 Unloading solenoid A +12V, 3-way solenoid controlled by logic signals that reduces back
pressure on the compressor during start-up and periods of low
demand. Also vents excess accumulator pressure to assist in
transporting water vapor from the air dryer.

M/ C Motor compressor ac powered and logic-controlled, supplies compressed air to the

ventilator when adequate wall air pressure is unavailable. Contains
internal over-temperature protection device.

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Theory of operation 2
Table 2-2: Elect ronic Component Descriptions (cont inued)

Reference
Component Descript ion
Designat or

-- Fans ac powered and logic-controlled, provides cooling air to the

compressor motor and heat exchanger. Fans run only when the
compressor motor is running.

-- Starting capacitor Provides added voltage to overcome mechanical friction upon

compressor motor start-up.

TH1 Thermostat Located on the compressor PCB, provides over-temperature

protection to the compressor system. Activates before compressor
motor internal protection device.

PC Compressor pressure transducer Located on the compressor PCB, measures accumulator pressure and
outputs are used by compressor control logic.

-- Relay Operated by compressor control logic, switches power to the

compressor motor and fan connectors on the PCB.

2.4.2 Overview of elect rical syst em operat ion

The 840 Ven ti lator System uses a dual -m icroprocessor archi tecture wi th an Ethernet n etwork
as the pri mary chan nel of com m un icati on between the two 68040 m icroprocessors. Th e BDU
m icroprocessor h andles the breath deli very control and m onitori ng fun ctions; th e GUI
m i croprocessor reads and interprets i nform ati on from / to the operator vi a th e keyboard,
knob, and displays. The BDU con tinues to operate independently of the GUI during a
tem porary loss of comm un ication . For safety, th e GUI’s CPU mon itors th e BDU’s CPU
activities. Th e BD CPU i s located on the BD CPU PCB, wh ile th e GUI CPU is l ocated on th e
GUI CPU PCB.
To start ven til ation, the operator enters data through th e GUI. The GUI CPU processes this
data, then stores i t i n m em ory. Th e BD CPU, i n conj un ction w ith th e an alog i nterface (AI)
PCB, uses thi s data to com m un icate with ven ti lator i ntern al an d extern al devi ces in cludi ng
the GUI, com pressor uni t, and BPS, and to control and m onitor th e fl ow of gas to and from
the pati en t. All anal og si gnal s to an d from th e system sen sors and actuators are con troll ed by
software run ni ng withi n th e BD CPU.
The BD CPU and AI PCBs plug i nto the motherboard PCB. Th e m otherboard PCB in terfaces
i nput/output (I/ O), industry pack (IP) bus, Ethernet sign als, an d power.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-47

2 Theory of operation

Thi s page i ntentionall y blank.

2-48 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2

GUI INSPIRATORY MODULE

GUI CPU PCB J3 P1
GUI LED PCB INSPIRATORY
FROM GUI ELECTRONICS
J6 VGA P9
TO UPPER CPU PCB J6, J8 PCB
J8 CONTROLLER SAFETY
LCD PANEL J7 J2
J7 VALVE
UPPERLCD
J16 VGA BACKLIGHT P6
TO LOWER PANEL P2
J18 CONTROLLER INVERTER AIR PSOL
LCD PANEL J3
P1 PCB PA (PSOL2)
LOWER LCD
REMOTE PANEL P5 OXYGEN
RS-232 ALARM J9 PI
PSOL
FROM GUI (PSOL1)
BD CPU P2 J7 M OTHERBOARD J20 J19 CPU PCB J16, J18
P1 INSP
PCB COLOR I/O
PWR P10 PRES
PCBs
XDUCER
P3 J8
A/ Z SOL
DIGITAL
TEST J5 (SOL1)
SIGNALS
9 LEDS KEYBD/KNOB TOUCH FRAM E
PCB P3 OXYGEN
DATA FLOW
KEY J12 SENSOR
AI PCB
P9 J9 (Q1)
J1
PWR &
ANALOG SIGNALS P1 P4 AIR FLOW
BD +5 V, BD +12 V, GUI +5 V, GUI +12 V, -15 V, +15 V, CTRL/ STATUS
J6 P10 J10 SENSOR
DIGITAL (Q2)
2 LEDS
SIGNALS J11 P7
P5 BPS
J13 OXYGEN
PTS2000 BPS PCB J3 PRESS
J2 SWITCH
+36 V
(PS1)
BATTERY J1 J3 POWERSUPPLY
CHARGED I/ O CONTROL AIR PRESS
BDU LED SWITCH
J1
PCB (PS2)
PWR F1
J2 BATTERY P1
SW
PACK OXYGEN
(S1) BATTERY F1 SENSOR
CHARGING S1

EXH M ODULE
HUMIDIFIER
OUTLET
EXH PRESS
XDUCER
A/ Z SOL
(SOL2) AC PANEL 100-120 V
POWER RELAY
COM PRESSOR UNIT J4 ONLY
COM PRESSOR PCB K1
EXH HEATER J1 CB2
(EXH HTR) J6 BLU
PC RELAY
BRN
J1
UNLOADING
EXH FLOW SOLENOID
SENSOR (SOL3) CB1 E4
(Q3) TH1 AC BLU
J5 FILTER BRN
PCB E3
EXH VALVE J2 J3
(EV) EQUIPOTENTIALITY
CONNECTOR J4

COMP
EXH PCB
M OTOR
TRANSDUCER
FAN 1 FAN 2
PE STARTING
CAPACITOR
elecsys dgm

Figure 2-41. Elect rical system block

diagram

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 2-49
2 Theory of operation

2.4.3 ac distribution component s

The ac distribution com pon en ts i ncl ude
• a power cord
• ac pan el
• power swi tch
• interfaci ng cabl es, wi res, and com pon en ts.
M ain s (ac) power (or facili ty power) i s appli ed th rough th e power cord to the ac receptacle
an d main an d auxi li ary ci rcuit breakers. From th e m ain circuit breaker, power is appli ed
through the ac fil ter PCB di rectly to the power supply. Power to the power supply bypasses
the power switch , en abli ng the pow er suppl y to contin ual ly ch arge the BPS. W hen the pow er
swi tch i s set to off, the secon daries th at power th e venti lator electroni cs are not acti ve. From
the auxil iary circuit breaker, power i s appl ied via the power rel ay to th e compressor
com partm en t ac receptacle an d the hum i difi er receptacl e. Th e com pressor com partm ent
power cord plugs into receptacle J4, suppl yin g ac power to th e com pressor unit, wh ile th e
h umi di fier receptacl e i s intended to power an opti on al hum idi fier.

2.4.3.1 Power cord

The 840 Venti lator System in cludes a detachable power cord. The power cord h as an IEC-
standard, three-pron g conn ector. The pl ug end vari es, correspon din g to differen t coun try
requirem ents.

2.4.3.2 ac panel
The ac panel (Figure 2-42 and Fi gure 2-43), a si ngle fi el d-repl aceabl e un it (FRU), i ncl udes
com ponen ts that appl y ac to the ventil ator head, compressor unit, and optional hum idifier.
The ac panel includes ac receptacl e J1, circui t breakers CB1 and CB2, ac fil ter PCB, power relay
K1, com pressor receptacle J4, and potenti al equali zation con nector J2. A hum i difi er
receptacle (J3), which is conn ected to but is not a part of the ac pan el, is on the front of the
venti lator.
• The a c recept a cle (J1) receives facil ity ac power via the power cord.

Warning
Ensure that the power cord retainer bracket is properly installed and secures the power cord
to the ac receptacle (J1).

• The ac panel h ouses two push-to-reset type circui t breakers. Th e 5 A m a in circu it brea ker
(CB1) li mi ts curren t to the power supply. The 10 A (100 – 120 V) or 5 A (220 – 240 V)
a u xilia ry circu it brea ker (CB2) li m its curren t to the com pressor and hum idi fier ci rcuits.
• The a c filt er PCB reduces ac lin e noi se to and from the ventil ator.
• The power rela y (K1 ) swi tches power to h um idifier receptacle J3 and com pressor
receptacle J4 when th e power switch (S1) is on. The rel ay is powered from a dedicated
+12 V power suppl y output, whi ch i s active when the power switch i s on .
• The com pressor recept a cle (J4) recei ves ac power vi a K1 an d provi des the ac power outlet
for the com pressor power cord.
• The h u m id ifier recept a cle (J3) receives ac power via K1 an d provides an ac power outlet
for the hum i difi er power cord.
• The pot en t ia l equ a liza t ion con n ect or (J2 ) i nterfaces th e equipm en t an d th e potential
equali zation bus bar.

2-50 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2

ac receptacle
(J1)
M ain
circuit
breaker
(CB1)

Auxiliary Potential equalization

(compressor/ connector (J2)
humidifier)
circuit breaker Compressor
(CB2) receptacle (J4)

8-00288

ac filter M ain circuit

PCB breaker (CB1)

Power
relay
(K1)

Fuse

Auxiliary (compressor/
humidifier circuit breaker (CB2) 8-00246

Figure 2-42. ac panel

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2 Theory of operation

acac power
Auxiliary mains
receptacle
circuit breaker

EXTERIOR OF
AC PANEL
Potential
Compressor/ humidifier equalization
circuit breaker point

Compressor
receptacle

GRN/YEL
BRN
J1
C1 BLU 4
2
L N

G CB1
BLU
INTERIOR OF E2 E1 BRN
AC PANEL J2
C2 1 3
K1 GRN/YEL
2 4

E4 E3 BRN
CB2
J4

L N 1 3
L G

BRN BLU
GRN/YEL

BRN
BRN
BRN
BLU
BLU BLU
1 3 BLU

4 6 BLU BRN

7 9 BRN

A B
LEGEND:
CB1 Power supply circuit breaker
CB2 Auxiliary mains circuit breaker
J1 Mains inlet
BRN
J2 Potential equalization point BRN
BLU
J4 Compressor outlet To power supply
K1 Power relay RED BLK compartment
8-00125

AC PANEL M ODULE

Figure 2-43. 840 Ventilator System int erconnect diagram – ac panel

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Theory of operation 2
2.4.3.3 Power swit ch
The logic-dri ven rocker-type power swi tch (S1), sh own i n Fi gure 2-44, en ables the power
supply secondary outputs that are used by ven ti lator el ectronics. W h en the power switch is
off, the power rel ay is open , preven ting ac distribution to the humi difi er and com pressor
receptacl es J3 and J4. Regardl ess of the power switch positi on , ac power i s supplied di rectl y to
the power suppl y to perm it charging of the BPS. Secondary circuits that power ventil ator
el ectroni cs are n ot active wh en the power switch is off.
A cover protects th e power sw itch an d prevents i t from acciden tall y bei ng turned off. An LED
i ndicator beside the power swi tch lights to indi cate th at power i s avai labl e to the ventilator.

Power
switch
(S1)
LED
Indicator

8-00289

Figure 2-44. Pow er sw itch (S1) and indicat or

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2 Theory of operation

2.4.4 Pow er supply

The power supply (Fi gure 2-45 and Fi gure 2-46), w hich is a si ngle FRU (Field Reparabl e Un it),
outputs +5, +12, +15, an d -15 V to power th e venti lator system . It also provides dc power for
BPS chargi ng. Power suppl y i nputs are either ac from facil ity power or BPS dc power (battery
power). Th e power suppl y accepts i nputs of 80 to 269 V ac rm s at 47 to 63 Hz. Specifi call y, th e
power supply’s outputs are as foll ows:
• VH +5 V (rem otel y sensed)
• VH +12 V
• VH +15 V
• VH -15 V
• GUI +5 V (rem otely sensed)
• GUI +12 V (rem otely sensed)
• BPS +36 V
• Relay +12 V (from th e prim ary)
A power fail ci rcui t in the power supply detects the drop of the bulk +31.5 V (the i nput to the
power supply’s m ain converter) and notifi es the BD CPU PCB. The BD CPU PCB i n turn
generates a nonm askable in terrupt (NM I) sign al.
The ac m oni tor circuit provi des an anal og vol tage scal ed to th e ac input vol tage. Thi s vol tage
i s fed to the AI PCB an d m oni tored by software. The power supply is protected agai nst
n om inal li ne tran sien ts, overtem perature, overload, an d short circuit con diti on s.
The power supply has no test points, and cann ot be fi eld-adj usted. Power supply voltages are
di spl ayed duri ng the an alog data display test in EST.

8-00169

Figure 2-45. Pow er supply assembly

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Theory of operation 2

BD alarm MOTHERBOARD PCB

BDU LED PCB J11 J12 P1 J13

Inspiratory dc blindmate Exhalation I/ O

blindmate cable assy cable assy
cable assy

Comms
outlet/ hmd
cable assy

Power switch (S1) Connects to rear

of power supply
POWER SUPPLY
COM PARTM ENT ac blindmate
cable assy
ac
indicator

Humidifier
outlet (J1) dc blindmate
(100 – 120 V only)
INSPIRATORY
M ODULE Connects to Inspiratory
inspiratory blindmate
COM PARTM ENT
module To ac
panel

POWER SUPPLY

To backup
power supply
(BPS)

(This side is located

adjacent to
inspiratory module)

8-00128

Figure 2-46. 840 Vent ilator Syst em interconnect diagram – Pow er dist ribut ion

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2 Theory of operation

2.4.5 BPS
The BPS, sh own in Fi gure 2-47, provi des a dc power source durin g a bri ef ac li ne fai lure or
tem porary disconnect. A ful ly charged BPS suppli es at least 30 m i nutes of power backup to
the ventil ator. Th e BPS does not power the opti onal com pressor or hum i difier; these operate
from ac li ne power.

NOTE:
It is assumed that the ventilator is powered from an outlet connected to the hospital’s
emergency generator ac backup system.

W h en th e ven tilator power switch (S1) is on, the BPS provi des a +19 to +30 V supply voltage
to the power supply. The ventil ator software m oni tors thi s voltage to determ in e wh eth er the
battery i s present and the battery status. Th e softw are triggers a m edium-urgen cy alarm if th e
battery capacity falls below 2 m inutes run tim e.
The BPSelectroni cs charge th e battery pack as necessary w henever ac is present and suffi ci ent
(> 80 V), even i f the power switch is off. An i ndi cator di splays the batteri es’ ch arging status:
yel low m eans the batteries are chargin g, and green m eans th e batteri es are are approxim ately
75% charged rel ative to n om in al. Good batteri es can be ch arged withi n 8 h ours. Th e BPS has
overcurrent (overcharging) protection.

NOTE:
Battery packs, BPS assemblies, or units with BPS’s that are unused or in storage for over 6
months, or have been depleted by continuous usage require a minimum of 8 hours to
recharge the battery pack.

The BPS contai ns a battery pack (Fi gure 2-48) (w hich i ncl udes two +12 V, lead-aci d batteri es
an d a 15 A fuse) an d a PCB (Fi gure 2-49).

8-00199

Figure 2-47. BPS

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Theory of operation 2

Fuse

8-00273

Figure 2-48. BPS bat tery pack

8-00272

Figure 2-49. BPS PCB

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2 Theory of operation

2.4.6 Card Cage

The card cage, sh own in Figure 2-50 and Figure 2-51, i ncl udes th e m oth erboard PCB, the BD
CPU PCB, and the AI PCB.

BDU CPU PCB

AI PCB

M otherboard PCB

8-00156

Figure 2-50. Card cage w it h all PCBs installed

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Theory of operation 2
Power
BD alarm switch (SI)
To ac
panel

BDU LED Inspiratory

display PCB Exhalation I/O
blindmate dc blindmate
cable assy
cable assy cable assy

BDU LED PCB/

alarm/ power switch
cable assy
J11 J12 P1 J13
Motherboard PCB
4-070900-00
J9 J10

J7 J8

J6

J4

J2

P2 P3

CPU PCB
BREATH DELIVERY
UNIT (BDU)

TEST
switch
(SW2)
P1

LED
indicator

GUI-to-BDU
cable assy

P9 P10

AI PCB

PTS 2000
connection
9-pin J1
J6
P5

Data BDU/ compressor

key dc cable

8-00124

Figure 2-51. 840 Ventilat or Syst em interconnect diagram – Card cage

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2 Theory of operation

2.4.6.1 M ot herboard PCB

The m oth erboard PCB, shown in Fi gure 2-52, Fi gure 2-53, and Fi gure 2-54, resi des in the card
cage. It is the pri mary electri cal i nterconn ect for th e plug-i n PCBs, power supply, and BDU
electronics. The m otherboard PCB consists of a m ul til ayer PCB, connectors for pl ug-i n boards
an d I/O i nterface, and related el ectrical fi lters an d protecti ve devices.

AI PCB connectors

BD CPU PCB
connectors

8-00290

Figure 2-52. M otherboard PCB

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M otherboard PCB

8-00157

Figure 2-53. M ot herboard PCB in place

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2 Theory of operation

P1 J7
BD +5 V, BD +12 V

J8

TO/ FROM BPS & POWER SUPPLY STATUS

POWER
SUPPLY GUI +5 V, GUI +12 V, GUI +5 V SENSE, GUI +12 V SENSE

PWRSW ON

GUI +5 V SENSE, GUI +12 V SENSE

TO/ FROM
BD CPU PCB

J11
TO BDU BDU LEDS
LED PCB

J9

PWRSW POSITIONS
FROM PWRSW

TO BDU 12 V BDU LED PCB

LED PCB

TO ALARM
PWR RELAY
COMP CTRL/

TO PWR RELAY
J10
DATA, ADDRESS,

(AC PANEL)
CTRL, STATUS

STATUS

J13
+15 V, -15 V

TO/ FROM
AI PCB
EXH MOD PWR & SENS
TO/ FROM
EXHALATION
MODULE
BD ALARM

+12 V EXH AZ

EXH MODULE CTRL

J12
INSP MOD PWR & SENS
TO/ FROM
INSPIRATORY
INSP MODULE CTRL
MODULE

8-00300

Figure 2-54. M ot herboard PCB block diagram

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Theory of operation 2
2.4.6.2 BDU CPU PCB
The BD CPU PCB (Fi gure 2-55), in conj un cti on with the AI PCB, provi des mi croprocessor
control of all breath deli very functi ons for th e 840 Ventil ator System . It al so com municates
wi th the GUI CPU PCB for displ ay and control i nformation from the operator. All an alog
sign al s to and from the sensors and actuators of th e system are controll ed by software
run nin g in the BD CPU.
The PCB resi des wi thin the card cage, next to the AI PCB. Th ese two boards are closel y
coupl ed and provide the m ai n intell igen ce and drive for all the mechanical devices an d
el ectroni c sen sors used in ven tilati on.
The BD CPU PCB pl ugs i nto the m otherboard usin g two standard DIN 96-pi n con nectors. The
first con nector (P2) is used for power. The second con nector (P3) is an En han ced Eurocard
DIN 96 connector wi th additi on al con necti on s for power an d ground.
The BD CPU PCB con trols an d m oni tors the status of ven ti lator power, th e BPS, th e
compressor, the AI PCB, and the opti on PCBs. The BD CPU PCB includes these circuits, wh ich
perform th e in dicated functions:
• The CPU a n d con t rol circu it s i ncl ude a M otorola 68040 mi croprocessor (wh ich in cludes
an onboard m ath coprocessor), operating at 24 M Hz, al ong with supportin g devices to
perform ven tilator control functi ons. In addi ti on to executin g instructi ons, th ese
function s i ncl ude passi ng data back an d forth between m em ory an d I/O devices;
gen erati ng address signal s used to access m em ory locations; generatin g read/ write,
tim in g, and other control si gn als; and processi ng in terrupts from the various system
devi ces.
• The PCB’s m em ory i ncl udes 2 M B of fl ash m em ory (soldered; n o sockets) th at con tain s the
operational software for the BD. Thi s software is down loadabl e vi a a PC. A boot mem ory
PROM contains the ventil ator’s in iti al izati on and POST code and provides a basi c
com m un ications program to perm it downloadi ng of system software. Downloaded
software is not written to the boot memory PROM ; it cannot be written to i n the fiel d.
4 M B of dyn am ic random access memory (DRAM ) i s used for on goin g cal cul ations and
data storage and as a m essage an d com m and buffer for the Eth ernet control ler.
• 16 KB of NOVRAM circu it (nonvolati le RAM ) stores essenti al, persisten t variables an d
confi gurati on i nform ati on; current breath m ode setti ngs (for obtaini ng defaul t
param eters at power on); POST and exten ded self test (EST) fault inform ati on; the reset
stack poi nter; and oth ers (see Table 2-4). Th e NOVRAM devices are soldered in place (no
sockets). Alth ough i nform ati on i n these devi ces is lost wh en the BD CPU PCB is repl aced,
m uch of this data is updated durin g POST and EST. Critical data speci fic to a particular
un it (i ncl udin g system serial n um bers) is stored on a data key devi ce whi ch stays with the
unit.
Each NOVRAM devi ce con si sts of an internal fl ash m em ory device (whi ch has the
advantages of bei ng abl e to retain data without th e appli cati on of power, an d wh ich also
can be easil y written to) and a static RAM device. Upon power-up, the data stored in fl ash
mem ory i s retri eved and stored in stati c RAM . Duri ng norm al operation, the NOVRAM
behaves like stati c RAM . Upon detectin g l ow suppl y voltage, the NOVRAM stores data
from static RAM i nto i ntern al flash m emory for nonvol atile storage. This operation takes
2.5 m s. The BD CPU PCB provi des an i solated, decoupled power suppl y (V CAP),
indepen dent of the +5 V supply, to the NOVRAM to en sure th e power-down ram p i s long
en ough to store the stati c RAM con ten ts.

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2 Theory of operation

TEST button

GUI port 8-00266

Figure 2-55. BD CPU PCB

• The rea l-t im e clock tracks the ven tilator operational tim e and sh ort-durati on power l osses
(up to 60 m i nutes). W hen the ven til ator i s operati ng, th e real -ti m e cl ock is powered by
V CC. W hen power is lost or rem oved, a bui lt-in battery powers the cl ock. Thi s battery has
a 10-year l ife expectancy.
• The w a t ch d og circu it m oni tors th e BD CPU for safe operation. W h en a tim e-out occurs,
indicati ng a l ack of bus acti vity, a system reset occurs. Probl ems with the CPU, clock, or
software can cause a watchdog tim e-out.
• The GUI-BD U in t erfa ce provides for Ethernet comm un ication between both BD an d GUI
CPU PCBs. This control ler sends an in terrupt to th e BD CPU to inform it of a
com m un ication from the GUI CPU. Com m an ds an d m essages to be tran sferred (vi a direct
m em ory access, DM A) are stored in DRAM . The GUI-BDU i nterface uses isolation
tran sform ers an d an isolated power supply, but i s connected to standard system ground.
There i s no isolation from any external devi ce that m ay be attached.
• An RS-2 32C ch a n n el i s avail abl e for developm en tal use onl y.
• A d ia gn ost ic LED a rra y (with supporting circuitry) indicates the status of the BD CPU
PCB. Duri ng POST, they i ndi cate the curren t test step. A n in th LED di spl ays th e
supervisory m ode status of th e CPU.

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• The pow er fa il d et ect ion circu it causes an NM I to be generated if the power suppl y
gen erates a power fail si gnal . The power supply generates a power fail si gnal i f the output
of the bul k suppl y i s less than 19.30 V.
• The d igit a l I/O in t er fa ce circu it provi des th ese outputs:
– A signal (redundant) to declare a ven ti lator i noperative con diti on and to l ight an LED.
– A signal to place the BDU hardware into a safety val ve open (SVO) state an d to li gh t an
LED.
– BD LED PCB con trol signals, i ncl uding loss of user i nterface (LOUI) LED, safety valve
open (SVO) LED, and ven til ator inoperative (VENT INOP) LED.
– Com pressor control sign als (representin g on, standby, an d off). The on com m and runs
the compressor contin uously wh en the ventil ator is operating on compressed air (that
i s, when the wall air suppl y h as dropped bel ow 14 psi g). Standby causes the
compressor to cycle to main tain accum ulator pressure; wall ai r pressure drops to
between 14 and 26 psi g, and the com pressor suppl em en ts th e wall air pressure. The off
comm and overrides the com pressor autom atic cycl ing control (to m aintain
accum ulator pressure) to en sure the com pressor is off for self test purposes.
– Power m ode si gnal suspen ds battery charging to all ow a true readin g of battery
voltage.
– Low ac power si gnal (ac < 80% of n omi nal) to com pressor.
– Si gn als to pl ace the venti lator in to the service m ode (i n conj unction with a
m om entary push-button swi tch) and to di sable the two POST 10-s tim ers (n ecessary to
all ow test m ode).
Th e di gi tal I/O interface provi des th ese i nputs:
– Com pressor status signal s, in cl udi ng: com pressor present; com pressor com partmen t
overtem perature; ac i nput to com pressor low; compressor accum ul ator pressure
adequate for ven tilation; com pressor i n stan dby m ode, com pressor off, or com pressor
on .
– BPS status si gnal s including: battery bei ng charged, battery in use, and battery fully
charged.
– Servi ce m ode enabled
• The AI PCB in t er fa ce provides for com m uni cation between the BD CPU an d th e AI PCB.
• The BDU LED displa y d river s in terface the BDU LED PCB.
• The ser vice m ode sw it ch is a push-button on the board edge used to activate thi s mode.
The BD CPU PCB generates an NM I un der any of these con dition s:
• Ethernet parity error detected
• Power fail si gn al
• A/ D con verter system error

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2 Theory of operation

Table 2-3: NOVRAM contents

Paramet er Not es Where dat a are st ored

Background alarm Status of all DEVICE ALERT alarms BD alarm statuses are stored in
status BD NOVRAM. GUI alarm
statuses are stored in GUI
NOVRAM.

Ventilator settings All settings are stored in GUI

NOVRAM . BD-applicable
settings (that is, nominal line
voltage, patient circuit type,
and a subset of the breath-
related settings) are stored in
BD NOVRAM.

Diagnostic logs This includes the System Diagnostic Log, System Information BD events are stored in BD
Log, and EST/ SST Diagnostic Log (which are actually stored in NOVRAM . GUI events are
two separate locations -- one for EST, one for SST). stored in GUI NOVRAM .

Alarm history log History of alarm events for the current/ previous patient GUI NOVRAM

NOTE:
The alarm history log is automatically cleared upon
successful completion of a new patient setup. (A new
patient setup is required to start normal ventilation after
exiting the service mode.)

EST and SST result Result and status information for each EST and SST test BD information is stored in BD
information NOVRAM . GUI information is
stored in GUI NOVRAM .

Ventilator and BD NOVRAM

compressor
operational hours

POST test status Status of each of the POST/ kernel tests BD statuses are stored in BD
NOVRAM . GUI statuses are
stored in GUI NOVRAM .

PSOL lift-off Calculated during EST BD NOVRAM

information

Compliance Calculated during SST BD NOVRAM

calibration

Inspiratory and Calculated during SST BD NOVRAM

expiratory resistance

Oxygen and air flow Calculated during EST BD NOVRAM

sensor (Q1 and Q2)
offsets

Absolute pressure Calculated during PA calibration BD NOVRAM

transducer (PA) offset

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Theory of operation 2
2.4.6.3 Analog int erface (AI) PCB
The AI PCB (Figure 2-56) provides an in terface between the ven tilator’s m i croprocessor
circuits an d i ts an alog system s vi a an IP bus. Th ese analog system s in cl ude the com pressor, dc
el ectroni cs, val ves, BD (con tinuous-tone) audio alarm , and tran sducers. The com pressor
control and dc status sign als and dc power pass th rough the AI PCB. The PCB i ncludes these
circuits, wh ich perform th e i ndi cated functions:
• The d igit a l in t erfa ce circu it provides for com m un ication between the BD CPU PCB an d
the analog ci rcui ts on the AI PCB.
• The pressu re a n d flow sen sor filt ers m i nim i ze pn eum atic n oi se i n th ese com pon ents’
readi ngs.
• The +10 V referen ce produces a reference voltage for use by anal og-to-digi tal and digi tal-
to-an alog converters and pressure transducers (in spi ratory electron ics PCB and exhalati on
transducer PCB).
• The d a t a key in t er fa ce provides clock and data l atch es to handl e the flow of data between
the BD CPU an d data key.
• The t h erm ist or a m plifiers am pl ify i nput sign als from the m an ifold heater therm istor and
the motor m agnet th erm i stor, both located in th e exhalati on compartm ent.
• The va lve con t rol a n d d rive circu it provides drive si gnals for th e PSOLs, EV, an d th e EV
stabili zer devi ce.

PTS 2000
connector

Data key
connector

Compressor
connector

AI LEDs

8-00267

Figure 2-56. AI PCB

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2 Theory of operation

• The BD a la rm circu it acti vates th e BD al arm . The alarm i s activated under any of these
con di ti ons:
– A venti lator in operati ve condi ti on is declared
– The BD CPU detects a l oss of comm unicati on wi th the GUI
– A GUI alarm faul t i s detected
– The power swi tch fail s
– The +5 V sen try on th e AI PCB detects a low voltage condition
Under m ost con diti on s, the +5 V powers th e al arm. If the +5 V sentry circuit on the AI
PCB detects a power fai lure, a power fail capaci tor powers the alarm for a m i nim um of 2
m in.
• The PSOL pow er d iscon n ect circu it rem oves power from the PSOL drivers wh en the
ventil ator is in the safety val ve open state.
• The exh a la t ion va lve circu it drives the ex hal ation valve m otor. Pressure readi ngs provide
feedback to th e software that determ ines the am ount of valve dampening requi red. The
circui t includes pow er di scon nect ci rcuitry, wh ich rem oves power from the exhal ation
valve dri ver when th e ven tilator is i n the safety valve open state.
• The sa fet y va lve circu it control s an d drives the safety val ve. Full power to the safety val ve
pul ls the valve cl osed. After a sh ort in terval , power i s reduced to keep the val ve closed.
The safety valve circui t ensures full power i s applied in th e even t of a loss of +12 V
(required to reopen the val ve).
• The volt a ge sen t ry circu it creates si gnals that are proportional to voltages used in the
system . Th ese signal s are used in software m oni toring of th ese vol tages: +10 V referen ce
and +5, +12, +15, an d -15 V supply vol tages.
In addition, th e sentry circuit generates a global reset i f +5 V i s out of ran ge. A rel ay, wh ich
i s part of the sentry ci rcuit, en sures th at a power fail reset occurs during vol tage tran sients.
• The BPS m od el sign a l b u ffer provides a signal THAT yi elds BPSm odel type i nform ati on in
an an alog form. The software reads th is sign al to determ in e whether the BPS i s currentl y
con nected to the ventil ator.
• Other bu ffers provide condi tioni ng for vari ous ven tilator sign als.
• The com p ressor in t erfa ce circu it , i n conj un ction with the com pressor PCB, controls and
m on itors th e com pressor operation.

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Theory of operation 2
2.4.7 Dat a key subsyst em

NOTE:
Call your Puritan Bennett representative if the data key requires replacement due
to loss or failure.

The 840 Ven til ator System uses a data key (Figure 2-57) to record data speci fic to a particular
ven til ator uni t. The data key provides a way to retain data when PCBs or the battery are
rem oved from the ven til ator. Th e data key pl ugs into a receptacle on the venti lator. Data is
read from or written to flash m emory on the data key. Thi s serial data is tran sferred to th e BD
CPU th rough th e data key i nterface. The data key must always be installed in the ventilator for
proper operation.
The data key stores this data:
• Seri al numbers of th e GUI and BDU.
• Hours of ventilator operation .

Figure 2-57. Data key

2.4.8 GUI
The GUI (Fi gure 2-60), wh ich detach es from the ven til ator h ead for servici ng, is an enclosure
that houses th e GUI CPU PCB, keyboard, GUI LED PCB, backlight i nverter PCBs, knob, two
10.4-inch or 9.4-i nch color LCD flat panels, a touch fram e PCB, and an al arm speaker.

2.4.8.1 GUI CPU PCB

The GUI CPU PCB, shown in Figure 2-58 and Figure 2-59, provi des m i croprocessor con trol
and m onitoring of the di splay and user i nterface system . The board is based on the M otorola
68040 m icroprocessor.

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2 Theory of operation

Figure 2-58. 10.4” GUI CPU PCB

GUI CPU
PCB

Backlight
inverter PCB
8-00166

Figure 2-59. 9.4” GUI CPU PCB and backlight inverter PCB in place

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Theory of operation 2
The GUI CPU PCB i ncludes th ese circuits, whi ch perform the in dicated functions:
• The CPU a n d con t rol circu it includes a M otorola 68040 m icroprocessor (whi ch i ncl udes
an onboard m ath coprocessor), operating at 24 M Hz, al ong with supportin g devices to
perform ven tilator control functi ons. In addi ti on to executin g instructi ons, th ese
function s i ncl ude passi ng data back an d forth between m em ory an d I/O devices;
gen erati ng address signal s used to access m em ory locations; generatin g read/ write,
tim in g, and other control si gn als; and processi ng in terrupts from the various system
devi ces.
• The PCB’s m em or y incl udes 4 M B of flash m em ory (soldered; n o sockets) that contain s the
operational software for the GUI. A boot PROM contai ns ventil ator in iti alization and
POST code and provides a basic com m un ications program to perm it dow nloading of
system software. Downl oaded software is not written to th e boot m em ory PROM ; the
PROM cann ot be written to i n the fi eld. 4 M B of DRAM i s used for on goin g cal cul ati ons
an d data storage and as a m essage an d com m and buffer for th e Eth ernet con troll er.
• 64 KB of NOVRAM (nonvolati le RAM ) stores essential, persisten t variabl es and
confi gurati on i nform ati on; current breath m ode setti ngs (for obtaini ng defaul t
param eters at power on); POST and EST fault i nform ati on; the reset stack pointer; and
oth ers (see Table 2-3). The NOVRAM devices are soldered in place (no sockets). Al though
inform ation in these devices is l ost when the GUI CPU PCB is repl aced, m uch of this data
is updated duri ng POST and EST. Critical data specifi c to a parti cular uni t (i ncl udi ng
system serial n um ber) i s stored on a data key devi ce, wh ich stays with th e uni t.
Each NOVRAM device consists of an i nternal flash mem ory devi ce (wh ich has th e
advan tages of bei ng abl e to retai n data wi thout the application of power, and whi ch also
can be easily written to) an d a stati c RAM devi ce. Duri ng power on, data stored in the
flash m em ory i s retrieved an d stored in static RAM . Durin g n orm al operation, the
NOVRAM behaves li ke static RAM . Upon detectin g l ow supply vol tage, th e NOVRAM
stores data from static RAM i nto i ntern al flash m em ory for nonvolati le storage. This
operation takes 10 m s. Th e GUI CPU PCB provi des an isol ated, decoupled power supply
(V CAP), i ndepen dent of the +5 V suppl y, to the NOVRAM to ensure th e power-down ramp
is long en ough to store the static RAM con tents.
• The rea l-t im e clock tracks the venti lator’s operational time and short-duration power
losses (up to 60 m in utes). W hen th e ven tilator i s operatin g, th e real-ti me clock i s powered
by V CC. W hen power is lost or rem oved, a bui lt-in battery powers the cl ock. Th is battery
has a 10-year l ife expectan cy. Th e real -tim e clock can be rem oved from i ts socket for field
replacem ent.
• +5 a n d +12 V m on it ors signal the mi croprocessor (vi a a n onm askable i nterrupt) wh en
+5 V i s too h igh or +12 V is out of ran ge. Thi s ci rcuit also generates a power fail reset i f the
+5 V output drops below +4.8 V.
• The w a t ch d og circu it moni tors the CPU for safe operation. W hen a ti me-out occurs,
indi catin g a lack of bus activity, a system reset occurs. Probl em s wi th the CPU, cl ock, or
software can cause a watchdog tim e-out.
• The GUI-BD U con t roller provides for Ethernet com m un icati on between both BD an d GUI
CPU PCBs. Th e control ler sen ds an in terrupt to th e GUI CPU to i nform i t of a
com m un ication from th e BD CPU. Com m an ds and messages to be transferred (via DM A)
are stored i n DRAM . The GUI-BDU i nterface uses i solati on transformers an d an isol ated
power supply, but i s conn ected to stan dard system ground. There i s n o i solati on from any
external devi ce that m ay be attached to it.
• Three RS-232 C ch a n n els provide output for digi tal com m un ications in terface and
external comm uni cations for servi ce mode. They are electri cal ly isol ated for safety. The
9.4-in ch GUI has onl y one RS-232 channel , al so electrical ly isol ated.

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2 Theory of operation

Backlight PCB
Upper LCD
Backlight cable panel
4-076689-SP Flex circuit,
video

Backlight PCB

Backlight cable Flex circuit,

video

Lower LCD
panel
4-076689-SP
GUI LED PCB

Alarm cable assy

GUI J1
alarm assy J2
GUI CPU PCB
P1
J3
J5
J7

J11

GUI-to-BDU cable assy J10

Touch frame PCB

Flex circuit,
RS-232
J19 J20

To BDU
RS-232
Remote alarm

J2 Keyboard
cable assy

Rear of keyboard
Touch frame
cable assy
GUI M ODULE GUI10_4wiring

Figure 2-60. 840 Ventilator System int erconnect diagram – GUI 10.4-inch LCD panels

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Theory of operation 2
• D ia gn ost ic LED a rra y uses ei gh t discrete LEDs, in con juncti on wi th supporti ng ci rcuitry,
to indi cate the status of the GUI. Duri ng POST, th e array in dicates the current test step. A
nin th LED displays the supervisory m ode status of the CPU, and a 10th LED in dicates
power on.
• The VGA vid eo con t rol circu it , com pri sin g two VGA LCD controll er ICs w ith 1 M B video
RAM , i nterfaces the two 640 x 480 x 256K col or 10.4-i nch LCD panel s. Older GUI versi on s
with 9.4-in ch, 4K color or m on ochrome (16 greyscale levels) displays contai nin g th e older
GUI CPU board contai n plug-i n IP in terface VGA LCD controll ers that in terface the LCD
panels.
• An in fra red t ou ch sca n n er in t er fa ce, which includes its own m icrocontroller, mon itors
the touch screen.
• The LED PCB in t erfa ce lets th e m icroprocessor control the di screte LEDs on th e GUI LED
PCB.
• The LCD ba ckligh t con t rol circu it con trols the brigh tness of the two fluorescent lam ps
that li ght th e fl at panel s based on software in put. It generates a pulse width m odulated
si gn al to th e backli gh t in verter PCB(s) (two PCBs on 10.4-in ch GUIs; one PCB on 9.4-inch
GUIs), wh ich controls the brightn ess of both LCD panels. There is n o user-adj ustable
bri ghtness con trol on color displays.
• The rem ot e a la rm rela y in t er fa ce enabl es/ disabl es an extern al al arm device (such as a
nurse’s call ). The rel ay contacts are closed when the un it i s i n a norm al ventil ation state
an d open ed wh en th e un it is off or in an al arm state.
• The sou n d gen era t or in t erfa ce produces the venti lator’s al arm sounds. Con sisti ng of a
m icrocon troller an d audio sign al processing hardware, th e interface produces ISO-
standard alarm sounds and provides keyboard entry audible feedback.
• The rot a r y en coder/d ecod er circu it determi nes the direction and am ount of knob
m ovem ent. Th e opti cal encoder i ncorporates an em i tter secti on , tw o codewheels, and a
detector secti on . Each codewheel has a pattern photographi call y pl ated on it. As th e knob
sh aft revolves, th e codewh eel s rotate with respect to th e em itter and ph otodetector
secti ons, causi ng th e l ight beam to be in terrupted by the pattern of spaces an d bars on th e
codewheels. Th e detectors are posi tioned such that a light period on one ph otodetector
corresponds to a dark period on the other photodetector. Usi ng the photodetector
outputs, the decoder can determ i ne th e knob posi tion.
• The keyboa rd in t erfa ce reads the keyswitches and controls the lighting of the LEDs on the
keyboard.
The GUI CPU PCB generates an NM I un der any of these condi tions:
• GUI +5 V i s hi gh
• GUI +12 V i s out of ran ge
• Ethernet parity error detected
• SAAS m icrocon troller fai lure

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2 Theory of operation

GUI cable assy, short

Color I/ O PCB
J2
Backlight PCB J3 Upper LCD
GUI cable assy, long panel
J1

Backlight
control
cable assy

Color I/O PCB

Lower LCD
panel
GUI LED PCB

Cable assy

GUI Color display

alarm assy cable assy
GUI CPU PCB J6

P1
J4 J5
J3
J7 J8 Color display
J9 cable assy

GUI-to-BDU cable assy

Color display
J16 cable assy

Touch Frame PCB VGA Controller PCB

J14 J15

J18 Color display

J19 J20
cable assy
To BDU

Remote alarm RS-232

Keyboard
J5
cable assy

Touch Frame Rear of keyboard

cable assy

GUI M ODULE 8-00122

Figure 2-61. 840 Ventilator Syst em int erconnect diagram – GUI 9.4-inch LCD panels

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Theory of operation 2
2.4.8.2 Touch frame PCB
The touch fram e PCB i s responsible for detectin g operator inputs on the GUI screen. Different
touch fram e designs are used in the 10.4-in ch GUI and the 9.4-i nch GUI.
On the 10.4-in ch GUI, th e touch fram e PCB comm unicates with the GUI CPU PCB usi ng a
serial in terface, an d operates from a sin gle 5V supply, drawi ng no more th an 100m A. Infrared
(IR) tran sm ittin g LEDs are m oun ted on all sides of the PCB and IR detectors, at whi ch
i nvisible IR light beam s are aim ed, are l ocated at strategic poin ts aroun d th e PCB. Thi s
arran gem ent of LEDs and detectors define an in tersecti ng pattern of li gh t beams th at is used
to determ i ne th e l ocation of an input on th e GUI screen. See Figure 2-62.

Photosensitive
diodes

Light-emitting
diodes

10.4” GUI 9.4” GUI

Figure 2-62. Touch Frame PCB

A m icro-con troll er located on th e touch fram e PCB scans the touchscreen for operator inputs
by swi tchi ng on th e LEDs one at a ti me in a pseudo random pattern , and then sam pl ing the
output results from the logi cally associ ated IR detectors. A com plete scan of al l the LEDs
occurs 39 ti m es per secon d. W h en the GUI screen is touch ed, som e of the li gh t beam s don ’t
reach th ei r associated IR detectors, and as a result, there is no output from those detectors and
they are consi dered "blocked." Th e m icrocon troller ch ecks pairs of LEDs and IR detectors for
bl ocked beam s, uses a mathem atical coordi nate con version routin e to l ocate the touch in th e
i ntersectin g area of l ight beam s, and sends the information to the GUI CPU board for
processin g.
To i m prove touch fram e rel iabil ity, each LED output i s received by two IR detectors. The
bl ocked beam s are detected si m ul tan eously in di fferent intersecti ng areas provi din g
redun dancy whi ch all ows conti nued operation of th e touch fram e in the event an LED or IR
detector burns out. Durin g n orm al conditions, wh en all LEDs and IR detectors are
functi onin g properly, th e redun dant detectors are used to provi de a m ore accurate output by
averagin g the locations of th e blocked beam s.

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2 Theory of operation

On th e 9.4-inch GUI, the touch fram e com m uni cates wi th th e GUI CPU PCB vi a a Carrol l-
Touch propri-*+9I CPU PCB sequenti ally pul ses the LEDs, creating an invisibl e grid of IR l ight
beam s just in fron t of th e di spl ay surface. The phototransistors sense these l ight beam s.
W h en th e screen is touch ed, the light beam s from certain LEDs are obstructed and do not
reach their correspon din g ph ototransi stors. The interface constantl y m onitors the presen ce,
or in thi s case the absence, of th e IR light beam s recei ved by the phototransi stors and can
thus determ ine th e X - and Y-coordi nates of the touch acti vati on.
On both th e 10.4-in ch and 9.4-inch GUIs, th e touch fram e i s attached to th e face of the
di spl ay, wh ere i t is con cealed behi nd an IR-transparent bezel (a type of en cl osure that is
opaque to the eye, but th at al lows IR l ight to pass through).

2.4.8.3 Keyboard assembly wit h knob

A m embrane keyboard assem bly (Figure 2-63) is attached to th e GUI CPU PCB. A software
debounce routine protects again st uni ntended multiple keystrokes.

The m ultiposition knob assem bl y, w hich is part of th e keyboard assem bly, perm i ts ventil ator
setting selection s or chan ges. Kn ob encoder/ decoder circui try on the GUI CPU PCB
determ in es th e di recti on and positi on of th e shaft based on en coder outputs.

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Theory of operation 2

Figure 2-63. Keyboard assembly

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2 Theory of operation

2.4.8.4 GUI LED PCB

The GUI LED PCB, shown in Figure 2-64, contai ns ten LED-based vi sual indicators and LED
drivers. Th ese com ponents operate under control of the GUI CPU PCB. The i ndi cators
i llum inate (backlight) speci fic m essages/ icons on th e GUI LED pan el.
Each i ndi cator con sists of on e or m ore LED li ght bars, m ade up of in dividual LEDs. Li gh t bars
of different sizes are used to accom m odate the differen t-size icons that m ake up th e in dicator
panel di splay. Th e i ndi cators are color-coded red, yel low, or green to sh ow status. Each
i ndi cator (except "com pressor operati ng" an d "on BPS power") includes redundant LED
strings so the indicators wil l stay li t if an LED bar burn s out.

8-00294

Figure 2-64. GUI LED PCB

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Theory of operation 2
2.4.8.5 Backlight invert er PCB and LCD lamps
The 10.4-inch GUI uses two backl ight i nverter PCBs to convert +12V to a h igh-voltage ac
l evel that indivi dually powers the fluorescen t lam p tubes in the upper and lower di spl ays.
These lam ps backl igh t th e LCD flat panels. Indi vidual pulse-width m odul ated si gnals from
the GUI CPU PCB determ in e the m agn itude of the voltage, which in turn determi nes the
brigh tness of each LCD pan el. (There is n o user-accessi bl e brightness or contrast adj ustm en t
avail abl e wi th col or LCD panels.) Th e l am ps on th e 10.4-in ch LCD panels do not requi re
replacem ent.
The 9.4-i nch GUI uses on e backl ight i nverter PCB to perform th e sam e fun cti on described
above, and con trols th e backli ght for both LCD panels si m ultaneousl y. Th e LCD l amps are
part of the 10,000-h our preventive m ai nten ance ki t on th e 9.4-in ch GUI.

Figure 2-65. 10.4” GUI LCD panels

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2 Theory of operation

LCD panels

8--00184

Tube
element
8-00185

Figure 2-66. 9.4-inch LCD panels and backlight tubes

2.4.8.6 GUI alarm assembly

The GUI al arm assembl y (Fi gure 2-67), the venti lator’s prim ary al arm, em its alarm sounds
under con trol of th e GUI CPU PCB.

8-00295

Figure 2-67. GUI alarm assembly

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Theory of operation 2
2.4.9 BDU LED PCB
The BDU LED PCB (vent head
LED PCB), sh own in Figure 2-68,
contain s three LED-based visual
i ndi cators an d LED drivers.
These com ponen ts operate
under control of th e BD CPU
PCB. The in dicators (safety valve
open , ventil ator inoperative, and
l oss of GUI) backl igh t the
ven til ator head status panel . Al l
backlights are powered from
+12 V.
8 00118
Figure 2-68. BDU LED PCB
Figure 2-68. BDU LED PCB

2.4.10 Inspirat ory elect ronics PCB

The inspi ratory electroni cs PCB (Figure 2-69 an d Fi gure 2-70), whi ch is housed in th e
i nspiratory module, serves as an electrical interface between the card cage electron ics an d the
el ectroni cs in the inspiratory module. The PCB con tai ns inspiratory an d atm ospheric
(absolute) pressure transducers (PI an d PA). It also contains an in terface circui t for the oxygen
concen trati on sen sor, wh ich m ounts to th e PCB. In additi on , proporti onal solenoid valve,
safety valve, i nspiratory pressure transducer autozero sol enoid (SOL1), pressure sw itch, and
fl ow sen sor si gnals pass th rough the PCB.

PA

PI

8-00285

Figure 2-69. Inspirat ory elect ronics PCB

The PCB includes th ese ci rcuits, wh ich perform the in dicated fun ctions:
• The in spir a t ory pressu re t ra n sd u cer (PI) senses the inspiratory pressure di fferen ce
rel ative to am bient air pressure. Pressure is sensed at the i nspiratory m odule.
• The a b solu t e pressu re t ra n sd u cer (PA) senses absolute pressure i n th e i nspi ratory
m odul e. It is used to determ i ne atm ospheric pressure for volum e del ivery.
• The oxygen sen sor (OS) a m plifier provides an in terface for the oxygen con centration
sensor m oun ted on the PCB.

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2 Theory of operation

Oxygen
sensor
4-072214-00
Inspiratory
pressure transducer/
autozero solenoid
(SOL1)
4-072215-SP

Blindmate connector

P2 44 pin

Inspiratory pressure transducer (P1)

P10
P9
Oxygen sensor
P1 cable assy
Inspiratory 4-074925-00
electronics PCB
Air 4-070100-SP
(PSOL2) Proportional solenoids
4-071800-SP Oxygen
(PSOL1)
4-071800-SP P6
P5 P3 P7 P4

Air flow
sensor (Q2)
4-072211-SP Oxygen flow
sensor (Q1)
4-072211-SP

Oxygen flow
sensor
Air flow
cable assy
sensor
cable assy 4-071322-00
4-071321-00

Press switch
harness assy
4-071326-00

Air pressure Oxygen pressure

switch (PS1) switch (PS2)
4-072206-00 4-072206-00

INSPIRATORY M ODULE
8-00123

Figure 2-70. 840 Ventilat or System int erconnect diagram – Inspirat ory module

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Theory of operation 2
2.4.11 Exhalation t ransducer PCB
The ex hal ation transducer PCB (Figure 2-71 an d Figure 2-72), which i s housed i n the
exh alation m odule, produces a voltage si gn al represen ti ng the pati ent pressure in th e
exh alati on circuit. Th is sign al is routed to the AI PCB and used by software. The expiratory
pressure transducer (PE), which is on th is PCB, senses th e pressure di fferen ce in the
exh alation circui t rel ative to am bi ent air pressure. The PCB uses a +10 V reference.

8-00296

Figure 2-71. Exhalation transducer PCB

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2 Theory of operation

Expiratory
pressure transducer/
autozero solenoid (SOL2)

Exhalation
heater assembly

Exhalation
flow sensor (Q3)

To
Exhalation motherboard
module Exhalation I/ O
cable assy cable assy

P1 J2
J13
Expiratory
Exhalation pressure transducer
valve (PE)

Exhalation
transducer PCB

8-00126

EXHALATION M ODULE

Figure 2-72. 840 Vent ilat or System int erconnect diagram – Exhalation module

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Theory of operation 2
2.4.11.1 BD (cont inuous-t one) alarm assembly
The BD (con tin uous-tone) alarm assem bl y i s sh own i n Fi gure 2-73. It i s activated under the
conditi on s described i n Section 2.4.6.2.
Under m ost conditions, the +5 V powers the al arm. If the +5 V sentry circui t on the AI PCB
detects a power fai lure, a power fail capacitor powers the al arm for a m i nim um of 2 m inutes.

BD alarm
assembly

8-00173

Figure 2-73. BD alarm assembly

2.4.12 806 Compressor unit

The 806 com pressor unit’s el ectri cal com ponen ts i nclude: ac power di stribution com ponents,
a com pressor motor, and a com pressor PCB. The com pressor unit is shown in Figure 2-74.

8-01257

Figure 2-74. 806 compressor

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2 Theory of operation

2.4.12.1 806 compressor unit ac power dist ribut ion component s and mot or
M ain s power i s appl ied to th e com pressor receptacle J4 through power rel ay K1 wh en the
power suppl y i s on .
The ac power to the com pressor un it i s provi ded by a field-replaceabl e power cord plugged
i nto receptacle J4. Th e ac-powered fans (Fi gure 2-75), an d m otor receive power vi a th e
com pressor PCB and are protected from overtem perature con diti on s by a th erm ostat (TH1).
The fans operate whenever th e com pressor is on . Ci rcui t breaker, CB2, protects the
com pressor from over-current condi tions.
The m otor compressor uses a 25 µF (100 V uni ts), 15 µF (120 V un its), or a 12.5 µF
(220 – 240 V, 50/60 Hz units) starting capacitor.

8-01256

Figure 2-75. 806 Compressor fans

2.4.12.2 806 compressor PCB
The 806 com pressor PCB (Fi gure 2-76, Figure 2-77, an d Fi gure 2-78) provides electronic
con trol of com pressor com partm ent devices, including th e com pressor m otor, cooli ng fans,
an d unloading solen oi d (SOL3). It i s l ocated i n the com pressor com partm ent. Th e com pressor
PCB’s prim ary functi on i s to con trol the pressure of the air delivered to the ven tilator wh en
wal l air i s not present or i s in sufficient.

Data
cable

Pressure Pow er
transducer cord
hose
Solenoid
Compressor cable
cable

Fan
cables

Ground
8-01272

Figure 2-76. 806 compressor PCBA inst alled

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Theory of operation 2
The PCB includes th ese ci rcuits, wh ich perform the in dicated fun ctions:
• The fla sh m em ory circu it s include a flash m emory devi ce, an el apsed ti me counter, and
ci rcui ts to perm it seri al data tran sfer between the AI PCB and the com pressor PCB. Th e
coun ter moni tors (in seconds) com pressor m otor operation. The counter value is
periodical ly read by th e ven tilator, w hich th en stores th e total el apsed ti m e (in hours) i n
com pressor flash m em ory. During a power-on reset, the ventilator l oads the current
com pressor fl ash m em ory value i nto the coun ter. The flash m em ory device al so contai ns
other com pressor-speci fic i nform ation, including th e com pressor i dentifi cation (ID).
• The m ot or st a rt -u p circu it i ncl udes a relay, ti mers, and l ogi c that togeth er orch estrate th e
m otor start-up sequen ce. Th is sequence i nvol ves energizi ng SOL3, which vents
com pressor output, and then energizin g th e relay to apply power to the com pressor.
(Venting com pressor output m om entaril y reduces the l oad on the com pressor.)
• The com pressor pressu re t r a n sd u cer (PC) circu it m onitors accum ul ator pressure vi a
several com parators in th e ci rcuit. W hen a com parator detects an accumulator pressure
equal to or greater than predefi ned trip poin ts, i t si gnals the com pressor control l ogic.
• The com pressor con t rol logic controls the m otor, fans, and SOL3. It also provi des
com pressor status signals. Secti on 2.4.12.3 describes how th is l ogic controls com pressor
com ponen t operation. This logic sh uts off th e com pressor wh en ac i s inadequate or the
therm ostat on the PCB detects overtem perature.

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2 Theory of operation

COM PRESSOR PCB

J1
12 V COMPS
UNLOADING
SOLENOID SOLENOID
CKT (SOL3)

J2

FAN1

J6

FROM
ac PANEL J3

FAN2
J4

COMP COMPRESSOR RELAY

PRESS PRESS
XDUCER STARTING
(PC) CKTS CAPACITOR
J5

MOTOR
COMP
COMPRESSOR
CONTROL
HOUSING
CKTS
TO/ FROM
AI PANEL

EEPROM
CKTS

COMP OVERTEMP

+5 V COMP
THERMOSTAT
+12 V COMP

806compbd

Figure 2-77. 806 compressor PCB block diagram

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Theory of operation 2

To AI PCB
M otor mounting
plate
BDU compressor
dc cable
4-074223-00

Compressor
motor
Top view of compressor
Compressor base
plate

GRN/ YEL

GRN/ YEL GRN/ YEL

Capacitor

BLK (4) Ground wire

from base
plate
Grommet GRN/ YEL 4-076299-00

Compressor PCB
4-075802-SP

Unloading
solenoid
J5 J6
(SOL3)
J4
J3 J2
J1
Hose to BDU

Compressor Fan harness (2)

ac power cord 4-076236-00
4-076287-00

To ac panel
806conn1

Figure 2-78. 840 Ventilat or System interconnect

diagram – Compressor unit

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2 Theory of operation

2.4.12.3 806 Compressor unit operat ion

The 806 compressor operates i n two modes: run and stan dby. A special start-up sequen ce
ensures that the m otor starts with an unloaded compressor h ead.

2.4.12.3.1 Run mode

W h en ac mains power i s > 80% of nom inal, the compressor is avai lable for use if wall ai r is
unavail able or th e pressure is < 26 psig. In run m ode, the com pressor acts as the air source for
the ventilator, con tinuously suppl ying ai r to m eet th e venti lator’s full fl ow requi rem ents (200
L/ m in peak fl ow, 2.5 L breath vol um e). W h en accum ul ator pressure reaches 27 psi g, SOL3 is
energi zed, ventin g excess flow to assi st transporting water vapor out of the air dryer. The
solen oi d becom es de-energized when th e pressure drops below 22.5 psig (see Fi gure 2-79).
This cycl e repeats as pressure rises and fal ls in the accum ul ator.

2.4.12.3.2 St andby mode

The com pressor en ters stan d-by m ode when there i s sufficient wal l ai r pressure to suppl y the
venti lator. W hen the venti lator is powered up, it runs through POST and detects the presen ce
of the com pressor. The com pressor turns on an d pressurizes th e accum ul ator. During this
cycl e, the green com pressor ready in dicator on the GUI ill um i nates when th e accum ul ator
pressure reaches at least 13 psig. W h en the accumulator pressure reaches 27 psig, th e
com pressor turn s off. If pressure i n th e accum ulator drops below 22.5 psi g (due to sm all leaks
i n the system or cool in g of com pressed air), th e compressor starts an d recharges the
accum ulator to 27 psig (see Fi gure 2-79).

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Theory of operation 2

27 psig
Accumulator
pressure 22.5 psig

Compressor
motor

St andby m ode: ac > 80% nominal

27 psig
Accumulator
pressure
22.5 psig

SOL3

Compressor
motor

Breath
interval 8-00195

Run mode: ac > 80% nominal

Figure 2-79. Compressor operat ional sequence

2.4.12.3.3 Compressor st art -up

Any tim e the com pressor m otor i s n eeded (run m ode), a start-up sequence (Figure 2-79)
en sures that th e m otor starts wi th an un loaded com pressor head. Logic on the compressor
PCB starts a tim er an d en ergizes unloadin g sol enoid (SOL3). Energizi ng SOL3 reli eves pressure
on the compressor pum p and, because of i ts ori entation , preven ts the accumulator from
l osi ng pressure during start-up. After 1 second, a sol id-state relay on the PCB i s en ergi zed.
After another 0.5 seconds, SOL3 is de-en ergized.

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2 Theory of operation

1 3

SOL3
(Dump compressor
head pressure)

1.0 s 0.5 s

M otor relay

8-00191

Figure 2-80. Compressor unit st art-up sequence

2.5 Breat h delivery

The ven ti lator deli vers two types of breath: mandatory an d spontaneous. A breath cycle
i ncl udes inspiration and exhalation phases. The venti lator uses operator setti ngs i nput through
the GUI to determ i ne breath type an d param eters.
Con sul t th e 840 Ventilator System Operator’s and Technical Reference Manual for a clin ical
perspective on breath deli very.

NOTE:
• Inspiratory and expiratory flows and tidal volumes in the ventilator are compliance-
compensated and corrected to body temperature and pressure, saturated (BTPS).
• Exhaled volumes delivered/ measured by the ventilator meet specified accuracies
when conventional humidification, heated wire systems, and heat-moisture
exchangers (HM Es) are used and SST is successfully completed.

2.5.1 Inspiration
Duri ng in spiration (Fi gure 2-81), the exh al ation valve (EV) i s en ergized cl osed and gas flows
to the patien t.
An in spiration i s triggered when any of the fol lowin g happen s:
• The venti lator senses patient in spi ratory effort (pressure or fl ow triggeri ng).
• The venti lator’s breath tim in g dictates.
• The operator presses the M ANUAL INSP key.
• The venti lator’s softw are oth erw ise dictates (such as apn ea tim e-out).

NOTE:
The ventilator does not autocycle when pressure sensitivity is greater than 1
cmH2O or when flow sensitivity is greater than 1 L/ min for pediatric patients or
1.5 L/ min for adult patients.

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Theory of operation 2

C NC Patient Wye

SOL2
PE EXH
HTR NO
WT WT
CV5

F9
H P Oxygen, Wall
Q3 Reg Oxygen
H P Air, Wall/Comp
Humidifier
ECV Reg Air
Mixed Gas F8
Atmosphere
Vacuum
EV To Patient
Water

Vent
PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS

CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2

WT1 F4

PA PI

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C
F12
Dryer
HB

i8-01288

Figure 2-81. Inspiration gas flow diagram

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2 Theory of operation

2.5.1.1 Pressure t riggering

As the pati ent draws gas from the pati en t ci rcuit, th e airway pressure drops below baseli ne.
W h en airway pressure drops below basel ine by at least the value selected for pressure
sen siti vity, th e BD CPU i niti ates a patien t-triggered inspiration.

2.5.1.2 Flow t riggering

W h en fl ow triggerin g i s sel ected, the BDU m ai ntai ns a constant flow of gas through th e
patient circuit (cal led base fl ow) durin g th e latter part of exhalation . (Durin g exh alation, the
base fl ow is 1.5 L/ mi n greater th an th e operator-selected val ue for flow sen sitivity.)
As the pati en t in spires from th e base flow, th e exhalation fl ow sensor (Q3) m easures less
exhal ed fl ow, wh ile deli vered flow (mon itored by in spirati on fl ow sensors Q1 and Q2)
rem ains con stan t. As th e patien t conti nues to in spire, the difference between the flows
m easured by the in spiration and exhal ation flow sensors i ncreases. W hen the fl ow in spired
by th e patien t (th at is, the di fference between th e measured flows) is equal to or greater than
the operator-selected fl ow sensitivity value, the ven tilator declares an in spirati on . (If the
patient is not in spiring, an y di fference between th e deli vered and ex hal ed flow i s due to
sen sor in accuracy or patient system l eaks.)

2.5.1.3 Time-cycling met hod

In som e cases, th e ven ti lator’s breath ti mi ng di ctates when an in spi ration i s triggered. For
exam pl e, when th e venti lator i s in th e SIM V m ode, a certai n m in im um respiratory rate m ay
be guaran teed. To m aintai n the rate, in the absence of patient effort, th e venti lator m ay have
to del iver ventil ator-i niti ated m andatory (VIM ) breath . Th is is call ed ti m e-cycled in spi rati on .
If, however, th e patient's in spiratory efforts reach the pressure or flow sensi ti vity settin g
before the breath cycle h as elapsed, the ventil ator deli vers a PIM .

2.5.1.4 Operat or t riggering

The operator can trigger an operator-i nitiated m andatory (OIM ) breath by pressi ng th e
M ANUAL INSP key. The ventil ator wi ll not del iver an OIM durin g an on goi ng inspiration , th e
restricted phase of exhalati on, or w hile occl usion and discon nect alarm s are acti ve.

2.5.2 Exhalat ion

Duri ng patient exhalation (Figure 2-82), th e exhal ation valve (EV) opens (m aintaini ng PEEP)
and gas expel led from the pati ent i s heated, filtered, and ven ted to the atm osph ere.
The ven ti lator declares exhal ation based on internal tri ggers or backup exh alati on l im its.
The ven tilator software can tri gger exhal ation (in ternal ly triggered exhal ation ) using:
• The ti m e-cycl in g m eth od (m onitorin g elapsed tim e)
• The end-inspiratory fl ow meth od (m oni torin g end-in spi ratory flow)
• The ai rway pressure m ethod (m on itori ng airw ay pressure at the end of in spi ration)
Backup l im its (tim e, circuit pressure, and ventil ator pressure) prevent in spi rati on s of excessive
durati on or pressure. If a particular breath i s subj ect to m ore th an one backup li m it,
exhalati on i s tri ggered by whi chever meth od goes in to effect first.

2-94 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
2.5.2.1 Time-cycling met hod
Durin g pressure- and volum e-based m andatory breaths, the ti me-cyclin g m eth od operates.
This m ethod uses a specifi ed i nspiratory tim e to term inate i nspiration and transi tion to
exh alation. The ven tilator term inates inspiration based on the set or com puted val ue for
i nspiratory tim e.

2.5.2.2 End-inspirat ory flow met hod

Durin g spontan eous breaths (with or w ith out pressure support), the ven til ator can use
m easurem en ts of end-inspiratory flow to in itiate exhal ation. The ven ti lator m onitors
del ivered fl ow through out the inspiratory phase at flow sen sors Q1 and Q2. Regardless of
wh eth er th e pati ent begi ns to exh ale, delivered flow decreases due to the decreasing pressure
gradien t in the pati en t wye measured at PE. W hen th e fl ow is equal to or less than (peak
fl ow x ESENS %)/ 100, th e venti lator i nitiates exhalation.

2.5.2.3 Airway pressure met hod

The ventil ator can use airway pressure to in itiate exhalati on wh en spon taneous inspirations
are delivered to a patient. The ven til ator m oni tors airway pressure throughout the inspiratory
phase at PE, an d ini ti ates a normal exh alation w hen th e pressure equals the i nspiratory
pressure target val ue plus an in crem ental value of 1.5 cm H 2 O, an d 600 m s of the breath have
el apsed.

2.5.2.4 Time limit

The ti m e l im it appl ies only to spon taneous breath s, whi ch norm all y h ave n o i nspi ratory tim e
l im it. If exhalati on has not been tri ggered by the tim e (1.99 + 0.02 x IBW ) seconds of
i nspiration have el apsed, the ven tilator ini ti ates exhal ation.

2.5.2.5 High circuit pressure limit

The high circui t pressure li mi t applies to all breaths. If the ai rway pressure (m easured at PE)
equals or exceeds the operator-sel ected hi gh circuit pressure l im it during any in spi ration, the
ven til ator term inates th e inspi rati on and in itiates exhalation .

2.5.2.6 High vent ilat or pressure limit

The high ventil ator pressure l im it appl ies to volum e-based m an datory breath s only. If the
i nspiratory pressure (measured at PI) equal s or exceeds 100 cm H 2O, th e ven til ator tran siti on s
to exh al ation.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-95

2 Theory of operation

C NC Patient Wye

SOL2
PE
EXH
HTR NO
WT WT
CV5

F9
H P Oxygen, Wall
Q3 Reg Oxygen
H P Air, Wall/Comp
Humidifier
ECV Reg Air
Mixed Gas F8
Atmosphere
Vacuum
EV To Patient
Water

Vent
PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS

CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2
WT1 F4

PA PI

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C
F12
Dryer
HB

8-01285

Figure 2-82. Exhalation gas flow diagram

2-96 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
2.6 Ot her hardw are operat ions

2.6.1 Gas supply and cont rol

To del iver its air/ oxygen m ixture, the venti lator needs hi gh -pressure oxygen and air from
external sources. Oxygen com es from a bottled or wall source. Ai r com es from an optional
compressor uni t or a bottl ed or wal l source.
The BD CPU m oni tors gas source availabi lity through oxygen and ai r pressure switch es PS1
and PS2 and the com pressor pressure tran sducer (PC). If a compressor i s presen t, th e
ven til ator uses it as ei ther th e backup or prim ary ai r source, based on state of PS2. If the wall
air source i s restricted, i t i s suppl emen ted or replaced by the com pressor unit wi thout the
ven til ator alarm in g. If either oxygen or ai r is totall y lost, however, th e ven ti lator al arms,
although ventil ation con tinues on a si ngle gas. If both gas sources are totall y lost, the
ven til ator enters th e SVO state.

2.6.2 Dat a monit oring

Breaths are delivered based on operator-sel ected ven tilator settin gs an d ventil ator-moni tored
param eters. M any of these m onitored param eters are displayed by the upper screen duri ng
ven til ation. These param eters and thei r sources are l isted in Tabl e 2-4.

Table 2-4: M onitored data

Paramet er M eaning Source Range

Breath type Indicates the type and phase of the Type: Control, assist, or
breath being delivered. spontaneous
Phase: Inspiration or
exhalation

Delivered O2% (O2%) Percentage of oxygen in the gas Oxygen sensor (OS) 0 to 103%
delivered to the patient. The high and
low O2% alarms are set internally and
are based on the set O2% value.

End expiratory pressure Pressure at end of previous breath’s Based on expiratory and -20.0 to 100 cmH2O
(PE END) expiratory phase. Reflects level of any inspiratory pressure
active lung PEEP. transducer (PE and PI)
readings

End inspiratory pressure Pressure at end of current breath’s Based on expiratory and -20.0 to 130 cmH2O
(PI END) inspiratory phase. If plateau is active, it inspiratory pressure
reflects level of end-plateau pressure. transducer (PE and PI)
readings

Exhaled minute volume Calculated total of exhaled volumes for Net flow, based on 0.00 to 99.9 L
.
(V E TOT) mandatory and spontaneous breaths exhalation (Q3), oxygen
for previous 1-minute interval. It is (Q1), and air (Q2) flow
compliance- and BTPS-compensated. sensor readings

Exhaled tidal volume Exhaled volume for previous Net flow, based on 0 to 6000 mL
(VTE) mandatory or spontaneous breath. It is exhalation (Q3), oxygen
compliance- and BTPS-compensated. (Q1), and air (Q2) flow
sensor readings

NOTE:
A significant change to the O2% setting can cause the VTE (exhaled tidal volume) to be
transiently displayed as lower or higher than the actual exhaled volume. This is a result of
initial spirometry calculations and does not reflect actual volume exhaled by the patient.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-97

2 Theory of operation

Table 2-4: M onit ored data (continued)

Paramet er M eaning Source Range

I:E ratio Ratio of inspiratory time to expiratory ≥ 1:599 and ≤ 9.99:1

time for the previous breath,
regardless of type.
Due to limitations in setting the I:E
ratio in pressure control ventilation,
the monitored data display and the
setting may not match precisely.

M ean airway pressure Average airway pressure over entire Based on expiratory and -20.0 to 120 cmH2O
(PMEAN) breath cycle of previous breath, inspiratory pressure
regardless of type. transducer (PE and PI)
readings

M aximum circuit Indicates the maximum pressure Based on expiratory and -20.0 to 130 cmH2O
pressure during the previous breath, relative to inspiratory pressure
(PPEAK) the patient wye, including the transducer (PE and PI)
inspiratory and expiratory phases. readings
Updated at the beginning of the next
inspiration.

Spontaneous minute
volume (VE SPONT)
Displays a calculated total of the Net flow, based on 0.00 to 99.9 L
volumes exhaled by the patient for exhalation (Q3), oxygen
spontaneous breaths for the previous (Q1), and air (Q2) flow
1-minute interval. Values for sensor readings
mandatory breaths during this period
are not included. The displayed value
is compliance- and BTPS-
compensated. Updated at the
beginning of the next inspiration.

Total respiratory rate Displays a calculated value of the 0 to 200 breaths/ min
(fTOT) number of mandatory and
spontaneous breaths delivered to the
patient for the previous 1-minute
interval. Updated at the beginning of
the next inspiration.

2.6.3 Pressure transducer autozero

The in spiratory pressure transducer (PI) is zeroed by autozero solenoi d SOL1. The expi ratory
pressure tran sducer (PE) is zeroed by autozero solenoid SOL2. The two autozero transducers
are zeroed during two consecutive breaths. The voltage correspondi ng to the zero pressure
di fferential i s recorded i n DRAM . The recorded vol tage is used as an offset for transducers.
Figure 2-83 depi cts the autozero sequence.
Autozeroi ng i s perform ed at th e begi nn in g of exh alation. PI and PE requi re autozeroin g l ess
often as th e venti lator warm s up. Autozeroi ng i s perform ed every m inute for 20 mi nutes;
every 2 m i nutes after 20 m in utes, up to on e hour; and every 5 m inutes after 1 hour.

2-98 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2

C NC Patient Wye

SOL2
PE
EXH
HTR NO
WT WT
CV5

F9
H P Oxygen, Wall
Q3 Reg Oxygen
H P Air, Wall/Comp
Humidifier
EVC Reg Air
Mixed Gas F8
Atmosphere
Vacuum
EV To Patient
Water

Vent
PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS

CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2

WT1 F4

PA PI

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C
F12
Dryer
HB

8-01142

Figure 2-83. Pressure t ransducer aut ozero mode gas flow diagram

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-99

2 Theory of operation

2.6.4 Pow er monit oring and power fail handling

2.6.4.1 Loss of power source
Power to the dc/dc converter in th e power supply i s either derived from faci li ty ac power or it
i s dc from the BPS. If ac power i s avail able and adequate, the power supply con verts it to
+31.5 V nomi nal and outputs it from a bulk suppl y. If th e bul k suppl y’s output is i nsuffi cien t
(< +31.5 V, equivalen t to < 80 V ac), h owever, the dc/ dc con verter uses the or BPSpow er (+19
to +30 V).
a c p ow er loss a n d BPS sw it ch o ver (Fi gure 2-84). An ac m oni tor gen erates a voltage scaled to
the ac in put voltage. It feeds this ac monitor vol tage to the AI PCB for readin g by the
software. W h en this ac m oni tor voltage falls so th at the venti lator can no longer support the
com pressor, th e software disables th e compressor and si gnals from th e power suppl y and BPS
PCB turn on the appropriate BPS battery swi tch. The software continual ly samples the BPS
status l in es, an d wh en i t determ i nes that th e BPS i s poweri ng th e venti lator, th e venti lator
i mm edi ately an nunci ates a l ow-urgen cy al arm. Th e GUI di splays th e al arm m essages "ac
POW ER LOSS" and "Operati ng on battery." (A new, full y charged BPScan power th e venti lator
(BDU), excludin g th e com pressor and humi difier, for at l east for at least 30 mi nutes.) W h en
the ventilator estim ates that 2 m in utes of battery power rem ain , the alarm level escalates to
m edium urgen cy, and the ventil ator changes the m essage "Operatin g on battery" to
"Operational tim e < 2 mi nutes."
To ta l lo ss o f p o w er. W hen th e BPS discharges to a point wh ere th e BDU is no l onger
operational (< +19.30 V), a power fail circuit i n the power suppl y detects the loss of the bulk
supply (the i nput to the power supply’s m ai n converter) an d n otifi es th e BD CPU PCB. The
BD CPU PCB i n turn gen erates a nonm askable interrupt (NM I). The software tri ggers a
conti nuous-tone high-urgency alarm . The capaci tor-driven BD al arm is sounded. Although
the BDU i s nonfunctional at thi s point of power loss, there i s en ough power for the GUI to
conti nue to di splay text an d, with th e LED array, the curren t al arm state.
p

ac input < 80 V ac
level

31.50 V dc
Bulk 24 V dc
supply

24 V dc nominal 19.30 V dc
BPS or external
battery output

NMI
(generated by
power fail)

BPS: 30 minutes minimum

Ext. battery: 60 minutes minimum prior to switching to BPS
(with new fully charged battery)
Figure 2-84. Pow er loss sequence

2-100 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
2.6.4.2 Supply volt age monit oring
The venti lator ch ecks for and respon ds to out-of-tolerance supply voltages, as foll ows:

Table 2-5: Out-of-t olerance supply voltages

Where
Volt age Source Not es
monit ored

BD +5 V Power supply AI PCB • A hardware circuit checks for a low voltage.

If voltage is low, it (1) issues a global reset
and (2) sounds the BD alarm (capacitor-
driven). The global reset results in a
ventilator inoperative condition being
declared. A relay, which is part of the sentry
circuit, ensures that a power fail reset occurs
during voltage transients.
• Converted into a scaled voltage for reading
by software during background and other
checks.

GUI +5 V AI PCB Converted into a scaled voltage for reading by

software during background and other checks.

GUI CPU PCB If voltage is low, this circuit issues a PCB reset. If
voltage is high, an NMI is generated.

BD +12 V AI PCB Converted into a scaled voltage for reading by

software during background and other checks.

GUI +12 V AI PCB Converted into a scaled voltage for reading by

software during background and other checks.

GUI CPU PCB If voltage is low or high, an NMI is generated.

+15 V AI PCB Converted into a scaled voltage for reading by

software during background and other checks.

-15 V AI PCB Converted into a scaled voltage for reading by

software during background and other checks.

+10 V reference AI PCB AI PCB Converted into a scaled voltage for reading by
software during background and other checks.

2.7 Emergency modes of operat ion

This subsecti on descri bes how the venti lator operates under un expected conditions.

2.7.1 Safet y valve open (SVO) st ate

The safety valve has two im portant functions. Fi rst, i f outlet pressure exceeds th e m axi mum
operatin g pressure of th e patient circuit, th e safety valve passi vel y reli eves th e excess pressure.
The actual reli ef pressure vari es dependin g on the pati en t flow rate. Second, i f th e control
system detects a catastrophi c fai lure, th e safety valve i s opened an d the pati ent can freel y
breath e room air.
W hen th e ven tilator is i n the SVO state (Fi gure 2-85), a patient can spontaneously breathe
room air an d exhale. Ch eck valves in th e inspiratory an d exhal ati on m odules (CV3 an d CV5)
m i ni m ize rebreath ing exhaled gas during SVO. W h en the safety val ve i s com m anded duri ng
SVO, the ventil ator:
• Di splays the elapsed ti me si nce th e l oss of ven til atory support on th e GUI
• Does not display patien t data, incl udi ng waveforms, on th e GUI
• Does not detect patient ci rcui t occl usion or di sconnect conditions

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-101

2 Theory of operation

C NC Patient Wye

SOL2
PE
EXH
HTR NO
WT WT
CV5

F9
H P Oxygen, Wall
Q3 Reg Oxygen
H P Air, Wall/Comp
Humidifier
EVC Reg Air
Mixed Gas F8
Atmosphere
Vacuum
EV To Patient
Water

Vent
PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS

CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2
WT1 F4

PA PI

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C
F12
Dryer
HB

8-01143

Figure 2-85. Safet y valve open diagram

2-102 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Theory of operation 2
2.7.2 Occlusion handling
The ventil ator detects severe pati ent circui t occl usions to protect the patien t agai nst excessive
airway pressures over exten ded peri ods of ti m e. The venti lator is also designed to detect
patient circui t di scon nects, because they can cause the patien t to receive li ttl e or no gas from
the venti lator, and require i m mediate cli nical attenti on . Figure 2-86 depi cts the ven tilator
pneum ati cs during occlusion handl ing.

2.7.2.1 When t he vent ilat or declares an occlusion

The ventil ator decl ares a severe occlusion if all these are true:
• The in spiratory or expiratory tube is com pletely occluded.
• The ven ti lator EX HAUST port or device attach ed to i t is ful ly blocked.
• The exhalati on valve fai ls in the cl osed posi tion (occl usion detection at the FROM
PATIENT port begin s after 195 m s of exh al ation have passed).
The ventil ator does not declare a severe occlusi on i f an y of th ese are true:
• The pressure di fferen ce between the inspiratory l im b and th e expiratory lim b i s l ess than
or equal to 5 cm H 2 O.
• Water i n a l azy loop of th e pati ent tubing (i nspiratory or expiratory) does n ot com pletely
occlude the lum en.
• The exh alati on valve fails in the closed posi tion an d the pressure in th e ex hal ation li m b is
less th an 2 cm H 2O.
• A Wright spirom eter or 6 ft of si licon e tubin g is attached to the EX HAUST port of the
venti lator.

2.7.2.2 Occlusion det ect ion and handling

The ven til ator ch ecks th e patien t ci rcuit for occl usi on s duri ng all m odes of breath ing (except
i dle m ode, safety val ve open and durin g pressure transducer autozeroi ng) at every breath
del ivery cycl e. On ce the ci rcui t ch eck begins, th e venti lator detects a severe occlusion of the
patient circui t wi thin 200 m s.
The venti lator ch ecks the EXH AUST port for occlusion s duri ng the expiratory phase of every
breath (except whi le th e ven tilator is in disconnect ventil ation, i n the SVO condition , durin g
an in spiratory/ expiratory pause, or duri ng pressure tran sducer autozeroin g). On ce the
EXHAUST port check begins, the ven til ator detects a severe occl usion wi th in 100 m s.
Once a severe occl usion is detected, the ventil ator ann un ci ates an occl usion al arm . It
term inates norm al venti lati on an d acts to m ini m ize airway pressure by entering the safety
valve open state (PSOLs and exhalati on valve de-en ergi zed and safety val ve open) for 15
seconds or unti l in spi ratory pressure drops to 5 cmH 2O or less, whichever com es first. The
ven til ator ini ti ates occlusion status cyclin g (OSC).
W hil e the ventil ator is in OSC, it periodi cal ly attem pts to deliver a pressure-based breath
wh ile m onitorin g the in spiration and expiration ph ases for the exi stence of a severe
occl usion.
If th e con diti on that caused a severe occl usion is corrected, th e ven tilator declares the
occl usion corrected after two com pl ete breath cycles with n o occlusion detected. Th e
ven til ator resets th e occlusi on al arm and reinstates breath delivery accordin g to curren t
settings.

NOTE:
During a severe occlusion, apnea detection, expiratory pause, manual inspirations, and
maneuvers are suspended, and the ↑ PMEAN (high airway pressure) alarm limit is disabled.
The GUI does allow you to change ventilator settings.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 2-103

2 Theory of operation

C NC Patient Wye

SOL2
PE
EXH
HTR NO
WT WT
CV5

F9
H P Oxygen, Wall
Q3 Reg Oxygen
H P Air, Wall/Comp
Humidifier
EVC Reg Air
Mixed Gas F8
Atmosphere
Vacuum
EV To Patient
Water

Vent
PSOL1
PS1 Q1
F7
F3
REG1
TP1 CV3
SV
F5
F1 OS

CV2
PS2
NO
Vent
Q2 SOL1
CV4 PSOL2
F2 REG2
F6
NC C
TP2
WT1 F4

PA PI

RV
M/C
HE PC

Accumulator
R1/F11
F13
SOL3
NC
F10
WT2 NO C
F12
Dryer
HB

8-01144

Figure 2-86. Pressure release, patient circuit occluded diagram

2-104 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
 SECTION
S EC T I O N

Self tests 3 3
3.1 Int roduct ion
This section describes the 840 Ven ti lator System buil t-in sel f tests, i ncl uding h ow to run
them. For a li sting of ventil ator diagnosti c codes an d messages generated duri ng these self
tests, refer to Section 6.

3.2 How t o ent er Service M ode

In order to access the Extended Self Test (EST) an d other service fun ctions, you m ust fi rst
bri ng the ven til ator up in Service M ode, as follows:
Enter service m ode and ini tiate EST as follows:
1 Turn on power to ven tilator. (If power i s already on, turn it off, then back on .)
2 W h ile BDU ventil ator inoperative i ndicator is l it and al arm briefl y ceases, press TEST
button with in on e second. (The TEST button is l ocated on the ri ght si de panel .)
The venti lator autom ati cal ly enters the service m ode. Do not continueto depress or cyclethe
TEST button while entering service mode.

3.3 Self t est s and background checks

The 840 Ven til ator has self test capabil iti es that i nclude POST (power-on sel f test), SST (short
self test), EST (extended sel f test), and background checks. These sel f test operati ons are
descri bed in Table 3-1, and Tabl e 3-2 detail s the com pon en ts tested by various self tests.

3.3.1 POST
POST tests th e i ntegrity of the ven tilator’s electroni cs with out operator i ntervention. It i s
executed when the ventil ator is powered up, before i t enters servi ce mode, or i f th e ventil ator
detects selected faul t conditions. Breath deli very cannot start until th e venti lator com pletes
POST with no m ajor errors.

3.3.2 SST
The SST is a short (about 3 mi nutes) and si m ple sequen ce of tests that verifies proper
operation of breath del ivery hardware (in cluding pressure and fl ow sensors), ch ecks the
patient circui t (i ncl udi ng tubin g, hum idi fi cation device, and fi lters) for leaks, and m easures
the ci rcui t com pl ian ce and resistan ce. SST also checks the exhal ation fil ter resistance. SST i s a
user-ini tiated ch eck prim aril y in tended for use by the operator. The ven ti lator does n ot begi n
SST i f it sen ses that a patien t is conn ected.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 3-1
3 Self tests

3.3.3 EST
EST is a user-ini ti ated sel f test, intended to be run by the service tech ni cian, that verifies the
i ntegri ty of th e ventilator’s subsystems usin g operator parti cipation. EST ch ecks the
pn eum ati cs, m em ory, safety system , front panel con trols, i ndi cators, di gital an d anal og
electronics, power suppli es, tran sducers and opti on s. EST requi res a “ gold stan dard” test
ci rcuit, avail abl e from Puritan -Ben nett. All required software support to perform an EST i s
residen t on th e ven ti lator. EST testing, excludin g tests of opti on al equipm en t, such as the
com pressor, takes about 15 min utes to com pl ete.

3.3.4 Background checks

Background ch ecks are con ti nual ly perform ed duri ng ventil ati on . W h en an error is detected
duri ng a background check, the ven tilator ann unciates a DEVICE ALERT al arm . As i t does for
an y alarm , the ventil ator di splays a m essage, i nvokes audio and visual alarm s, and logs th e
error i nform ati on .
The System Diagnostic Log sh ows the code th at triggered the DEVICE ALERT. The al arm log
al so i ndicates that there was a DEVICE ALERT. Ventilati on m ay or m ay n ot be affected,
depen ding on the severi ty of th e condition. Som e device alerts are autom ati call y reset i f the
triggeri ng condi tion disappears. In general , device al erts are caused by anal og device
problem s.

3.3.5 When self test s are run

Several self tests may check the sam e component; however, th ese ch ecks may n ot be
equivalent. For exam ple, whi le POST m ight perform a voltage check of a com pon ent, EST
m ight perform a system -level test of the same com ponen t.
Table 3-1 descri bes the purpose of each self test and when each i s run.

Table 3-1: Self t ests

Name Purpose When it is run

POST (long) Verifies the integrity of the ventilator electronics, Automatically

including compressor, if applicable. After long
POST, the ventilator requests new patient
settings. Long POST lasts under 10 seconds.
• after the user cycles power
• when power is restored from an inadvertent
power-down, if power has been off for
5 minutes or more1
• before the ventilator enters service mode
• after an intentional ventilator reset (for
example, after certain fault conditions are
detected, after SST or EST is run)

POST (short) Verifies the integrity of the ventilator electronics. Automatically

It does not include a full test of the BDU, nor a • after an unintentional ventilator reset
test of the compressor. Short POST lasts under • when power is restored after a short
5 seconds. interruption (< 5 min.)1

SST A short sequence of tests intended to be run
primarily by the operator. Checks pneumatics
and electronics. SST also characterizes system
leaks and system/ tubing compliance to
compensate during breath delivery. POST is run
as part of SST, both at the start and end.
• Before patient is connected to ventilator
• After patient circuit or humidifier is changed
• When ventilator is serviced
• Every 15 days

1. POST will run only if there is no BPSinstalled, or if the BPS battery is discharged. Otherwise, during a temporary loss of ac power, the vent
will automatically switch to BPS power, and POST will not run.

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Table 3-1: Self t ests (cont inued)

Name Purpose When it is run

EST Tests operational integrity of ventilator, both • When ventilator is serviced

electronics and pneumatics. POST is run as part • As part of ventilator performance verification
of EST, both at the start and end. (every six months)

NOTE:
• SST is not run as part of EST. To
determine patient circuit resistance and
compliance, run SST.
• The performance verification,
described in Section 5 of this manual, is
a more thorough test of the ventilator
to verify specifications are met.

Ongoing Includes these checks: memory, power supply, Automatically, continually during ventilation
background checks dc voltages, pressure transducers, analog input
validity, and more. These checks do not disrupt
normal operation.

3.4 Power on self t est (POST)

Table 3-2: Components t ested by self test s

Background Service mode

Component t est ed POST SST EST
checks calibrat ions

Pow er supply/ volt age checks

ac monitor voltage X

Supply voltages (including BDU and X X

GUI voltages)

BPS supply voltage/ current X X X

BPS charging and discharging X X

BPS model X X

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Table 3-2: Components t ested by self t ests (cont inued)

Background Service mode

Component t est ed POST SST EST
checks calibrat ions

Pat ient syst em

Patient circuit leak X

Patient circuit occlusions/ resistance X

Patient circuit compliance X

Expiratory filter occlusion/ resistance X

Pneum at ics

System leak X

Oxygen and air pressure switches X X

Oxygen and air flow and temperature X X X X

sensors

Oxygen and air/ exhalation flow X X

sensor cross-check

Inspiratory check valve operation X

Oxygen and air PSOL current X X X X

Oxygen and air PSOL forward leak X X X

Oxygen and air PSOLs stuck open or X X X X

stuck in other position

Inspiration and exhalation pressure X X X

transducer autozero solenoids

Inspiration pressure transducer X X X X

Exhalation pressure transducer X X X X

Inspiration and exhalation pressure X X

transducer cross-check

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Table 3-2: Components test ed by self t ests (cont inued)

Background Service mode

Component t est ed POST SST EST
checks calibrat ions

Pneumat ics ( cont inued)

Oxygen sensor reading X X

Safety valve operation X

Safety valve current X X X

Safety valve opening/ closing X X

Safety valve peak and cracking X

pressure

Exhalation valve motor current X X X

Exhalation valve coil temperature X X X

Exhalation valve operation X X X

Expiratory valve seal and poppet X

Expiratory valve velocity transducer X

Expiratory valve calibration check X

Exhalation manifold heater X X X

Exhalation flow sensor and X X X

temperature sensors

Compressor subsystem, including X X

timer, pressure switch, operating
states, and leak. Pressure test for
worst-case delivery.

Atmospheric pressure transducer X X X

Elect ronics

CPU kernel electronics (processor, X partially X

memory, time-of-day clock, timers
and counters)

Audio alarm and user interface sound- X X X

producing subsystem

Alarm cable (BDU) X X X

Nurse’s call relay X

+10 V reference (used by ADCs and X X X

DACs)

ADC/ DAC functionality X X

Power fail capacitor X X X

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Table 3-2: Components t ested by self t ests (cont inued)

Background Service mode

Component t est ed POST SST EST
checks calibrat ions

Elect ronics ( cont inued)

Keyboard X partially X

Knob X

GUI and BDU LEDs (operator test) X X

GUI and BDU audio (operator test) X X

GUI touch screen X X

Ethernet controller X X

GUI serial port X

Safet y syst em

Ventilator inoperative signal and safe- X X X X

state verification

NOTE:
A fault identified in POST indicates that the ventilator or an associated component
is defective. A defective ventilator or associated component should be repaired
before the ventilator is returned to service, unless it can be determined with
certainty that the defect cannot create a hazard for the patient, or add to the risks
which may arise from other hazards.

There are tw o versions of POST: l on g POST, whi ch is run when the user cycl es power, and
short POST, wh ich is run fol lowin g an un intended h ardware reset.

NOTE:
The graphic user interface (GUI) indicates a POST is in progress but does not
indicate a long or short POST.

The graphic user interface (GUI) and the breath delivery unit (BDU) subsystems each has its own
POST that tests the major hardware electronics systems. POST does not check the ventilator’s
pneumatics, options, or accessories that are not directly related to ventilation. POST is designed to
detect major problems before proceeding to normal ventilation, and to provide a confidence
check before a patient is connected to the ventilator.
POST routin es are ordered so that each routi ne requires successively m ore operati onal
h ardw are than the last. Thi s sequence all ow s POST to system ati cal ly excl ude electronic
com pon en ts as causes of system m alfunctions.

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3.4.1 Safety
The ventil ator does not provide ventil atory support to the pati ent duri ng POST. Th e
ven til ator alarm s if POST l asts lon ger than 10 secon ds or i f an unexpected fault i s detected.
POST i s designed to m i nim i ze the delay until n orm al venti lati on begi ns and to provi de
i mm ediate notification in case a fault is detected.
Durin g POST the ven tilator proportional sol en oid valves (PSOLs) are closed and the
exh alati on valve an d safety valve are open to al low the patien t to breathe room air, and the
ven til ator displays a m essage that POST i s in progress.
Once POST i s complete, ventil ator startup (foll owi ng power-up) or norm al ven ti lati on begin s,
unless service m ode i s requested or the ventilator detects any of the fol lowin g:
• An un corrected m ajor system fault.
• An un corrected m aj or POST fault.
• An un corrected sh ort self test (SST) fail ure or n on -overri dden SST al ert.
• An un corrected exten ded self test (EST) fai lure or non-overridden EST al ert.
• The ven ti lator i s turned on for the first ti me fol lowin g a software down load, but has not
yet successful ly com pleted one of th e fol lowing: exhal ation valve cali bration, flow sen sor
calibration, atm ospheri c pressure transducer cal ibrati on , SST, or EST.
• An un com pl eted system in itiali zation .

NOTE:
When a compressor is installed and wall air is not present, there may be a short
interval following a successful POST before the compressor achieves operational
pressures. If so, the ventilator annunciates a NO AIRSUPPLY alarm, which resets as
soon as the compressor charges the system to operational pressure.

3.4.2 POST characterist ics

POST runs autom ati cally when you cycl e power to the venti lator. If possible, th e venti lator
displays the revisi on of the in stal led software in the Ven t Confi gurati on screen. Each
processor i n the ven til ator run s its own POST. Upon com pletion, each processor reports its
test results to the GUI processor. POST starts wi th the software kernel, th en tests the hardware
that directly i nterfaces to the kern el . POST th en tests th e rest of th e hardware. Hardware that
i s l in ked to each processor through a comm un ication ch ann el is checked on ce th e
comm uni cati on l ink is verified.
The mai n characteristi cs of POST are:
• Th e kernel of every subsystem i s desi gn ed to i nclude th e sm all est number of com ponents
possible, an d each kernel can run i ndependently of the rest of th e system .
• POST verifi es system in tegrity by checking th at al l m ain electri cal connectors are correctly
attached an d th at i nterfaces to al l el ectroni c subsystem s (such as th e keyboard or audi bl e
alarm ) are fun ctional. POST perform s all electrical hardware checks that do not require
operator interven ti on.
• POST checks safety hardware, such as the watchdog ci rcuitry an d bus ti me-out monitorin g
circui try.
• POST’s m em ory test preserves all data necessary to determ in e ven ti lator settin gs an d
ini ti al izes the rem ain in g m em ory to a predefin ed state.
• Any other processors i n th e system in itiates i ts own POST an d reports the test results to
the host processor.

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To ensure that th ere is an alarm i f th e central processin g uni t (CPU) fails, audi o, visual , an d
rem ote alarm s are norm all y on, and turn off once system in iti ali zation (that is, the process
that occurs betw een POST com pl eti on and the start of ventil ation) is com pl eted and
com m un ication is establ ished.
An alarm turns on i f POST l asts m ore than 10 seconds or if POST restarts three ti mes without
com pl eti on. Th e 10-secon d ti m er is a redundant check i n case POST fail s to al arm upon
detectin g a faul t. The ch eck for three restarts can detect a con ti nuous l oop, and prevents
POST from run nin g for m ore th an 10 seconds.

3.4.3 POST following pow er interruptions

If th ere is n o BPS i nstall ed or the BPS battery i s discharged, POST i s invoked un der the
foll owi ng condition s:
• The ventil ator executes long POST foll owi ng a power in terrupti on of 5 m i nutes or m ore
wh ile the power switch is on. The ven til ator run s a full POST after a l on g power
interruption under th e assumpti on that the pati en t woul d h ave been di sconn ected and
ventil ated by other means, and because circum stan ces that cause a length y power loss
warrant a full POST.
• The venti lator runs a sh ort POST (wh ich test s the BDU on ly) if power i s in terrupted for
less than 5 m inutes. After a short power interruption (duri ng which th e status of the
patient cann ot be assum ed), the ventil ator resum es n orm al ven tilati on as soon as
possi bl e, in case th e pati ent rem ain s con nected. Run ning a short POST (3 secon ds or l ess
from return of ac power to begi nn ing breath delivery) al lows for short power i nterrupti on s
due to comm on events (for exam ple, sw itchi ng to generator power) th at do not require a
norm al POST, an d assum es that a pati ent may sti ll be conn ected to the ven ti lator. Short
POST checks th e software kernel, veri fi es checksums for code, an d determ ines what even t
invoked POST.

NOTE:
Puritan Bennett recommends that a BPS is always installed on the ventilator. If
there is a loss of ac power with a charged BPS installed, the ventilator will switch
to the dc source and will not run POST upon restoration of ac power.

3.4.4 POST user int erface

POST in cl udes these visual i ndi cators:
• A Safety Val ve Open (SVO) in dicator si gnals that the ventil ator i s not deli veri ng breath s.
• Di screte vi sual i ndicators on th e BDU an d GUI CPU PCBs th at i ndi cate the curren t test
and step num ber.
• The VENT INOP indicator on th e BDU sign als th at the user can press TEST to tri gger
servi ce m ode.
• If possi bl e, a display of fault inform ation in case POST detects a fail ure.
Duri ng th e different phases of POST, speci fic LEDs are ill um inated on th e GUI LED array an d
the BDU LED array. Audio, vi sual , and rem ote alarm s are turned on then off after the software
kernel is veri fied (Ph ase 1) to en sure an alarm sounds i f a CPU failure occurs. Refer to
Table 3-3 to see which i ndi cators are acti ve during each phase of POST.

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3.4.5 St ruct ure of POST
W hen POST i s started, two “ POSTs” actually run si m ultaneously: the graph ic user in terface
(GUI) an d the breath del ivery un it (BDU) POSTs. These two POSTs run i ndependen tl y of each
other.
The fol lowin g phases compri se th e GUI POST and BDU POST:
Ph a se 1 (k ern el) - Tests the m i crocon troll ers and associated circui try. For each POST, thi s
secti on of code resi des in a sin gl e PROM al ong with kernel operatin g system and
download util ity. Th is part of POST is not down loadabl e. It is i dentical for both th e GUI
an d BDU POSTs, wi th the exception of the roll in g th un der test, wh ich i s confi ned to th e
BDU CPU.
Ph a se 2 - Tests com ponen ts outside of the kern el. Thi s portion of POST differs for the GUI
an d BDU subsystem s.
Ph a se 3 - Consi sts of tests com m on to both CPUs, and those th at depen d on the
venti lator operating system to i niti ali ze som e h ardware com ponents before th e test.
Table 3-3 com pares the BDU and GUI POST sequen ces, i ndi cates the tests perform ed an d
shows which indicators are active durin g each phase.

Table 3-4: POST outcomes

Sympt oms
How t o respond
What you see and hear What is happening

• POST stops. • M ajor failure detected. • If possible, check LEDs on

• Ventilator inoperative alarm
(audible and visible).
• Each CPU attempts to sound
its own alarm.
• No ventilation if there is a
BDU failure.
• Ventilator inoperative
condition declared.
• Communication with other
CPU prevented.
BDU or GUI CPU PCBs to
determine which test failed
and its error code;
troubleshoot. Otherwise,
replace BDU or GUI CPU PCB,
as appropriate.

• POST continues to end.
• Ventilator inoperative alarm
(audible and visible).
• Ventilation disallowed.
• Previous run of POST failed • Run EST/ service ventilator.
and was not corrected,
although POST passed
subsequent run.
• Ventilator inoperative
condition declared.

• Although POST ran to end, it • Run EST/ service ventilator.

detected a condition
requiring service.
• Ventilator inoperative
condition declared.

• POST continues to end. • M inor fault detected. • Check System Diagnostic Log
• Ventilation proceeds. for any associated error codes.
• A DEVICE ALERT is • Rerun POST/ EST.
annunciated.

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Table 3-3: POST St ructure

POST (7.25 seconds)

Phase 1 Phase 2 Phase 3 POST end

(2 s) (2 s) (2 s) (1.25 s)

GUI CPU POST • Initializes processor • Tests GUI on-board • Tests GUI CPU • Updates NOVRAM
• Tests power, GUI electronics, GUI 5V memory manage- • Initializes hardware
CPU, time of day sentry, GUI 12V ment and floating
clock, kernel sentry, POST point units, down-
DRAM/ NOVRAM, NOVRAM, bus load OS boot,
boot PROM , timer, DRAM , application boot
interrupt timer, SAAS, Ethernet
watchdog timer, controller,
flash memory unexpected reset
checksum, umpire test
EEPROM checksum

No communication occurs between GUI and • GUI and BDU CPUs • Ventilator begins
BDU CPU boards during Phases 1 and 2 establish flowing air at
communication 10 L/ min to check
for patient
connection

BDU CPU POST • Initializes processor • Tests BDU on- • Tests BDU CPU • Initializes hardware
• Tests power, BDU board electronics, memory manage-
CPU, time of day VH 5V, VH 12V, ment and floating
clock, kernel POST NOVRAM, point units, down-
DRAM/ NOVRAM, bus timer, DRAM , load OS boot,
boot PROM , vent INOP, application boot
interrupt timer, Ethernet controller,
watchdog timer, service mode
flash memory switch, unexpected
checksum, reset umpire test,
EEPROM • AI PCB test
checksum, rolling • Analog devices
thunder test test:
PS1/ PS2
Q1/ Q2/ Q3
PSOL1/ PSOL2
PA/ PI/ PE
O2 sensor
safety valve
exhalation valve
exh. valve heater
• ADC and DAC tests
• ac voltage test

Visual and • GUI LEDs: SVO LED • GUI LEDs: all LEDs • GUI LEDs: all OFF • GUI: start-up
audible indicat ors ON ON except green screen displays if
• BDU LEDs: SVO • BDU LEDs: all LEDs “ normal” indicator POST passes
LED ON, loss of UI ON • BDU LEDs: all OFF • BDU: all LEDs off if
LED ON • BDU continuous • GUI audible alarm POST passes
• BDU continuous tone alarm OFF turned on then off • No audible alarms/
tone alarm ON (2 beeps if OK) LEDs active1
• BDU continuous
tone alarm turned
on and off twice

AI PCB LEDs Red LED ON Red LED ON Green LED ON Green LED flashing

1. This is true only if both air and O 2 supplies are connected and have adequate pressure, and the patient circuit is not connected, and no
failures or fault conditions are detected by ongoing diagnostics (including POST 10 second timer).

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Self tests 3
3.5 SST (short self t est )
Warning
• Always disconnect the ventilator from the patient before running SST. Running SST while
the ventilator is connected to the patient can injure the patient
• When running SST, make sure the patient circuit is configured exactly as it will be used on
the patient (for example, with same accessories). If accessories are changed or added to
the patient circuit after SST has completed, you must run SST again with the new
configuration installed to calculate for compliance and check for leaks.
• An ALERT identified in SST indicates that the ventilator or an associated component is
defective. A defective ventilator or associated component should be repaired before the
ventilator is returned to service, unless it can be determined with certainty that the defect
cannot create a hazard for the patient, or add to the risks which may arise from other
hazards.

NOTE:
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in service mode before running SST, to ensure accurate
testing.
• Puritan Bennett recommends that you run SST every 15 days, between patients, after a
major service or repair (refer to Table 5-2 on page 6), and when you change the patient
circuit. Puritan Bennett recognizes that the protocol for running SST varies widely among
health care institutions. It is not possible for Puritan Bennett to specify or require specific
practices that will meet all needs, or to be responsible for the effectiveness of those
practices.
•

Table 3-6 l ists the tests that com prise SST. For m ore detail s about these tests and associ ated
diagnosti c codes, see Secti on 6 of th is m anual. For a theory of operation of SST, consult th e
840 Ventilator System Operator’s and Technical Reference Manual.

3.5.1 When to run

The operator runs SST i n the fol lowin g situations:
• Every 15 days, between patien ts
• W h en chan ging the patien t ci rcuit
• W h en changing the pati en t circuit configurati on
Changes to th e pati ent circuit configurati on i ncl ude:
• Changi ng the hum idi fier type
• Addin g or rem oving an in -lin e water trap
• Using a different type or styl e of patient circui t
• Installi ng a new or steril ized exh alation fi lter
The service tech nician runs SST after servicing the venti lator and as needed to veri fy the
i ntegrity of the bacteri a fi lters and patient circui t.

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3.5.2 Hardware requirem ents

Runn ing SST requires th e equi pm en t li sted i n Table 3-5.

Table 3-5: Hardw are requirement s for SST

M anufact urer or model or Purit an Bennet t part

Descript ion
number

Patient circuit Varies

NOTE:
To ensure that compliance compensation
functions correctly, the user must run SST
with the circuit configured as intended for
use on the patient.

Stopper, wye (no. 2) 4-009523-00

1 Compressed air source, 35 to 100 psi (241 to 690 Local supplier
kPa) or the compressor option 806 Compressor Unit

NOTE:
Due to the excessive restriction of Air
Liquide, Dräger, and SIS air/ oxygen hose
assemblies, certain SST tests may fail when
supply pressures< 50 psi (345 kPa) are used
in conjunction with these hoses.

Oxygen source, 35 to 100 psi (241 to 690 kPa) Local supplier

NOTE:
Due to the excessive restriction of Air
Liquide, Dräger, and SIS air/ oxygen hose
assemblies, certain SST tests may fail when
supply pressures< 50 psi (345 kPa) are used
in conjunction with these hoses.

1. If necessary, the compressor can be used as the only gas source. However, only the gas pathway, flow sensor, and PSOL
of the single gas (air or O2) will be verified during SST.

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3.5.3 Running SST
1 If attached, rem ove gold stan dard circuit (test circui t desi gn ed for use with EST) from
venti lator. Instal l th e circuit to be used on patien t. (Fi gure 3-1).
Do n ot attach a test l ung or a humi di fi er to the circuit at thi s ti m e.

NOTE:
To ensure accurate circuit resistance measurement, check that the circuit is not
obstructed and is properly connected to the ventilator.

2 En sure that pati ent i s n ot con nected to circuit and that patient w ye i s unblocked.
3 Turn on power switch to start norm al ventil ation.
4 Verify that the ventil ator is operati ng on full ac power before runni ng SST. If ful l ac
power is n ot present, test fai lures may result.
5 At Ventilator Startup screen (lower GUI screen ), touch SST, then press TEST button (on
si de of ven ti lator) wi thi n 5 seconds. Wai ting l on ger than 5 secon ds can cels th e SST
prom pt.

Tubing configured
for use on patient

(Block wye when prompted by SST) 8-01210

Figure 3-1. Pat ient circuit setup for SST

6 At SST Setup screen (l ower GUI screen), select patient circui t an d h um idification types,
then press ACCEPT.

Warning
Incorrectly specifying the patient circuit type or humidifier during SST setup, or changing
either type after you have run SST can affect the accuracy of compliance calculation and the
delivered and measured exhaled tidal volumes. You must rerun SST after changing the
patient circuit type, installing a new patient circuit, or after adding or changing accessories.

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NOTE:
During ventilation, the humidification type can be changed by touching the
OTHER SCREENS button, then the More Settings button. However, the preferred
operation in this case is to rerun SST after making such a change.

7 The venti lator autom ati cal l y i niti ates th e test sequence (Table 3-6).
In st a lla t ion of h u m id ifier: Th e SST Fl ow Sensor test wi ll pause durin g executi on and
prom pt for i nstallation of humi difi er. If appl icabl e, fil l the hum idi fier with water and
connect as shown in Fi gure 3-1. (Th e hum idi fi er m ust be fi lled with water to ensure
proper com pliance com pensation.) Press ACCEPT to con ti nue SST.
The SST Expi ratory Fi lter, Circuit Resi stan ce, and Compli ance Cal ibrati on tests requi re
your i ntervention , and wil l wait indefi nitely for your response. Respond when
prom pted; then press ACCEPT. Otherwise you don’t need to do anythi ng until a test
result is ALERT or FAILURE, or SST is com plete.
8 As each test is perform ed, the SST Status screen shows test results (see Table 3-7). SST
results can be viewed in servi ce m ode in th e SST Results subscreen . You can also review
resul tin g error i nform ati on th rough the EST/SST Diagnostic Log after SST is compl eted
(refer to Section 6).
9 You can touch EXIT SST during SST to halt testin g. You can touch EXIT SST again to
resum e testin g, or press ACCEPT to restart the ventilator (if SST h as not detected an
ALERT or FAILURE).

Warning
• To ensure ventilation that correctly compensates for circuit resistance and compliance, do
not exit SST and begin normal ventilation until the ent ire SST has been successfully
completed with the circuit to be used on the patient installed.
• To ensure reliable SST results, do not repeat an individual test with a different patient
circuit if the test result is FAILURE or ALERT. If you suspect a defective patient circuit,
restart SST from the beginning with a different patient circuit.

NOTE:
• If SST is interrupted, you can restart normal ventilation as long as no errors have occurred
that would otherwise prevent it.
• Tests that result in an alert or failure and are successfully rerun are not written into the
EST/ SST Diagnostic Log if they are successfully rerun during the same SST test sequence.

10 W h en all of the tests in SST are com plete, th e SST Status screen di spl ays all in divi dual test
results an d SST outcome. Table 3-8 sum m arizes overal l SST outcom es and how to
proceed in each case.
11 To begi n norm al ven til ati on (if SST has not detected an ALERT or FAILURE), touch EX IT
SST, th en press ACCEPT. The ventil ator rerun s POST, th en displays th e Ventilator Startup
screen.

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Table 3-6: SST t est s
Test st ep Funct ion
SST Flow Sensor Test 1. Verifies that at least one gas is con-
nected. (If only one gas is connected
then only that gas pathway (flow sen-
sor and PSOL) is verified during SST.)
2. Cross-checks air and oxygen flow sen-
sors against exhalation flow sensor at
four different gas flows.
3. Verifies that proportional solenoid
(PSOL) command current is in range
for each test flow.
Circuit Pressure Test 1. Verifies that system is running on ac.
2. Exercises air and oxygen PSOLs.
3. Checks inspiration and exhalation
autozero solenoids.
4. Cross-checks inspiration and exhala-
tion pressure transducers at various
pressures.
Circuit leak Displays drop in circuit pressure in 10 s.
(Determines ability of circuit to hold
pressure.)
Expiratory filter Displays pressure drop across expiratory
filter.
840 Ventilator System Service Manual
3
Comment s
When prompted, do the following:
• M ake sure inspiratory filter is installed.
• Connect patient circuit with inspiratory
filter, but without the humidifier.
• Block wye.
• When later prompted, and If applicable,
install the humidifier with jar filled with
water.
NOTE:
To ensure proper compliance
compensation when using a
humidifier, make sure the jar is full of
water.
FAILURE if not passed (cannot be
overridden).
FAILURE if not passed (cannot be
overridden).
Overriding an ALERT could cause improper
compliance compensation, inaccurate tidal
volume delivery, or autocycling.
FAILURE reported if test detects excessive
leak.
Connect and disconnect tubing when
prompted.
Overriding an ALERT could cause inaccurate
patient pressure estimation.
FAILURE if test detects exhalation
compartment occlusion, expiratory filter
occlusion or damage, or you did not follow
prompts to detach and reattach tubing
correctly.
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Table 3-6: SST test s (continued)

Test st ep Funct ion Comment s

Circuit Resistance Displays pressure drop across inspiratory
and expiratory limbs, including effect of all
devices on each limb (filters, humidifier,
water traps).
Unblock wye when prompted.
Overriding an ALERT could cause inaccurate
patient pressure estimation.
FAILURE if test detects excessive or low limb
resistance, or if you did not follow the
prompt to unblock the wye.

Compliance calibration
Displays patient circuit compliance.
Block and unblock wye when prompted.
Overriding an ALERT could cause improper
compliance compensation or inaccurate
tidal volume delivery. FAILURE if test detects
out of range compliance.

Table 3-7: SST individual t est result s

If t he t est result is: It means: Do t his:

Passed No faults found. Nothing, unless prompted by the ventilator.

ALERT Test results not ideal, but not Repeat t est by touching REPEAT.
critical. SST halts. Skip t o next t est by touching NEXT.
Repeat SST from t he beginning by touching RESTART SST.
Exit SST in order to service ventilator by touching EXIT SST.

FAILURE A critical problem has been Repeat failed t est by touching REPEAT.
detected, and SST cannot complete Repeat SST from t he beginning by touching RESTART SST.
until the ventilator passes the failed Exit SST in order to service ventilator by touching EXIT SST.
test.

Table 3-8: Overall SST outcomes

If t he SST
It means: Do t his:
out come is:

Passed All tests passed. Touch EXIT SST.

ALERT One or more faults were detected. Repeat SST from t he beginning by touching RESTART SST.
If it can be determined with Override ALERT, as allowed by your institution’s protocol, by
certainty that this cannot create a touching OVERRIDE, followed by EXIT SST.
hazard for the patient, or add to
the risks which may arise from
other hazards, the user can choose
to override the ALERT status and
authorize ventilation.

FAILURE One or more critical faults were Repeat SST from t he beginning by pressing RESTART SST.
detected. A ventilator inoperative Exit SST in order to service ventilator or review error codes by
condition is declared. pressing EXIT SST.

OVERRIDDEN An ALERT status was overridden, Touch EXIT SST.

and ventilation is authorized.

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Self tests 3
3.6 EST (ext ended self t est )
Warning
• Always disconnect the ventilator from the patient before running EST. Running EST while
the ventilator is connected to the patient can injure the patient.
• A fault identified in EST indicates that the ventilator or an associated component is
defective. A defective ventilator or associated component should be repaired before the
ventilator is returned to service, unless it can be determined with certainty that the defect
cannot create a hazard for the patient, or add to the risks which may arise from other
hazards.

NOTE:
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in service mode before running EST to ensure accurate
testing.
• Be aware that each time EST is performed, the patient alarm log is cleared.

3.6.1 Descript ion

Table 3-10 l ists the tests that com prise EST. For m ore detail s about these tests and associ ated
diagnosti c codes, see Section 6. For a theory of operation of EST, consult th e 840 Ventilator
System Operator’s and Technical Reference Manual.

3.6.2 When to run

Run EST before pl aci ng the ventil ator into operation foll ow ing servi ce and as part of the
ventil ator’s routi ne perform an ce veri ficati on.

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3 Self tests

3.6.3 Hardware requirem ents

Runn ing EST requi res the equi pm ent l isted i n Table 3-9. Both air an d oxygen gas are required
for this testin g.

Table 3-9: Hardware requirement s for EST

M anufact urer or model or

Descript ion
Purit an Bennet t part number

Test (gold standard) circuit 4-018506-00

Stopper, wye (no. 2) 4-009523-00

Compressed air source, 241 to 690 kPa (35 to 100 Local supplier
psi) or compressor option

NOTE:
Due to excessive restriction of Air Liquide,
Dräger, and SISair/oxygen hose assemblies,
certain EST tests may fail when supply
pressures < 50 psi (345 kPa) are used in
conjunction with these hoses.

Oxygen source, 241 to 690 kPa (35 to 100 psi) Local supplier

NOTE:
Due to excessive restriction of Air Liquide,
Dräger, and SISair/oxygen hose assemblies,
certain EST tests may fail when supply
pressures < 50 psi (345 kPa) are used in
conjunction with these hoses.

3.6.4 Running EST

1 Ensure th at th e patient i s NOT connect to venti lator.
2 Before runni ng EST, you m ust verify th e foll ow ing:
• The ven til ator i s operati ng on full ac power.
• The green BPS ready LED is li t, indicating that the batteries are charged to 95% of
n om i nal .
• Air and oxygen gas sources are con nected to th e ven ti lator and pressures are wi thi n the
range of 35 - 100psi (241-690 kPa).
Fail ure to ensure that all th ree condi tions are true wil l cause EST to fail.
3 Enter service m ode and in itiate EST as foll ows:
a. Turn on power to ven tilator. (If power i s al ready on, turn it off, then back on .)
b. W h ile BDU ventil ator in operative i ndi cator i s l it and al arm briefl y ceases, press TEST
button with in one second. The ventil ator autom aticall y enters the service m ode. Do
not continue to depress or cycle the TEST button while entering service mode.
c. On l ower screen, touch EST.
d. In stall the gold standard circuit between To patient and From patient ports (Fi gure 3-2).
Do not install an inspiratory filter.

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Self tests 3

Gold
standard
tube
8-01211

Figure 3-2. EST setup

4 The venti lator automati cally starts the test sequence (Tabl e 3-10). Some tests require your
i ntervention, and wi ll wai t i ndefin itely for your response. Others, such as the GUI Knob
test and the GUI Keyboard test, require your respon se wi thin a 15-second tim eout
period. Failure to respond before the tim eout peri od expires wi ll result in test failure or
al ert.
Otherwise, you don ’t n eed to do anythi ng unti l a test result i s ALERT or FAILURE, or EST
i s com pl ete.
5 As each test i s perform ed, the displays resemble th ose in Fi gure 3-3, wi th test data
di spl ayed on th e upper GUI. Overall test results are shown in the “ Result” column (see
Tabl e 3-11). Error codes begi nn ing wi th an A indi cate an alert an d error codes begi nn ing
with an F i ndi cate a fai lure. You can review resulti ng error i nform ation th rough th e EST/
SST Di agnostic Log after EST is com pl eted (see Secti on 6).
6 You can touch EX IT EST durin g EST to hal t testin g. You can touch EX IT EST again to
resum e testin g, or press ACCEPT to restart the venti lator (if EST has n ot detected an
ALERT or FAILURE).

NOTE:
• If EST is interrupted, you can restart normal ventilation as long as no errors have occurred
that would otherwise prevent it. You must press the EXIT button on the GUI screen then
the ACCEPT key to exit EST properly.
• Tests that result in an alert or failure and are successfully rerun during the same test
sequence are not written into the EST/ SST Diagnostic Log.
• It may be useful to complete EST even with errors, because information on multiple errors
can facilitate troubleshooting.

7 W h en all of the tests i n EST are com plete, the Extended Self Test screen displays al l
i ndi vidual test results and EST outcom e. Refer to Tables Tabl e 3-10, Table 3-11, and
Tabl e 3-12 for addi tional inform ation.

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08:28 18 Jul 2003

18 Jul
18 Jul 03
03

Figure 3-3. EST screens during t esting

NOTE:
These screens are examples only. Your unit may vary slightly in appearance.

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Self tests 3

Table 3-10: EST test s

Test st ep Funct ion Comment s

Circuit Pressure Test
Checks that the system is running on ac power, prompts
user to set up the vent for EST, and exercises the PSOLs.
Calibrates inspiratory and exhalation transducers to
atmospheric pressure.
Cross-checks inspiration and exhalation pressure
transducers at various pressures.
Checks inspiration and exhalation autozero solenoids.
• Leaks or occlusions in the
expiratory filter or elsewhere will
cause this test to fail.
• Connect ac power if ventilator is
running on battery power and ac
is not connected.
• M ake sure green BPS ready
indicator is lit on GUI LED panel.
• M ake sure air and oxygen are
connected.
• Remove inspiratory filter and
connect gold standard circuit as
directed.

Flow Sensors Cross Controla los sensores de flujo de aire y oxígeno contra • Leaks or occlusions in the
Check Test el sensor de flujo de exhalación en cinco flujos de gas expiratory filter or elsewhere will
diferentes. Verifica que la corriente de comando del cause this test to fail.
solenoide proporcional (PSOL) esté dentro del rango • Low source gas pressures may also
para cada flujo de prueba. Realiza aire / O 2 Calibración cause this test to fail.
de corriente de despegue PSOL. • Exhalation flow sensor has
separate air and O2 calibration
tables. During EST, the system
uses the calibration table(s)
appropriate for the source gas(es)
used during EST.

Gas Supply/ SV Test
Tests air and oxygen pressure switch gross functionality, • Leaks or occlusions will cause this
tests PSOL forward leak, tests safety valve cracking test to fail.
pressure, and tests flow sensor zero offsets. • Block and unblock To patient port
as directed.
• Disconnect and reconnect air and
oxygen as directed.

SM Leak Test Checks for system leaks by pressurizing the system and • Leaks or occlusions in the
verifying that pressure drops by no more than 5 cmH2O expiratory filter or elsewhere will
in 10 s. cause this test to fail.

GUI Keyboard Test Verifies that GUI keys are functioning by prompting the Press keys within 15 s when
operator to press a key. prompted.

GUI Knob Test Verifies GUI knob rotation direction by prompting the Turn GUI knob as prompted, within
operator to rotate the knob in one direction, then the 15 s.
other.

GUI Lamp Test Verifies that GUI LEDs are functioning by prompting the Observe GUI indicators and press
operator to acknowledge that the LEDs are turned on. ACCEPT (if on) or CLEAR (if not on).

BDU Lamp Test Verifies that BDU lights are functioning. Observe BDU indicators and press
ACCEPT (if on) or CLEAR (if not on).

NOTE:
The ventilator inoperative and safety valve open
LEDs on the GUI are hard-wired to the BDU and
are considered BDU LEDs.

GUI Audio Test Verifies that GUI audio is functioning by prompting the Listen for GUI audio. Press ACCEPT (if
operator to listen for the alarm sound. on) or CLEAR (if not on).

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3 Self tests

Table 3-10: EST t ests (continued)

Test st ep Funct ion Comment s

GUI Nurse Call Verifies that nurse’s call relay is functioning. If not testing nurse’s call, press
CLEAR. If testing nurse’s call, press
ACCEPT, then verify nurse’s call
operation as prompted.

BDU Audio Test Verifies that BDU audio is functioning. Also verifies that Listen for BDU audio alarm.
power fail capacitor can operate loss-of-power alarm for
at least 2 minutes.

PSOL Loopback Test Checks PSOL loopback and command currents at three
different points by comparing the difference between
the two currents with the maximum allowable
difference.

Safety System Test Tests safety valve and inspiratory check valve operation
by checking for occlusions when the safety valve is open,
checking safety valve loopback current, and checking
inspiratory check valve reverse flow.

Exp Valve Loopback Test Checks exhalation valve loopback and command current
at three different points by comparing the difference
between the two currents with the maximum allowable
difference.

Exp Valve Pressure Verifies that exhalation valve seal and poppet friction are
Accuracy Test acceptable.

Exp Valve Test Verifies that current versus pressure values in flash
memory correspond with actual installed exhalation
valve.

EV Velocity Transducer Checks that the velocity transducer is sending a signal

Test and that the control circuit recognizes the signal. It does
not verify the quality of the signal.

Exp Heater Test Verifies that gas flow temperature increases and
decreases in response to commanding the heater on and
off.

Compressor Test Tests compressor operation. This test checks the timer, • If wall air is connected, disconnect
compressor pressure switch, and compressor operating wall air as directed.
states (run, standby, and disabled). • If ac is not connected, connect ac
power as directed.

Compressor Load Test Tests compressor operation. This test checks the
compressor’s ability to maintain sufficient air pressure
during worst-case breath delivery (200 lpm).

Compressor Leak Test Verifies that a fully charged compressor (if installed) does • Disconnect and connect wall air as
not leak enough to cause the compressor to turn on directed.
within 1 minute while in standby mode with wall air • Test takes 1 minutes to complete.
connected.

Analog Data Display Reads and displays analog data channels in engineering O2 sensor data is displayed in DAC
units. counts.

GUI Touch Test Checks for GUI touch screen errors.

GUI Serial Port Test Verifies that GUI serial port can send and receive data.

Battery Test With ac disconnected, tests BPS under discharging and Test takes 5 minutes to complete.
charging conditions.

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Table 3-11: EST individual test result s

If t he t est result
It means: Do this:
is:

Passed No faults found. Nothing, unless prompted by the ventilator.

ALERT Test results not ideal, but not
critical. EST halts.
Repeat t est by touching REPEAT.
Skip t o next t est by touching NEXT.
Repeat EST from the beginning by touching RESTART EST.
Exit EST in order to service ventilator or review error codes by
touching EXIT EST.

FAILURE A critical problem has been
detected, and EST cannot
complete until the ventilator passes
the failed test.
Repita la prueba fallida tocando REPEAT.Skip para la
siguiente prueba tocando NEXT.Repita EST desde el
principio tocando RESTART EST. Salga de EST para reparar
el ventilador o revisar los códigos de error por
tocando EXITEST.

Table 3-12: Overall EST outcomes

If t he EST
It means: Do t his:
out come is:

Passed All tests passed. Touch EXIT EST.

ALERT One or more faults were detected. Repeat EST from t he beginning by touching RESTART EST.
Override t he alert in order to service ventilator or review error
codes by touching OVERRIDE, followed by EXIT EST.

NOTE:
Although you can override an alert in EST, normal
ventilation is not allowed until the problem is corrected
and all EST tests passed.

FAILURE One or more critical faults were Repeat EST from t he beginning by touching RESTART EST.
detected. A ventilator inoperative Exit EST in order to service ventilator or review error codes by
condition is declared. touching EXIT EST.

OVERRIDDEN An ALERT status was overridden. Touch EXIT EST.

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Thi s page i ntentionall y blank.

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 SECTION
S EC T I O N

Service mode 4 4
The 840 Ven til ator System operates in two m odes: pati ent ventil ation and service m ode. The
service m ode i s i ntended for use by a trai ned service techn ici an to aid in ven til ator testing
and troublesh ootin g an d to perform system cal ibrations.
This section detai ls th e service m ode, includin g prom pts an d expected system responses.

Warning
Do not enter the service mode while a patient or other person is connected to the ventilator.
To do so may cause patient injury or death. Normal ventilator operation is not accessible
while in the service mode.

4.1 Accessing service mode

Access service m ode as fol lows:
1 En sure a patient i s not attached to venti lator an d th at the pati ent circuit i s disconn ected.
2 Turn on power to ven tilator. (If power i s already on, turn it off, then back on .)
3 W h ile audi ble al arm briefly ceases and BDU venti lator in operati ve indicator i s li t, press
TEST key with in one second. (The TEST key is located on the l eft side of the BDU above
the GUI cabl e con necti on .)
The ventil ator autom atical ly enters the servi ce mode (see Fi gure 4-1). Do not hold TEST
button in while entering service mode.
4 At th e Servi ce M ode screen, touch the desired selecti on, th en fol low on-screen prom pts.

NOTE:
During service mode startup, certain functions may automatically execute to
program data into BDU and/ or GUI NOVRAM . Refer to Section 4.2.16 for details.
While in the Service Mode, normal ventilation is not allowed.

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4 Service mode

Figure 4-1. SERVICE MODE screens

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Service mode 4
4.2 Service mode funct ions
Table 4-1 sum m arizes the ven tilator’s servi ce m ode functions. Fi gure 4-2 shows h ow to
n avi gate amon g th e functi on s.
It is im portant to al ways run th e fi rst four EST tests before perform ing any ventil ator sen sor
cali brati ons. Al l system l eaks m ust be el im inated before proceedi ng wi th any cal ibrati on s.

Table 4-1: Service mode funct ions

Funct ion Purpose

Upper screen

SST RESULT Displays the latest SST test results, including test name, date and time
each test was last run, individual test results, and overall test outcome.

NOTE:
When reviewing SST results, be aware that not all of the results
for each SST test may be from the same date and time run.

DIAG LOG Displays the contents of System Diagnostic Log, System Information
Log, and EST/ SST Diagnostic Log.

Alarm log Displays the history of most recent ventilator alarms for the previous
patient.

NOTE:
Running EST or selecting New Patient will erase this log.

VENT CONFIG Displays software revisions and serial numbers. Software revisions
displayed include: GUI and BDU boot PROM and application software
as well as GUI audible alarm subsystem (SAAS). Serial numbers
displayed are for BDU, GUI, and compressor unit (if installed); these
serial numbers are read from the data key and compressor (if
installed).

OPERATION TIM E Displays accumulated ventilator and compressor operational time, in

hours.

TEST SUM M ARY Displays the latest EST and SST test results, including date and time
each was last run and overall test outcome.

Low er screen

EST Displays the details of the last EST run. Runs EST to thoroughly test the
operational integrity of the ventilator, both electronics and
pneumatics.

DATE/ TIM E Adjusts current date and time.

EXIT Exits service mode.

Ot her Screens Performs miscellaneous service, test, and calibration functions.

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SST VENT OPERATION TEST

RESULT DIAG LOG Alarm log CONFIG TIM E SUM M ARY

Software Ventilator hours EST and SST

revisions Compressor test outcomes
Service mode
Serial numbers hours
test outcomes
System System EST/ SST
Diagnostic Information Diagnostic
Log Log Log

UPPER SCREEN

Other
EST DATE/ TIM E EXIT Screens

At mospheric Serial
Service External Exp Valve Vent Inop Flow Sensor Pressure Datakey Loopback
M ode Setup Test Control Calibration Test Calibration Transducer Update Test
Calibration (10.4 GUI only)

Nominal External Pressure

Line Voltage Control Unit
Baud Rate

8-00210

LOWER SCREEN

Figure 4-2. Service mode functions

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Service mode 4
4.2.1 SST RESULT: Displaying SST result s
This functi on lets you read the l atest SST test resul ts, includin g: test nam e, date an d ti m e each
test w as last run, i ndi vidual test results, an d overal l test outcom e.

NOTE:
SST lets you exit and resume patient ventilation if required. Thus, the results shown are not
necessarily all from the same SST run. If a partial SST run is performed, the results of the first few
tests might be more recent than the results of later tests.

4.2.2 DIAG LOG: Displaying error and stat us logs

NOTE:
System Diagnostic Information and EST/ SST Diagnostic logs can only be erased by
using the 840 VTS Breath Labs Software. The alarm log is automatically erased
each time a new patient is setup is selected and when EST is run.

This functi on lets you read the contents of th e venti lator’s error and status logs. The l ogs are
as fol lows:
• The Syst em D ia gn ost ic Log stores data on unexpected conditions detected duri ng POST,
backgroun d checks. This in cl udes alerts an d fai lures.
• The Syst em In form a t io n Lo g (Fi gure 4-3) stores data on venti lator even ts, in cludin g
detail s on GUI/ BDU com m un icati on .
• The EST/ SST D ia gn o stic Lo g (Figure 4-4) stores data on overall test outcomes and even ts
durin g SST an d EST.

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03

03

03

03

03

03

03

Figure 4-3. System Information Log

03

03

03

03

03

03

Figure 4-4. EST/ SST Diagnostic Log

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4.2.3 Alarm log: Displaying t he alarm history
This functi on l ets you read the history of th e m ost recen t venti lator al arm events. Thi s
i ncludes such i nform ati on as autoreset, user reset, alarm si lence, and chan ges in urgency. Th e
alarm log is autom ati cal ly cl eared when a new patient setup i s com pl eted. W hen you exit th e
service m ode to start ventil ation, a new pati ent setup is required.
See Section 7 to in terpret the events in the alarm l og.

4.2.4 VENT CONFIG: Displaying soft ware revisions and serial numbers
This functi on di spl ays software revisions an d seri al num bers. Software revisions di spl ayed
i nclude: GUI an d BDU boot PROM an d applicati on software as well as GUI audible al arm
subsystem (SAAS). Serial num bers di splayed are for BDU, GUI, and com pressor unit (if
i nstalled); these serial numbers are read from the data key.

4.2.5 OPERATION TIM E: Displaying vent ilat or and compressor elapsed hours
This functi on displ ays accum ul ated venti lator and com pressor operati onal tim e, i n hours.
This h el ps determ i ne wh en preventive m ai ntenance is needed.

4.2.6 TEST SUM M ARY: Displaying results from EST and SST
This functi on displays the latest EST and SST overall test outcom es, includin g date and tim e
each was l ast run.

4.2.7 EST: Ext ended self t est

This functi on lets you run the ful l EST. It shows detai ls of th e l ast execution of each
i ndivi dual EST test. For detai ls on the EST functi on an d other venti lator testin g, refer to
Section 3.

NOTE:
The performance verification, described in Section 5 of this manual, is a more
thorough test of the ventilator to verify it meets specifications.

4.2.8 DATE/ TIM E: Adjusting date and time

This functi on l ets you adjust the current date an d ti m e. Any ch ange i s recorded i n the
i nform ation and di agnostic logs.

4.2.9 EXIT: Exit ing service mode

This functi on l ets you exi t th e service m ode.

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4.2.10 Ot her screens

This functi on (Table 4-2) l ets you perform m iscel laneous servi ce, test, and calibrati on
function s. Tabl e 5-2 tells you when and in what order to perform these fun ctions.

Table 4-2: Ot her screens

Funct ion Purpose

Serial Loopback Test (10.4-inch Tests the serial communication ports on the 10.4-inch GUI.
GUI only)

Dat akey Updat e Transfers the operational hours from the ventilator to the new
datakey. For use after software options have been installed.

Service M ode Set up Lets you adjust nominal line voltage lower limit, baud rate for RS-232
port, and lets you choose the unit for display of pressures (cmH2O or
hPa).

Ext ernal Test Cont rol Lets you test the ventilator using a computer, 840 VTS Breath Labs
Software, and PTS 2000 tester, to run performance verification. Also
used to download new application software to the 840.

Exp Valve Calibrat ion Performs calibration. For use after a new exhalation valve, AI PCB, or
BDU CPU PCB is installed, or as part of the performance verification.

Vent Inop Test Exercises ventilator inoperative circuitry during five test phases.

Flow Sensor Calibrat ion Performs calibration. For use after a flow sensor replacement or as part
of the performance verification.

At mospheric Pressure Performs calibration. For use after an Inspiratory or Expiratory

Transducer Electronics PCB replacement, new vent installation, if the vent has
been moved ± 1000 feet in elevation, or as part of the performance
verification.

4.2.11 Service M ode Setup

This functi on l ets you adjust the settings in dicated in Tabl e 4-3.

Table 4-3: Service M ode Setup

Funct ion Purpose

Nominal Line Volt age Nominal line voltage lower limit. This setting is used to detect low
power alarm conditions. It has no direct effect on power supply
function. Improper line voltage settings will cause a Device Alert,
preventing normal operation.

Ext ernal Cont rol Baud Rat e For GUI RS-232 port. The baud rate takes effect when you restart the
ventilator in the service mode.

Pressure Unit Unit for display of pressures (cmH2O or hPa).

4.2.12 Ext ernal Test Cont rol: Performing remot e vent ilat or t esting
This functi on l ets you test th e ven tilator usin g a computer to conduct the ventilator
perform ance verifi cati on . Refer to Secti on 5 for detail s. W hen the Extern al Text Control m ode
i s active, press the Other Screen s button or power th e venti lator off then on to exit the
function .

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4.2.13 Exp Valve Calibration

NOTE:
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in service mode before performing this calibration, to
ensure a successful calibration.
• Ensure that the ventilator has passed the Leak Test in EST prior to performing this
calibration.

This functi on builds the exhal ation valve cali bration table. This table l ists exhal ati on valve
DAC comm ands versus exh alati on pressure. The exh alation val ve cal ibrati on requires a gol d
standard test ci rcuit and l asts approxi mately 3 m in utes.
If th e cali bration fail s, try rerunn in g i t. If it conti nues to fail , refer to Table 4-4 to troublesh oot
any errors. Run EST to assist i n troubl eshooting.

NOTE:
A system leak is a common source of failure, particularly expiratory filter leaks.
Make sure the expiratory filter collector vial is secured tightly, the drain port is
capped, and the filter is mounted securely to the ventilator. M ake sure the test
circuit is securely attached.

4.2.13.1 Running Exp Valve Calibrat ion

1 M ake sure pati ent is n ot con nected to th e venti lator.
2 En ter servi ce m ode and sel ect the Oth er Screen s button.
3 En sure ai r and oxygen are conn ected to th e venti lator.
4 Con nect the gol d stan dard circuit between the To Patient an d From Patien t ports. (Do
not use a patient fil ter.)
5 On th e lower screen, select th e Exp Valve Cali bration button .
6 Press the Start button.
7 Press Accept.
The ventil ator autom atical ly starts the cali bration. W hen th e cali brati on i s com pl ete, press
the Oth er Screen s button again to return to the Other Screen s m enu.

Table 4-4: Exhalat ion valve calibrat ion errors

M essage displayed Error t ype Addit ional informat ion

ac power not connected Failure Verify ac power is connected.

Bad exp valve loopback current Failure Exhalation valve and/ or analog interface PCB
may be out of specification. Try cleaning the
exhalation valve if inspection warrants and re-
run the calibration.

Both insp and exp autozero failed Failure Analog Interface PCB may be out of
specification.

Calibration failed: current limit exceeded Failure Exhalation valve and/ or analog interface PCB
may be out of specification.

Calibration failed: gain resolution Failure Exhalation valve and/ or analog interface PCB
may be out of specification.

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4 Service mode
Table 4-4: Exhalat ion valve calibrat ion errors (continued)
M essage displayed
Calibration failed: Pressure build time-
out.
Exhalation pressure transducer autozero
failed
Exhalation valve temperature out of
range
Flow sensor cross-check: unable to
establish flow
Flow sensor cross-check failed
Flow sensor info invalid
Inspiration autozero failed
No air connected
Pressure sensor cross-check: unable to
build pressure
Pressure sensor cross-check alert:
approaching spec limit
Pressure sensor cross-check failed
Unable to establish flow
Unable to program flash
4-10 4-070496-00 Rev. A (08/ 03)
Error t ype Addit ional informat ion
Failure Verify that gold standard circuit is still
connected and expiratory filter is locked in
place. Verify that seal is placed over collector
vial drain and vial is securely fastened to
expiratory filter.
Failure Exhalation pressure transducer DAC count at
0 cmH2O is out of range.
Failure Exhalation valve temperature out of range.
Failure Flow controller is not able to establish a 5 L/ min
test flow via the air flow sensor.
Failure Exhalation air flow is out of range with respect
to the 5 L/ min inspiration-controlled test flow.
Verify gold circuit is connected. Check for
expiratory filter leaks.
Failure Flow sensor calibration table checksum error
occurred.
Failure Inspiration pressure transducer DAC count at
0 cmH2O is out of range.
Failure Wall and compressor air pressure switches
detect no air connected. Verify air is connected.
Failure Pressurization algorithm is unable to pressurize
system to one or more of five test pressures via
the inspiration pressure transducer. Check for
expiratory filter leaks.
Alert Pressure cross-check alert occurred at one or
more of five test pressures, no cross-check
failures occurred.
Failure Pressure transducer cross-check failed at one or
more of these five test pressures (5, 25, 50, 75,
and 100 cmH2O).
Failure Flow controller is not able to establish a 5 L/ min
test flow via the exhalation flow sensor.
Failure Unable to program calibration table into BDU
NOVRAM. Check BDU +12 V supply and BDU
CPU PCB.
840 Ventilator System Service Manual
Service mode 4
4.2.14 Vent Inop Test
This functi on exerci ses th e ven tilator i noperative circuitry.

4.2.14.1 Running t he Vent Inop Test

1 En ter Servi ce M ode and select the Other Screens button.
2 En sure ai r and oxygen are conn ected to th e venti lator.
3 Con nect the gol d stan dard circuit between the To Patient an d From Patien t ports.
4 Sel ect the Vent Inop Test button an d press Accept.
5 The Ven t In op Test i s com posed of th e phases i ndi cated i n Table 4-5. At th e end of each
test phase, turn th e ven tilator power off, then on and restart Servi ce M ode as i nstructed.
Observe the audio and visual alarm s an d respond as prom pted.

Table 4-5: Vent Inop Test phases

Test phase Vent inop indicators t ested

GUI Vent Inop test 1. BDU alarm on (user prompt).

2. Ventilator inoperative and safety valve open
LEDs on (user prompt).
3. PSOLs/ exhalation valve/ safety valve inactive.

Vent Inop A test PSOLs/ exhalation valve/ safety valve inactive.

Vent Inop B test PSOLs/ exhalation valve/ safety valve inactive.

Vent Inop A ten second test PSOLs/ exhalation valve/ safety valve inactive.

Vent Inop B ten second test PSOLs/ exhalation valve/ safety valve inactive.

If a test ph ase fai ls (“ Ven t Inop Test fai led” message i n lower screen ), poweri ng the venti lator
dow n and back up into servi ce m ode wi ll in voke the n orm al service m ode. Troubl eshoot as
i ndicated in Table 4-6. You m ust repeat the Vent In op Test and pass it wi th no fail ures before
ven tilation is al lowed.

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4 Service mode

Table 4-6: Vent Inop Test t roubleshooting

Test phase Type of failure Correct ive act ion

GUI vent inop test phase BDU alarm (alone) Check BDU alarm or AI PCB.

Ventilator inoperative or SVO LED Check appropriate BDU or GUI LED

failure (alone) panel, BD CPU PCB, BDU-GUI cable, or
GUI CPU PCB.

NOTE:
The BD CPU PCB controls the
ventilator inoperative and safety
valve open LEDs on both the
BDU and GUI CPU PCBs,
sending the two LED signals to
the GUI via the BDU-GUI cable.

BDU alarm and ventilator inoperative Check BDU-GUI cable, BD CPU PCB, or
and safety valve open LEDs GUI CPU PCB.

PSOLs/ exhalation valve/ safety valve Check BD CPU PCB or AI PCB. If alarm
inactive and/ or LED failure occurred also, check
BDU-GUI cable, GUI CPU.

Any other test phase Any Check BD CPU PCB or AI PCB.

4.2.14.2 Flow Sensor Calibrat ion

NOTE:
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in service mode before performing this calibration, to
ensure a successful calibration.
• It is very important that the ventilator passes the leak test during EST prior to running a
flow sensor calibration.
• A system leak is a common source of failure, particularly expiratory filter leaks. Make sure
the expiratory filter collector vial is secured tightly, the drain port is capped, and the filter
is mounted securely to the ventilator. Make sure the test circuit is securely attached.
• Use both air and oxygen gas sources to run Flow Sensor calibration.

This fun cti on buil ds a tabl e of exh alati on flow sensor (Q3) offsets. Th e flow sensor cali bration
requires a gold stan dard test circuit.
If th e cali bration fai ls, make sure that the test ci rcui t is attach ed and th at th e expiratory fi lter
i s securel y connected and free of l eaks, th en try rerun ni ng it. If the cali bration conti nues to
fai l, refer to Table 4-7 to troubleshoot an y errors.

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Service mode 4
4.2.15 Running Flow Sensor Calibration
1 Enter Service M ode.
2 En sure both air an d oxygen are con n ected to the ventil ator.
3 Con nect the gol d stan dard circuit between the To Patient an d From Patien t ports.
4 En sure that there are n o leaks or occl usions by run ning EST and ensure th at th e
venti lator passes the EST Leak Test. Once thi s test has passed, exi t EST.
5 Sel ect the Other Screens button .
6 Sel ect Flow Sen sor Cal ibrati on .
7 Press the Start button and press Accept.
The ventil ator autom atical ly starts the cali bration. W hen th e cali brati on i s com pl ete, press
the Oth er Screen s button again to return to the Other Screen s m enu.

Table 4-7: Flow sensor calibrat ion errors

M essage displayed Error t ype Addit ional informat ion

ac power not connected Failure Verify ac power is connected.

Air offset out of range Failure 1. Replace air flow sensor (Q2).
2. Replace exhalation flow sensor (Q3).
3. Replace AI PCB.

Cannot achieve minimum air flow Failure System cannot sustain a minimum 60 L/ min flow. Check
air supply pressure and REG2.

Cannot achieve minimum O2 flow Failure System cannot sustain a minimum 60 L/ min flow. Check
oxygen supply pressure and REG1.

No air connected Failure Wall air pressure switch (PS2) detects no air connected.
Verify air is connected.

No O2 connected Failure Oxygen pressure switch (PS1) detects no oxygen

connected. Verify oxygen is connected.

O2 offset out of range Failure 1. Replace oxygen flow sensor (Q1).

2. Replace exhalation flow sensor (Q3).
3. Replace AI PCB.

4.2.15.1 At mospheric Pressure Transducer

NOTE:
When calibrating the atmospheric pressure transducer, make sure that the
pressure in the room is stable and not subject to pressure changes caused by door
closures, heavy foot traffic, or the startup of an air conditioning system. Any such
environmental changes will result in an incorrect adjustment being made to the
ventilator.

This functi on cali brates the atmospheric pressure tran sducer usi ng an external barom eter.
Refer to Table 1-5 for barom eter accuracy speci ficati ons.
Allow the barom etri c pressure readi ng to stabil ize, then in put th e pressure (in m m Hg)
m easured by th is external barometer, as prom pted.
(1 m m Hg = 1.333 m bars = 133.33 Pa = 0.019 psia.)

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4 Service mode

If th e cali bration fai ls, try rerun nin g it, m akin g sure you correctly in put th e barom etri c
pressure. If the cal ibrati on contin ues to fail , try rerun nin g EST, then repl aci ng th e i nspiratory
pressure tran sducer autozero solenoi d (SOL1) an d th en the inspiratory el ectron ics PCB.

4.2.16 Aut omat ically executed service mode functions

Before allowi ng venti lati on , th e ven ti lator m ust h ave vali d seri al num bers, flow sensor
cali bration data, and exhalation valve cali bration data i n BDU and GUI NOVRAM . If the
venti lator determ i nes th at thi s data i s n ot avai labl e, i t invokes certain functions as required to
copy thi s data into th e appropriate CPU’s N OVRAM . These fun ctions are described below.

4.2.16.1 Init ialize Flow Sensor

This fun ction copi es fl ow sen sor calibration data from each flow sen sor’s serial EEPROM to
BDU NOVRAM . It autom atical ly runs when th e flow sensor cali bration data i n BDU
NOVRAM does n ot m atch the correspon din g data i n th e seri al EEPROM of on e or m ore of th e
flow sen sors (for exam pl e, wh en BDU NOVRAM is cleared due to downl oadi ng of new
software or when a fl ow sensor i s changed). Thi s function is al ways followed by the Cal Info
Duplication fun cti on described below.
If th is fun ction fai ls, refer to Table 4-8 to troubl eshoot any errors.

Table 4-8: Init ialize Flow Sensor errors

M essage displayed Addit ional informat ion

Unable to read air flow sensor Error reading air flow sensor (Q2) serial EEPROM
data. Check Q2 and AI PCB.

Unable to read O2 flow sensor Error reading oxygen flow sensor (Q1) serial
EEPROM data. Check Q1 and AI PCB.

Unable to read the expiratory flow sensor Error reading exhalation flow sensor (Q3) serial
EEPROM data. Check Q3 and AI PCB.

Unable to program flash BDU NOVRAM cannot be successfully

programmed. Check BDU +12 V supply and BD
CPU PCB.

4.2.16.2 Cal Info Duplicat ion

This fun ction copies flow sensor and exhalati on valve cali bration data from BDU NOVRAM
to GUI NOVRAM . It autom ati call y runs whenever cali bration data in GUI NOVRAM i s i nvalid
or does n ot m atch the corresponding data in BDU NOVRAM (for exam ple, after flow sen sor
i nitiali zation or after exhal ation valve calibrati on).
If th is fun ction fai ls, refer to Table 4-9 to troubl eshoot any errors.

Table 4-9: Cal Info Duplicat ion errors

M essage displayed Addit ional informat ion

Unable to receive flash data GUI did not receive all calibration data from BDU
within 10 s. Check BDU/ GUI cable, BD CPU PCB, or
GUI CPU PCB.

Unable to burn flash GUI NOVRAM cannot be successfully

programmed. Check GUI CPU PCB.

4-14 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Service mode 4
4.2.17 Serial num ber setup
This functi on copies the seri al num bers on the data key i nto NOVRAM . This copy operation
i s perform ed on ly if BDU or GUI NOVRAM con tain s a default seri al n um ber (for exam pl e,
after th e BDU an d/ or GUI CPU PCB i s replaced or after n ew softw are is dow nloaded).

4.2.17.1 Running Serial Number Set up

1 En ter servi ce m ode foll owi ng CPU PCB replacement or softw are down load.
2 Serial num ber setup autom ati call y starts.
3 Foll ow on-screen prom pts. If thi s function fails, refer to Table 4-10 to troubl eshoot an y
errors.

NOTE:
• You are given the option to “ Proceed without setting serial number.” You may want to
use this option for troubleshooting purposes. For example, if a new BDU or GUI CPU PCB
is inserted temporarily for testing, you may find it useful to maintain the default serial
number on that PCB; otherwise, by setting the serial number the test CPU PCB will
become “ committed” to the ventilator used to initialize it. If you choose not to initialize
the serial numbers, be aware that ventilation is not allowed until serial numbers are
copied from the data key.
• It is possible to have one CPU with a valid serial number in NOVRAM but the other CPU
containing the default serial number. For example, when the BDU only is downloaded
with new software, the BDU serial number in NOVRAM is set to the default, but the GUI
serial number in NOVRAM is unaffected.
• Do not use the same data key to initialize the serial numbers in more than one ventilator.

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4 Service mode

Table 4-10: Serial number setup errors

M essage displayed Addit ional inform at ion

Cannot program flash BDU and/ or GUI NOVRAM cannot be successfully

programmed. Check BDU and GUI +12 V supplies, BD
CPU PCB, and GUI CPU PCB.

Data key is not installed
If a data key is installed but not being detected, try
inserting the key into a known good ventilator whose
serial numbers have already been initialized. Then
power the ventilator up into service mode and verify
that the ventilator sees an invalid data key (that is, the
message “ Serial number(s) doesn’t match the data key”
is displayed). If the data key is still not detected, replace
it; otherwise, replace the AI PCB. Alternatively, try using
a known good data key in the suspect ventilator and
verify that it is detected.

NOTE:
If no data key is inserted, you can proceed with
service mode but ventilation is not allowed.

Serial number(s) doesn’t match the data key Press ACCEPT to confirm and proceed with service
mode.

NOTE:
If an invalid data key is inserted, you can proceed
with service mode but ventilation is not allowed.

4.2.18 Datakey Updat e

A new datakey i s supplied when software options are added to the ven til ator. Thi s datakey
m ust be updated with th e correct venti lator operational h ours after the software contai nin g
the options h as been downloaded, seri al n um ber setup is com plete, an d all cali brations
perform ed.

NOTE:
If the datakey is updated before calibrations have been run, the operational hours
will be lost or become corrupted.

Running Datakey Updat e

1 Enter Service M ode.
2 Press the Oth er Screen s button.
3 Press the Datakey Update button.
4 Fol low the prom pts.
5 W h en you have com pl eted th e update, exit Service M ode an d ch eck th e operati on al
hours by pressi ng th e Other Screens button, then th e Operational Tim e Log button. The
correct operational hours shoul d be displayed.
If th e wron g operati on al hours are displ ayed, refer to Table 4-11 to correct the probl em .

4-16 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Service mode 4

Table 4-11: Dat akey updat e error

Problem Addit ional Informat ion

Invalid value displayed when operational hours are Proceed as follows:

accessed. 1. Reinstall original datakey.
2. Reinstall ventilator software to erase NOVRAM .
3. Accept serial number and verify correct hours.
4. If correct, repeat the datakey update.
5. If problem persists, you must obtain a duplicate
datakey containing the correct serial numbers
and software options from your Puritan Bennett
representative.

4.2.19 Serial Loopback Test

On the 10.4-in ch GUI on ly, use the Serial Loopback Test to check the functi on of th e serial
ports on the back of the GUI.
Required Equipment : Nul l modem cable (p/ n 4-075361-00) or equival en t.
Running t he Serial Loopback Test
1 Enter Service M ode.
2 Sel ect the Other Screens button .
3 Sel ect the Serial Loopback Test button.
4 Fol low th e on-screen prompts. If thi s functi on fails, refer to Tabl e 4-12 to troublesh oot
an y errors.

Table 4-12: Serial Loopback Test error

Problem Addit ional Informat ion

Serial Loopback Test failed 1. Check null modem test cable.

2. Replace Serial Port Flex Circuit.
3. Replace GUI CPU PCB.

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4 Service mode

Thi s page i ntentionall y blank.

4-18 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
 SECTION
S EC T I O N

Performance verification 5 5
Conduct th e perform ance verifi cation to ch eck the perform an ce of th e 840 Ventil ator
System. Field performance veri fication testing i ncl udes electri cal safety tests, the extended
self test (EST), plus speci fic perform ance veri fication tests, using the Puritan Bennett PTS2000
Perform ance Test System with 840 VTSsoftware. A m anual ventilator check can be perform ed
to check gen eral ven til ator perform an ce.

NOTE:
Performance verification procedures do not apply to ventilator accessories. Refer
to the specific accessory operator’s or service manual for performance verification
information. Malfunctioning accessories may affect some ventilator functions and
may result in false test results.

5.1 Tools, t est equipment , and service mat erials

In additi on to th e stan dard set of tool s listed in Section 1 of thi s manual, th e test
equipm ent and m aterials li sted i n Table 5-1 are requi red for perform an ce veri fi cati on
procedures. Speci fic parts required for conducti ng the perform an ce verifi cation,
usin g the PTS 2000 Perform an ce Test System wi th Breath Lab® 840 Ventil ator Test
Software (VTS), are i ndi cated with “ X” in th e th ird colum n.

5.2 When t o run

Run the en tire perform ance verification after servi ci ng or repairing th e venti lator. The left-
h an d col um n of Tabl e 5-2 li sts the types of servi ce activity that requi re performan ce
verifi cation. In addi tion, run the electrical safety tests, whi ch are part of the perform ance
verifi cation, in accordance wi th your hospi tal ’s requi rem ents.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 5-1
5 Performance verification

Table 5-1: Tools, equipment , and service mat erials required for
performance verificat ion

M anufact urer/ model or Required for

Descript ion Purit an Bennet t PTS 2000
part number use?

Pentium 166 Mhz computer, equipped, at a minimum, with the Local supplier X
following:
• 32 M B RAM (64 M B for NT systems)
• 800x600 screen display resolution with 256 colors
• Two available serial ports
• Windows® 95, 98, 2000, XP or NT 4.0 operating system
• Mouse or equivalent pointer device
• 2x or higher CD-ROM drive
• 1 Gigabyte available hard disk space
• One available TCP/ IP network port with BNC connector (if software
download desired)

840 VTS (Ventilator Test Software) 4-075359-00 and X

current revision Software
Download CD-ROM

EtherLink III 3C589C LAN PC card for 10BASE-T or later revision, or Software
equivalent card Download
only

EtherLink III 3C589C Combo Cable for EtherLink III PC Card or Software
equivalent Download
only

840 Software Download Cable (BNC to BNC) 4-075731 or Local Supplier Software
Download
only

840 Software Download Box 4-075497-00 Software

Download
only

Adapter, patient pressure (“ T” connector) *4-011521-00 X

Cable, trigger *4-075360-00 X

Cable, null modem *4-075361-00 X

Connector, barbed *4-000845-00 X

Coupling, barbed connector (quantity = 2) *4-003443-00 X

Digital multimeter (DMM ) accurate to 3 decimal places, with test Fluke Model 87 or equivalent
leads

Disinfectant/ cleaner See Table 1-5 for acceptable

products.

Double banana jack for ground isolation test Pomona Electronics,

P/ N 1330-2

* Th ese parts m ay be purch ased in dividually or by orderin g an 840 VTS Accessories Kit, P/N 4-076599-00.

5-2 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Performance verification 5
Table 5-1: Tools, equipment, and service materials required for
performance verificat ion (cont inued)

M anufact urer/ model or Required for

Descript ion Purit an Bennett PTS 2000
part number use?

Electrical safety analyzer capable of measuring ground resistance and Dale Model 600, Dale
leakage current Technology Inc., P.O. Box 196,
401 Claremont Ave.,
Thornwood, NY 10594 USA,
800.544.3253
http:/ / www.daletech.com/
or equivalent

Exhalation port text hose assembly *4-076704-00 X

Filter, inspiratory, Re/ Flex (for use on PTS 2000 port) 4-074600-00 X

Finger cots or gloves Local supplier

Fitting, Luer, bulkhead *4-012470-00

Gold standard tube [flex tube, 21.0 in. (53.4 cm)] (quantity = 2) *4-018506-00 X

Hose, regulator calibration *4-079050-00 (quick X

disconnect) (4-079050-00
4-079051-00 (female) only)

Luer fitting, female Local supplier X

Patient circuit, adult (reusable, without water traps or heated wire) *N-4401008 X
(quantity = 2)

Patient circuit, pediatric (reusable, without traps or heated wire) G-061223-00

Patient circuit, neonatal (disposable) Allegiance Healthcare

PN 7441-452

Mounting plate, NeoMode 4-076405-00

Filter, expiratory bacteria filter DAR 351P19005

Filter, expiratory bacteria filter, reusable (Re/ X800) 4-070305-00 X

Pneumatic calibration analyzer or equivalent devices capable of Puritan Bennett PTS 2000 X
measuring oxygen percent, flow, BTPS volume, pressure, and Performance Test System (also requires
barometric pressure. Oxygen analyzer connector tee. Required (4-074686-00) (includes 840 VTS
accuracies: accessory kit with serial cable) software)
• Flow: 2.75% of reading ±0.05 slpm for performance verification; or
• Volume: 2% of reading or ±1 digit equivalent device for manual
• Low pressure (-150 to +150 cmH2O): 0.75% of reading ±0.04 ventilator check
cmH2O
• High pressure (0 to 150 psig): 1.0% of reading ±0.1 psi
• Oxygen percentage: ±2% oxygen
• Barometric pressure: Range: 10 to 16 psia; resolution: 0.0 to 1 psia;
operating temperature: 10 to 40 °C; measurement accuracy: ±0.75
of reading; response: ≤ 100 ms

Serial Card, Socket I/ O Ruggedized or equivalent (Provides second Socket Communications Corp.
serial port) Newark, CA
http:/ / www.socketcom.com/

* Th ese parts m ay be purchased in dividually or by orderin g an 840 VTS Accessories Kit, P/ N 4-076599-00.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 5-3

5 Performance verification

Table 5-1: Tools, equipment , and service mat erials required for
performance verificat ion (cont inued)

M anufact urer/ model or Required for

Descript ion Purit an Bennet t PTS 2000
part number use?

Resistor for ground isolation test, 1K ± 1% Allied Electronics,

P/ N 697-3356 or equivalent

Static-dissipative field service kit (includes wrist strap, static dissipative 4-018149-00
mat, and earth (ground) cord)

Stoppers, no. 1, 5, and 5.5 Local supplier X

(with center bore and luer fitting: 4-071856-00)

Stopper, no. 1 (quantity = 1) *4-009523-00

Stopper, no. 5 *4-076828-00 X

Stopper, no. 5.5 with center bore and 4-076467-00

Fitting, luer, bulkhead 4-012470-00

Test lung, 0.5 L 4-000612-00 X

Test lung, 3 L N-3800006 X

Test lung, 4 L 4-075578-00 X

Tubing, silicone, 3/ 16 in. ID x 5/ 16 in. OD, 36 in. (91.4 cm) 4-008577-00 X

Tubing, silicone, 1/ 8 in. ID x 1/ 4 in. OD, 4.75 in. (12.1 cm) *4-008578-00 X

Vacuum cleaner, ESD-safe, with 0.2 µm filter (rated for photocopiers Local supplier
and laser printers)

Wye, patient circuit *4-000338-00 X

* Th ese parts m ay be purch ased in dividually or by orderin g an 840 VTS Accessories Kit, P/N 4-076599-00.

5.3 Preliminary vent ilat or cleaning and inspect ion

Clean an d inspect th e ven tilator as fol lows:

Warning
To prevent disease transmission, use personal protective equipment when handling
contaminated bacterial filters or other patient accessories. Refer to the 840 Ventilator System
Operator’s and Technical Reference Manual for instructions on sterilizing patient system parts.

Caut ion
Do not soak any portion of the ventilator in solvent, alcohol, or any other cleaning agent.
Soaking ventilator components may damage the ventilator.

1 Clean ventil ator exterior using an approved cleaner/ di sin fectan t.

2 Rem ove any water from h um idi fier j ar and col lector vi al ; dry. Reattach coll ector vi al.
3 Inspect air an d extern al water trap assem blies. Cl ean or replace as requi red.
4 Visual ly in spect ven til ator exterior for obvi ous problem s such as m issin g or broken parts;
loose assem bl ies; or di scon nected w ires, con nectors, or tubi ng. Repai r as needed.

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Performance verification 5
5.4 Preliminary vent ilat or set up

NOTE:
A humidification device is not necessary for performance verification, but is
required for completion of SST.

Set up the ventilator for perform ance veri fi cation as follows:

1 Install expi ratory fi lter an d coll ector vial .
2 Con nect ventil ator to air an d oxygen sources (35 to 100 psi).
3 Con nect ventil ator power cord to ac power source.
4 M ake sure BPS i s securely attached an d connected.
5 If ven til ator is equi pped with optional com pressor, verify al l el ectri cal and pneum atic
conn ections w ith BDU.

5.5 Preliminary calibrat ions and t est s

Before runnin g th e perform an ce veri fi cation tests, perform th e appli cable cali brations an d
tests in Table 5-2. Th e num bers in th e colum ns in dicate th e sequence in wh ich the
cali brations/ tests m u st be perform ed.

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5 Performance verification

Table 5-2: Pre-performance verification testing and calibration requirement s

verificat ion t est ing (PVT)

Test or calibrat ion

Ext ended self test (EST)

t ransducer calibrat ion
At mospheric pressure

Oxygen sensor (OS)

Short self t est (SST)
Vent ilat or w arm-up

Expirat ory valve

Vent inop t est

Performance
Flow sensor
calibration

calibration

calibration
Download
Soft ware
cycle1
Type of service

Ventilator installation 1 -- 2 3 4 5 6 7 8 92

Software update or software 1 2 3 4 5 6 7 8 9 --3

option installation

10,000-hour preventive 1 -- 2 3 4 5 6 7 8 9
maintenance (ventilator or
compressor)

Oxygen sensor 2 1

PSOL1, PSOL2, flow sensors, 1 -- 2 3 4 5 6 7 8 9

expiratory valve, safety valve,
SOL1, SOL2, AI PCB, inspiratory
electronics PCB, exhalation
transducer PCB, regulators‘,
power supply, BPS PCB, battery
pack, alarms, motherboard, all
blindmate cables, BDU and GUI
LED PCBs, touchframe PCB, LCD
panels, backlight inverters,
keyboard, knob

Compressor 15,000 hour 1 24

preventative maintenance

Compressor, compressor PCB, -- -- -- -- -- 1 -- -- -- --

keyboard assembly, LED panel,
VGA controller PCB, backlight
inverter PCB

BD CPU PCB or GUI CPU PCB 1 2 3 4 5 6 7 8 9 10

replacement

6 month ventilator check 1 -- -- -- -- 2 -- -- -- --

Yearly ventilator check 1 -- 2 3 4 5 6 7 8 --

1. Warm-up m ust be done in the service mode.

2. Perform the electrical safety test only.
3. Performance verification testing (PVT) is not required for simple software updates, provided all of the following conditions exist:
The ventilator passes the Extended Self Test before the software is updated.
The reason for service is software update or software option installation only.
There are no events or entries in the ventilator’s diagnostic logs that indicate a need for hardware repair.
No functional hardware repairs are conducted or required during the software update service call.
Unless the ventilator meets all of these requirements, PVT must be performed following the repair.
4. Perform EST and electrical safety testing only.

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Performance verification 5
5.6 Performance verificat ion guidelines

NOTE:
To ensure that the ventilator performs within specifications, Puritan Bennett
recommends that you use the Puritan Bennett PTS2000 Performance Test System
in conjunction with the BreathLab 840 Verification Test Software. If this
equipment is not available, you can use an alternative test that checks some
parameters but does not guarantee the integrity of the entire system. Refer to
Table 5-3 to determine the approximate test limits if you use equipment other
than the PTS 2000 Performance Test System.

To en sure systematic performance verification and l ogical fault diagn osis, perform tests in the
order gi ven. Foll ow th ese general guideli nes when runni ng the perform ance verification:

Warning
Follow accepted safety procedures for electrical equipment when making connections,
adjustments, or repairs.

• If a probl em is encountered durin g the perform an ce veri fication, veri fy th at procedures

have been correctl y fol lowed before attem pti ng to repair th e venti lator.
• Do n ot chan ge the con trol setti ngs duri ng performance verificati on procedures, unl ess
specifical ly in structed.
• M alfuncti on s detected durin g perform ance verification must be corrected before the uni t
is return ed to service. Refer to Section 8 for required repairs. W h en repairs are completed,
repeat the perform ance veri fication tests.

5.7 Performance verificat ion t est s

Run th e followi ng perform ance veri ficati on tests in th e sequence given. Beforeperforming these
tests, be sure you have cleaned and inspected the ventilator (Section 5.3).

Warning
Do not enter the service mode while a patient or other person is connected to the ventilator.
To do so may cause patient injury or death. While in the service mode, normal ventilator
operation is not accessible.

NOTE:
The procedures that follow do not verify the performance of accessories. Verify the
performance of accessories using the appropriate procedures in the applicable
operator’s or service manual.

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5 Performance verification

5.7.1 Electrical safety t est

The el ectri cal safety test veri fies ground conti nui ty and veri fi es that forward l eakage curren t
are with in safe li mi ts. Perform th is test whenever the ventil ator i s serviced and i n accordance
with hospital requirem ents.

Warning
If the ventilator fails an electrical safety test, do not proceed to the next electrical safety test
until the problem is corrected and the ventilator is retested.

Caut ion
To prevent possible equipment damage, do not attempt to perform HI-POT testing on the
ventilator. The ventilator design incorporates high-voltage protective devices that may be
damaged if HI-POT testing is performed on the entire system. The ventilator is HI-POT-
tested during manufacturing, using processes that do not damage the protective devices.

NOTE:
• After servicing the ventilator, perform an electrical safety test before putting the
unit back into operation.
• Before performing the electrical safety test, make sure the compressor unit (if
installed) and all accessories are connected and operational.

1 Verify th at ventil ator pow er switch i s off.

2 Verify th at ground resi stan ce is < 0.1 Ω.
3 Turn on ven ti lator.
4 If ven ti lator h as a com pressor uni t i nstalled, disconnect external ai r supply from
venti lator and verify that pressure from hose has been rel ieved.
5 Verify th at com pressor unit (if appli cabl e) is runn in g. Fai lure to do so will produce an
inaccurate total leakage current reading.
6 Verify th at forward-curren t an d reverse-current l eakage to earth ground is ≤ 300 µA
(100 – 120 V ac) or ≤ 500 µA (220 – 240 V ac).
7 Turn off ventil ator.
8 Reattach external ai r suppl y, i f appli cable.

5.7.2 Ground isolat ion check

This check veri fies that the di gi tal ground has n ot been di srupted. It requi res a DM M , test
l eads, and a 1K resistor pl aced in parall el between the leads.
1 With th e ventilator power cord disconnected from ac an d the venti lator turn ed off:
a. Set the DM M to th e 1Ω setti ng and VERIFY that resi stan ce between pin 3 of PTS 2000
tester port (on the AI PCB) and ven ti lator ch assis (at the power supply cooli ng fin s)
is > 975Ω.
2 With th e ventilator power cord connected to ac and the ventilator turned on:
a. Set the DM M to the ac setting and veri fy the readin g i s < 100 mV ac.
b. Set the DM M to the dc setti ng and verify the readin g i s < 100 mV dc.
3 Turn th e venti lator off an d discon nect th e test leads.

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Performance verification 5
5.7.3 Ext ended self test (EST)

NOTE:
• A test (gold standard) patient circuit and a no. 1 stopper are required to perform EST.
• The nurse’s call circuit is tested during EST and may be bypassed by selecting the CLEAR
button.
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in service mode before running EST, to ensure accurate
testing.

1 Enter servi ce m ode. (Refer to Secti on 3.2 for in structi on s.)

2 On l ower screen, select EST, and foll ow prom pts to bei ng testin g.
The test currently runn in g i s highl ighted, an d any m easurem ent data is di spl ayed on th e
upper screen . (Thi s inform ation m ay also be vi ewed l ater by pressing th e indivi dual test
button to repopulate th e upper screen with th e data param eters.) All l ower and upper
screen sel ect buttons an d th e EST subscreen TEST SELECT button s are hidden. Th e date/
tim e an d outcome are sh own onl y for tests that have al ready run.

NOTE:
During testing, it is sometimes necessary for the user to perform test-related tasks,
such as disconnecting a gas supply or blocking the To Patient port. For each such
step, messages are displayed in the prompt area.

3 Verify that EST com pletes al l test with a PASS result. Perform ance verificati on i s not
com pl ete if any EST test results in an ALERT, OVERRIDE, or FAILURE. If a test fails, refer
to Secti on 8 for repair i nform ation .

5.7.4 Regulator set ting verification

Caution
To prevent damage to ESD-sensitive components, always follow ESD guidelines when
performing this procedure.

NOTE:
Regulator performance must be verified each time performance verification or a
manual ventilator check is performed. Use the appropriate type of regulator
calibration hose (see Table 5-1).

1 Rem ove i nspiratory cover from BDU.

2 Attach appropriate regulator cali bration hose to pneum atic an alyzer, and veri fy th at
an alyzer does not regi ster pressure.
3 Rem ove air si de test port cover an d set aside. Attach hose to test port. Verify that analyzer
reads 10.5 ± 1.5 psi.

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5 Performance verification

4 Rem ove h ose from test port, an d verify that anal yzer does n ot register pressure. Replace
test port cover.
5 Repeat steps 3 an d 4 for oxygen si de.

NOTE:
If regulators are out of specification, refer to Section 8 for service and repair of the
inspiratory module.

5.7.5 Serial loopback test (10.4-inch GUI only)

A seri al l oop back test can be accessed through the servi ce m ode oth er screen functi on . Th is
test i s on ly requi red when performi ng PVT on a 10.4-in ch GUI.
1 Connect a nul l m odem cabl e between the two top serial ports.
2 Fol low the on-screen test prom pts.

5.7.6 Per formance verification using PTS2000 Performance Test Syst em and
Breat hLab 840 VTS soft ware
1 Assem ble test equipm en t indi cated in Tabl e 5-1. (Software in stal lati on i nstructi ons are
provi ded with BreathLab 840 VTS Software.)
2 Turn on com puter, an d bri ng up th e VTS program .
3 Turn venti lator on , and bri ng up in service m ode.
4 Usin g venti lator test program , press START TEST to begin test appli cation.
5 Fol low prom pts di splayed on computer screen to com plete perform an ce veri ficati on .
Access th e 840 VTS Software Hel p Screen for addi tional in form ation.

5.7.7 M anual ventilat or check using equipment ot her t han PTS 2000
Perform ance Test System

NOTE:
• To ensure proper ventilator performance, Puritan Bennett recommends that you use the
Puritan Bennett PTS 2000 Performance Test System along with the BreathLab 840 VTS
software.
• If you are using a pneumatic analyzer other than the PTS 2000 Performance Test System,
you must also have an oxygen analyzer available.
• The manual ventilator check (i.e., without PTS2000 PTS and 840 VTS software) does not
satisfy the manufacturer’sperformance testing requirements. The manual ventilator check
can be used as a general indicator of ventilator condition.

1 Before beginni ng your ventil ator check, perform these al arm tests:
a. Verify that rem ote al arm (n urse’s cal l) relay is fun ctional by in voki ng an alarm an d
veri fying that your nurse’s call system regi sters appropriate alarm .
b. Verify that the BDU annunciates the “ l oss of GUI” alarm when GUI is disconnected.
c. Verify that low-, m edi um -, and h igh -urgen cy alarm s sound by creating an alarm ed
event for each of these. Refer to Operator’s and Technical Reference Manual for
assi stan ce.
2 M easure ven tilator parameters, and verify that they m eet specifications i n Tabl e 5-3.

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Performance verification 5
NOTE:
To accurately measure the parameters listed in Table 5-3, add the tolerance of
your measurement device to the target value of the ventilator. The test results you
obtain are approximate and may not guarantee the accuracy of the ventilator.

Table 5-3: M anual ventilat or check target values

Vent ilat ion paramet er Range Accuracy

Volume1 25 to 2500 ml ±10 ml +10% of setting

5 to 315 ml2 ± 4 mL + 10% of setting for

neonatal circuits

Pressure control 5 to 90 cmH2O ±3 +4% of setting3

Pressure support 5 to 70 cmH2O ±3 +4% of setting2

Breath rate 1 to 100 breaths/ min ±0.5 breaths/ min

Oxygen concentration 21 to 100% O2 ±3%

PEEP 0 to 45 cmH2O ±2 +4% of setting4

Spirometry 0 to 6000 ml ±10 ml +10% of reading

Inspiratory/ expiratory pressure -20 to 100 cmH2O ±2 + 4% of reading

BPS 10 to 30 min5 Verified during EST

1. Compliance- and BTPS-compensated where TE = time to exhale 90% of exhaled volume

2. When equipped with NeoM ode software and accessories
3. End inspiratory pressure at patient wye after 1 second
4. PEEP measured at patient wye with return flow less than 5 L/min
5. These values are for a new fully charged battery. Actual duration depends on ventilation parameters, battery age, and
level of battery charge.

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Thi s page i ntentionall y blank.

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 SECTION
S EC T I O N

Diagnostic codes 6 6
6.1 Int roduct ion
This section con tain s in form ation to assi st i n th e i nterpretation of di agn ostics codes,
i ndi cated in the venti lator’s error an d status l ogs, as well as di agnostic codes reported by the
diagnosti c LED arrays on the BD CPU PCB and the GUI CPU PCB.
The ventil ator’s di agnostic an d status l ogs also contai n oth er information that can be useful
wh en troubl eshooti ng the ventil ator. The logs are:
• Syst em Dia gn ostic Lo g: Stores data on un expected condi tions detected during POST,
backgroun d checks, an d cal ibrati on s. Th is i ncl udes al erts an d failures.
• Syst em In fo rm a t io n Lo g: Stores data on ventil ator events, in cl udi ng detai ls on
GUI/BD com m un i cati on .
• EST/ SST D ia gn o stic Lo g: Stores data on un ex pected condi tions detected duri ng SST and
EST, al ong with overall resul ts at com pletion of SST an d EST.
You access th ese l ogs through the service m ode, as described in Section 4.2.2.

6.2 Reference Tables

This section contai ns the foll owing reference tables:

Table Page

Table 6-1: Values of diagnostic code digits 6-4

Table 6-2: 840 Ventilator diagnostic codes 6-7
Table 6-3: Address codes for BDU POST analog devices test errors 6-54
Table 6-4: BDU and GUI—Phase 1 (kernal) POST diagnostic codes 6-56
Table 6-5: BDU only—Phase 2 POST diagnostic codes 6-58
Table 6-6: GUI only—Phase 2 POST diagnostic codes 6-61
Table 6-7: BDU or GUI—Phase 3 POST diagnostic codes 6-63
Table 6-8: Interrupt errors and test failures – POST self tests 6-64
Table 6-9: SST diagnostic codes 6-66
Table 6-10: EST test sequence 6-77
Table 6-11: UT0002 Fault Addresses for LCD inverter PCB errors 6-102

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-1
6 Diagnostic codes

6.3 Troubleshoot ing

The tabl e of di agn ostic codes (Table 6-2) l ists repai r and replacem ent actions that are
sequenced to correct the m ost probable m alfuncti on or to present th e m ost efficient
correcti ve action first. (The proposed fixes l isted, however, may not al ways correct the
particular probl em .)
Also, keep th e fol lowin g in m in d wh en troubl eshootin g th e ven ti lator:
• Verify secure connections of cabl es and ven ti lator m odul es.
• If possi bl e, run full EST, bypassi ng an y failures or faults that may occur, to further
diagn ose a problem .
• Replace BD or GUI CPU PCB only after al l other rem edies have been attem pted. Contact
Puritan-Ben nett Techni cal Support for further assistance.
• Check for system l eaks, particularly at the expi ratory fil ter. M ake sure the expi ratory fil ter
collector vial is secured ti gh tl y, th e drain port is capped, and the fil ter i s m ounted securel y
to the venti lator. M ake sure th e test circui t is securely attached.
• Before runnin g SST or EST, ensure th at th e un it h as been warm ed up for at l east 10
m inutes i n am bient temperature. Fail ure to warm up th e venti lator m ay resul t in fal se
flow sen sor or pressure transducer fai lures.
• W hen troublesh ootin g SST or EST, always use a known good patient ci rcui t or gold
stan dard circuit an d fil ter(s).

6.4 POST fault handling

Duri ng POST (or a backgroun d check), either the BD or the GUI processor uses its
correspondi ng CPU LED array to displ ay a unique test code for each self test as it executes. If
POST is runn ing i n a n o-faul t state, the LED array(s) display discrete an d ch anging LED
patterns.

NOTE:
The alphanumeric diagnostic code for each of the self tests is not identified in this
manual. This information is not necessary for field service repairs.

If th e system detects a faul t duri ng POST (or a background check), each of the four pairs of
LEDs i n th e correspondi ng LED array wil l li ght, in sequen ce, creati ng a flashi ng effect. Th e
sam e LED array th en di spl ays the di agnostic code corresponding to th e detected faul t. Thi s
LED pattern of display—fl ash ing LED pai rs fol lowed by a diagn osti c code—cycles
conti nuousl y an d is a visual i ndi cator of a system fault. Use the tables i n this section to
convert the diagnostic code LED pattern to an al phanum eric di agnostic code.
Additi on all y, under a fault condi tion, the processor of the corresponding CPU PCB attem pts
to l og the fault i nform ati on , with a ti m e-stamp, in its nonvolati le ran dom access m em ory
(NOVRAM ). Upon compl etion of its POST, each processor reports i ts test results to th e GUI
processor for di spl ay an d transfer i nto the System Diagnosti cs Log.
POST fail ures are cl assified as m i nor or m aj or faults:
Min or PO ST fa u lt i s a fault that does not affect venti lati on or pati ent safety ch ecks. A m i nor
fault does n ot i nterrupt the regular POST sequence. The GUI di splays POST fault in form ation
an d logs it in to NOVRAM of the corresponding CPU PCB. Th e System Diagn ostic Log di spl ays
an alert. Normal venti lati on wi ll begin if POST detects a m in or faul t.
Ma jo r POST fa u lt is a fault that affects venti lati on or pati ent safety checks. A m aj or faul t
i nterrupts th e regular sequen ce of POST and causes a VENT INOP condi tion. Fault
i nform ati on is sen t to the GUI (i f possible) an d to the LED array on the correspondi ng CPU
PCB (BD or GUI). Th e safety valve an d exh alati on val ve rem ai n open to allow the pati en t to

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Diagnostic codes 6
breath e room ai r. Th e software does n ot perm it normal venti lation whi le a m aj or faul t exists.
To clear a m aj or fault, both CPU processors m ust com pl ete thei r respective POST, wi th no
m ajor POST faul ts. If onl y a mi nor fault exists, n orm al ven tilati on wi ll begin .

6.5 Diagnost ic CPU LED arrays

The diagn osti c LED arrays, resi dent on th e BD and GUI CPU PCBs, report di agnostic codes for
background ch eck and POST self test faults that may assist in troubl eshooti ng the 840
ven til ator.
To view the BD diagnostic LED array, you must disconnect the GUI cabl e from th e BDU and
rem ove the BDU exh alati on module cover (Secti on 8.15.9.2). Th e BD LED array is visi ble on
the outsi de edge of the BD CPU PCB. (See Figure 6-1 below.)
The GUI CPU diagnosti c LED array is visi bl e di rectly th rough the clear wi ndow on the rear
pan el of the newer styl e 10.4-in ch GUI. The earlier 9.4-inch GUI requires rem oval of the GUI
rear panel to view i ts CPU PCB diagn ostic LED array. (See Secti on 8.14.6 for rem oval of the
9.4-i nch rear cover.)
The pattern of the eight LEDs (lit and un li t) i n each LED array represents a diagnostic code.
Always read the LED arrays from top to bottom . You w ill n otice that there are ten , rath er than
ei ght LEDs present on the 10.4-i nch GUI LED array. Ign ore the top-m ost and the bottom-
m ost LEDs an d use the ei ght LEDs in between to determ in e the diagn osti c code.

Status LED
diagnostic code LEDs
(read from top
to bottom)

8-00156

Figure 6-1. Locat ion of BD LED array

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6 Diagnostic codes

6.6 Diagnost ic codes

W h en a fault occurs, th e software, records a si x-digit alphan um eri c diagn osti c code i n th e
System Di agnostic Log, i f possible.
Di agnostic codes for som e of the POST kernal test faults cann ot be di spl ayed by the GUI and
are reported on ly by the di agn ostic LED array on the applicable CPU PCB. Th e system i s
unable to record th ese particular faul ts in th e System Di agn ostic Log.

6.6.1 How t o int erpret diagnost ic codes

The fi rst letter of a di agnostic code in the System Diagnosti c Log i dentifi es the m odul e (BD or
GUI) where the fault was detected and whether it was m inor or m aj or. Fi rst letters in a
di agnostic code of L and K den ote BD CPU m i nor an d m ajor faults, respecti vely, whi le th e
l etters Z and X denote GUI CPU m in or and m aj or faults.
The second letter in the six-digit code in di cates where the fault occurred in th e software. The
l ast four diagnostic code characters can provi de additional error code inform ation.
X XXS bel ow outli nes the possibl e val ues of certain di gi ts i n the alph anum eri c diagn ostic
code and provides top-l evel interpretati ons.
a b cccc
abccccc

Error identifier
Diagnostic type
Reportability classification

Table 6-1: Values of diagnost ic code digits

where: may be... which means...

a A Alert (during SST/ EST)

D or H BDU problem that resulted in soft reset during operation (as opposed
to during POST)

E BDU user event (not an error)

F Failure (during SST/ EST)

G BDU illegal instruction trap, watchdog reset, or illegal address trap

that resulted in BDU soft reset

J BDU watchdog umpire (3 “ strikes” in 24 hours) caused Safety Valve

Open (SVO)

K BDU failure (during POST or background check) caused SVO

L POST or background check alert or communication error in BDU

S GUI user event

U or V GUI problem that resulted in soft reset during operation

X GUI failure (during POST or background check) caused GUI or

ventilator inoperative condition

Z POST or background check alert or communication error in GUI

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Diagnostic codes 6
Table 6-1: Values of diagnost ic code digit s

w here: may be... which means...

b B Background check

C Communications test

E EST

N Nonmaskable interrupt

P POST or initialization software

S SST

T Hardware-detected failure (trap)

Y GUI watchdog umpire (3 “ strikes” in 24 hours) causes GUI

inoperative condition

(None) Soft fault (assertion)

cccc (Varies) Other error identification information

6.7 Organizat ion of diagnost ic codes t able

Table 6-2 i s a com preh ensi ve sum m ary of the diagn ostic codes that th e 840 software can
report. The organ izati on of the information in this table is as foll ows:
• The first colum n l ists, i n alph anum eri c order, th e codes.
• The secon d colum n l ists th e accom panyin g m essage.
• The third colum n lists the part of software th at was runn ing when the error was detected.
• The fourth column li sts the venti lator’s respon se to th e condition, as fol lows:

ALERT Test resul t not i deal , but not cri tical.

In POST: POST contin ues to end an d ventil ation starts. A DEVICE
ALERT al arm is an nun ciated (Section 7).
In SST/ EST: SST/ EST contin ues to end. You can override the alert and
start ven tilation.
In a backgroun d check: Ventil ation conti nues, and a DEVICE ALERT
alarm i s ann unciated.
FAILURE Criti cal probl em detected.
In POST: Ventilator inoperative con dition is declared.
In SST/ EST: You can conti nue tryi ng to pass SST or EST, but if test does
not pass, ventil ator in operati ve conditi on i s declared.In a backgroun d
check: Ventil ator i noperati ve condition is declared.
BDU RESET Circuitry in the BDU i s reset, which causes BDU POST to be rerun. If
POST passes, ven tilation conti nues. If POST fail s, it generates an alert or
fai lure.
GUI RESET Circuitry in the GUI is reset, which causes GUI POST to be rerun . If
POST passes, GUI operati on resum es. If GUI POST does not pass, it
declares a GUI i nop con diti on .
VENT INOP Ven tilator is put into SVO state, permi tti ng patient to breathe room air.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-5
6 Diagnostic codes

ALERT Test resul t not ideal , but not cri tical.

In POST: POST contin ues to end an d ventil ation starts. A DEVICE
ALERT al arm is ann unciated (Section 7).
In SST/ EST: SST/ EST contin ues to end. You can overri de the alert and
start ventil ation.
In a background check: Venti lati on conti nues, an d a DEVICE ALERT
alarm i s ann unciated.
FAILURE Cri ti cal probl em detected.
In POST: Ventilator inoperative con dition is declared.
In SST/ EST: You can continue tryi ng to pass SST or EST, but if test does
not pass, venti lator in operati ve conditi on i s declared.In a background
check: Ventil ator i noperative condition is decl ared.
GUI INOP Th e BDU alarm s, ventil ator setti ngs are locked, and a message is
di spl ayed.
STATUS Code/m essage li sted for in form ation onl y; requires n o action.

• The fifth col um n provides addi tional in form ation and/ or identi fies possi bl e causes.
• The sixth colum n suggests how to correct th e con diti on . Th ese actions are sequen ced to
correct th e m ost probable m al functi on or to present the m ost efficien t corrective action
first. The proposed fi xes li sted, however, m ay not al ways correct th e parti cul ar probl em .
In addition to the actions suggested in the tables i n th is section, keep the fol lowing i n mi nd
when troubleshooti ng the ventil ator:
• Verify secure connections of cabl es and ven ti lator m odul es.
• If possi bl e, run full EST, bypassi ng an y failures or faults that may occur, to further
diagn ose a problem .
• Replace BD or GUI CPU PCB only after al l other rem edies have been attem pted. Contact
Puritan-Ben nett Techni cal Support for further assistance.
• Check for system l eaks, particularly at the expi ratory fil ter. M ake sure the expi ratory fil ter
collector vial is secured ti gh tl y, th e drain port is capped, and the fil ter i s m ounted securel y
to the venti lator. M ake sure th e test circui t is securely attached.
• Before runnin g SST or EST, ensure th at th e un it h as been warm ed up for at l east 10
m inutes i n am bient temperature. Fail ure to warm up th e venti lator m ay resul t in fal se
flow sen sor or pressure transducer fai lures.
W h en troubl eshooting SST or EST, al ways use a kn own good patien t ci rcuit or gol d standard
ci rcuit and filter(s).

6-6 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6

Table 6-2: 840 Vent ilator diagnost ic codes

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE0110 Unable to EST Flow Alert Flow controller unable 1. Make sure oxygen supply is
establish O2 sensors cross to establish and control connected and unrestricted.
flow check Test oxygen flow at 2. Verify oxygen regulator pres-
120 L/ min. sure is set between 9-12 psi.
3. Switch PSOLs to see if failure
transfers to the other gas side.
If yes, return the air PSOL to its
original position and replace
the oxygen PSOL.
4. Run the leak test in EST to
check for leaks/ occlusions.
5. Perform a flow sensor calibra-
tion.
6. Replace Q1.
7. Replace the Inspiratory Elec-
tronics PCB.
8. Replace the AI PCB.

AE0111 Unable to EST Flow Alert Flow controller unable 1. Make sure air supply is con-
establish air flow sensors cross to establish and control nected and unrestricted.
check Test air flow at 120 L/ min. 2. Verify air regulator pressure is
set between 9-12 psi.
3. Switch PSOL's to see if failure
transfers to the other gas side.
If yes, return Oxygen PSOL to
its original position and replace
the Air PSOL.
4. Run the leak test in EST to
check for leaks/ occlusions.
5. Perform a flow sensor calibra-
tion.
6. Replace Q2.
7. Replace the Inspiratory Elec-
tronics PCB.
8. Replace the AI PCB.

AE0213 Air PSOL leak EST Gas Alert Air PSOL (PSOL2) 1. Check for leaks around the Q2
Supply/ SV Test forward leak was O-rings.
detected via excessive 2. Make sure air supply is con-
pressure buildup nected and unrestricted.
( > 50 cmH2O but 3. Reseat Air PSOL.
< 100 cmH2O) in 4. Replace Air PSOL.
blocked inspiratory 5. Replace AI PCB.
module.
AE0214 O2 PSOL leak EST Gas Alert Oxygen PSOL (PSOL1) 1. Check for leaks around the Q1
Supply/ SV Test forward leak was O-rings.
detected via excessive 2. Make sure oxygen supply is
pressure buildup connected and unrestricted.
( > 50 cmH2O but 3. Reseat oxygen PSOL.
< 100 cmH2O) in 4. Replace oxygen PSOL.
blocked inspiratory 5. Replace AI PCB.
module.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-7
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE0306 Test circuit not EST Leak Test Alert Pressure not detected 1. M ake sure test circuit is prop-
connected on expiratory side erly connected.
2. Replace expiratory bacteria
filter.
3. Check for leaks around the Q3
flow sensor.
4. Check/ replace the exhalation
valve.
5. Replace the expiratory pressure
transducer PCB.

AE0601 GUI High Alarm EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.
AE0602 GUI M edium EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
Alarm LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

AE0603 GUI Low Alarm EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

AE0604 GUI Normal LED EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

AE0605 GUI Batt Backup EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB
2. Replace the GUI LED PCB.

AE0606 GUI On Batt Pwr EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.
AE0607 GUI Compressor EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
Ready LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

AE0608 GUI Compressor EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
Operating LED Test indicate LED not on. cable between the GUI LED
fails. PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

AE0609 GUI 100% O2 EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace keyboard.
AE0610 GUI Alarm EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
Silence LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

6-8 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE0611 GUI Screen Lock EST GUI Lamp Alert CLEAR key pressed to 1. Check/ replace interconnect
LED fails. Test indicate LED not on. cable between the GUI LED
PCB and the GUI CPU PCB.
2. Replace the GUI LED PCB.

AE0702 Bad Vent inop EST BD Lamp Alert CLEAR key pressed to Replace BD LED PCB.
LED Test indicate one or both
ventilator inoperative
LEDs not on.

AE0703 Bad SVO LED EST BD Lamp Alert CLEAR key pressed to Replace BDU LED PCB.
Test indicate one or both
SVO LEDs not on.

AE0704 Bad Loss of GUI EST BD Lamp Alert CLEAR key pressed to Replace BDU LED PCB.
LED Test indicate loss of GUI LED
not on.

AE1001 Air PSOL EST PSOL Alert Air PSOL (PSOL2) 1. Verify that the air supply is
loopback Loopback Test loopback current out of good.
current OOR range of drive current. 2. Verify air regulator pressure set
to between 9 and 12 psi.
3. Switch PSOLs to see if failure
transfers to the other gas side.
If yes, return oxygen PSOL
(PSOL1) to its original position
and replace PSOL2.
4. Switch Q1 and Q2, run a flow
sensor calibration and rerun
test. If the problem transfers to
the other gas side, return Q1 to
its original position and replace
Q2.
5. Replace the AI PCB.
6. Replace the Inspiratory
Electronics PCB.

AE1002 O2 PSOL EST PSOL Alert Oxygen PSOL (PSOL1) 1. Verify that the oxygen supply is
loopback Loopback Test loopback current out of good.
current OOR range of drive current. 2. Verify oxygen regulator pres-
sure set to between 9 and 12
psi.
3. Switch PSOLs to see if failure
transfers to the other gas side.
If yes, return the air PSOL to its
original position and replace
PSOL1.
4. Switch Q1 and Q2, run a flow
sensor calibration and rerun
test. If the problem transfers to
the other gas side, return Q2 to
its original position and replace
Q1.
5. Replace the AI PCB.
6. Replace the Inspiratory
Electronics PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-9
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE1104 Insp check valve EST Safety Alert It took too little time to 1. M ake sure test circuit is con-
test failed System Test relieve excess pressure nected.
through open safety 2. M ake sure CV3 is not installed
valve, indicating backward.
inspiratory check valve 3. Replace CV3.
(CV3) may be damaged
or incorrectly mounted.

AE1201 Exp valve EST Exp Valve Alert Exhalation valve 1. Verify that the system has no
loopback Loopback Test loopback current is out leaks or occlusions by running
current OOR of range of drive the leak test in EST.
current. 2. Clean exhalation valve
diaphragm.
3. Calibrate the exhalation valve.
4. Clean/ replace the exhalation
valve.
5. Replace the AI PCB.
AE1305 Seal test failed EST Exp Valve Alert Seal test ∆ pressure is 1. Verify that the system has no
Seal Test above alert level but leaks or occlusions by running
below failure level. the leak test in EST.
2. Clean the exhalation valve.
3. Calibrate exhalation valve.
4. Replace the exhalation valve.
5. Replace the AI PCB.
AE1600 Compressor EST Status Ventilator did not sense No action required.
Test - Not Compressor a compressor attached
installed Test and skipped test.
AE1601 Wall air pressure EST Alert Wall air pressure switch 1. M ake sure air supply is discon-
detected Compressor (PS2) detected air after nected.
Test user was prompted to 2. Disconnect PS2 and rerun test.
disconnect air. If test passes, replace PS2.

AE1602 ac power not EST Alert System is still running 1. Plug in ventilator power cord
connected Compressor on battery power after and check the cord connec-
Test prompting user to tion at the ventilator.
connect ac power. 2. Check ac.
Compressor can only 3. Disconnect BPS to isolate prob-
run on ac (facility) lem.
power. 4. Replace power supply.

AE1603 Compressor EST Alert Compressor pressure 1. Run compressor leak test to
pressure not Compressor transducer (PC) check for leaks.
detected Test indicates that a. Use leak detector to check
compressor air is not for leaks at the accumulator
present, although fittings and other tubing
compressor motor is connections.
on. b. Verify no leaks at CV2 within
the ventilator by plugging
the air inlet fitting.
2. Replace compressor PCB.
3. Contact Puritan-Bennett Tech-
nical Support.

6-10 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE1604 Run mode time EST Alert Compressor timer is not Listen for motor. If motor is on,
OOR Compressor running while replace compressor PCB.
Test compressor motor is Otherwise, replace compressor.
on.

AE1606 Compressor EST Alert Compressor pressure Replace compressor PCB.

pressure Compressor transducer (PC)
detected Test indicates that
compressor air is
present after
compressor motor is
disabled and
accumulator drained.

AE1607 Disabled mode EST Alert Compressor timer is Replace compressor PCB.
time OOR Compressor running while
Test compressor motor is
off.
AE1608 Unable to test EST Alert Compressor standby 1. Troubleshoot code AE1604 or
standby mode Compressor mode check cannot be AE1607, if present.
Test run, because of inability 2. Replace compressor PCB.
to verify timer
functionality during
compressor run and
disabled tests.
AE1609 Standby mode EST Alert Compressor motor is Replace compressor PCB.
time OOR Compressor still running. During
Test standby mode test
phase, compressor
motor should
eventually turn off.

AE1610 Unable to EST Alert Compressor load test Troubleshoot code AE1603 or
perform Compressor cannot be run, because AE1606.
compressor load Test of inability to verify PC
test during compressor run
and disabled tests.

AE1611 Compressor EST Alert Compressor unable to 1. Run compressor leak test to
load test failed Compressor maintain minimum check for compressor leak.
Test pressure under worst- a. Use leak detector to check
case breath delivery for leaks at the accumulator
waveform. fittings and other tubing
connections.
b. Verify no leaks at CV2 within
the ventilator by plugging
the air inlet fitting.
2. Replace compressor.
3. Replace compressor PCB.

AE1700 Compressor EST Status Ventilator did not sense No action required.
Leak Test - Not Compressor a compressor attached
installed Leak Test and skipped test.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-11
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE1701 Unable to EST Alert Compressor leak test 1. Troubleshoot accompanying

perform Compressor cannot be run, because code AE1604 or AE1607.
compressor leak Leak Test of inability to verify 2. Replace compressor PCB.
test timer functionality.

AE1702 Wall air pressure EST Alert Wall air pressure switch 1. M ake sure air supply is discon-
detected Compressor (PS2) detected air nected.
Leak Test presence after user was 2. Disconnect PS2 and rerun test.
prompted to If test passes, replace PS2.
disconnect air.
AE1703 Wall air pressure EST Alert Wall air pressure switch 1. M ake sure air supply is con-
not detected Compressor (PS2) did not detect air nected.
Leak Test presence after user was 2. Run Gas Supply/ SV Test.
prompted to connect
air.

AE1704 Compressor EST Alert Compressor leak was Troubleshoot compressor

leak detected Compressor detected using compartment or inspiratory
Leak Test compressor timer to module for leaks.
detect compressor
turning on momentarily
during test.

AE1901 GUI touch: Error EST GUI Touch Alert Touch screen error 1. Clean touch screen, removing
Test occurred (e.g., blocked any obstructions.
beam or low-level 2. Replace touch frame PCB.
error), buffer cannot be 3. Replace GUI CPU PCB.
read, or report is
invalid.

AE2001 Bad GUI serial EST GUI Serial Alert While in loopback Replace GUI CPU PCB.
port Port Test mode, failed to verify
received message was
identical to transmitted
message.

AE2101 Battery not EST Battery Alert BPSnot fully charged at 1. Allow BPS to fully charge, then
charged Test start of test. repeat test.
2. Replace BPS PCB.
3. Replace battery pack.
4. Replace BD CPU PCB.

AE2102 Battery not EST Battery Alert BPS not discharging 1. Verify ac power is disconnected
discharging Test after ac power was when prompted.
disconnected. 2. Replace BPS PCB.
3. Replace battery pack.
4. Replace BD CPU PCB.

6-12 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

AE2103 Bad Backup EST Battery Alert While BPS was 1. Ensure that the battery pack is
Power Supply Test discharging, BPS fully charged by checking that
voltage dropped below the green LED on the BPS is lit
accepted level or prior to initiating an EST. If the
dropped too quickly. amber LED is lit, allow the unit
to charge the batteries prior to
rerunning EST.
2. Replace the battery pack.
3. Replace the BPS PCB.
4. Replace the AI PCB.
5. Replace the power supply.

AE2104 Battery not EST Battery Alert BPS not charging after 1. Verify that ac power is recon-
charging Test ac power was nected when prompted and
reconnected. that ac is good.
2. Replace BPS PCB.
3. Replace the battery pack.
4. Replace the power supply.
5. Replace the BD CPU.
6. Replace the AI PCB.

AE2300 GUI Nurse Call EST Test Status User pressed CLEAR to No action required.
Test - Not indicate nurse’s call
installed device not installed.
Test was skipped.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-13
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

AS0010 Unable to SST flow sensor Alert Flow controller unable 1. M ake sure oxygen supply is
establish O2 test to establish and control connected and unrestricted.
flow oxygen flow at 2. Verify that the oxygen supply
120 L/ min. meets minimum pressure
requirements.
3. Verify that the patient circuit
system has no leaks or occlu-
sions. If not sure, run the first
four tests in EST to get to the
leak test. If the leak test passes
in EST, exit out of EST. Correct
the leak or occlusion in the
patient circuit used in SST and
rerun or try another patient cir-
cuit.
4. Check the oxygen inlet filter
assembly.
5. Verify that the oxygen regula-
tor pressure is set between 9-
12 psi.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the air side, return Q2 back to
its original position and replace
Q1.
8. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL2 back to its
original position and replace
PSOL1.

6-14 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

AS0011 Unable to SST flow sensor Alert 1. Flow controller 1. Make sure air supply is con-
establish air flow test unable to establish nected and unrestricted.
and control air flow 2. Verify that the air supply meets
at 120 L/ min. minimum pressure require-
ments.
3. Verify that the patient circuit
system has no leaks or occlu-
sions. If not sure, run the first
four tests in EST to get to the
leak test. If the leak test passes
in EST, exit out of EST. Correct
the leak or occlusion in the
patient circuit used in SST and
rerun or try another patient cir-
cuit.
4. Check the air inlet filter (F2).
5. Verify that the air regulator
pressure is set between 9-12
psi.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the oxygen side, return Q1
back to its original position and
replace Q2.
8. Switch PSOLs to see if the fail-
ure transfers to the oxygen
side. If yes, return PSOL1 back
to its original position and
replace PSOL2.

AS0012 O2 pressure not SST flow sensor Alert Oxygen pressure not Make sure oxygen supply is
detected test detected via PS1. Only connected.
air available for SST.

AS0013 Wall air pressure SST flow sensor Alert Air pressure not Make sure air supply is connected.
not detected test detected via PS2 or PC.
Only oxygen available
for SST.
AS0202 Excessive leak SST Circuit leak Alert Pressure drops to 85 1. Make sure patient circuit is
cmH2O in 10 s, connected and is not leaking.
then in 10 s more by 2. Check exhalation valve opera-
≥ 10 cmH2O. tion.
3. Verify connections of bacteria
filters and humidifier are
secure.

AS0305 Occluded SST Expiratory Alert Pressure drop across Consider replacing expiratory
expiratory filter filter filter > 2 cmH2O, but filter.
< 3 cmH2O.

AS0308 Occluded SST Expiratory Alert Exhalation 1. Check compartment for

expiratory filter compartment pressure obstruction.
compartment > 3 cmH2O but 2. Verify exhalation valve opera-
< 4 cmH2O. tion by running EST.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-15
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

AS0311 Low expiratory SST Expiratory Alert Pressure drop 1. Repeat test, following direc-
filter ∆P filter across expiratory filter tions more closely.
< 0.4 cmH2O, but 2. Replace filter.
> 0.1 cmH2O.

AS0403 Occluded SST Circuit Alert Inspiratory limb Check for occluded patient tubing.
inspiratory limb Resistance pressure > 8.5 cmH2O
(adult) or 5.5 cmH2O
(pediatric), but
< 12.5 cmH2O (adult)
or 7.5 cmH2O
(pediatric), indicating
occlusion.

AS0406 Occluded SST Circuit Alert Expiratory limb Check for occluded patient tubing.
exhalation limb Resistance pressure > 8.5 cmH2O
(adult) or 5.5 cmH2O
(pediatric) but > 12.5
cmH2O (adult) or
7.5 cmH2O (pediatric),
indicating occlusion.

AS0407 Unable to reach SST Circuit Alert During characterization Check for kinked or occluded
min peak flow Resistance of total circuit patient tubing.
resistance over a range
of flows, peak flow
< 80 L/ min but > 60 L/
min.
AS0411 Unable to reach SST Circuit Alert During characterization Check for kinked or occluded
min peak flow Resistance of total circuit patient tubing.
resistance over a range
of flows, peak flow was
less than alert
threshold.

AS0413 Insp limb SST Circuit Alert Inspiratory limb 1. M ake sure inspiratory filter is
resistance low Resistance pressure < 0.6 cmH2O installed.
(adult) or 5.5 cmH2O 2. Repeat test, following direc-
(pediatric), but tions more closely.
> 0.2 cmH2O. 3. Replace inspiratory filter.
4. Replace patient circuit.
AS0414 Exp limb SST Circuit Alert Expiratory limb Replace patient circuit.
resistance low Resistance pressure < 0.6 cmH2O
(adult) or 0.5 cmH2O
(pediatric), but
> 0.2 cmH2O.

AS0505 Excessive SST Alert High compliance 1. M ake sure correct patient tub-
compliance Compliance >6 mL/ cmH2O (adult) ing type was specified in SST.
calibration or 4.5 mL/ cmH2O 2. Replace patient circuit.
(pediatric), but
< 12 mL/ cmH2O (adult)
or 9 mL/ cmH2O
(pediatric).

6-16 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

AS0507 Compliance low SST Alert High compliance falls 1. Make sure correct patient tub-
Compliance below 1.56 mL/ cmH2O ing type was specified in SST.
calibration (adult) or 1.34 mL/ 2. Replace patient circuit with a
cmH2O (pediatric) but known good circuit and filter
not lower than set.
1.05 mL/ cmH2O. 3. Run EST to check the operation
of PI and PE during the Circuit
Pressure Test. Replace applica-
ble pressure transducer.
4. Run Atmospheric Pressure
Transducer calibration.
AS0509 Excessive SST Alert Low compliance > 1. Make sure correct patient tub-
compliance Compliance 6 mL/ cmH2O (adult) or ing type was specified in SST.
calibration 4.5 mL/ cmH2O 2. Replace patient circuit with a
(pediatric), but < known good circuit and filter
12 mL/ cmH2O (adult) set.
or 9 mL/ cmH2O 3. Run EST to check the operation
(pediatric). of PI and PE during the Circuit
Pressure Test. Replace applica-
ble pressure transducer.
4. Run Atmospheric Pressure
Transducer calibration.

AS0511 Compliance low SST Alert Low compliance falls 1. Make sure correct patient tub-
Compliance below 1.56 mL/ cmH2O ing type was specified in SST.
calibration (adult) or 1.34 mL/ 2. Replace patient circuit with a
cmH2O (pediatric), but known good circuit and filter
not below set.
1.05 mL/ cmH2O. 3. Run EST to check the operation
of PI and PE during the Circuit
Pressure Test. Replace applica-
ble pressure transducer.
4. Run Atmospheric Pressure
Transducer calibration.

Dxxxxx Assertion Background Failure that System generated a Replace the BDCPU PCB.
Checks (BD) results in a reset to correct a
POST or a boundary check or
reset possible data
corruption of control
variables.

DT0002 Bus error / Background Failure that Hardware trap from an Replace the BD CPU PCB.
Access fault Checks (BD) results in a access fault due to a
POST or a bad memory chip, bad
reset control line, or a
hardware timing issue.

Exxxxx Varies Background Status A status message

Checks (GUI) indicating an event that
was intentionally
caused.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-17
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

NOTE:
For all "FE" codes (failures reported during EST), diagnose the problem and perform the repair.
Run a complete EST to reset the EST test failure in memory. If there is a failed EST test result in
memory, normal operation is prevented until the failed EST test is rerun and passes.

FE0001 Inspiratory EST Circuit Failure Inspiratory pressure 1. Replace SOL1.

autozero out of Pressure Test transducer ADC count 2. Replace Inspiratory Electronics
range at 0 cmH2O is out of PCB.
range. 3. Replace AI PCB.
FE0002 Expiratory EST Circuit Failure Exhalation pressure 1. Replace SOL2.
autozero out of Pressure Test sensor ADC count at 2. Replace exhalation transducer
range 0 cmH2O is out of PCB.
range. 3. Replace AI PCB.

FE0003 Failed to reach EST Circuit Failure Unable to build 1. M ake sure that test circuit is
test pressure Pressure Test pressure (air) to installed and air supply or com-
10 cmH2O at pressor is available and good.
5 L/ min within time-out 2. Verify that the air regulator
period. pressure is set between 9-12
psi.
3. Verify that the patient circuit
system has no leaks or occlu-
sions by running the first four
tests in EST to get to the leak
test.

FE0004 Cross-check EST Circuit Failure Inspiratory/ expiratory 1. Verify that the system has no
failed Pressure Test pressure transducer leaks or occlusions. If not sure,
readings at 10 cmH2O run the first four tests in EST to
test pressure are too far run the leak test
apart. 2. If the leak test passes in EST,
exit out of EST. Review the
data for the Circuit Pressure
Test to determine which pres-
sure transducer is out of range:
PI or PE. Replace applicable
pressure transducer.
3. Replace AI PCB.

FE0005 Bad insp EST Circuit Failure Inspiratory pressure 1. Replace SOL1.
autozero Pressure Test reading (taken after 2. Replace Inspiratory Electronics
solenoid inspiratory pressure PCB.
transducer autozero 3. Replace AI PCB.
solenoid (SOL1)
actuated) out of range
(-0.60 to 0.60 cmH2O).

FE0006 Bad exp EST Circuit Failure Expiratory pressure 1. Replace SOL2.
autozero sol Pressure Test reading (taken after 2. Replace exhalation transducer
expiratory pressure PCB.
transducer autozero 3. Replace AI PCB.
solenoid (SOL2)
actuated) out of range
(-0.60 to 0.60 cmH2O).

6-18 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0007 Cross-check EST Circuit Failure Inspiratory/ expiratory 1. Replace the expiratory bacteria
failed Pressure Test pressure transducer filter.
measurements at 50 or 2. Verify that the system has no
100 cmH2O test leaks or occlusions. If not sure,
pressure are too far run the first four tests in EST to
apart. run the leak test.
3. If the leak test passes in EST,
exit out of EST. Review the data
for the Circuit Pressure Test to
determine which pressure
transducer is out of range: PI or
PE. Replace applicable pres-
sure transducer.
4. Replace AI PCB.

FE0008 Failed to reach EST Circuit Failure Unable to build 1. Make sure air supply or com-
test pressure Pressure Test pressure (air) to 50 or pressor is available.
100 cmH2O at 5 L/ min 2. Check for system leak at the
within time-out period. expiratory bacteria filter or O2
sensor. If not sure, run the first
four tests in EST to run the leak
test.

FE0010 ac power not EST Circuit Failure System is still running 1. Plug in ventilator power cord.
connected Pressure Test on battery power after 2. Disconnect BPS to isolate prob-
prompting user to lem.
connect ac power. EST 3. Replace power supply.
can only run on ac
(facility) power.
FE0101 O2 flow sensor EST Flow Failure Oxygen flow sensor 1. Make sure oxygen supply is
cross check sensors cross (Q1) cross-check failed. connected and unrestricted.
failed check Test 2. Verify that the oxygen supply is
good.
3. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
4. Run a flow sensor calibration.6.
Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the air side, return Q2 back to
its original position and replace
Q1.
5. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL2 back to its
original position and replace
PSOL1.
6. Replace exhalation flow sensor
(Q3)
7. Replace AI PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-19
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0102 O2 PSOLcurrent EST Flow Failure Oxygen PSOL (PSOL1) 1. M ake sure oxygen supply is
out of range sensors cross current is out of range connected and unrestricted.
check Test with respect to flow 2. Verify that the oxygen supply is
sensor (Q1). good.
3. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
4. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL2 back to its
original position and replace
PSOL1.
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the air side, return Q2 back to
its original position and replace
Q1.
FE0103 Air flow sensor EST Flow Failure Inspiratory module air 1. M ake sure air supply is con-
cross check sensors cross flow sensor (Q2) cross- nected and unrestricted.
failed check Test check failed. 2. Verify that the air supply is
good.
3. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
4. Run a flow sensor calibration.
5. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the oxygen side, return Q1
back to its original position and
replace Q2.
6. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL back to its
original position and replace
PSOL2
7. Replace exhalation flow sensor
(Q3).
8. Replace AI PCB.

6-20 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0104 Air PSOL current EST Flow Failure Air PSOL (PSOL2) 1. Make sure air supply is con-
out of range sensors cross current is out of range nected and unrestricted.
check Test with respect to air flow 2. Verify that the air supply is
sensor (Q2). good.
3. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
4. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL back to its
original position and replace
PSOL2
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the oxygen side, return Q1
back to its original position and
replace Q2.
FE0106 Unable to EST Flow Failure Flow controller unable 1. Make sure oxygen supply is
establish O2 sensors cross to establish and control connected.
flow check Test oxygen flow at 60, 5, 2. Check regulated oxygen pres-
and 1 L/ min. sure.
3. Replace PSOL1 or Q1.
4. Replace AI PCB.

FE0107 Unable to EST Flow Failure Flow controller unable 1. Make sure air supply is con-
establish air flow sensors cross to establish and control nected.
check Test air flow at 60, 5, and 1 2. Check regulated air pressure.
L/ min. 3. Perform flow sensor calibra-
tion.
4. Replace PSOL2 or Q2.
5. Replace AI PCB.

FE0108 O2 zero flow EST Flow Failure Inspiratory flow > 1. Verify no leaks at the Q1
check failed sensors cross 0.153 L/ min with O-rings.
check Test oxygen PSOL (PSOL1) 2. Run EST Gas Supply Test to
commanded to 0 check for PSOL1 leak. Remove
(closed). and then reseat PSOL1
3. Replace PSOL1.
4. Perform a flow sensor calibra-
tion.
5. Replace Q1.

FE0109 Air zero flow EST Flow Failure Inspiratory flow > 0.153 1. Verify no leaks at the Q2
check failed sensors cross L/ min with air PSOL O-rings.
check Test (PSOL2) commanded 2. Run EST Gas Supply Test to
to 0 (closed). check for PSOL2 leak. Remove
and then reseat PSOL2
3. Replace PSOL2.
4. Perform a flow sensor calibra-
tion.
5. Replace Q2.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-21
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0204 Wall air pressure EST Gas Failure Wall air not detected 1. M ake sure air supply is con-
not detected Supply/ SV Test initially and wall air still nected.
not detected after user 2. Check PS2: Remove the wiring
was prompted to connectors from PS2 and
connect wall air. jumper the connectors to each
other. If the system now rec-
ognizes the air supply, replace
PS2.

FE0205 O2 pressure not EST Gas Failure Oxygen pressure not 1. M ake sure oxygen supply is
detected Supply/ SV Test detected initially and connected.
oxygen pressure still 2. Check PS1: Remove the wiring
not detected after user connectors from PS1 and
was prompted to jumper the connectors to each
connect oxygen. other. If the system now rec-
ognizes the air supply, replace
PS1.
FE0206 O2 pressure EST Gas Failure Oxygen pressure switch 1. M ake sure oxygen supply is dis-
detected (O2 Supply/ SV Test detected presence of connected.
not oxygen after user was 2. Replace Inspiratory Electronics
disconnected) prompted to PCB.
disconnect oxygen. 3. Replace PS1.

FE0207 Air PSOL leak EST Gas Failure Air PSOL (PSOL2)
Supply/ SV Test forward leak was
detected via excessive
pressure buildup (> 100
cmH2O) in blocked
inspiratory module.
1. Check for leaks around the Q2
O-rings.
2. Verify that the safety valve
relieves pressures above 100
cmH2O. Listen for the pressure
relief while watching the
numeric digital display of sys-
tem pressure in the upper
screen. If the safety valve does
not crack open, replace the
safety valve.
3. Replace PSOL2.

FE0208 Wall air pressure EST Gas Failure Wall air pressure switch 1. M ake sure air supply is discon-
detected Supply/ SV Test (PS2) detected wall air nected.
after user was 2. Replace Inspiratory Electronics
prompted to PCB.
disconnect it. 3. Replace PS2.

FE0209 O2 PSOL leak EST Gas Failure Oxygen PSOL (PSOL1)
Supply/ SV Test forward leak was
detected via excessive
pressure buildup (> 100
cmH2O) in blocked
inspiratory module.
1. Check for leaks around the Q1
O-rings.
2. Verify that the safety valve
relieves pressures above 100
cmH2O. Listen for the pressure
relief while watching the
numeric digital display of sys-
tem pressure in the upper
screen. If the safety valve does
not crack open, replace the
safety valve.
3. Replace PSOL1.

6-22 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0210 SV pressure EST Gas Failure Safety valve cracking 1. Make sure To patient port is
relief failed Supply/ SV Test pressure and/ or peak blocked.
steady-state pressure is 2. Check for leaks at the O2 sen-
out of range. sor, SOL1 or PI.
3. Replace the safety valve.
4. Replace PI.

FE0211 O2 pressure not EST Gas Failure PS1 did not detect 1. Make sure oxygen supply is
detected Supply/ SV Test oxygen after user was connected.
prompted to connect it. 2. Replace Inspiratory Electronics
PCB.

FE0212 Compressor EST Gas Failure Compressor pressure Replace compressor PCB.
pressure Supply/ SV Test transducer (PC)
detected detected that
compressor was
pressurized.

FE0215 Air zero flow EST Gas Failure During zero-flow check, 1. Make sure gas supplies are dis-
check failed Supply/ SV Test air flow sensor (Q2) connected.
reads > 0.05 L/ min. 2. Make sure compressor is not
running.
3. Verify no leaks at the Q2
O-rings.
4. Check for PSOL2 leak.
5. Remove and then reseat
PSOL2.
6. Perform a flow sensor calibra-
tion.
7. Replace PSOL2.
8. Replace Q2.

FE0216 O2 zero flow EST Gas Failure During zero-flow check, 1. Make sure gas supplies are dis-
check failed Supply/ SV Test oxygen flow sensor connected.
(Q1) reads > 0.05 L/ 2. Make sure compressor is not
min. running.
3. Verify no leaks at the Q2
O-rings.
4. Check for PSOL2 leak.
5. Remove and then reseat
PSOL2.
6. Perform a flow sensor calibra-
tion.
7. Replace PSOL2.
8. Replace Q2.

FE0217 Exp zero flow EST Gas Failure During zero-flow check, 1. Make sure gas supplies are dis-
check failed Supply/ SV Test exhalation flow sensor connected.
(Q3) reads > 0.1 L/ min. 2. Make sure compressor is not
running.
3. Verify no leaks at the Q3
O-rings.
4. Perform a flow sensor calibra-
tion.
5. Replace Q3.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-23
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0301 Excessive leak EST Leak Test Failure System pressure 1. M ake sure test circuit is con-
dropped below failure nected and is not leaking.
pressure level. 2. Check for system leaks or
occlusions especially at the O2
sensor and expiratory filter.
3. Verify secure connection of
expiratory filter.
4. Check exhalation valve opera-
tion.
FE0305 Unable to EST Leak Test Failure System cannot attain 1. M ake sure test circuit is con-
establish leak test starting nected and is not leaking.
pressure pressure using oxygen 2. Check exhalation valve opera-
or air within time-out tion, and verify secure connec-
period. tion of expiratory filter.
FE0401 Accept key fails. EST GUI Failure Wrong key pressed or 1. Repeat test.
Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0402 Clear key fails. EST GUI Failure Wrong key pressed or 1. Repeat test.
Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0403 Insp. Pause key EST GUI Failure Wrong key pressed or 1. Repeat test.
fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0404 Exp. Pause key EST GUI Failure Wrong key pressed or 1. Repeat test.
fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0405 Man Insp fails. EST GUI Failure Wrong key pressed or 1. Repeat test.
Keyboard Test key not pressed within 2. Replace keyboard.
15 s.
FE0406 100% O2/ CAL EST GUI Failure Wrong key pressed or 1. Repeat test.
key fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0407 Info key fails. EST GUI Failure Wrong key pressed or 1. Repeat test.
Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0408 Alarm Reset key EST GUI Failure Wrong key pressed or 1. Repeat test.
fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0409 Alarm Silence EST GUI Failure Wrong key pressed or 1. Repeat test.
key fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0410 Alarm Volume EST GUI Failure Wrong key pressed or 1. Repeat test.
key fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0411 Screen EST GUI Failure Wrong key pressed or 1. Repeat test.
brightness fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

6-24 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE0412 Screen contrast EST GUI Failure Wrong key pressed or 1. Repeat test.
key fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0413 Screen lock key EST GUI Failure Wrong key pressed or 1. Repeat test.
fails. Keyboard Test key not pressed within 2. Replace keyboard.
15 s.

FE0501 Bad knob EST GUI Knob Failure Knob was not turned in 1. Repeat test.
Test direction as prompted 2. Replace keyboard.
within 15 s.

FE0801 SAAS EST GUI Audio Failure CLEAR key pressed to 1. Verify the GUI alarm cable con-
(Safety Audible Test indicate GUI audio nection to the GUI CPU PCB.
Alarm System) diagnostic failed. 2. Replace GUI alarm assembly.
test failed 3. Replace GUI CPU PCB.

FE0901 Bad alarm cable EST BDU Audio Failure Alarm cable voltage is 1. Make sure BD alarm cable is
Test out of range (< 3.5 or connected.
> 5.05 V). 2. Replace BD alarm.
3. Replace AI PCB.
4. Replace BD alarm cable.

FE0902 Bad power fail EST BDU Audio Failure Power failure capacitor 1. Make sure BD alarm cable is
cap Test initial voltage is out of connected.
range (< 4.5 or > 5.05 2. Replace BD alarm.
V). 3. Replace AI PCB.
4. Replace BD alarm cable.
5. Replace Motherboard PCB.

FE0903 Bad power fail EST BDU Audio Failure Power failure capacitor 1. Make sure BD alarm cable is
cap Test final voltage is out of connected.
range or RC constant 2. Replace BD alarm.
< 60 s. 3. Replace AI PCB.

FE0904 Bad BD audio EST BDU Audio Failure CLEAR key pressed to 1. Make sure BD alarm cable is
Test indicate user did not connected.
hear alarm, although 2. Replace BD alarm.
alarm was active. 3. Replace AI PCB.
4. Replace BD alarm cable.

FE1101 Safety valve EST Safety Failure Excessive safety valve Replace safety valve.
occluded System Test back pressure when
safety valve is open.

FE1102 Bad safety valve EST Safety Failure Safety valve loopback 1. Replace safety valve.
driver or System Test current is out of range 2. Replace AI PCB.
loopback during one or more of 3. Replace Inspiratory Electronics
timed test points. PCB.
FE1103 Insp check valve EST Safety Failure It took too long to 1. Make sure proper test circuit is
test failed System Test relieve excess pressure used.
through open safety 2. Make sure CV3 is not installed
valve, indicating backward.
inspiratory check valve 3. Replace CV3.
(CV3) is occluded or 4. Replace Safety Valve (SV).
test circuit is too large.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-25
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE1105 Unable to EST Safety Failure Flow controller unable 1. M ake sure air supply is con-
establish flow System Test to establish and control nected and unrestricted.
gas flow at 60 L/ min. 2. Check air regulator pressure.
3. Run flow sensor calibration.
4. Switch PSOLs to see if test
passes. If it does, return PSOL1
to its original position and
replace PSOL2.
5. Replace Q2.
FE1301 Seal test failed EST Exp Valve Failure Seal test ∆ pressure is 1. Clean exhalation valve.
Seal Test above failure level. 2. Calibrate exhalation valve.
3. Run flow sensor calibration.
4. Replace exhalation valve.
5. Replace AI PCB.
6. Replace PE.

FE1302 Exp valve temp EST Exp Valve Failure Exhalation valve 1. Ensure the unit has been
OOR Seal Test magnet temperature warmed up at ambient temper-
out of range (10 to ature for at least 10 minutes.
100oC). 2. Calibrate the exhalation valve
(EV).
3. Replace exhalation valve (EV).
4. Replace AI PCB.

FE1303 Unable to EST Exp Valve Failure Flow controller unable 1. M ake sure proper test circuit it
establish exp Seal Test to establish and control used and that there are no
flow air flow measured by leaks or occlusions.
exhalation flow sensor 2. M ake sure air supply is still con-
(Q3). nected.
3. Run flow sensor calibration.
4. Replace Q3.
5. Replace Q2.
6. Replace the exhalation valve.

FE1304 Exp valve not EST Exp Valve Failure Exhalation valve table 1. Check for leaks or occlusions.
calibrated Seal Test checksum isnot valid or Correct and then run the exha-
last calibration lation valve calibration.
performed was not 2. Replace the exhalation valve.
completed successfully. 3. Replace the AI PCB.
4. Replace Q3.
5. Replace Q2.
FE1401 Bad calibration EST Exp Valve Failure Measured system 1. Calibrate exhalation valve.
Test pressure at one or more 2. Replace exhalation valve.
test points is out of 3. Replace AI PCB.
range. 4. Replace the Exhalation Pressure
Transducer PCB.
FE1402 Exp valve not EST Exp Valve Failure Exhalation valve table 1. Check for leaks or occlusions.
calibrated Test checksum isnot valid or Correct and then run the exha-
last calibration lation valve calibration.
performed was not 2. Replace the exhalation valve.
completed successfully. 3. Replace the AI PCB.
4. Replace Q3.
5. Replace Q2.

6-26 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FE1403 Unable to EST Exp Valve Failure Flow controller unable 1. Check for leaks or occlusions.
establish exp Test to establish and control Correct and then run the exha-
flow air flow measured by lation valve calibration.
exhalation flow sensor 2. Replace the exhalation valve.
(Q3). 3. Replace the AI PCB.
4. Replace Q3.
5. Replace Q2.
FE1501 Unable to EST Exp Heater Failure Flow controller unable 1. Make sure air supply is con-
establish air flow Test to establish and control nected and unrestricted.
60 L/ min air flow. 2. Check air regulator pressure.
3. Run flow sensor calibration.
4. Switch PSOLs to see if test
passes. If it does, return PSOL1
to its original position and
replace PSOL2.
5. Replace Q2.

FE1502 Bad exp heater EST Exp Heater Failure Exhalation heater 1. Replace exhalation heater.
Test temperature did not 2. Replace AI PCB.
rise sufficiently when 3. Replace interconnect cable
heater was turned on. between exhalation compart-
ment and motherboard.
FE1503 Bad exp heater EST Exp Heater Failure Heater temperature did 1. Replace exhalation heater.
Test not drop sufficiently 2. Replace AI PCB.
during an interval after
heater was turned off.

FE2201 Low exp ∆P EV Velocity Failure Expiratory ∆ P too low, 1. Check for leaks or occlusions.
Transducer Test indicating velocity Correct and then run the exha-
transducer not lation valve calibration.
responding properly. 2. Run flow sensor calibration.
3. Replace exhalation valve.
4. Replace Q3.
5. Replace Q2.

FE2301 Nurse call stuck EST GUI Nurse Failure CLEAR key pressed to 1. Make sure test equipment is
on Call Test indicate nurse’s call connected properly to remote
(remote alarm) relay is alarm port.
stuck on when it should 2. Replace GUI CPU PCB.
be off.

FE2302 Nurse call stuck EST GUI Nurse Failure CLEAR key pressed to 1. Make sure test equipment is
off Call Test indicate nurse’s call connected properly to remote
(remote alarm) relay is alarm port.
stuck off when it should 2. Replace GUI CPU PCB.
be on.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-27
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

NOTE:
For all "FS" codes (failures reported during SST), if the corrective action indicated is to run an EST
to further diagnose the problem, perform the repair after the EST, verify the fix in EST, and then
rerun SST in order to enter normal ventilator operation. If there is a failed SST test result in
memory, normal operation until is prevented until the failed SST test is rerun and passes.

FS0001 O2 flow sensor SST Flow Failure Oxygen flow sensor 1. Correct the leak or occlusion in
cross check Sensor Test (Q1) cross-check failed. the SST patient circuit and
failed rerun or try known good
patient circuit and filter set.
2. Verify that the ventilator sys-
tem has no leaks or occlusions
by running the first four tests in
EST to run the leak test.
a. If the leak test fails in EST,
troubleshoot the expiratory
filter or ventilator system for
leaks or occlusions.
b. If the leak test passes in EST,
troubleshoot the SST patient
circuit.
3. Run a flow sensor calibration.
4. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the air side, return Q2 back to
its original position and replace
Q1.
5. Replace Q3
6. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL2 back to its
original position and replace
PSOL1.

FS0002 O2 PSOLcurrent SST Flow Failure Oxygen PSOL (PSOL1) 1. M ake sure oxygen supply is
out of range Sensor Test command current is connected and unrestricted.
out of range with 2. Verify that the oxygen supply is
respect to oxygen flow good.
sensor (Q1). 3. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
4. Run a flow sensor calibration.
5. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the air side, return Q2 back to
its original position and replace
Q1.
6. Replace Q3.
7. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL2 back to its
original position and replace
PSOL1.

6-28 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FS0003 Air flow sensor SST Flow Failure Air flow sensor (Q2) 1. Correct the leak or occlusion in
cross check Sensor Test cross-check failed. the SST patient circuit and
failed rerun or try known good
patient circuit and filter set.
2. Verify that the ventilator sys-
tem has no leaks or occlusions
by running the first four tests in
EST to run the leak test.
3. If the leak test fails in EST, trou-
bleshoot the expiratory filter or
ventilator system for leaks or
occlusions.
4. If the leak test passes in EST,
troubleshoot the SST patient
circuit.
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the oxygen side, return Q1
back to its original position and
replace Q2.
7. Replace Q3.
8. Switch PSOLs to see if the fail-
ure transfers to the oxygen
side. If yes, return PSOL1 back
to its original position and
replace PSOL2.

FS0004 Air PSOL current SST Flow Failure Air PSOL (PSOL2) 1. Make sure air supply is con-
out of range Sensor Test command current is nected and unrestricted.
out of range with 2. Verify that the air supply is
respect to air flow good.
sensor (Q2). 3. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
4. Run a flow sensor calibration.
5. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the oxygen side, return Q1
back to its original position and
replace Q2.
6. Replace Q3.
7. Switch PSOLs to see if the fail-
ure transfers to the oxygen
side. If yes, return PSOL1 back
to its original position and
replace PSOL2.

FS0005 Gas not SST Flow Failure No gas is available Connect gas supply.
connected Sensor Test (neither PS1, PS2, nor
PC detects pressure).

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-29
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FS0006 Unable to SST Flow Failure Flow controller unable 1. M ake sure oxygen supply is
establish O2 Sensor Test to establish and control connected and unrestricted.
flow oxygen flow at 60, 5, 2. Verify that the oxygen supply is
and 1 L/ min. good.
3. Check regulated oxygen pres-
sure.
4. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the air side, return Q2 back to
its original position and replace
Q1.
7. Replace exhalation flow sensor
(Q3).
8. Switch PSOLs to see if the fail-
ure transfers to the air side. If
yes, return PSOL2 back to its
original position and replace
PSOL1.
FS0007 Unable to SST Flow Failure Flow controller unable 1. M ake sure air supply is con-
establish air flow Sensor Test to establish and control nected unrestricted.
air flow at 60, 5, and 2. Verify that the air supply is ade-
1 L/ min. quate.
3. Check regulated air pressure.
4. Verify that the system has no
leaks or occlusions. If not sure,
run the first four tests in EST to
run the leak test.
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and
EST. If the failure transfers to
the oxygen side, return Q1
back to its original position and
replace Q2.
7. Replace exhalation flow sensor
(Q3).
8. Switch PSOLs to see if the fail-
ure transfers to the oxygen
side. If yes, return PSOL1 back
to its original position and
replace PSOL2.

6-30 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FS0008 O2 zero flow SST Flow Failure Inspiratory flow > 0.153 1. Verify no leaks at the Q1
check failed Sensor Test L/ min with oxygen O-rings.
PSOL (PSOL1) 2. Run EST Gas Supply Test to
commanded to 0 check for PSOL1 leak.
(closed). 3. Remove and then reseat
PSOL1.
4. Replace PSOL1.
5. Perform a flow sensor calibra-
tion.
6. Replace Q1.

FS0009 Air zero flow SST Flow Failure Inspiratory flow > 0.153 1. Verify no leaks at the Q2
check failed Sensor Test L/ min with air PSOL O-rings.
(PSOL2) commanded 2. Run EST Gas Supply Test to
to 0 (closed). check for PSOL2 leak.
3. Remove and then reseat
PSOL2.
4. Replace PSOL2.
5. Perform a flow sensor calibra-
tion.
6. Replace Q2.

FS0101 Inspiratory SST circuit Failure Inspiratory pressure 1. Replace Inspiratory Electronics
autozero out of pressure test transducer ADC count PCB
range at 0 cmH2O is out of 2. Replace AI PCB.
range.

FS0102 Expiratory SST circuit Failure Expiratory pressure 1. Replace exhalation transducer
autozero out of pressure test transducer ADC count PCB.
range at 0 cmH2O is out of 2. Replace AI PCB.
range. 3. Replace SOL1.

FS0103 Failed to reach SST circuit Failure Unable to build 1. Verify that the patient circuit
test pressure pressure test pressure (air) to 10 system has no leaks or occlu-
cmH2O at sions or use a known good
5 L/ min within time-out patient circuit and filter set.
period. 2. Verify that the air supply or
compressor is available and
adequate.
3. Verify that the ventilator sys-
tem has no leaks or occlu-
sions. If not sure, run the first
four tests in EST to run the leak
test.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-31
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FS0104 Cross-check SST circuit Failure Inspiratory/ expiratory 1. Verify that the patient circuit
failed pressure test pressure transducer system has no leaks or occlu-
readings at 10 cmH20 sions or use a known good
test pressure are too far patient circuit and filter set.
apart. 2. Verify that the ventilator sys-
tem has no leaks or occlu-
sions. If not sure, run the first
four tests in EST to run the leak
test.
3. If the leak test passes in EST,
exit out of EST. Review the
data for the Circuit Pressure
Test to determine which pres-
sure transducer is out of range:
PI or PE. Replace applicable
pressure transducer.
4. Replace AI PCB.

FS0105 Bad insp SST circuit Failure Inspiratory pressure 1. Replace SOL1.
autozero pressure test reading taken after 2. Replace Inspiratory Electronics
solenoid actuating inspiratory PCB.
pressure transducer 3. Replace AI PCB.
autozero solenoid
(SOL1) is out of range
(-0.60 to 0.60 cmH2O).
FS0106 Bad exp SST circuit Failure Expiratory pressure 1. Replace SOL2.
autozero sol pressure test reading taken after 2. Replace exhalation transducer
actuating expiratory PCB.
transducer autozero 3. Replace AI PCB.
solenoid (SOL2) is out
of range (-0.60 to
0.60 cmH2O).
FS0107 Cross-check SST circuit Failure Inspiratory/ expiratory 1. Replace the expiratory bacteria
failed pressure test pressure transducer filter.
readings at 50 or 100 2. Verify that the system has no
cmH2O test pressure leaks or occlusions. If not sure,
are too far apart. run the first four tests in EST to
run the leak test.
3. If the leak test passes in EST,
exit out of EST. Review the
data for the EST Circuit Pres-
sure Test to determine which
pressure transducer is out of
range: PI or PE. Replace appli-
cable pressure transducer.
4. Replace AI PCB.

FS0108 Failed to reach SST circuit Failure Unable to build 1. M ake sure air supply or com-
test pressure pressure test pressure (air) to 50 or pressor is available.
100 cmH2O at 2. Check for system leak.
5 L/ min within time-out
period.

6-32 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

FS0201 Excessive leak SST Circuit leak Failure System pressure 1. Make sure patient circuit is
dropped below failure connected and is not leaking.
pressure level. 2. Check exhalation valve opera-
tion, and verify secure connec-
tions of bacteria filters, water
traps, and humidifier.

FS0205 Unable to SST Circuit leak Failure Unable to attain leak 1. Make sure patient circuit is
establish test starting pressure connected and is not leaking.
pressure within time-out period 2. Check exhalation valve opera-
using oxygen or air. tion, and verify secure connec-
tions of bacteria filters, water
traps, and humidifier.

FS0301 Unable to SST Expiratory Failure Flow controller unable Make sure gas supply is still
establish flow filter to establish and control connected.
gas flow.

FS0303 Occluded SST Expiratory Failure Exhalation 1. Check compartment for

expiratory filter compartment pressure obstruction.
compartment > 4 cmH2O. 2. Verify exhalation valve opera-
tion by running EST.
FS0304 Occluded SST Expiratory Failure Pressure drop across Replace expiratory filter.
expiratory filter filter filter > 3 cmH2O.

FS0306 Patient circuit SST Expiratory Failure A test flow was used to Make sure patient circuit is
not filter verify that circuit was disconnected at expiratory filter.
disconnected disconnected, and an
expiratory flow was
detected.

FS0307 Patient circuit SST Expiratory Failure A test flow was used to Make sure patient circuit is
not filter verify that circuit was connected at expiratory filter.
reconnected reconnected, and an
expiratory flow was not
detected.

FS0310 Low expiratory SST Expiratory Failure Pressure drop across 1. Repeat test, following direc-
filter ∆P filter expiratory filter < 0.1 tions more closely.
cmH2O. 2. Replace filter.
FS0401 Unable to SST Circuit Failure Flow controller unable Make sure gas supply is connected.
establish flow Resistance to establish and control
gas flow.

FS0402 Occluded SST Circuit Failure Inspiratory limb Check for occluded patient tubing.
inspiratory limb Resistance pressure > 12.5 cmH2O
(adult) or 7.5 cmH2O
(pediatric), indicating
occlusion.

FS0404 Unable to reach SST Circuit Failure During characterization Check for kinked or occluded
min peak flow Resistance of total circuit patient tubing.
resistance over a range
of flows, peak flow was
less than failure
threshold.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-33
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

FS0405 Occluded SST Circuit Failure Expiratory limb Check for occluded patient tubing.
exhalation limb Resistance pressure > 12.5 cmH2O
(adult) or 7.5 cmH2O
(pediatric), indicating
occlusion.

FS0408 Insp limb SST Circuit Failure Inspiratory limb 1. M ake sure inspiratory filter is
resistance low Resistance pressure < 0.2 cmH2O. installed.
2. Repeat test, following direc-
tions more closely.
3. Replace inspiratory filter.
4. Replace patient circuit.

FS0409 Exp limb SST Circuit Failure Expiratory limb Replace patient circuit.
resistance low Resistance pressure < 0.2 cmH2O.

FS0410 Unable to reach SST Circuit Failure During characterization Check for kinked or occluded
min peak flow Resistance of total circuit patient tubing.
resistance over a range
of flows, peak flow was
less than failure
threshold.
FS0412 Wye not SST Circuit Failure Unable to pressurize 1. Block wye when prompted.
blocked Resistance system within time-out 2. Check for circuit leaks.
period.

FS0501 Unable to SST Failure System cannot Check patient circuit for leaks.
pressurize Compliance pressurize to one of the Replace as necessary.
circuit calibration test pressure points.

FS0502 Unable to SST Failure System cannot Check patient circuit for leaks.
pressurize Compliance pressurize to one of the Replace as necessary.
circuit calibration test pressure points.

FS0503 Compliance SST Failure Out-of-range pressure 1. Repeat test, making sure circuit
calculation Compliance ratio calculation. is undisturbed during test.
failure calibration 2. Repeat SST to retest pressure
transducers.
3. Run EST and verify all pneu-
matics tests pass.
FS0504 Excessive SST Failure High compliance > 1. M ake sure correct patient tub-
compliance Compliance 12 mL/ cmH2O (adult) ing type was specified in SST.
calibration or 9 mL/ cmH2O 2. Replace patient circuit.
(pediatric).

FS0506 Compliance low SST Failure High compliance falls 1. M ake sure correct patient tub-
Compliance below 1.05 mL/ cmH2O ing type was specified in SST.
calibration 2. Replace patient circuit.

FS0508 Excessive SST Failure Low compliance > 1. M ake sure correct patient tub-
compliance Compliance 12 mL/ cmH2O (adult) ing type was specified in SST.
calibration or 9 mL/ cmH2O 2. Replace patient circuit.
(pediatric).

FS0510 Compliance low SST Failure Low compliance falls 1. M ake sure correct patient tub-
Compliance below 1.05 mL/ cmH2O ing type was specified in SST.
calibration 2. Replace patient circuit.

6-34 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

HN0001 Non-maskable Other (BDU) BDU reset Replace BD CPU PCB.

interrupt (NMI):
Dynamic
random access
memory
(DRAM) Parity
Error

HN0002 NM I: Ethernet Other (BDU) BDU reset Replace BD CPU PCB.

Parity Error
HN0016 NM I: Analog Other (BDU) BDU reset 1. Replace AI PCB.
Interface Error: 2. Replace BD CPU PCB.
analog to digital
converter (ADC)
Channel
Sequencer Fault

HN0016 NM I: Analog Other (BDU) BDU reset 1. Replace AI PCB.

Interface Error: 2. Replace BD CPU PCB.
ADC Timing
Fault

HN0016 NM I: Analog Other (BDU) BDU reset 1. Replace AI PCB.

Interface Error: 2. Replace BD CPU PCB.
Hamming
Decode Fault

HN0080 NM I: Analog Other (BDU) BDU reset Replace AI PCB.

Interface Error:
ADC Timing
Fault

HN0129 NM I: DRAM Other (BDU) BDU reset 1. Check GUI/ BD cable connec-
Parity Error tions.
2. Replace power supply.
3. Replace BD CPU PCB.
HN0130 NM I: Ethernet Other (BDU) BDU reset 1. Check GUI/ BD cable connec-
Parity Error tions.
2. Replace power supply.
3. Replace BD CPU PCB.

KB0001 Bad safety valve Background Vent inop Measured voltage on 1. Replace safety valve.
switched side check (BDU) safety valve switched 2. Replace AI PCB.
side indicates valve is 3. Replace Inspiratory Electronics
not in expected state. PCB.
4. Replace interconnect cable
between the mother board and
the Inspiratory Electronics PCB.

KB0002 Bad expiratory Background Vent inop Exhalation flow sensor 1. If possible, run EST and use the
flow check (BDU) (Q3) reading out of Flow Sensor Cross Check test
range to determine if Q3 is failing.
Replace Q3 if applicable.
2. Perform flow sensor calibra-
tion.
3. Replace AI PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-35
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

KB0003 Bad O2 PSOL Background Vent inop Oxygen PSOL (PSOL1) 1. If possible, run EST to deter-
current check (BDU) current out of range mine if PSOL1 is failing. Switch
PSOLs to see if the failure trans-
fers to the other side. Replace
PSOL1 if applicable.
2. Replace AI PCB.
3. Replace Inspiratory Electronics
PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.
KB0004 Bad air PSOL Background Vent inop Air PSOL (PSOL2) 1. If possible, run EST to deter-
current check (BDU) current out of range mine if PSOL2 is failing. Switch
PSOLs to see if the failure trans-
fers to the other side. Replace
PSOL2 if applicable.
2. Replace AI PCB.
3. Replace Inspiratory Electronics
PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.

KB0005 Bad exp motor Background Vent inop Current to exhalation 1. Perform exhalation valve (EV)
current check (BDU) valve motor out of calibration.
range 2. Replace EV.
3. Replace AI PCB.

KB0007 Bad exp Background Vent inop PE reading out of range 1. Replace exhalation transducer
pressure check (BDU) PCB.
2. Replace AI PCB.

KB0008 Bad insp Background Vent inop PI reading out of range 1. Replace Inspiratory Electronics
pressure check (BDU) PCB.
2. Replace AI PCB.

KB0009 Air flow out of Background Vent inop Q2 reading too high 1. Perform flow sensor calibra-
range HIGH check (BDU) tion.
2. Replace Q2.
3. Replace AI PCB.

KB0012 O2 flow out of Background Vent inop Q1 reading too high 1. Perform flow sensor calibra-
range HIGH check (BDU) tion.
2. Replace Q1.
3. Replace AI PCB.

KB0016 Bad BD 10V Background Vent inop BDU +10 V supply out Replace AI PCB.
supply check (BDU) of range

KB0017 Bad BD 12 V Background Vent inop BDU +12 V supply out 1. Replace AI PCB.
supply check (BDU) of range 2. Replace power supply or other
power input components.

KB0018 Bad BD 15 V Background Vent inop BDU +15 V supply out 1. Replace AI PCB.
supply check (BDU) of range 2. Replace power supply or other
power input components.

6-36 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

KB0019 Bad BD -15 V Background Vent inop BDU -15 V supply out 1. Replace AI PCB.
check (BDU) of range 2. Replace power supply or other
power input components.

KB0022 Bad BD 5 V Background Vent inop BDU +5 V supply out of 1. Replace AI PCB.
supply check (BDU) range 2. Replace power supply or other
power input components.

KB0023 O2 PSOL stuck Background Vent inop Oxygen PSOL (PSOL1) 3. If possible, run EST to deter-
check (BDU) command current out mine if PSOL1 is failing. Switch
of range PSOLs to see if the failure trans-
fers to the other side. Replace
PSOL1 if applicable.
4. Replace AI PCB.
5. Replace Inspiratory Electronics
PCB.
6. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.

KB0024 Air PSOL stuck Background Vent inop Air PSOL (PSOL2) 1. If possible, run EST to deter-
check (BDU) command current out mine if PSOL2 is failing. Switch
of range PSOLs to see if the failure trans-
fers to the other side. Replace
PSOL2 if applicable.
2. Replace AI PCB.
3. Replace Inspiratory Electronics
PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.
KB0025 Air PSOL stuck Background Vent inop Air PSOL (PSOL2) 1. If possible, run EST to deter-
open check (BDU) command current mine if PSOL2 is failing. Switch
reading indicates PSOL PSOLs to see if the failure trans-
stuck open fers to the other side. Replace
PSOL2 if applicable.
2. Replace AI PCB.
3. Replace Inspiratory Electronics
PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.

KB0026 O2 PSOL stuck Background Vent inop PSOL1 command 1. If possible, run EST to deter-
open check (BDU) current reading mine if PSOL1 is failing. Switch
indicates PSOL stuck PSOLs to see if the failure trans-
open fers to the other side. Replace
PSOL1 if applicable.
2. Replace AI PCB.
3. Replace Inspiratory Electronics
PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-37
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

KB0030 Bad safety valve Background Vent inop Current to safety valve 1. Replace safety valve.
current check (BDU) out of range 2. Replace AI PCB.
3. Replace Inspiratory Electronics
PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.
KB0031 Insp pressure Background Vent inop Inspiratory pressure 1. Replace Inspiratory Electronics
stuck check (BDU) transducer (PI) reading PCB.
indicates transducer is 2. Replace AI PCB.
stuck

KB0032 Exp pressure Background Vent inop Expiratory pressure 1. Replace exhalation transducer
stuck check (BDU) transducer (PE) reading PCB.
indicates transducer is 2. Replace AI PCB.
stuck

KB0033 Insp pressure Background Vent inop Inspiratory pressure 1. Replace inspiratory pressure
autozero offset check (BDU) transducer (PI) reading transducer autozero solenoid
failed following autozero out (SOL1).
of range 2. Replace Inspiratory Electronics
PCB.
3. Replace AI PCB.

KB0034 Exp pressure Background Vent inop Expiratory pressure 1. Replace expiratory pressure
autozero offset check (BDU) transducer (PE) reading transducer autozero solenoid
failed following autozero out (SOL2).
of range 2. Replace exhalation transducer
PCB.
3. Replace AI PCB.

KB0037 Analog-Digital Background Vent inop Analog-to-digital Replace AI PCB.

converter failed check (BDU) converter failure
high

KB0038 Analog-Digital Background Vent inop Analog-to-digital Replace AI PCB.

converter failed check (BDU) converter failure
low

KB0039 Analog-Digital Background Vent inop Analog-to-digital Replace AI PCB.

loopback failed check (BDU) converter failure

KB0044 BD NOVRAM Background Vent inop BD NOVRAM failure Replace BD CPU PCB.
checksum error check (BDU)

KB0053 BD EEPROM Background Vent inop BD EEPROM failure Replace BD CPU PCB.
checksum error check (BDU)

KB0064 LV Ref out of Background Vent inop Low-voltage reference Replace AI PCB.
range check (BDU) out of range

KB0065 SV current out Background Vent inop Safety valve current out 1. Replace safety valve.
of range check (BDU) of range 2. Replace Inspiratory Electronics
PCB.
3. Replace AI PCB.
4. Replace interconnect cable
between the motherboard and
the Inspiratory Electronics PCB.

6-38 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

KB0076 Task M onitor Background Vent inop Replace BD CPU PCB.

check (BDU)

KB0079 BK vent inop Background Vent inop Ventilator inoperative 1. Run the VENT INOP test.
occurred check (BDU) signal read by BDU is a. If the test passes, run EST to
active. This could mean reset the Device Alert. Run
GUI has declared a the unit for 48 hours and
ventilator inoperative then put back into service if
condition. the code cannot be dupli-
cated.
b. If the test fails, troubleshoot
per Table 6-5, VENT INOP
Test troubleshooting.

KB0082 Watchdog Background Vent inop Replace BD CPU PCB.

failure occurred check (BDU)

KP0001 Processor POST (BDU) Vent inop Replace BD CPU PCB.

Initialization

KP0002 Integer Unit POST (BDU) Vent inop Replace BD CPU PCB.
Test

KP0003 DRAM Refresh POST (BDU) Vent inop Replace BD CPU PCB.
Timer Test

KP0004 Kernel DRAM POST (BDU) Vent inop Replace BD CPU PCB.
Test

KP0005 Boot EPROM POST (BDU) Vent inop Replace BD CPU PCB.
Checksum Test

KP0006 POST Phase 2 POST (BDU) Vent inop Replace BD CPU PCB.
Initialization

KP0007 Addressing POST (BDU) Vent inop Replace BD CPU PCB.

Mode Test

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-39
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

KP0008 Kernel POST (BDU) Vent inop Replace BD CPU PCB.

NOVRAM Test

KP0009 Rolling Thunder POST (BDU) Vent inop POST has started (but 1. Replace AI PCB.
Test not run to completion) 2. Replace BD CPU PCB.
three or more times, for 3. Replace motherboard.
reasons unrelated to
power.
KP0011 Time of Day POST (BDU) Vent inop Replace BD CPU PCB.
Clock Test

KP0012 Timer Test POST (BDU) Vent inop Timer failed Replace BD CPU PCB.
comparison test with
real-time clock
(external timing
reference)
or
Timer failed to generate
interrupt

KP0013 Watchdog POST (BDU) Vent inop Watchdog timer did Replace BD CPU PCB.
Timer Test not time out as
expected

KP0015 FLASH Memory POST (BDU) Vent inop Replace BD CPU PCB.
Checksum Test

KP0081 Memory POST (BDU) Vent inop Replace BD CPU PCB.

Management
Unit Test

KP0082 Bus Timer Test POST (BDU) Vent inop Activity has ceased on Replace BD CPU PCB.
local bus
or
Bus time-out circuit did
not generate an
interrupt as expected

KP0083 NMI Source POST (BDU) Vent inop Replace BD CPU PCB.
Register Test

KP0084 POST DRAM POST (BDU) Vent inop Replace BD CPU PCB.
Test

6-40 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

KP0087 Unexpected POST (BDU) Vent inop POST has been invoked 1. Check associated errors in the
Reset Umpire three times in 24 System Diagnostic and System
Test operational hours due Information log to determine
to unexpected resets. why POST was invoked three
times within 24 hours.
If the codes indicate that the BD
CPU generated the resets,
replace the BD CPU (Other
codes may be present
indicating that the GUI lost
communications with the BD).
2. Run a complete EST to check
for analog device failures.

KP0089 Floating Point POST (BDU) Vent inop Replace BD CPU PCB.
Unit Test

KP0090 DRAM Parity POST (BDU) Vent inop Replace BD CPU PCB.
Circuit Test

KP0113 Analog Interface POST (BDU) Vent inop 1. Replace BD CPU PCB.
PCB Test 2. Replace AI PCB.
3. Replace motherboard.

KP0114 ADC Test POST (BDU) Vent inop Analog-to-digital 1. Replace AI PCB.
converter data not 2. Replace motherboard.
available to CPU as
expected
KP0115 DAC Test POST (BDU) Vent inop Digital-to-analog 1. Replace AI PCB.
converter data not as 2. Replace motherboard.
expected

KP0116 Analog Devices POST (BDU) Vent inop Critical analog data out 1. Refer to Section 6.8 to identify
Test of range which analog device is failing.
2. Run EST to get more informa-
tion on the analog device fail-
ure.
3. Replace the AI PCB.
4. Replace the motherboard.
5. Replace the interconnect cable
between the Inspiratory Elec-
tronics PCB and the mother-
board.

KP0117 BD Serial Device POST (BDU) Vent inop 1. Replace AI PCB.

Test 2. Replace BD CPU PCB.
3. Replace the motherboard.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-41
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

KP0120 Safe State POST (BDU) Vent inop Places PSOLs and 1. Look up associated codes
System Test exhalation valve into reported in Diagnostic Log
safe state and verifies and/ or the BD CPU LED array
that they cannot be to get more information about
commanded. other possible system, soft-
ware, or hardware faults.
Troubleshoot those codes.
2. Run a Ground Isolation Test to
troubleshoot shorts.
3. Try another inspiratory mod-
ule and see if the code can be
reset by running the VENT
INOP, EST and POST tests.
a. If the unit passes with a
known good inspiratory
module, replace the Inspira-
tory Electronics PCB.
b. If the unit fails, replace the
inspiratory blind mate inter-
connect cable.
4. Replace the Inspiratory Elec-
tronics PCB.
5. Replace the AI PCB.
6. Replace the BD CPU PCB.
KP0128 Download POST (BDU) Vent inop Replace BD CPU PCB.
operating
system (OS)
Boot

KP0129 Application OS POST (BDU) Vent inop Replace BD CPU PCB.

Boot

KP0130 PB-MON Boot POST (BDU) Vent inop Replace BD CPU PCB.

KP0131 Application POST (BDU) Vent inop Replace BD CPU PCB.

Boot

LB0006 Bad exhalation Background Alert Exhalation valve coil 1. Replace exhalation valve.
valve coil temp. check (BDU) temperature out of 2. Replace AI PCB.
range 3. Replace interconnect harness
between the exhalation com-
partment connector and the
motherboard.
LB0010 Air flow out of Background Alert Air flow sensor (Q2) 1. Perform flow sensor calibra-
range LOW check (BDU) reading too low tion.
2. Replace Q2.
3. Replace AI PCB.

6-42 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

LB0011 Bad air flow Background Alert Air flow sensor (Q2) 1. Replace Q2.
temperature check (BDU) thermistor reading out 2. Replace AI PCB.
of range

LB0013 O2 flow out of Background Alert Oxygen flow sensor 1. Ensure that the ventilator has
range LOW check (BDU) (Q1) reading too low been warmed up for at least 10
minutes in service mode at
ambient temperature.
2. Run a flow sensor calibration.
3. Replace Q1.4.Replace the AI
PCB.

LB0014 Bad O2 flow Background Alert Oxygen flow sensor 1. Replace Q1.
temp. check (BDU) (Q1) thermistor reading 2. Replace AI PCB.
out of range

LB0015 Bad expiratory Background Alert Expiratory flow sensor 1. Replace Q3.
flow temp check (BDU) (Q3) thermistor reading 2. Replace AI PCB.
out of range

LB0020 Bad GUI 12V Background Alert GUI +12 V supply out of 1. Check cabling from BD CPU
supply check (BDU) range PCB to GUI CPU PCB.
2. Replace AI PCB.
3. Replace power supply.
4. Check whether or not the cable
from the GUI to the BDU was
reconnected to the unit while
the ventilator power was on. If
yes, run EST to reset the
DEVICE ALERT.
LB0021 Bad GUI 5V Background Alert GUI +5 V supply out of 1. Check cabling from BD CPU
supply check (BDU) range. PCB to GUI CPU PCB.
2. Replace AI PCB.
3. Replace power supply.
4. Check whether or not the cable
from the GUI to the BDU was
reconnected to the unit while
the ventilator power was on. If
yes, run EST to reset the
DEVICE ALERT.

LB0027 Bad Background Alert Atmospheric pressure 1. Perform atmospheric pressure

atmospheric check (BDU) transducer reading out calibration.
press OOR of range 2. Replace Inspiratory Electronics
PCB.
3. Replace AI PCB.

LB0028 Bad O2 sensor Background Alert Oxygen sensor 1. Calibrate oxygen sensor.
OOR check (BDU) (percentage) reading 2. Replace oxygen sensor.
out of range

LB0029 Bad O2 sensor Background Status A status message No action required.

OOR reset check (BDU) indicating that alert was
reset

LB0035 Bad power fail Background Alert Power fail capacitor 1. Replace AI PCB.
capacitor check (BDU) voltage out of range 2. Replace power supply.
voltage

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-43
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

LB0036 Alarm cable Background Alert Alarm cable voltage out 1. Check cabling to main alarm.
error check (BDU) of range 2. Replace BD alarm.
3. Replace AI PCB.

LB0039 ADC loopback Background Alert Replace AI PCB.

constant checks (BDU)

LB0043 ac switch stuck Background Alert Power switch is in off 1. Replace power switch.
check (BDU) state but power fail 2. Replace AI PCB.
NMI did not occur
LB0045 BD Time of Day Background Alert Real-time clock failure Replace BD CPU PCB.
failed check (BDU)

LB0048 Bad backup Background Alert BPS voltage out of 1. Replace BPS battery pack.
power supply check (BDU) range 2. Replace AI PCB.
voltage 3. Replace BPS PCB.

LB0049 Bad backup Background Alert BPS current out of 1. Replace BPS battery pack.
power supply check (BDU) range 2. Replace AI PCB.
current 3. Replace BPS PCB.

LB0050 Bad backup Background Alert Model information Replace BPS PCB.
power supply check (BDU) incorrect
model

LB0051 Bad exp heater Background Alert Exhalation heater 1. Replace exhalation heater.
check (BDU) thermistor reading out 2. Replace AI PCB.
of range 3. Replace interconnect cable
between the exhalation com-
partment and the mother-
board.

LB0056 Compressor Background Alert Compressor timer Replace compressor PCB.

elapsed timer check (BDU) failure
error

LB0057 Compressor bad Background Alert Data in compressor Replace compressor PCB.
eprom data check (BDU) EPROM not as expected

LB0058 Loss of GUI Background Alert 1. This code indicates that the BD
communication check (BDU) logged a loss of communica-
tions with the GUI. Check for
codes generated by the GUI
indicating a GUI fault.
2. Check cabling from BD CPU
PCB to the GUI CPU PCB.
3. Replace GUI CPU PCB or BD
CPU PCB.

LB0060 Resume GUI Background Status A status message No action required.

communication check (BDU) indicating that
communication with
GUI was resumed
LB0062 Est required Background Alert EST is required, but user Run EST.
check (BDU) cycled power into
normal operation,
rather than into service
mode

6-44 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

LB0075 Data key update Background Alert 1. Plug in data key.

failed check (BDU) 2. Contact Service or your
Puritan Bennett representative
for a new data key.

LB0076 Task monitor Background Alert No action required unless XP0087

checks (BDU) error is also present.

LB0080 Breath delivery Background Alert Replace BD CPU PCB.

extended checks (BDU)
LB0083 Init Resume GUI Background Status A status message No action.
Communication check (BDU) indicating that
communication with
GUI was resumed

LB0085 Init Loss GUI Background Status A status message No action.

Communication check (BDU) indicating that
communication with
GUI was lost

LB0087 Compressor S/ N Background Status No action.

updated check (BDU)
LB0088 10000 hours Background Alert Compressor hours Replace the compressor PCB.
stored for check (BDU) corrupted. Contact
elapsed time your Puritan Bennett
representative to reset.

LB0089 Cannot Background Alert Replace data key.

determine check (BDU)
datakey size
LB0092 Battery Event Background Alert A status message 1. Ensure that the green LED is lit
checks (BDU) regarding the state of on the front of the BPS.
the battery. a. If the green LED is not lit,
allow the BPSto charge until
the green LED lights.
b. If the green LED does not
light (within 6-8 hours or
less), replace the battery
pack.
c. Replace the BPS PCB
2. Once the green LED is lit, run
EST to test the BPS and use EST
diagnostics to determine if fur-
ther corrective action is
needed.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-45
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

LC1xxx Varies Communi- Alert 1. Ensure that the green LED is lit
cations error on the front of the BPS.
(BDU) a. If the green LED is not lit,
allow the BPSto charge until
the green LED lights.
b. If the green LED does not
light (within 6-8 hours or
less), replace the battery
pack.
c. Replace the BPS PCB
2. Once the green LED is lit, run
EST to test the BPS and use EST
diagnostics to determine if fur-
ther corrective action is
needed.

LP0008 Kernel POST (BD) Alert Noncritical NOVRAM Replace the BD CPU PCB.
NOVRAM Test data failure

LP0010 Interrupt POST (BD) Alert Replace BD CPU PC.

Controller Test

LP0011 Time of Day POST (BD) aLERT Replace BD CPU PCB.

Clock Test

LP0085 Ethernet Self- POST (BD) Alert Replace BD CPU PCB.

Test Start

LP0086 Ethernet Self- POST (BDU) Alert Replace BD CPU PCB.

Test End

LP0087 Unexpected POST (BDU) Alert POST was invoked due 1. Check all logs to see associated
Reset Umpire to a watchdog time-out errors occurring around the
Test (unexpected reset) same time and date as this
code.
2. Run EST to get more informa-
tion.

LP0088 POST NOVRAM POST (BDU) Alert Noncritical NOVRAM 1. Check all logs to see associated
Test data failure errors occurring around the
same time and date as this
code.
2. Run EST to get more informa-
tion.

LP0112 Ventilator INOP POST (BDU) Alert Ventilator inoperative 1. Replace the interconnect cable
Test signal not in expected between the Inspiratory Elec-
state tronics PCB and the mother-
board.
2. Run VENT INOP Test.
3. Replace BD CPU PCB.
LP0114 ADC Test POST (BD) Alert Replace AI PCB.

6-46 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

LP0115 DAC Test POST (BD) Alert Replace AI PCB.

LP0116 Analog Devices POST (BDU) Alert Noncritical analog data 1. Refer to Table 6-3: "Address
Test out of range codes for BDU POST analog
devices test errors".
2. Replace AI PCB.
LP0121 Service Switch POST (BDU) Alert Service switch appears 1. Turn off ventilator. Release
Stuck Test to be closed. (Only switch.
requests to enter 2. Check for mechanical obstruc-
service mode made tion to switch.
after this test are 3. Replace BD CPU PCB.
honored by system.)

LP0122 ac Voltage Test POST (BDU) Alert ac monitor voltage not 1. Make sure ventilator is plugged
within set nominal line into ac source.
voltage ±20% 2. Make sure nominal line voltage
is set correctly.

Sxxxxx Varies Other Status Status message that No action required.

indicates an
intentionally caused
event

Uxxxxx Assertion Failure Background Alert Check System Information and

check (GUI) Patient logs for any messages
occurring with a high
frequency.
Otherwise, no corrective action
unless accompanied by XP0087
diagnostic code.

U04004 Assertion Failure Background Alert Can occur if there is an 1. Check all cable connections.
check (GUI) intermittent connection 2. Perform Ground Isolation Test.
to any digital I/ O line. 3. Replace GUI CPU PCB.

U05013 Assertion Failure Background Alert Can occur if there is an 1. Check all cable connections.
check (GUI) intermittent connection 2. Perform Ground Isolation Test.
to any digital I/ O line. 3. Replace GUI CPU PCB.

U08002 Assertion Failure Background Alert Occurs when the GUI is 1. Check for wet expiratory or
check (BDU) overloaded with invalid inspiratory filter.
data from the serial 2. Check all cable connections:
port. Caused by the GUI, Serial, Internal cables.
host device transmit- 3. Review the ventilator logs,
ting bad data that is including patient logs, observe
generating over-run, any occurrences of rapidly
parity, or framing repeating messages. This pat-
errors. The GUI gener- tern may contribute to a buffer
ates a soft reset or overflow situation that the ven-
assertion to clear the tilator will attempt to clear by
condition and resyn- running POST.
chronize with the BDU. 4. Perform Ground Isolation Test.
5. Replace GUI CPU PCB.

U08012 Assertion Failure Background Alert The GUI generates a 1. Check all cable connections.
check (GUI) soft reset or assertion to 2. Perform Ground Isolation Test.
clear the condition and 3. Replace GUI CPU PCB.
re synchronize with the
BDU.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-47
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

U14019 Assertion Failure Background Alert The GUI generates a 1. Check all cable connections.
check (GUI) soft reset or assertion to 2. Perform Ground Isolation Test.
clear the condition and 3. Replace GUI CPU PCB.
resynthesized with the
BDU.

U14021 Assertion Failure Background Alert If the time stamps 1. Check all cable connections.
check (GUI) between the GUI and 2. Perform Ground Isolation Test.
the BD are out of range, 3. Replace GUI CPU PCB.
the GUI generates a soft
reset or assertion to
clear the condition
and re synchronize with
the BDU.

UT0002 Assertion Failure Background Alert A reset of the GUI has NOTE:
check (GUI) occurred as a result of a Refer to Section 6.10.1 for
hardware-trap further information
detection. regarding for this error
code.

1. Refer to Table 6-3: "Address

codes for BDU POST analog
devices test errors".

VN0129 NMI: DRAM Other (GUI) GUI reset 1. Check GUI/ BD cable connec-
Parity Error tions.
2. Replace power supply.
3. Replace GUI CPU PCB.

VN0130 NMI: Ethernet Other (GUI) GUI reset 1. Check GUI/ BD cable connec-
Parity Error tions.
2. Replace power supply.
3. Replace GUI CPU PCB.

VN0132 NMI: +5 V dc Other (GUI) GUI reset 1. Check GUI/ BD cable connec-
Overvoltage tions.
2. Replace power supply.
3. Replace GUI CPU PCB.

VN0136 NMI: +12 V dc Other (GUI) GUI reset 1. Check GUI/ BD cable connec-
Overvoltage tions.
2. Replace power supply.
3. Replace GUI CPU PCB.
VN0144 NMI: +12 V dc Other (GUI) GUI reset 1. Check GUI/ BD cable connec-
Undervoltage tions.
2. Replace power supply.
3. Replace GUI CPU PCB.

XB0066 Monitor alarms Background Vent inop Call Technical Support or your
fail checks (GUI) Puritan Bennett representative.

XB0067 Monitor apnea Background Vent inop Call Technical Support or your
alarm fails checks (GUI) Puritan Bennett representative.
XB0068 Monitor apnea Background Vent inop Call Technical Support or your
int fails checks (GUI) Puritan Bennett representative.

XB0069 Monitor hip fails Background Vent inop Call Technical Support or your
checks (GUI) Puritan Bennett representative.

6-48 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

XB0070 Monitor insp Background Vent inop Call Technical Support or your
time fails checks (GUI) Puritan Bennett representative.

XB0071 Monitor no data Background Vent inop Call Technical Support or your
checks (GUI) Puritan Bennett representative.

XB0072 Monitor data Background Vent inop Call Technical Support or your
corrupted checks (GUI) Puritan Bennett representative.

XB0073 Monitor O2 Background Vent inop Call Technical Support or your

mixture fails checks (GUI) Puritan Bennett representative.
XB0074 Monitor breath Background Vent inop Replace GUI CPU PCB.
time fails checks (GUI)

XP0001 Processor POST (GUI) GUI inop Replace GUI CPU PCB.
Initialization

XP0002 Integer Unit POST (GUI) GUI inop Replace GUI CPU PCB.
Test

XP0003 DRAM Refresh POST (GUI) GUI inop Replace GUI CPU PCB.
Timer Test

XP0004 Kernel DRAM POST (GUI) GUI inop Replace GUI CPU PCB.
Test

XP0005 Boot EPROM POST (GUI) GUI inop Replace GUI CPU PCB.
Checksum Test

XP0006 POST Phase 2 POST (GUI) GUI inop Replace GUI CPU PCB.
Initialization

XP0007 Addressing POST (GUI) GUI inop Replace GUI CPU PCB.
Mode Test

XP0008 Kernel POST (GUI) GUI inop Replace GUI CPU PCB.
NOVRAM Test

XP0010 Interrupt POST (GUI) GUI inop Replace GUI CPU PCB.
Controller Test

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-49
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

XP0011 Time of Day POST (GUI) GUI inop Replace GUI CPU PCB.
Clock Test

XP0012 Timer Test POST (GUI) GUI inop Replace GUI CPU PCB.

XP0013 Watchdog POST (GUI) GUI reset Watchdog timer did 1. M ake sure ventilator is plugged
Timer Test not time out as in to wall power and BPS is
expected fully charged.
2. Replace GUI CPU PCB.
XP0015 FLASH Memory POST (GUI) GUI inop Replace GUI CPU PCB.
Checksum Test

XP0081 Memory POST (GUI) GUI inop Replace GUI CPU PCB.
Management
Unit Test

XP0082 Bus Timer Test POST (GUI) GUI inop Replace GUI CPU PCB.

XP0083 NM I Source POST (GUI) GUI inop Replace GUI CPU PCB.
Register Test

XP0084 POST DRAM POST (GUI) GUI inop Replace GUI CPU PCB.
Test

XP0087 Unexpected POST (GUI) GUI inop POST has been invoked Check associated errors in log. Call
Reset Umpire three times in 24 Technical Support or your Puritan
Test operational hours due Bennett representative.
to unexpected resets.
XP0089 Floating Point POST (GUI) GUI inop Replace GUI CPU PCB.
Unit Test

XP0090 DRAM Parity POST (GUI) GUI inop Replace GUI CPU PCB.
Circuit Test

XP0097 SAAS Self-Test POST (GUI) GUI inop Replace GUI CPU PCB.
Start

6-50 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

XP0098 SAAS Self-Test POST (GUI) GUI inop Replace GUI CPU PCB.
End

XP0128 Download OS POST (GUI) GUI inop Replace GUI CPU PCB.
Boot

XP0129 Application OS POST (GUI) GUI inop Replace GUI CPU PCB.
Boot

XP0130 PB-M ON Boot POST (GUI) GUI inop Replace GUI CPU PCB.

XP0131 Application POST (GUI) GUI inop Replace GUI CPU PCB.
Boot

ZB0040 Touch screen Background Alert Replace touch frame.

failed checks (GUI)

ZB0041 Touch screen Background Alert 1. Check for obstruction on

blocked checks (GUI) screen or clean screen.
2. Replace touch frame.

ZB0042 Touch screen Background Status A status message No action required.

resumed checks (GUI) indicating that
communication with
touch screen was
resumed

ZB0046 GUI Time of Day Background Alert Replace GUI CPU PCB.
failed checks (GUI)
ZB0047 GUI NOVRAM Background Alert Noncritical NOVRAM 1. Replace GUI CPU PCB.
checksum error checks (GUI) data failure 2. Call Technical Support or your
Puritan
Bennett representative.

ZB0052 GUI key stuck Background Alert 1. Replace keyboard.

checks (GUI) 2. Replace GUI CPU PCB.

ZB0054 GUI EEPROM Background Alert Replace GUI CPU PCB.

checksum error checks (GUI)
ZB0055 GUI SAAS Background Alert Replace GUI CPU PCB.
communication checks (GUI)
failed

ZB0059 Loss of BD Background Alert 1. Check cabling from BD CPU

communication checks (GUI) PCB to GUI CPU PCB.
2. Replace BD CPU PCB or GUI
CPU PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-51
6 Diagnostic codes

Table 6-2: 840 Vent ilat or diagnost ic codes (cont inued)

M essage Inform at ion / Possible

Code Test Response Correct ive act ion
displayed cause

ZB0061 Resume BD Background Status A status message No action required.

communication checks (GUI) indicating that
communication with
BD was resumed

ZB0063 GUI SAASAudio Background Alert 1. Replace GUI alarm assembly.

failed checks (GUI) 2. Replace GUI CPU PCB.

ZB0076 Task Monitor Background Alert No action required unless a

checks (GUI) XP0087 error is also present.
ZB0077 GUI dropped a Background Status A status message No action required.
waveform checks (GUI) indicating a waveform
packet data packet was lost in
transmission from the
BD.

ZB0084 Init Resume BD Background Status A status message No action required.

communication checks (GUI) indicating that
communication with
BD was resumed.

ZB0086 Init Loss of BD Background Alert A status message See associated error codes.
communication checks (GUI) indicating that
communication with
BD was lost.

ZB0090 Touch Screen Background Alert 1. Remove visible items from GUI
blocked checks (GUI) screen.
2. Clean GUI screen.
3. Replace touchscreen PCB.
ZB0091 Touch Screen Background Status Status message
resumed checks (GUI) indicates that a touch
screen blocked error is
cleared.

ZC0xxx Varies Communica- Alert No action required unless a

tions error ZB0059 error is also present.
(GUI)

ZC0xxx Varies Communi- Alert 1. Ensure that the green LED is lit
cations error on the front of the BPS.
(BDU) a. If the green LED is not lit,
allow the BPSto charge until
the green LED lights.
b. If the green LED does not
light (within 6-8 hours or
less), replace the battery
pack.
c. Replace the BPS PCB
2. Once the green LED is lit, run
EST to test the BPS and use EST
diagnostics to determine if fur-
ther corrective action is
needed.

ZC1xxx Varies Communica- Alert No action required unless a

tions error ZB0059 error is also present.
(GUI)

6-52 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-2: 840 Vent ilat or diagnostic codes (cont inued)

M essage Informat ion / Possible

Code Test Response Correct ive act ion
displayed cause

ZC2000 DCI parity error Communica- Alert Check parity of host device.
tions error
(GUI)

ZC2001 DCI input buffer Communica- Alert 1. Check cabling between ventila-
overflow error tions error tor and host.
(GUI) 2. Check baud rate of host device.

ZC2002 DCI command Communica- Alert Undefined command 1. Check host software for com-
error tions error received patibility with ventilator.
(GUI) 2. Check cabling between ventila-
tor and host.
ZC2003 DCI unknown Communica- Alert 1. Check host software for com-
error tions error patibility with ventilator.
(GUI) 2. Check cabling between ventila-
tor and host.

ZP0008 Kernel POST (GUI) Alert Noncritical NOVRAM Call Technical Support or your
NOVRAM Test data failure Puritan Bennett representative.

ZP0085 Ethernet Self- POST (GUI) Alert Spec says failure Replace GUI CPU PCB.
Test Start

ZP0086 Ethernet Self- POST (GUI) Alert Spec says failure Replace GUI CPU PCB.
Test End

ZP0087 Unexpected POST (GUI) Alert POST was invoked due Check associated errors in log. No
Reset Umpire to an unexpected reset. action required unless other errors
Test are present.

ZP0088 POST NOVRAM POST (GUI) Alert Noncritical NOVRAM Replace GUI CPUPCB.
Test data failure

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-53
6 Diagnostic codes

6.8 Syst em Diagnost ic Log and BDU POST analog devices t est
Anal og device errors reported durin g th e BDU POST anal og devices test are recorded in th e
System Di agnostic Log. These errors are reported as di agn ostic codes KP0116 an d LP0116.
In form ation in the NOTES col um n of the l og iden ti fies the analog ch ann el on whi ch the
error occurred.
Using an exam ple of a BDU POST analog devi ce error, as i t m i gh t be reported in the System
Di agnosti c Log:

TIM E TEST/ EVENT CODE TYPE NOTES

12:55:59 ANALOG DEVICE KP0116 FAILURE PC: 0x000202DD EV: 0

08 Aug 03 NMI: 0xC0 Err Code: 0xCC

The error address (NOTES) identi fies the anal og channel :

PC: 0x0 002 02DD

HEX Code (counts)

Analog Channel (5th and 6th digits), displayed in Hexidecimal

The di agnosti c codes, KP0116 (BDU) an d LP0116 (GUI), are m aj or faults (VENT INOP) th at
can occur durin g the Anal og Devices Test (Ph ase 2 POST).
If th ere are m ultiple KP0116 an d/ or LP0116 diagnosti c codes, ch eck the PC channel s and
determ in e i f they are all th e sam e. If the chann el s are al l th e sam e, repl ace the associated
an al og device or the AI PCB. If the chan nels are differen t, but ori gi nate from the sam e
m odul e, check and/ or replace the associated m odul e, in terconnect cabl e or AI PCB.
Using the fifth an d sixth digits of error address reported in the System Diagnosti c Log an d
Table 6-3, th e an alog channel on w hich th e error occurred can be iden tified.

Table 6-3: Address codes for BDU POST analog devices test errors

If t he 5t h and 6t h
digit s of t he error Paramet er M easured Replace This:
address are:

00 Inspiratory Pressure Filtered Inspiratory Electronics PCB

01 Expiratory Pressure Filtered Expiratory PCB

02 Q (O2) Filtered Q1 (O2) Flow Sensor

03 Q (O2) Temperature Q1 (O2) Flow Sensor

04 Q (air) Filtered Q2 (air) Flow Sensor

05 Q (air) Temperature Q2 (air) Flow Sensor

06 Q (exh) Filtered Q3 (exh) Flow Sensor

07 Q (exh) Temperature Q3 (exh) Flow Sensor

08 SUBMUX 0: DACWRAP AI PCB

09 Safety Valve Switched Side Safety Valve (SV) Assembly;

check Inspiratory M odule
connections

0A 12 V GUI Sentry GUI CPU PCB

6-54 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-3: Address codes for BDU POST analog devices t est errors

If t he 5t h and 6t h
digit s of t he error Paramet er M easured Replace This:
address are:

0B Alarm Cable Voltage GUI CPU PCB or alarm cable

assembly

0C O2 PSOL Current O2 PSOL or AI PCB

0D Air PSOL Current Air PSOL or AI PCB

0E Low Voltage Reference Power Supply

0F Atmospheric Pressure Transducer Inspiratory Electronics PCB

10 Exhalation Coil Temperature Exhalation Valve

11 Exhalation Pressure Transducer Expiratory PCB

12 O2 Sensor O2 Sensor

13 GUI 5V dc Sentry GUI CPU PCB

14 12V dc Sentry Power Supply

15 Safety Valve Current Safety Valve or Inspiratory

Electronics PCB or AI PCB

16 +15V Sentry Power Supply or AI PCB

17 -15V Sentry Power Supply or AI PCB

18 Power Fail Cap Voltage Power Supply

19 Exhalation Manifold Heater Temp Exhalation Heater

1A BPS Battery Voltage Signal BPS PCB

1B 5V dc Venthead Power Supply

1C BPS Battery Current BPS PCB

1D ac Line Voltage Power Supply or AI PCB

1E Exhalation Motor Current Exhalation Valve Assembly

1F 10V Sentry Power Supply

6.9 Diagnost ic codes for POST fault s

Use th e fol lowi ng tables to determ ine the error code associated with th e pattern of eith er th e
BD or the GUI LED array wh en a fault occurs duri ng POST.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-55
6 Diagnostic codes

Table 6-4: BDU and GUI—Phase 1 (kernal) POST diagnost ic codes

BD and GUI LED arrays

Test Fault Correct ive
Test GUI GUI
Descript ion BDU Type Act ion
(10.4-inch) (9.4-inch)
Diag. code
Diag. code Diag. code

Processor Prepares the Major 1. Check the diagnostic

Initialization processor for codes’ corrective
executing actions in Table 6-2.
instructions 2. Replace affected CPU
KP0001 XP0001 XP0001 PCB.

Integer Unit General CPU Major 1. Check the diagnostic

Test confidence test codes’ corrective
actions in Table 6-2.
2. Replace affected CPU
KP0002 XP0002 XP0002 PCB.

DRAM Refresh TestsDRAM refresh Major 1. Check the diagnostic

Timer Test circuitry codes’ corrective
actions in Table 6-2.
2. Replace affected CPU
KP0003 XP0003 XP0003 PCB.

Kernel DRAM Tests read/ write Major 1. Check the diagnostic

Test function of DRAM codes’ corrective
actions in Table 6-2.
2. Replace affected CPU
KP0004 XP0004 XP0004 PCB.

Boot PROM Verifies kernel Major 1. Check the diagnostic

Checksum PROM integrity codes’ corrective
Test actions in Table 6-2.
2. Replace affected CPU
KP0005 XP0005 XP0005 PCB.

Addressing Verifies CPU Major 1. Check the diagnostic

Mode Test functions in codes’ corrective
preparation for actions in Table 6-2.
testsusing multiple 2. Replace affected CPU
addressing modes KP0007 XP0007 XP0007 PCB.

Kernel Validates ranges Major 1. Check the diagnostic

NOVRAM Test for NOVRAM codes’ corrective
variables used in actions in Table 6-2.
later tests 2. Replace affected CPU
KP0008 XP0008 XP0008 PCB.

Rolling Checks for N/ A N/ A Major 1. Check the diagnostic

Thunder Test unexpected resets codes’ corrective
(BDU only) during POST. actions in Table 6-2.
Three or more 2. Replace AI PCB.
resets not related KP0009 3. Replace BD CPU PCB.
to ac failures 4. Replace mother-
causes the test to board.
fail.

6-56 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-4: BDU and GUI—Phase 1 (kernal) POST diagnost ic codes (cont inued)

BD and GUI LED arrays

Test Fault Correct ive
Test GUI GUI
Descript ion BDU Type Act ion
(10.4-inch) (9.4-inch)
Diag. code
Diag. code Diag. code

Time of Day Verifies Major or 1. Check the diagnostic

Clock Test functionality of the Minor codes’ corrective
Time of Day clock actions in Table 6-2.
2. Replace affected CPU
KP0011 or XP0011 or XP0011 or PCB.
LP0011 ZP0011 ZP0011

Timer Test Compares system M ajor 1. Check the diagnostic

timer to Time of codes’ corrective
Day clock to verify actions in Table 6-2.
functionality 2. Replace affected CPU
KP0012 XP0012 XP0012 PCB.

Watchdog Verifies watchdog M ajor 1. Check the diagnostic

Timer Test timer times out as codes’ corrective
expected actions in Table 6-2.
2. Replace affected CPU
KP0013 XP0013 XP0013 PCB.

EEPROM Verifies integrity of M ajor 1. Check the diagnostic

Checksum flash memory codes’ corrective
Test actions in Table 6-2.
2. Replace affected CPU
KP0015 XP0015 XP0015 PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-57
6 Diagnostic codes
BDU Test
ac Voltage Test
ADC Test
Analog Devices Test
Analog Interface Test
Bus Timer Test *
DAC Test
DRAM M emory Test *
DRAM Parity Error
Test *
*
Tested in Short POST
6-58 4-070496-00 Rev A (08/ 03)
Table 6-5: BDU only—Phase 2 POST diagnostic codes
BDU Test
Descript ion
Comparesac monitor voltage
to specified range
Checks analog-to-digital
converter data availability
Performs a range check on
each of the 32 analog
channels
Tests analog interface
circuitry
M onitors activity on the local
bus
Tests digital-to-analog
converter data
Tests DRAM by writing and
verifying data patterns to
memory
Checks the ability to detect a
parity error upon reading
defective parity from memory
BDU
BDU Correct ive
Fault
Diag. Code Act ion
Type
M inor 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Make sure ventilator is plugged
into ac source.
LP0122 3. Make sure nominal line volt-
age is set correctly.
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace AI PCB.
KP0114
Major 1. Check the diagnostic code’s
or corrective actions in Table 6-2.
M inor 2. Refer to Section 6.8 for addi-
tional troubleshooting informa-
KP0116 or tion regarding this fault.
LP0116 3. Replace affected component.
4. Replace AI PCB.
5. Call Technical Support or your
Puritan Bennett representative.
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
3. Replace AI PCB.
KP0113 4. Replace mother board.
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
KP0082
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace AI PCB.
KP0115
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
KP0084
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
KP0090
840 Ventilator System Service Manual
Diagnostic codes
Table 6-5: BDU only—Phase 2 POST diagnostic codes (continued)
BDU Test
BDU Test
Descript ion
Ethernet Self-Test End
Ethernet Self-Test Internal routine verifies
Start functionality of Ethernet
controller
NMI Register Test * Verifies NMI source register is
in reset state (no bits set)
Phase 2 Initialization* Start non-kernel portion of
POST
Phase 2 NOVRAM Compares NOVRAM data to
Test * valid states and ranges
Safe State Test Places PSOLs and exhalation
valve into safe state and
verifies that they cannot be
commanded
Serial Device Test Writes to serial EEPROM to
verify accessibility
Service Switch Test
End*
*
Tested in Short POST
840 Ventilator System Service Manual
6
BDU
BDU Correct ive
Fault
Diag. Code Act ion
Type
Minor 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
LP0086
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
KP0085
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
KP0083
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace BD CPU PCB.
KP0006
Minor 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Call Technical Support or your
Puritan Bennett representative.
LP0088
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace AI PCB.
3. Replace BD CPU PCB.
KP0120
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Replace AI PCB.
3. Replace BD CPU PCB.
KP0117
Minor 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Turn off ventilator. Release
switch.
LP0121 3. Check for mechanical obstruc-
tion to switch.
4. Replace BD CPU PCB.
4-070496-00 Rev A (08/ 03) 6-59
6 Diagnostic codes
Table 6-5: BDU only—Phase 2 POST diagnost ic codes (continued)
BDU Test
BDU Test
Descript ion
Service Switch Test Checks that the service mode
Start * switch is not stuck, and
prevents entry into Service
M ode from a power fail
condition
Unexpected Reset Checks for unexpected resets
Umpire Test * of the CPU. Three resets
(strikes) in 24 hours will cause
a VENT INOP condition.
VENT INOP Test Checks to see if the ventilator
is in the VENT INOP state
*
Tested in Short POST
6-60 4-070496-00 Rev A (08/ 03)
BDU
BDU Correct ive
Fault
Diag. Code Act ion
Type
M inor 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Turn off ventilator. Release
switch.
LP0121 3. Check for mechanical obstruc-
tion to switch.
4. Replace BD CPU PCB.
Major 1. Check the diagnostic code’s
or corrective actions in Table 6-2.
M inor 2. Check associated errors in the
System Diagnostic and System
KP0087 or Information log to determine
LP0087 why POST was invoked three
times within 24 hours.
a. If the codes indicate that the
BD CPU generated the
resets, replace the BD CPU
(Other codes may be
present indicating that the
GUI lost communications
with the BD).
b. If the codes indicated that
the GUI CPU generated the
resets, replace the GUI CPU
(Other codes may be
present indicating that the
BD lost communications
with the GUI.
3. Run a complete EST to check
for analog device failures.
Major 1. Check the diagnostic code’s
corrective actions in Table 6-2.
2. Check cabling from BD CPU
PCB to GUI CPU PCB.
KP0112 3. Replace BD CPU PCB.
4. Call Technical Support or your
Puritan Bennett representative.
840 Ventilator System Service Manual
Diagnostic codes 6

Table 6-6: GUI only—Phase 2 POST diagnost ic codes

GUI GUI GUI

GUI Test Correct ive
GUI Test (10.4-inch) 9.4-inch) Fault
Descript ion Act ion
Diag. code Diag. code Type

Bus Timer Test M onitors activity on Major 1. Check the diag-

the local bus nostic code’s cor-
rective actions in
Table 6-2.
XP0082 XP0082 2. Replace GUI CPU
PCB.

DRAM Memory Test Tests DRAM by Major 1. Check the diag-

writing and verifying nostic code’s cor-
data patterns to rective actions in
memory Table 6-2.
XP0084 XP0084 2. Replace GUI CPU
PCB.

DRAM Parity Error Checks the ability to Major 1. Check the diag-
Test detect a parity error nostic code’s cor-
upon reading rective actions in
defective parity from Table 6-2.
memory XP0090 XP0090 2. Replace GUI CPU
PCB.

Ethernet Self-test End M inor 1. Check the diag-

nostic code’s cor-
rective actions in
Table 6-2.
ZP0086 ZP0086 2. Replace GUI CPU
PCB.

Ethernet Self-Test Internal routine Major 1. Check the diag-

Start verifies functionality nostic code’s cor-
of Ethernet controller rective actions in
Table 6-2.
XP0085 XP0085 2. Replace GUI CPU
PCB.

NMI Register Test
Verifies NMI source Major 1. Check the diag-
register is in reset nostic code’s cor-
state (no bits set) rective actions in
Table 6-2.
XP0083 XP0083 2. Replace GUI CPU
PCB.

Phase 2 Initialization Start non-kernel Major 1. Check the diag-

portion of POST nostic code’s cor-
rective actions in
Table 6-2.
XP0006 XP0006 2. Replace GUI CPU
PCB.

Phase 2 NOVRAM Compares NOVRAM M inor 1. Check the diag-

Test data to valid states nostic code’s cor-
and ranges rective actions in
Table 6-2.
ZP0088 ZP0088 2. Replace GUI CPU
PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-61
6 Diagnostic codes

Table 6-6: GUI only—Phase 2 POST diagnost ic codes (cont inued)

GUI GUI GUI

GUI Test Correct ive
GUI Test (10.4-inch) 9.4-inch) Fault
Descript ion Act ion
Diag. code Diag. code Type

SAAS Self-test End Major 1. Check the diag-

nostic code’s cor-
rective actions in
Table 6-2.
XP0098 XP0098 2. Replace GUI audio
alarm.
3. Replace GUI CPU
PCB.

SAAS Self-test Start Detectsinternal errors Major 1. Check the diag-

of alarm circuitry and nostic code’s cor-
lack of audio feedback rective actions in
Table 6-2.
XP0097 XP0097 2. Replace GUI audio
alarm.
3. Replace GUI CPU
PCB.

Unexpected Reset Checks for Major 1. Check the diag-

Umpire Test unexpected resets of or nostic code’s cor-
the CPU. Three resets M inor rective actions in
(strikes) in 24 hours Table 6-2.
will cause a VENT XP0087 or XP0087 or 2. Check associated
INOP condition. ZP0087 ZP0087 errors in System
Diagnostic Log.
3. Call Technical Sup-
port or your Puri-
tan Bennett
representative.

6-62 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6

Table 6-7: BDU or GUI—Phase 3 POST diagnostic codes

Diag. code Diag. code

Diag. code
GUI PCB GUI PCB Fault
Test St ep Test Descript ion BDU PCB Correct ive Act ion
LEDs LEDs Type
LEDs
(10.4-inch) (9.4-inch)

Operating Loads operating Major 1. Check the diag-

System system nostic codes’ cor-
Initialization* rective actions in
Table 6-2.
KP0129 XP0129 XP0129 2. Replace affected
CPU PCB.

Floating Point Tests floating Major 1. Check the diag-

Unit Test* point functional- nostic codes’ cor-
ity of the micro- rective actions in
processor Table 6-2.
KP0089 XP0089 XP0089 2. Replace affected
CPU PCB.

Memory Tests micropro- Major 1. Check the diag-

Management cessor’s memory nostic codes’ cor-
Unit Test* management rective actions in
unit Table 6-2.
KP0081 XP0081 XP0081 2. Replace affected
CPU PCB.

Application Loads applica- Major 1. Check the diag-

Initialization* tion software nostic codes’ cor-
rective actions in
Table 6-2.
KP0131 XP0131 XP0131 2. Replace affected
CPU PCB.
*
Tested in Short POST

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-63
6 Diagnostic codes

6.9.1 POST int errupt errors and t est failures

Table 6-8 bel ow lists the errors that can occur during particular POST test steps. These errors,
reported by the diagn ostic LED array on th e appli cabl e CPU PCB, are of two types: in terrupts
and test fai lures. An i nterrupt error m ay i ndicate that an external event (e.g. a power fail
i nterrupt) occurred during the test step. A test failure i ndi cates that the test fai led to meet i ts
speci fi cati ons.

Table 6-8: Interrupt errors and test failures – POST self t est s

BD and GUI LED arrays

M ay be
Error BDU GUI GUI Error Type
caused by
Diag. code (10.4-inch) (9.4-inch)
Diag. code Diag. code

Unknown NMI Interrupt CPU PCB

Ethernet Parity Interrupt CPU PCB

Error

DRAM Parity Interrupt CPU PCB

Error

Analog Interface Interrupt AI PCB

Error

Power Fail NMI Interrupt Loss of ac

(BDU only) power during
POST

5 Vdc Interrupt Power Supply

overvoltage (GUI
only)

12 Vdc Interrupt Power Supply

overvoltage (GUI
only)

12 Vdc Interrupt Power Supply

undervoltage
(GUI only)

6-64 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-8: Interrupt errors and test failures – POST self test s (cont inued)

BD and GUI LED arrays

M ay be
Error BDU GUI GUI Error Type
caused by
Diag. code (10.4-inch) (9.4-inch)
Diag. code Diag. code

SAAS NMI Interrupt GUI alarm or

alarm cabling

Access fault/ Bus Interrupt CPU PCB

error

Other Interrupt CPU PCB

Unexpected
interrupt

POST Internal Interrupt CPU PCB

Software Failure

Test Failed Failure Specific

analog device
or CPU PCB

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-65
6 Diagnostic codes

6.10 SST and EST t est sequences and diagnost ic codes

Table 6-9 and Tabl e 6-10 list, i n sequen ce, the tests th at com pri se SST an d EST, respectivel y,
an d provide detail ed descriptions of each test. The tabl es in clude correcti ve actions for
fai lures that m ay occur duri ng each test.

Table 6-9: SST diagnostic codes

Code and
Test descript ion and failure modes Correct ive act ions
message

SST Flow Sensor Test

Test : Checks oxygen (PS1) and wall air (PS2)

pressure switches and compressor pressure
transducer (PC) to determine whether any gases
are connected.

Failure: No gas is available (neither PS1, PS2, nor FS0005 Connect gas supply.
PC detects pressure). Gas not
connected

Failure: Only air is available (only PS2 or PC AS0012 Make sure oxygen supply is connected.
detects pressure). O2 pressure not
detected

Failure: Only oxygen is available (only PS1 detects AS0013 Make sure air supply is connected.
pressure). Wall air pressure
not detected

Prompts user to connect inspiratory filter, connect

patient circuit (without humidifier), and block
wye.

Test : Runs test only if oxygen available. For

oxygen flows of 120 60, 5, and 1 L/ min, verifies
that flow is stable.

Failure: Flow controller unable to establish and
control oxygen flow at 120 L/ min.
AS0010 1. M ake sure oxygen supply is connected and
Unable to unrestricted.
establish O2 flow 2. Verify that the oxygen supply is good.
3. Verify that the patient circuit system has no
leaks or occlusions. If not sure, run the first
four tests in EST to get to the leak test. If the
leak test passes in EST, exit out of EST. Correct
the leak or occlusion in the patient circuit used
in SST and rerun or try another patient circuit.
4. Verify that the oxygen regulator pressure is set
between 9-12 psi.
5. Switch PSOLs to see if the failure transfers to
the air side. If yes, return PSOL2 back to its
original position and replace PSOL1.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the flow sensor cali-
bration and EST. If the failure transfers to the
air side, return Q2 back to its original position
and replace Q1.

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Diagnostic codes 6
Table 6-9: SST diagnost ic codes (cont inued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Failure: Flow controller unable to establish and
control oxygen flow at 60, 5, and 1 L/ min.
FS0006 1. Make sure oxygen supply is connected and
Unable to unrestricted.
establish O2 flow 2. Verify that the oxygen supply is good.
3. Check regulated oxygen pressure.
4. Verify that the system has no leaks or occlu-
sions. If not sure, run the first four tests in EST
to run the leak test.
5. Switch PSOLs to see if the failure transfers to
the air side. If yes, return PSOL2 back to its
original position and replace PSOL1.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the flow sensor cali-
bration and EST. If the failure transfers to the
air side, return Q2 back to its original position
and replace Q1.
8. Replace Q3.

Test : Runs test only if oxygen available. For

oxygen flows of 120 60, 5, and 1 L/ min, verifies
that oxygen (Q1) and exhalation (Q3) flow sensor
readings are in range.

Failure: Q1 and Q3 readings are too far apart. FS0001 1. Check for leak.
O2 flow sensor 2. Verify that safety valve is closed.
cross check failed 3. Perform flow sensor calibration.
4. Replace Q1.
5. Replace Q3.
6. Replace AI PCB.

Test : Runs test only if oxygen available. For

oxygen flows of 120, 60, 5, or 1 L/ min, verifies
that oxygen PSOL (PSOL1) command current is in
range.

Failure: PSOL1 command current is out of range. FS0002 1. Check for leak.
O2 PSOL current 2. Verify safety valve is closed.
out of range 3. Check regulated oxygen pressure.
4. Replace PSOL1.
5. Replace AI PCB.

Test : Runs test only if oxygen available.

Commands oxygen PSOL (PSOL1) to deliver 0 L/
min (closed).

Failure: Oxygen flow > 0.153 L/ min. FS0008 1. Verify no leaks at the Q1
O2 zero flow O-rings.
check failed 2. Run EST Gas Supply Test to check for PSOL1
leak.
3. Remove and then reseat PSOL1.
4. Replace PSOL1.
5. Perform a flow sensor calibration.
6. Replace Q1.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-67
6 Diagnostic codes
Table 6-9: SST diagnostic codes (continued)
Test descript ion and failure modes
Test : Runs test only if air available. For air flows of
120, 60, 5, and 1 L/ min, verifies that flow is stable.
Failure: Flow controller unable to establish and
control air flow at 120 L/ min.
Failure: Flow controller unable to establish and
control air flow at 60, 5, and 1 L/ min.
6-68 4-070496-00 Rev A (08/ 03)
Code and
Correct ive act ions
message
AS0011 1. M ake sure air supply is connected and unre-
Unable to stricted.
establish air flow 2. Verify that the air supply is good.
3. Verify that the patient circuit system has no
leaks or occlusions. If not sure, run the first
four tests in EST to get to the leak test. If the
leak test passes in EST, exit out of EST. Correct
the leak or occlusion in the patient circuit used
in SST and rerun or try another patient circuit.
4. Verify that the air regulator pressure is set
between 9-12 psi.
5. Switch PSOLs to see if the failure transfers to
the oxygen side. If yes, return PSOL1 back to
its original position and replace PSOL2.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the flow sensor cali-
bration and EST. If the failure transfers to the
oxygen side, return Q1 back to its original
position and replace Q2.
FS0007 1. Make sure air supply is connected unrestricted.
Unable to 2. Verify that the air supply is adequate.
establish air flow 3. Check regulated air pressure.
4. Verify that the system has no leaks or occlu-
sions. If not sure, run the first four tests in EST
to run the leak test.
5. Switch PSOLs to see if the failure transfers to
the oxygen side. If yes, return PSOL1 back to
its original position and replace PSOL2.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the flow sensor cali-
bration and EST. If the failure transfers to the
oxygen side, return Q1 back to its original
position and replace Q2.
8. Replace Q3.
840 Ventilator System Service Manual
Diagnostic codes
Table 6-9: SST diagnost ic codes (cont inued)
Test descript ion and failure modes
Test : Runs test only if air available. For air flows of
120, 60, 5, and 1 L/ min, verifies that air (Q2) and
exhalation (Q3) flow sensor readings are in range.
Failure: Q2 and Q3 readings are too far apart.
Test : Runs test only if air available. For air flows of
120, 60, 5, and 1 L/ min, verifies that air PSOL
(PSOL2) command current is in range.
Failure: PSOL2 command current out of range.
840 Ventilator System Service Manual
6
Code and
Correct ive act ions
message
FS0003 1. Correct the leak or occlusion in the SST patient
Air flow sensor circuit and rerun or try known good patient
cross-check circuit and filter set.
failed 2. Verify that the ventilator system has no leaks or
occlusions by running the first four tests in EST
to run the leak test.
3. If the leak test fails in EST, troubleshoot the
expiratory filter or ventilator system for leaks or
occlusions.
4. If the leak test passes in EST, troubleshoot the
SST patient circuit.
5. Switch PSOLs to see if the failure transfers to
the oxygen side. If yes, return PSOL1 back to
its original position and replace PSOL2.
6. Run a flow sensor calibration.
7. Switch Q1 and Q2. Rerun the flow sensor cali-
bration and EST. If the failure transfers to the
oxygen side, return Q1 back to its original
position and replace Q2.
8. Replace Q3.
FS0004 1. Make sure air supply is connected and unre-
Air PSOL current stricted.
out of range 2. Verify that the air supply is good.
3. Verify that the system has no leaks or occlu-
sions. If not sure, run the first four tests in EST
to run the leak test.
4. Switch PSOLs to see if the failure transfers to
the oxygen side. If yes, return PSOL1 back to
its original position and replace PSOL2.
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the flow sensor cali-
bration and EST. If the failure transfers to the
oxygen side, return Q1 back to its original
position and replace Q2.
7. Replace Q3.
4-070496-00 Rev A (08/ 03) 6-69
6 Diagnostic codes

Table 6-9: SST diagnostic codes (continued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Test : Runs test only if air available. Commands air

PSOL (PSOL2) to deliver 0 L/ min (closed).

Failure: Air flow > 0.153 L/ min. FS0009 1. Verify no leaks at the Q2
Air zero flow O-rings.
check failed 2. Run EST Gas Supply Test to check for PSOL2
leak.
3. Remove and then reseat PSOL2.
4. Replace PSOL2.
5. Perform a flow sensor calibration.
6. Replace Q2.

Performs lift-off calibration for PSOL1 and PSOL2,

as applicable.

Prompts user to connect humidifier, if applicable.

Circuit Pr essure Test

Test : Autozeroes inspiratory pressure transducer

(PI), then reads pressure. Stores pressure reading.

Failure: Inspiratory pressure transducer ADC FS0101 1. Replace Inspiratory Electronics PCB.
count at 0 cmH2O is out of range. Inspiratory 2. Replace AI PCB.
autozero out of
range

Test : Autozeroes expiratory pressure transducer

(PE), then reads pressure. Stores pressure reading.

Failure: Expiratory pressure transducer ADC count FS0102 1. Replace exhalation transducer PCB.
at 0 cmH2O is out of range. Expiratory 2. Replace AI PCB.
autozero out of 3. Replace SOL1.
range

Test : Pressurizes system to 10 cmH2O using a gas

flow of 5 L/ min.

Failure: Unable to build pressure to 10 cmH2O at
5 L/ min within time-out period.
FS0103 1. Verify that the patient circuit system has no
Failed to reach leaks or occlusions or use a known good
test pressure patient circuit and filter set.
2. Verify that the air supply or compressor is
available and adequate.
3. Verify that the ventilator system has no leaks or
occlusions. If not sure, run the first four tests
in EST to run the leak test.

6-70 4-070496-00 Rev A (08/ 03) 840 Ventilator System Service Manual
Diagnostic codes 6
Table 6-9: SST diagnost ic codes (cont inued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Test : Reads inspiratory and expiratory pressure

transducers at 10 cmH2O.

Failure: Inspiratory/ expiratory pressure transducer
readings are too far apart.
FS0104 1. Verify that the patient circuit system has no
Cross-check leaks or occlusions or use a known good
failed patient circuit and filter set.
2. Verify that the ventilator system has no leaks or
occlusions. If not sure, run the first four tests
in EST to run the leak test.
3. If the leak test passes in EST, exit out of EST.
Review the data for the Circuit Pressure Test to
determine which pressure transducer is out of
range: PI or PE. Replace applicable pressure
transducer.
4. Replace AI PCB.

Test : Opens inspiratory pressure transducer

autozero solenoid (SOL1) and reads inspiratory
pressure.

Failure: Inspiratory pressure reading out of range FS0105 1. Replace SOL1.

(-0.60 to 0.60 cmH2O). Bad insp 2. Replace Inspiratory Electronics PCB.
autozero 3. Replace AI PCB.
solenoid

Test : Opens expiratory pressure transducer

autozero solenoid (SOL2) and reads expiratory
pressure.

Failure: Expiratory pressure reading out of range FS0106 1. Replace SOL2.

(−0.60 to 0.60 cmH2O). Bad exp 2. Replace exhalation transducer PCB.
autozero sol 3. Replace AI PCB.

Test : Pressurizes system to 50 and 100 cmH2O

using a gas flow of 5 L/ min.

Failure: Unable to build pressure to 50 or FS0108 1. Make sure gas source is available.
100 cmH2O at 5 L/ min within time-out period. Failed to reach 2. Check for system leak.
test pressure

Test : Reads inspiratory and expiratory pressure

transducers at 50 and 100 cmH2O.

Failure: Inspiratory/ expiratory pressure transducer
readings are too far apart.
FS0107 1. Replace the expiratory bacteria filter.
Cross-check 2. Verify that the system has no leaks or occlu-
failed sions. If not sure, run the first four tests in EST
to run the leak test.
3. If the leak test passes in EST, exit out of EST.
Review the data for the EST Circuit Pressure
Test to determine which pressure transducer is
out of range: PI or PE. Replace applicable
pressure transducer.
4. Replace AI PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-71
6 Diagnostic codes

Table 6-9: SST diagnostic codes (continued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Circuit leak

Test : Pressurizes system to 90 cmH2O with either

gas using 2 L/ min flow.

Failure: Unable to attain leak test starting pressure FS0205 1. M ake sure test circuit is connected and is not
within time-out period. Unable to leaking.
establish 2. Check exhalation valve operation, and verify
pressure secure connection of expiratory filter.

Test : Waits for pressure to decay, then verifies

adequate inspiratory pressure.

Failure: System pressure dropped below FS0201 1. M ake sure test circuit is connected.
85 cmH2O. Excessive leak 2. Check for system leaks.
3. Check exhalation valve operation.
4. Verify secure connection of expiratory filter.

Test : Waits until inspiratory pressure drops to

85 cmH2O or until 10 s elapse.
If pressure drops to 85 cmH2O, waits until
pressure drops by 5 cmH2O or until 10 s more
elapse. Checks pressure drop. Compares
inspiratory and expiratory pressure measurements.

Failure: Pressure drops to 85 cmH2O in 10 s, then FS0201 1. M ake sure patient circuit is connected.
in 10 s more by ≥ 30 cmH2O. Excessive leak 2. Check for system leaks.
3. Check exhalation valve operation.
4. Verify secure connections of bacteria filters and
humidifier.

Failure: Pressure drops to 85 cmH2O in 10 s, then AS0202 1. M ake sure patient circuit is connected.
in 10 s more by ≥ 10 cmH2O. Excessive leak 2. Check for system leaks.
3. Check exhalation valve operation.
4. Verify secure connections of bacteria filters and
humidifier.

Failure: Inspiratory/ expiratory pressure transducer AS0206 Make sure test circuit is connected properly.
readings are too far apart. Test circuit not
connected

Expirat or y f ilt er

Prompts user to disconnect circuit from expiratory

filter.

Test : Establishes 60 L/ min flow of either gas.

Failure: Unable to deliver stable gas flow. FS0301 Make sure gas supply is connected.
Unable to
establish flow

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Diagnostic codes 6
Table 6-9: SST diagnost ic codes (cont inued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Test : Reads inspiratory pressure and expiratory

flow. Verifies that circuit was disconnected
(expiratory flow ≤ 1 L/ min).

Failure: Expiratory flow detected, indicating that FS0306 Make sure patient circuit is disconnected at
circuit not disconnected. Patient circuit expiratory filter.
not disconnected

Prompts user to reconnect circuit to expiratory

filter.

Test : Establishes 60 L/ min flow of either gas.

Failure: Unable to deliver stable gas flow. FS0301 Make sure gas supply is connected.
Unable to
establish flow

Test : Reads inspiratory and expiratory pressure

and expiratory flow. Verifies that circuit was
reconnected by checking expiratory flow.

Failure: Expiratory flow reading indicates that FS0307 Make sure patient circuit is connected at
circuit not reconnected. Patient circuit expiratory filter.
not reconnected

Test : Verifies that pressure drop across exhalation

compartment within range.

Failure: Exhalation compartment pressure AS0308 1. Check compartment for obstruction.

> 3 cmH2O but < 4 cmH2O. Occluded 2. Verify exhalation valve operation by running
expiratory EST.
compartment

Failure: Exhalation compartment pressure FS0303 1. Check compartment for obstruction.

> 4 cmH2O. Occluded 2. Verify exhalation valve operation by running
expiratory EST.
compartment

Test : Calculates pressure drop across expiratory

filter and verifies that filter not occluded.

Failure: Pressure drop across filter > 2 cmH2O, but AS0305 Consider replacing expiratory filter.
< 3 cmH2O. Occluded
expiratory filter

Failure: Pressure drop across filter > 3 cmH2O. FS0304 Replace expiratory filter.
Occluded
expiratory filter

Failure: Pressure drop across expiratory filter AS0311 1. Repeat test, following directions more closely.
< 0.4 cmH2O, but > 0.1 cmH2O. Low expiratory 2. Replace filter.
filter ∆P

Failure: Pressure drop across expiratory filter FS0310 1. Repeat test, following directions more closely.
< 0.1 cmH2O. Low expiratory 2. Replace filter.
filter ∆P

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-73
6 Diagnostic codes

Table 6-9: SST diagnostic codes (continued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Circuit Resist ance

Test : If test is being repeated, prompts user to

block wye. Pressurizes system to 100 cmH2O at
60 L/ min.

Failure: Unable to pressurize system within time- FS0412 1. Block wye when prompted.
out period. Wye not blocked 2. Check for circuit leaks.

Test : Characterizes total circuit resistance over a

range of flows using either gas.

Failure: Peak flow < alert threshold but > failure AS0411 Check for kinked or occluded patient tubing.
threshold. Unable to reach
min peak flow

Failure: Peak flow < failure threshold. FS0410 Check for kinked or occluded patient tubing.
Unable to reach
min peak flow

Prompts user to unblock patient wye.

Test : Measures pressure drop across inspiratory

limb at 60 L/ min (adult) or 30 L/ min (pediatric).

Failure: Flow controller unable to establish and FS0401 Make sure gas supply is connected.
control gas flow. Unable to
establish flow

Test : Determines inspiratory limb pressure drop,

and checks for an occlusion.

Failure: Inspiratory limb pressure > 8.5 cmH2O AS0403 Check for occluded patient tubing.
(adult) or 5.5 cmH2O (pediatric), but Occluded
< 12.5 cmH2O (adult) or 7.5 cmH2O (pediatric), inspiratory limb
indicating occlusion.

Failure: Inspiratory limb pressure > 12.5 cmH2O FS0402 Check for occluded patient tubing.
(adult) or 7.5 cmH2O (pediatric), indicating Occluded
occlusion. inspiratory limb

Failure: Inspiratory limb pressure < 0.6 cmH2O AS0413 1. M ake sure inspiratory filter is installed.
(adult) or 5.5 cmH2O (pediatric), but > Insp limb 2. Repeat test, following directions more closely.
0.2 cmH2O. resistance low 3. Replace inspiratory filter.
4. Replace patient circuit

Failure: Inspiratory limb pressure < 0.2 cmH2O. FS0408 1. M ake sure inspiratory filter is installed.
Insp limb 2. Repeat test, following directions more closely.
resistance low 3. Replace inspiratory filter.
4. Replace patient circuit

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Diagnostic codes 6
Table 6-9: SST diagnost ic codes (cont inued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Test : Characterizes inspiratory limb resistance over

a range of flows using either gas.

Failure: Peak flow < 80 L/ min but > 60 L/ min. AS0407 Check for kinked or occluded patient tubing.
Unable to reach
min peak flow

Failure: Peak flow < 60 L/ min. FS0404 Check for kinked or occluded patient tubing.
Unable to reach
min peak flow

Test : Determines expiratory limb pressure drop,

and checks for an occlusion.

Failure: Expiratory limb pressure > 8.5 cmH2O AS0406 Check for occluded patient tubing.
(adult) or 5.5 cmH2O (pediatric) but Occluded
> 12.5 cmH2O (adult) or 7.5 cmH2O (pediatric), exhalation limb
indicating occlusion.

Failure: Expiratory limb pressure > 12.5 cmH2O FS0405 Check for occluded patient tubing.
(adult) or 7.5 cmH2O (pediatric), indicating Occluded
occlusion. exhalation limb

Failure: Expiratory limb pressure < 0.6 cmH2O AS0414 Replace patient circuit
(adult) or 0.5 cmH2O (pediatric), but > Exp limb
0.2 cmH2O. resistance low

Failure: Expiratory limb pressure < 0.2 cmH2O. FS0409 Replace patient circuit
Exp limb
resistance low

Comp liance calib rat ion

Prompts user to block wye.

Test : M easures circuit compliance using 10 L/ min

flow, storing pressure and volume measurements
at 5 cmH2O intervals from 5 to 100 cmH2O. Uses
air as default gas.

Failure: System cannot pressurize to one of the FS0501 Check patient circuit for leaks. Replace as
test pressure points. Unable to necessary.
pressurize circuit

Test : M easures circuit compliance using a high

flow, storing pressure and volume measurements
at 5 cmH2O intervals from 5 to 100 cmH2O.

Failure: System cannot pressurize to one of the FS0502 Check patient circuit for leaks. Replace as
test pressure points. Unable to necessary.
pressurize circuit

Failure: Out-of-range pressure ratio calculation. FS0503 1. Repeat test, making sure circuit is undisturbed
Compliance during test.
calculation 2. Repeat SST to retest pressure transducers.
failure 3. Run EST and verify all pneumatics tests pass.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-75
6 Diagnostic codes

Table 6-9: SST diagnostic codes (continued)

Code and
Test descript ion and failure modes Correct ive act ions
message

Test : Determines compliance and checks its

reasonableness.

Failure: High compliance > 6 mL/ cmH2O (adult) AS0505 1. M ake sure correct patient tubing type was
or 4.5 mL/ cmH2O (pediatric), but Excessive specified in SST.
< 12 mL/ cmH2O (adult) or 9 mL/ cmH2O compliance 2. Replace patient circuit.
(pediatric).

Failure: High compliance > 12 mL/ cmH2O (adult) FS0504 1. M ake sure correct patient tubing type was
or 9 mL/ cmH2O (pediatric). Excessive specified in SST.
compliance 2. Replace patient circuit.

Failure: High compliance falls below
1.56 mL/ cmH2O (adult) or 1.34 mL/ cmH2O
(pediatric) but not lower than 1.05 mL/ cmH2O.
AS0507 1. M ake sure correct patient tubing type was
Compliance low specified in SST.
2. Replace patient circuit with a known good cir-
cuit and filter set.
3. Run EST to check the operation of PI and PE
during the Circuit Pressure Test. Replace
applicable pressure transducer.
4. Run Atmospheric Pressure Transducer calibra-
tion.

Failure: High compliance falls below FS0506 1. M ake sure correct patient tubing type was
1.05 mL/ cmH2O. Compliance low specified in SST.
2. Replace patient circuit.

Failure: Low compliance > 6 mL/ cmH2O (adult) or AS0509 1. M ake sure correct patient tubing type was
4.5 mL/ cmH2O (pediatric), but < 12 mL/ cmH2O Excessive specified in SST.
(adult) or 9 mL/ cmH2O (pediatric). compliance 2. Replace patient circuit with a known good cir-
cuit and filter set.
3. Run EST to check the operation of PI and PE
during the Circuit Pressure Test. Replace
applicable pressure transducer.
4. Run Atmospheric Pressure Transducer calibra-
tion.

Failure: Low compliance > 12 mL/ cmH2O (adult) FS0508 1. M ake sure correct patient tubing type was
or 9 mL/ cmH2O (pediatric). Excessive specified in SST.
compliance 2. Replace patient circuit.

Failure: Low compliance falls below
1.56 mL/ cmH2O (adult) or 1.34 mL/ cmH2O
(pediatric), but not below 1.05 mL/ cmH2O.
AS0511 1. M ake sure correct patient tubing type was
Compliance low specified in SST.
2. Replace patient circuit with a known good cir-
cuit and filter set.
3. Run EST to check the operation of PI and PE
during the Circuit Pressure Test. Replace
applicable pressure transducer.
4. Run Atmospheric Pressure Transducer calibra-
tion.

Failure: Low compliance falls below FS0510 1. M ake sure correct patient tubing type was
1.05 mL/ cmH2O. Compliance low specified in SST.
2. Replace patient circuit.

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Diagnostic codes 6
Table 6-10: EST t est sequence

Code and
Descript ion Display Correct ive act ions
message

Circuit Pressure Test

Test : If ventilator is running on battery power,

prompts user to connect ac power, then verifies
that ventilator is connected to ac. EST can only
run on ac (facility) power.

Failure: System is still running on battery FE0010 1. Plug in ventilator power cord.
power. ac power not 2. Disconnect BPS to isolate
connected problem.
3. Replace power supply.

Prompts user to connect air and oxygen, to

remove inspiratory filter, and to install test
circuit.

Test : Autozeroes inspiratory pressure Inspiratory

transducer (PI), then reads pressure. Stores pressure
pressure reading. (counts)

Failure: Inspiratory pressure transducer ADC FE0001 1. Replace SOL1.

count at 0 cmH2O is out of range. Inspiratory 2. Replace Inspiratory Electronics
autozero out PCB.
of range 3. Replace AI PCB.

Test : Autozeroesexpiratory pressure transducer Expiratory

(PE), then reads pressure. Stores pressure pressure
reading. (counts)

Failure: Expiratory pressure transducer ADC FE0002 1. Replace SOL2.

count at 0 cmH2O is out of range. Expiratory 2. Replace exhalation transducer
autozero out PCB.
of range 3. Replace AI PCB.

Test : Pressurizes system to 10 cmH2O using an

air flow of 5 L/ min.

Failure: Unable to build pressure (air) to FE0003 Inspiratory 1. Make sure that test circuit is
10 cmH2O at 5 L/ min within time-out period. Failed to reach and expiratory installed and air supply or com-
test pressure pressure (only pressor is available and good.
if test fails) 2. Verify that the air regulator pres-
sure is set between 9-12 psi.
3. Verify that the patient circuit sys-
tem has no leaks or occlusions by
running the first four tests in EST
to get to the leak test.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-77
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Reads inspiratory and expiratory pressure Inspiratory

transducers at 10 cmH2O. and expiratory
pressure

Failure: Inspiratory/ expiratory pressure
transducer readings are too far apart.
FE0004 1. Verify that the system has no leaks
Cross-check or occlusions. If not sure, run the
failed first four tests in EST to run the
leak test
2. If the leak test passes in EST, exit
out of EST. Review the data for
the Circuit Pressure Test to deter-
mine which pressure transducer is
out of range: PI or PE. Replace
applicable pressure transducer.
3. Replace AI PCB.

Test : Opens inspiratory pressure transducer Inspiratory

autozero solenoid (SOL1) and reads inspiratory pressure
pressure.

Failure: Inspiratory pressure reading out of FE0005 1. Replace SOL1.

range (-0.60 to 0.60 cmH2O). Bad insp 2. Replace Inspiratory Electronics
autozero PCB.
solenoid 3. Replace AI PCB.

Test : Opens expiratory pressure transducer Expiratory

autozero solenoid (SOL2) and reads expiratory pressure
pressure.

Failure: Expiratory pressure reading out of FE0006 1. Replace SOL2.

range (-0.60 to 0.60 cmH2O). Bad exp 2. Replace exhalation transducer
autozero sol PCB.
3. Replace AI PCB.

Test : Pressurizes system to 50 or 100 cmH2O

using an air flow of 5 L/ min.

Failure: Unable to build pressure (air) to 50 or FE0008 Inspiratory 1. Make sure air supply or compres-
100 cmH2O at 5 L/ min within time-out period. Failed to reach and expiratory sor is available.
test pressure pressure (only 2. Check for system leak at the expi-
if test fails) ratory bacteria filter or O2 sen-
sor. If not sure, run the first four
tests in EST to run the leak test.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Reads inspiratory and expiratory pressure Inspiratory

transducers at 50 and 100 cmH2O. and expiratory
pressure

Failure: Inspiratory/ expiratory pressure
transducer readings are too far apart.
FE0007 1. Replace the expiratory bacteria fil-
Cross-check ter.
failed 2. Verify that the system has no leaks
or occlusions. If not sure, run the
first four tests in EST to run the
leak test.
3. If the leak test passes in EST, exit
out of EST. Review the data for the
Circuit Pressure Test to determine
which pressure transducer is out
of range: PI or PE. Replace appli-
cable pressure transducer.
4. Replace AI PCB.

Flow sen sors cr oss check Test

Test : For oxygen flows of 120, 60, 5, and Inspiratory

1 L/ min, verifies that flow is stable. and expiratory
flow and
oxygen PSOL
(PSOL1)
command
current

Failure: Flow controller unable to establish and AE0110 1. Make sure oxygen supply is con-
control oxygen flow at 120 L/ min. Unable to nected and unrestricted.
establish O2 2. Verify oxygen regulator pressure is
flow set between 9-12 psi.
3. Switch PSOLs to see if failure
transfers to the other gas side. If
yes, return the air PSOL to its orig-
inal position and replace the oxy-
gen PSOL.
4. Run the leak test in EST to check
for leaks/ occlusions.
5. Perform a flow sensor calibration.
6. Replace Q1.
7. Replace the Inspiratory Electronics
PCB.
8. Replace the AI PCB.

Failure: Flow controller unable to establish and FE0106 1. Make sure oxygen supply is con-
control oxygen flow at 60, 5, and 1 L/ min. Unable to nected.
establish O2 2. Check regulated oxygen pressure.
flow 3. Replace PSOL1 or oxygen flow
sensor (Q1).
4. Replace AI PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-79
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : For oxygen flows of 120 60, 5, and 1 L/ Inspiratory

min, verifies that oxygen (Q1) and exhalation and expiratory
(Q3) flow sensor readings are in range. flow

Failure: Q1 and Q3 readings are too far apart.
FE0101 1. Make sure oxygen supply is con-
O2 flow sensor nected and unrestricted.
cross check 2. Verify that the oxygen supply is
failed good.
3. Verify that the system has no leaks
or occlusions. If not sure, run the
first four tests in EST to run the
leak test.
4. Switch PSOLs to see if the failure
transfers to the air side. If yes,
return PSOL2 back to its original
position and replace PSOL1.
5. Run a flow sensor calibration.6.
Switch Q1 and Q2. Rerun the
flow sensor calibration and EST. If
the failure transfers to the air side,
return Q2 back to its original posi-
tion and replace Q1.

Test : For oxygen flows of 120, 60, 5, and 1 L/ POSL1

min, verifies that oxygen PSOL (PSOL1) command
command current is in range. current

Failure: PSOL1 command current is out of FE0102 1. Make sure oxygen supply is con-
range. O2 PSOL nected and unrestricted.
current out of 2. Verify that the oxygen supply is
range good.
3. Verify that the system has no leaks
or occlusions. If not sure, run the
first four tests in EST to run the
leak test.
4. Switch PSOLs to see if the failure
transfers to the air side. If yes,
return PSOL2 back to its original
position and replace PSOL1.
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and EST. If
the failure transfers to the air side,
return Q2 back to its original posi-
tion and replace Q1.

Test : Commands oxygen PSOL (PSOL1) to Inspiratory

deliver 0 L/ min (closed). flow

Failure: Oxygen flow > 0.153 L/ min. FE0108 1. Verify no leaks at the Q1 O-rings.
O2 zero flow 2. Run EST Gas Supply Test to check
check failed for PSOL1 leak. Remove and then
reseat PSOL1
3. Replace PSOL1.
4. Perform a flow sensor calibration.
5. Replace Q1.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : For air flows of 120, 60, 5, and 1 L/ min, Inspiratory

verifies that flow is stable. and expiratory
flow and air
PSOL (PSOL2)
command
current

Failure: Flow controller unable to establish and AE0111 1. Make sure air supply is connected
control air flow at 120 L/ min. Unable to and unrestricted.
establish air 2. Verify air regulator pressure is set
flow between 9-12 psi.
3. Switch PSOL's to see if failure
transfers to the other gas side. If
yes, return Oxygen PSOL to its
original position and replace the
Air PSOL.
4. Run the leak test in EST to check
for leaks/ occlusions.
5. Perform a flow sensor calibration.
6. Replace Q2.
7. Replace the Inspiratory Electronics
PCB.
8. Replace the AI PCB.

Failure: Flow controller unable to establish and FE0107 1. Make sure air supply is connected.
control air flow at 60, 5, and 1 L/ min. Unable to 2. Check regulated air pressure.
establish air 3. Perform flow sensor calibration.
flow 4. Replace PSOL2 or air flow sensor
(Q2).
5. Replace AI PCB.

Test : For air flows of 120 60, 5, and 1 L/ min, Inspiratory

verifies that air (Q2) and exhalation (Q3) flow and expiratory
sensor readings are in range. flow

Failure: Q2 and Q3 readings are too far apart.
FE0103 1. Make sure air supply is connected
Air flow sensor and unrestricted.
cross check 2. Verify that the air supply is good.
failed 3. Verify that the system has no leaks
or occlusions. If not sure, run the
first four tests in EST to run the
leak test.
4. Switch PSOLs to see if the failure
transfers to the air side. If yes,
return PSOL back to its original
position and replace PSOL2
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and EST. If
the failure transfers to the oxygen
side, return Q1 back to its original
position and replace Q2.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-81
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : For air flows of 120, 60, 5, or 1 L/ min, PSOL2

verifies that air PSOL (PSOL2) command command
current is in range. current

Failure: PSOL2 command current out of range.
FE0104 1. Make sure air supply is connected
Air PSOL and unrestricted.
current out of 2. Verify that the air supply is good.
range 3. Verify that the system has no leaks
or occlusions. If not sure, run the
first four tests in EST to run the
leak test.
4. Switch PSOLs to see if the failure
transfers to the air side. If yes,
return PSOL back to its original
position and replace PSOL2
5. Run a flow sensor calibration.
6. Switch Q1 and Q2. Rerun the
flow sensor calibration and EST. If
the failure transfers to the oxygen
side, return Q1 back to its original
position and replace Q2.

Test : Commands air PSOL (PSOL2) to deliver Inspiratory

0 L/ min (closed). flow

Failure: Air flow > 0.153 L/ min. FE0109 1. Verify no leaks at the Q2
Air zero flow O-rings.
check failed 2. Run EST Gas Supply Test to check
for PSOL2 leak. Remove and then
reseat PSOL2
3. Replace PSOL2.
4. Perform a flow sensor calibration.
5. Replace Q2.

Performs lift-off calibration for PSOL1 and

PSOL2.

EST Gas Supp ly/ SV Test

Test : Checks to see if wall air connected

(pressure switch PS2 closed). If not, prompts
user to connect wall air.

Failure: ACCEPT key was pressed but PS2 still FE0204 1. Make sure air supply is connected.
open. Wall air 2. Check PS2: Remove the wiring
pressure not connectors from PS2 and jumper
detected the connectors to each other. If
the system now recognizes the air
supply, replace PS2.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Checks to see if oxygen connected

(pressure switch PS1 closed). If not, prompts
user to connect oxygen.

Failure: ACCEPT key was pressed but PS1 still FE0205 1. Make sure oxygen supply is con-
open. O2 pressure nected.
not detected 2. Check PS1: Remove the wiring
connectors from PS1 and jumper
the connectors to each other. If
the system now recognizes the air
supply, replace PS1.

Prompts user to block To patient port.

Test : Establishes 1 L/ min flow and verifies that

it is stable.

Failure: Stable flow could not be established FE0210 1. Make sure To patient port is
within allotted time. SV pressure blocked.
relief failed 2. Check for leaks at the O2 sensor,
SOL1 or PI.
3. Replace the safety valve.
4. Replace PI.

Test : Determines safety valve cracking pressure Safety valve

and verifies it is in range. cracking
pressure

Failure: Cracking pressure out of range. FE0210 1. Make sure To patient port is
SV pressure blocked.
relief failed 2. Check for leaks at the O2 sensor,
SOL1 or PI.
3. Replace the safety valve.
4. Replace PI.

Test : Commands air PSOL (PSOL2) to deliver Peak pressure

100 L/ min. If PSOL2 cannot deliver this flow
within so many counts, commands oxygen
PSOL (PSOL1) to deliver this flow instead.
Samples inspiratory pressure and determines
peak pressure.

Failure: Neither PSOL could deliver 100 L/ min FE0210 1. Make sure To patient port is
within prescribed count. SV pressure blocked.
relief failed 2. Check for leaks at the O2 sensor,
SOL1 or PI.
3. Replace the safety valve.
4. Replace PI.

Failure: Peak pressure is too high. FE0210 1. Make sure To patient port is
SV pressure blocked.
relief failed 2. Check for leaks at the O2 sensor,
SOL1 or PI.
3. Replace the safety valve.
4. Replace PI.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-83
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Prompts user to disconnect oxygen.

Checks to see if oxygen disconnected (pressure
switch PS1 open).

Failure: PS1 closed instead of open. FE0206 1. Make sure oxygen supply is dis-
O2 pressure connected.
detected 2. Replace Inspiratory Electronics
(O2 not PCB.
disconnected) 3. Replace PS1.

Test : Opens safety valve, bleeds pressure, then Inspiratory

closes it. Reads inspiratory pressure. pressure

Failure: Air PSOL (PSOL2) forward leak was AE0213 1. Check for leaks around the Q2
detected via excessive pressure buildup Air PSOL leak O-rings.
(> 50 cmH2O but < 100 cmH2O) in blocked 2. Make sure air supply is connected
inspiratory module. and unrestricted.
3. Reseat Air PSOL.
4. Replace Air PSOL.
5. Replace AI PCB.

Failure: Air PSOL (PSOL2) forward leak was
detected via excessive pressure buildup
(> 100 cmH2O) in blocked inspiratory module.
FE0207 1. Check for leaks around the Q2 O-
Air PSOL leak rings.
2. Verify that the safety valve relieves
pressures above 100 cmH2O. Lis-
ten for the pressure relief while
watching the numeric digital dis-
play of system pressure in the
upper screen. If the safety valve
does not crack open, replace the
safety valve.
3. Replace PSOL2.

Test : Disables compressor control. If wall air is

the air source, prompts user to disconnect air.
Verifies that air is disconnected (pressure switch
PS2 open).

Failure: PS2 closed instead of open. FE0208 1. Make sure air supply is discon-
Wall air nected.
pressure 2. Replace Inspiratory Electronics
detected PCB.
3. Replace PS2.

Test : Verifies that compressor is depressurized

by reading compressor pressure transducer
(PC).

Failure: PC indicates that compressor is FE0212 Replace compressor PCB.

pressurized. Compressor
pressure
detected

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : At zero flow, reads air flow sensor (Q2), Q2 reading

oxygen flow sensor (Q1), and exhalation flow Q1 reading
sensor (Q3). Q3 reading

Failure: During zero-flow check, Q2 reads FE0215 1. Make sure gas supplies are discon-
> 0.05 L/ min. Air zero flow nected.
check failed 2. Make sure compressor is not run-
ning.
3. Verify no leaks at the Q2
O-rings.
4. Check for PSOL2 leak.
5. Remove and then reseat PSOL2.
6. Perform a flow sensor calibration.
7. Replace PSOL2.
8. Replace Q2.

Failure: During zero-flow check, Q1 reads FE0216 1. Make sure gas supplies are discon-
> 0.05 L/ min. O2 zero flow nected.
check failed 2. Make sure compressor is not run-
ning.
3. Verify no leaks at the Q2
O-rings.
4. Check for PSOL2 leak.
5. Remove and then reseat PSOL2.
6. Perform a flow sensor calibration.
7. Replace PSOL2.
8. Replace Q2.

Failure: During zero-flow check, Q3 reads > FE0217 1. Make sure gas supplies are discon-
0.1 L/ min. Exp zero flow nected.
check failed 2. Make sure compressor is not run-
ning.
3. Verify no leaks at the Q3
O-rings.
4. Perform a flow sensor calibration.
5. Replace Q3.

Test : Prompts user to connect oxygen. Checks

to see if oxygen connected (pressure switch
PS1 closed).

Failure: PS1 open instead of closed. FE0211 1. Make sure oxygen supply is con-
O2 pressure nected.
not detected 2. Replace Inspiratory Electronics
PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-85
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Opens safety valve, bleeds pressure, then Inspiratory

closes it. Reads inspiratory pressure. pressure

Failure: Oxygen PSOL (PSOL1) forward leak AE0214 1. Check for leaks around the Q1 O-
was detected via excessive pressure buildup O2 PSOL leak rings.
(> 50 cmH2O but < 100 cmH2O) in blocked 2. Make sure oxygen supply is con-
inspiratory module. nected and unrestricted.
3. Reseat oxygen PSOL.
4. Replace oxygen PSOL.
5. Replace AI PCB.

Failure: Oxygen PSOL (PSOL1) forward leak
was detected via excessive pressure buildup
(> 100 cmH2O) in blocked inspiratory module.
FE0209 1. Check for leaks around the Q1 O-
O2 PSOL leak rings.
2. Verify that the safety valve relieves
pressures above 100 cmH2O. Lis-
ten for the pressure relief while
watching the numeric digital dis-
play of system pressure in the
upper screen. If the safety valve
does not crack open, replace the
safety valve.
3. Replace PSOL1.

Re-enables compressor control. Promptsuser to

reconnect wall air, block To patient port, and
reconnect test circuit.

Leak Test

Test : Pressurizes system to 90 cmH2O with

either gas using 2 L/ min flow.

Failure: System cannot attain leak test starting FE0305 1. Make sure test circuit is con-
pressure using oxygen or air within time-out Unable to nected.
period. establish 2. Check for system leaks.
pressure 3. Check exhalation valve operation.
4. Verify secure connection of expira-
tory filter.

Test : Waits for pressure to decay, then verifies

adequate inspiratory pressure.

Failure: System pressure dropped below FE0301 1. Make sure test circuit is con-
85 cmH2O. Excessive leak nected.
2. Check for system leaks.
3. Check exhalation valve operation.
4. Verify secure connection of expira-
tory filter.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Waits until inspiratory pressure drops to

85 cmH2O or until 10 s elapse.
If pressure drops to 85 cmH2O, waits until
pressure drops by 5 cmH2O or until 10 s more
elapse. Checks pressure drop. Compares
inspiratory and expiratory pressure
measurements.

Failure: Pressure not detected on expiratory AE0306 Pressure drop 1. Make sure test circuit is properly
side (inspiratory/ expiratory pressure transducer Test circuit in 10 s connected.
readings are too far apart). not connected 2. Replace expiratory bacteria
filter.
3. Check for leaks around the Q3
flow sensor.
4. Check/ replace the exhalation
valve.
5. Replace the expiratory pressure
transducer PCB.

Failure: Pressure drops to 85 cmH2O in 10 s,
then in 10 s more by ≥ 5 cmH2O.
FE0301 1. Make sure test circuit is connected
Excessive leak and is not leaking.
2. Check for system leaks or occlu-
sions especially at the O2 sensor
and expiratory filter.
3. Verify secure connection of expira-
tory filter.
4. Check exhalation valve operation.

GUI Keyboard Test

Test : Prompts user to press key, then reads

keyswitch.

Failure: Wrong key pressed or key not pressed FE0401 1. Repeat test.
within 15 s. Accept key 2. Replace keyboard.
fails.

Failure: Wrong key pressed or key not pressed FE0402 1. Repeat test.
within 15 s. Clear key fails. 2. Replace keyboard.

Failure: Wrong key pressed or key not pressed FE0403 1. Repeat test.
within 15 s. Insp. Pause 2. Replace keyboard.
key fails.

Failure: Wrong key pressed or key not pressed FE0404 1. Repeat test.
within 15 s. Exp. Pause key 2. Replace keyboard.
fails.

Failure: Wrong key pressed or key not pressed FE0405 1. Repeat test.
within 15 s. Man Insp fails. 2. Replace keyboard.

Failure: Wrong key pressed or key not pressed FE0406 1. Repeat test.
within 15 s. 100% O2 / 2. Replace keyboard.
CAL key fails.

Failure: Wrong key pressed or key not pressed FE0407 1. Repeat test.
within 15 s. Info key fails. 2. Replace keyboard.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-87
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Failure: Wrong key pressed or key not pressed FE0408 1. Repeat test.
within 15 s. Alarm Reset 2. Replace keyboard.
key fails.

Failure: Wrong key pressed or key not pressed FE0409 1. Repeat test.
within 15 s. Alarm Silence 2. Replace keyboard.
key fails.

Failure: Wrong key pressed or key not pressed FE0410 1. Repeat test.
within 15 s. Alarm Volume 2. Replace keyboard.
key fails.

Failure: Wrong key pressed or key not pressed FE0411 1. Repeat test.
within 15 s. Screen 2. Replace keyboard.
brightness
fails.

Failure: Wrong key pressed or key not pressed FE0412 1. Repeat test.
within 15 s. Screen 2. Replace keyboard.
contrast key
fails.

Failure: Wrong key pressed or key not pressed FE0413 1. Repeat test.
within 15 s. Screen lock 2. Replace keyboard.
key fails.

EST GUI Knob Test

Test : Prompts user to turn knob

counterclockwise and clockwise.

Failure: Knob was not turned in direction as FE0501 1. Repeat test.

prompted within 15 s. Bad knob 2. Replace keyboard.

GUI Lam p Test

Test : Prompts user to acknowledge that LED is

on.

Failure: CLEAR key pressed to indicate LED not AE0601 1. Check/ replace interconnect cable
on. GUI High between the GUI LED PCB and the
Alarm LED GUI CPU PCB.
fails. 2. Replace the GUI LED PCB.

Failure: CLEAR key pressed to indicate LED not AE0602 1. Check/ replace interconnect cable
on. GUI Medium between the GUI LED PCB and the
Alarm LED GUI CPU PCB.
fails. 2. Replace the GUI LED PCB.

Failure: CLEAR key pressed to indicate LED not AE0603 1. Check/ replace interconnect cable
on. GUI Low between the GUI LED PCB and the
Alarm LED GUI CPU PCB.
fails. 2. Replace the GUI LED PCB.

Failure: CLEAR key pressed to indicate LED not AE0604 1. Check/ replace interconnect cable
on. GUI Normal between the GUI LED PCB and the
LED fails. GUI CPU PCB.
2. Replace the GUI LED PCB.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Failure: CLEAR key pressed to indicate LED not AE0605 1. Check/ replace interconnect cable
on. GUI Batt between the GUI LED PCB and the
Backup LED GUI CPU PCB.
fails. 2. Replace the GUI LED PCB.

Failure: CLEAR key pressed to indicate LED not AE0606 1. Check/ replace interconnect cable
on. GUI On Batt between the GUI LED PCB and the
Pwr LED fails. GUI CPU PCB.
2. Replace the GUI LED PCB.

Failure: CLEAR key pressed to indicate LED not AE0607 1. Check/ replace interconnect cable
on. GUI between the GUI LED PCB and the
Compressor GUI CPU PCB.
Ready LED 2. Replace the GUI LED PCB.
fails.

Failure: CLEAR key pressed to indicate LED not AE0608 1. Check/ replace interconnect cable
on. GUI between the GUI LED PCB and the
Compressor GUI CPU PCB.
Operating 2. Replace the GUI LED PCB.
LED fails.

Failure: CLEAR key pressed to indicate LED not AE0609 1. Check/ replace interconnect cable
on. GUI 100% O2 between the GUI LED PCB and the
LED fails. GUI CPU PCB.
2. Replace keyboard.

Failure: CLEAR key pressed to indicate LED not AE0610 1. Check/ replace interconnect cable
on. GUI Alarm between the GUI LED PCB and the
Silence LED GUI CPU PCB.
fails. 2. Replace keyboard.

Failure: CLEAR key pressed to indicate LED not AE0611 1. Check/ replace interconnect cable
on. GUI Screen between the GUI LED PCB and the
Lock LED fails. GUI CPU PCB.
2. Replace keyboard.

BD Lam p Test

Test : Prompts user to acknowledge that LEDs

are on.

Failure: CLEAR key pressed to indicate one or AE0702 Replace BDU LED PCB.
both ventilator inoperative LEDs not on. Bad Vent inop
LED

Test : Prompts user to acknowledge that LEDs

are on.

Failure: CLEAR key pressed to indicate one or AE0703 Replace BDU LED PCB.
both SVO LEDs not on. Bad SVO LED

Test : Prompts user to acknowledge that LED is

on.

Failure: CLEAR key pressed to indicate LED not AE0704 Replace BDU LED PCB.
on. Bad Loss of
GUI LED

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-89
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

GUI Audio Test

Test : Activates GUI high-urgency alarm sound

and prompts user to verify that GUI alarm
sounds.

Failure: CLEAR key pressed to indicate GUI FE0801 1. Verify the GUI alarm cable connec-
audio diagnostic failed. SAAS tion to the GUI CPU PCB.
(Safety Audible 2. Replace GUI alarm assembly.
Alarm System) 3. Replace GUI CPU PCB.
test failed

GUI Nurse Call Test

Prompts user to acknowledge whether test is to

be performed.

Test : Prompts user to indicate if nurse’s call

(remote alarm) is off.

Failure: CLEAR key pressed to indicate relay is FE2301 1. Make sure test equipment is con-
stuck on when it should be off. Nurse call nected properly to remote alarm
stuck on port.
2. Replace GUI CPU PCB.

Test : Activates nurse’s call (remote alarm) relay,

then prompts user to indicate if nurse’s call is
on.

Failure: CLEAR key pressed to indicate relay is FE2302 1. Make sure test equipment is con-
stuck off when it should be on. Nurse call nected properly to remote alarm
stuck off port.
2. Replace GUI CPU PCB.

Deactivates nurse’s call port.

BD Aud io Test

Test : Checks alarm cable voltage. Alarm cable

voltage

Failure: Voltage out of range FE0901 1. Make sure BD alarm cable is con-
(< 3.5 or > 5.05 V). Bad alarm nected.
cable 2. Replace BD alarm.
3. Replace AI PCB.
4. Replace BD alarm cable.

Test : Checks initial power failure capacitor Initial power

voltage. failure
capacitor
voltage

Failure: Voltage out of range FE0902 1. Make sure BD alarm cable is con-
(< 4.5 or > 5.05 V). Bad power fail nected.
cap 2. Replace BD alarm.
3. Replace AI PCB.
4. Replace BD alarm cable.
5. Replace M otherboard PCB.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Sounds BD alarm. Prompts user to

acknowledge audible alarm.

Failure: CLEAR key pressed to indicate user did FE0904 1. Make sure BD alarm cable is con-
not hear alarm, although alarm was active. Bad BD audio nected.
2. Replace BD alarm.
3. Replace AI PCB.
4. Replace BD alarm cable.

Test : M easures and compares power fail

capacitor voltages before and after alarm is
sounded.

Failure: Final capacitor voltage higher than FE0903 1. Make sure BD alarm cable is con-
initial voltage. Bad power fail nected.
cap 2. Replace BD alarm.
3. Replace AI PCB.

Test : Calculate and check RC constant. RC constant

for power fail
capacitor

Failure: RC constant < 60 s. FE0903 1. Make sure BD alarm cable is con-

Bad power fail nected.
cap 2. Replace BD alarm.
3. Replace AI PCB.

PSOL Loopback Test

Test : Reads air PSOL (PSOL2) loopback current PSOL2

at various drive currents. Verifies that PSOL2 loopback
loopback current is within range of drive current at
current. various drive
currents

Failure: PSOL2 loopback current out of range
(OOR) of drive current.
AE1001 1. Verify that the air supply is good.
Air PSOL 2. Verify air regulator pressure set to
loopback between 9 and 12 psi.
current OOR 3. Switch PSOLs to see if failure
transfers to the other gas side. If
yes, return oxygen PSOL (PSOL1)
to its original position and replace
PSOL2.
4. Switch Q1 and Q2, run a flow
sensor calibration and rerun test.
If the problem transfers to the
other gas side, return Q1 to its
original position and replace Q2.
5. Replace the AI PCB.
6. Replace the Inspiratory
Electronics PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-91
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Reads oxygen PSOL (PSOL1) loopback PSOL1

current at various drive currents. Verifies that loopback
PSOL1 loopback current is within range of drive current at
current. various drive
currents

Failure: PSOL1 loopback current out of range
(OOR) of drive current.
AE1002 1. Verify that the oxygen supply is
O2 PSOL good.
loopback 2. Verify oxygen regulator pressure
current OOR set to between 9 and 12 psi.
3. Switch PSOLs to see if failure
transfers to the other gas side. If
yes, return the air PSOL to its orig-
inal position and replace PSOL1.
4. Switch Q1 and Q2, run a flow sen-
sor calibration and rerun test. If
the problem transfers to the other
gas side, return Q2 to its original
position and replace Q1.
5. Replace the AI PCB.
6. Replace the Inspiratory
Electronics PCB.

Safet y Syst em Test

Test : Establishes an air flow of 60 L/ min.

Failure: Flow controller unable to establish and
control gas flow at 60 L/ min.
FE1105 1. Make sure air supply is connected
Unable to and unrestricted.
establish flow 2. Check air regulator pressure.
3. Run flow sensor calibration.
4. Switch PSOLs to see if test passes.
If it does, return PSOL1 to its origi-
nal position and replace PSOL2.
5. Replace Q2.

Test : Reads inspiratory pressure (safety valve Inspiratory

back pressure) and verifies that it is pressure
≤ 1.0 cmH2O. (safety valve
back pressure)

Failure: Excessive safety valve back pressure FE1101 Replace safety valve.
when safety valve is open. Safety valve
occluded

Test : Reads loopback current (safety valve open Safety valve

and closed; during low and high current loopback
conditions) and verifies it is in range. current

Failure: Safety valve loopback current out of FE1102 1. Replace safety valve.
range. Bad safety 2. Replace AI PCB.
valve driver or 3. Replace Inspiratory Electronics
loopback PCB.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Performs a reverse-flow check of Elapsed time

inspiratory check valve. Establishes a pressure of for pressure to
95 cmH2O with air flow of 5 L/ min. Reads drop from 85
inspiratory pressure. Then stops flow and opens to 5 cmH2O
safety valve. Determines time it takes for
pressure to drop from 85 to 5 cmH2O. Verifies
time is within range.

Failure: It took too long to relieve excess FE1103 1. Make sure proper test circuit is
pressure through open safety valve, indicating Insp check used.
inspiratory check valve (CV3) is occluded or test valve test 2. Make sure CV3 is not installed
circuit is too large. failed backward.
3. Replace CV3.
4. Replace Safety Valve (SV).

Failure: It took too little time to relieve excess AE1104 1. Make sure test circuit is con-
pressure through open safety valve, indicating Insp check nected.
inspiratory check valve (CV3) may be damaged valve test 2. Make sure CV3 is not installed
or incorrectly mounted. failed backward.
3. Replace CV3.

Exp Valve Loopb ack Test

Test : Reads exhalation valve loopback current Exhalation

and compares it to drive current for several size valve
openings. loopback
current

Failure: Exhalation valve loopback current is AE1201 1. Verify that the system has no leaks
out of range (OOR) of drive current. Exp valve or occlusions by running the leak
loopback test in EST.
current OOR 2. Clean exhalation valve
diaphragm.
3. Calibrate the exhalation valve.
4. Clean/ replace the exhalation
valve.
5. Replace the AI PCB.

Exp Valve Seal Test

Test : Verifies that exhalation valve calibration

table checksum is valid and that last calibration
performed wascompleted successfully (i.e., flag
set in BD NOVRAM).

Failure: Exhalation valve table checksum invalid FE1304 1. Check for leaks or occlusions. Cor-
or last calibration performed was not Exp valve not rect and then run the exhalation
completed successfully. calibrated valve calibration.
2. Replace the exhalation valve.
3. Replace the AI PCB.
4. Replace Q3.
5. Replace Q2.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-93
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Verifies that exhalation valve magnet

temperature is in range.

Failure: Exhalation valve magnet temperature FE1302 1. Ensure the unit has been warmed
out of range (OOR) (10 to 100 °C). Exp valve up at ambient temperature for at
temp OOR least 10 minutes.
2. Calibrate the exhalation valve
(EV).
3. Replace exhalation valve (EV).
4. Replace AI PCB.

Test : Using exhalation valve calibration table,

commands valve to generate system pressure
of 45 cmH2O. Establishes air flow of 5 L/ min
and waits a short interval for flow to stabilize.

Failure: Flow controller unable to establish and FE1303 1. Make sure proper test circuit it
control air flow measured by exhalation flow Unable to used and that there are no leaks or
sensor (Q3). establish exp occlusions.
flow 2. Make sure air supply is still con-
nected.
3. Run flow sensor calibration.
4. Replace Q3.
5. Replace Q2.
6. Replace the exhalation valve.

Test : Reads exhaled flow (for 5 L/ min) from Q3.

Reduces flow, then reads expiratory flow (for
0.3 L/ min). Verifies that test ∆ pressure is
acceptable.

Failure: Seal test ∆ pressure is above failure FE1301 1. Clean exhalation valve.
level. Seal test failed 2. Calibrate exhalation valve.
3. Run flow sensor calibration.
4. Replace exhalation valve.
5. Replace AI PCB.
6. Replace PE.

Failure: Seal test ∆ pressure is above alert level
but below failure level.
AE1305 1. Verify that the system has no leaks
Seal test failed or occlusions by running the leak
test in EST.
2. Clean the exhalation valve.
3. Calibrate exhalation valve.
4. Replace the exhalation valve.
5. Replace the AI PCB.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Exp Valve Test

Test : Verifies that exhalation valve calibration

table checksum is valid and that last calibration
performed wascompleted successfully (i.e., flag
set in BD NOVRAM).

Failure: Exhalation valve table checksum invalid FE1402 1. Check for leaks or occlusions. Cor-
or last calibration performed was not Exp valve not rect and then run the exhalation
completed successfully. calibrated valve calibration.
2. Replace the exhalation valve.
3. Replace the AI PCB.
4. Replace Q3.
5. Replace Q2.

Test : Establishes 5 L/ min expiratory-controlled

air flow. Commands exhalation valve gain port
to 0.5 V. Using expiratory valve calibration
table, commands exhalation valve to open as
required to maintain system pressure of
10 cmH2O.

Failure: Flow controller unable to establish and FE1403 1. Make sure air supply is connected.
control air flow measured by exhalation flow Unable to 2. Make sure proper test circuit is
sensor (Q3). establish exp used.
flow

Test : Reads expiratory pressure for several test Expiratory

points, and verifies it is within range. pressure

Failure: Measured system pressure at one or FE1401 1. Calibrate exhalation valve.

more test points is out of range. Bad 2. Replace exhalation valve.
calibration 3. Replace AI PCB.
4. Replace the Exhalation Pressure
Transducer PCB.

EV Velocit y Transducer Test

Test : Calculates ∆ P for expiratory pressures

made with exhalation valve commanded with
high and zero damping gains.

Failure: Expiratory ∆ P too low, indicating FE2201 1. Calibrate exhalation valve and
velocity transducer not responding properly. Low exp ∆P retest.
2. Replace exhalation valve.

Exp Heat er Test

Test : Establishes 60 L/ min inspiratory-

controlled air flow.

Failure: Flow controller unable to establish and FE1501 Make sure air supply is connected.
control 60 L/ min flow. Unable to
establish air
flow

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-95
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Turns on exhalation heater. Reads heater- Heater-on

on temperature periodically over an interval, temperature
checking for a temperature rise of ≥ 3 °C. (displayed as
Displays heater-on temperature as soon as it soon as it rises
rises ≥3 °C. ≥ 3 °C above
initial
temperature)

Failure: Heater temperature did not rise FE1502 1. Replace exhalation heater.
sufficiently during an interval after heater was Bad exp 2. Replace AI PCB.
turned on. heater

Test : Turns off exhalation heater. Reads heater- Heater-off

off temperature periodically over an interval, temperature
checking for a temperature drop of ≥ 2 °C from (displayed as
heater-on temperature. soon as it
drops ≥ 3 °C
below heater-
on
temperature)

Failure: Heater temperature did not drop FE1503 1. Replace exhalation heater.
sufficiently during an interval after heater was Bad exp 2. Replace AI PCB.
turned off. heater

Com pressor Test

Checks that compressor is installed.

Test : Checks whether unit is running on ac. If

unit is running on ac (BPSis not installed or BPS
is installed but battery power is not being
used), prompts user to connect ac.

Failure: System is still running on battery power AE1602 1. Plug in ventilator power cord and
(i.e., when polled, either BPS charged or BPS ac power not check the cord connection at the
charging line is active). Compressor can only connected ventilator.
run on ac (facility) power. 2. Check ac.
3. Disconnect BPS to isolate prob-
lem.
4. Replace power supply.

Test : Checks whether wall air is connected (air

pressure switch (PS2) closed). If so, prompts
user to disconnect it so compressor can be
tested. Verifies that PS2 is now open.

Failure: PS2 is closed when it should be open. AE1601 1. Make sure air supply is discon-
Wall air nected.
pressure 2. Disconnect PS2 and rerun test. If
detected test passes, replace PS2.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Reads initial compressor time, waits 15 s,

reads final compressor time, then calculates
compressor run elapsed time.

Failure: Calculated run time not within range, AE1604 Listen for motor. If motor is on,
perhaps because compressor timer is not Run mode replace compressor PCB. Otherwise,
running while compressor motor is on. time OOR replace compressor.

Test : Reads compressor pressure transducer

(PC) and verifies that there is compressor
pressure.

Failure: PC indicates that compressor air is not
present, although compressor motor is on.
AE1603 1. If compressor system is an 804
Compressor model, replace with the 806
pressure not model.
detected 2. Run compressor leak test to check
for leaks.
a. Use leak detector to check for
leaks at the accumulator fittings
and other tubing connections.
b. Verify no leaks at CV2 within
the ventilator by plugging the
air inlet fitting.
3. Replace compressor PCB.

Test : Disables compressor control and

commands compressor to disabled mode.
Reads compressor pressure transducer (PC) and
verifies that compressor air is not present.

Failure: PC indicates that compressor air is AE1606 Replace compressor PCB.

present after compressor motor is disabled and Compressor
accumulator drained. pressure
detected

Test : Reads initial compressor time, waits 15 s,

reads final compressor time, then calculates
compressor disabled elapsed time.

Failure: Calculated disabled time not within AE1607 Replace compressor PCB.
range, perhaps because compressor timer is Disabled
running while compressor motor is off. mode time
OOR

Test : Checks that compressor timer was verified

to be functional during previous compressor
run and disabled tests.

Failure: Compressor standby mode check AE1608 1. Troubleshoot code AE1604 or

cannot be run, because of inability to verify Unable to test AE1607, if present.
timer functionality. standby mode 2. Replace compressor PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-97
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

Test : Reads initial compressor time, waits 15 s,

reads final compressor time, then calculates
compressor standby mode elapsed time.

Failure: Calculated standby mode time not AE1609 Replace compressor PCB.
within range, perhaps because compressor Standby mode
motor is still running. During standby mode time OOR
test phase, compressor motor should eventually
turn off.

Test : Re-enables compressor control. Checks

that compressor pressure transducer (PC) was
verified to be functional during previous
compressor run and disabled tests.

Failure: Compressor load test cannot be run, AE1610 Troubleshoot code AE1603 or
because of inability to verify PC functionality. Unable to AE1606.
perform
compressor
load test

Test : Commands expiratory valve damping

gain DAC and expiratory valve DAC to values
corresponding to 45 cmH2O. Performs 1 cycle
of worst-case breath delivery waveform
(200 lpm). Stops flow control and verifies that
compressor air is present, as indicated by
compressor pressure switch (PC).

Failure: PC reading indicates compressor AE1611 1. Run compressor leak test to check
unable to maintain minimum pressure under Compressor for compressor leak.
worst-case breath delivery waveform. load test failed a. Use leak detector to check for
leaks at the accumulator fittings
and other tubing connections.
b. Verify no leaks at CV2 within
the ventilator by plugging the
air inlet fitting.
2. Replace compressor.
3. Replace compressor PCB.

Com pressor Leak Test

Checks that compressor is installed.

Test : Verifies that compressor timer tests

passed during Compressor Test.

Failure: Compressor leak test cannot be run, AE1701 1. Troubleshoot accompanying code
because of inability to verify timer functionality. Unable to AE1604 or AE1607.
perform 2. Replace compressor PCB.
compressor
leak test

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Disables compressor control and

commands compressor to disabled mode. If
wall air is connected (pressure switch PS2
closed), prompts user to disconnect wall air,
then verifies that PS2 is open.

Failure: PS2 is closed, but it should be open. AE1702 1. Make sure air supply is discon-
Compressor control is restored. Wall air nected.
pressure 2. Disconnect PS2 and rerun test. If
detected test passes, replace PS2.

Test : Prompts user to reconnect wall air, then

verifies that wall air pressure switch (PS2) is
closed.

Failure: PS2 is open, but it should be closed. AE1703 1. Make sure air supply is connected.
Compressor control is restored. Wall air 2. Run Gas Supply/ SV Test.
pressure not
detected

Test : Commands compressor to standby

mode, then lets compressor recharge. Checks
compressor pressure periodically over a
1-minute interval.

Failure: Compressor pressure transducer (PC) AE1704 Troubleshoot compressor

indicates loss of compressor pressure, pointing Compressor compartment or inspiratory module
to a leak. leak detected for leaks.

Test : Determines compressor elapsed time with Elapsed time

compressor in standby mode.

Failure: Compressor elapsed time > 1 s. This AE1704 Troubleshoot compressor

indicates compressor has been on when it Compressor compartment or inspiratory module
should not have been, pointing to a possible leak detected for leaks.
leak.

Analog Dat a Display

Reads analog data channels. All analog

data channel
measurements

GUI Touch Test

Test : Reads touchscreen error report buffer.

Failure: Touchscreen error occurred (e.g., AE1901 1. Clean touchscreen, removing any
blocked beam or low-level error), buffer cannot GUI touch: obstructions.
be read, or report is invalid. Error 2. Replace touchframe PCB.
3. Replace GUI CPU PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-99
6 Diagnostic codes

Table 6-10: EST test sequence (continued)

Code and
Descript ion Display Correct ive act ions
message

GUI Serial Port Test

Test : Activates GUI serial port loopback mode.

Transmits a character string. Verifies that
received string is identical to transmitted string.

Failure: Received message not identical to AE2001 Replace GUI CPU PCB.
transmitted message. Bad GUI serial
port

Bat t er y Test

Verifies that BPS is installed (by reading BPS

model line).

Test : Verifies that BPS is charged (BPS charged

bit off and BPS charging bit on).

Failure: BPS not fully charged. AE2101 1. Allow BPS to fully charge, then
Battery not repeat test.
charged 2. Replace BPS PCB.
3. Replace battery pack.
4. Replace BD CPU PCB.

Prompts user to disconnect ac.

Test : Loads BPS with known load. Verifies that

system is running on BPS (BPS charged bit on
and BPS charging bit on).

Failure: BPS not discharging. AE2102 1. Verify ac power is disconnected

Battery not when prompted.
discharging 2. Replace BPS PCB.
3. Replace battery pack.
4. Replace BD CPU PCB.

Test : Makes several BPS voltage readings while BPS voltage

BPS discharges and verifies that voltages are
within range.

Failure: BPS voltage dropped below accepted
level or dropped too quickly.
AE2103 1. Ensure that the battery pack is
Bad Backup fully charged by checking that the
Power Supply green LED on the BPS is lit prior to
initiating an EST. If the amber LED
is lit, allow the unit to charge the
batteries prior to rerunning EST.
2. Replace the battery pack.
3. Replace the BPS PCB.
4. Replace the AI PCB.
5. Replace the power supply.

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Diagnostic codes 6
Table 6-10: EST t est sequence (cont inued)

Code and
Descript ion Display Correct ive act ions
message

Test : Prompts user to reconnect ac. Verifies that

BPS is now charging (BPS charged bit on and
BPS charging bit off).

Failure: BPS not charging after ac power was AE2104 1. Verify that ac power is recon-
reconnected. Battery not nected when prompted and that
charging ac is good.
2. Replace BPS PCB.
3. Replace the battery pack.
4. Replace the power supply.
5. Replace the BD CPU.
6. Replace the AI PCB.

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 6-101
6 Diagnostic codes

6.10.1 How to troubleshoot LCD invert er PCB faults (UT0002)

For al l UT00002 errors, ch eck th e System Diagn ostic Log for the in dicators of a VGA
control ler fault. Check the th ree digits of th e Fault Address (FA) that im m ediatel y foll ow
“ 0x” . (Refer to exam pl e bel ow.)

TIM E TEST/ EVENT CODE TYPE NOTES

12:55:59 PC: 0xFF77B7FeTID'21

Bus Error/ Access Fault UT0002 FAILURE
08 Aug 03 FA: 0x02F0 0000

The NOTEScol um n i n the log contains the UT0002 Faul t Address (FA). Usin g the FA, you can
determ i ne i f there is a problem with an VGA control ler, and iden tify wh ether it i s th e
upper LCD PCB or the lower LCD PCB. If you cann ot locate a faul t code in Table 6-1 that
m atch es th e three di gi ts of the reported fault code then replace the GUI CPU PCB.

Table 6-11: UT0002 Fault Addresses for LCD invert er PCB errors

LCD invert er PCB Fault Address (FA)

Lower 0x020X XXXX

0x021x XXXX
0x022x XXXX
0x023x XXXX
0x024x XXXX
0x025x XXXX
0x026x XXXX
0x027x XXXX

Upper 0x028X XXXX

0x029X XXXX
0x02AX XXXX
0x02BX XXXX
0x02CX XXXX
0x02DX XXXX
0x02EX XXXX
0x02FX XXXX

The exam ple gi ven in dicates th at the upper VGA Controll er PCB shoul d be repl aced.

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 SECTION
S EC T I O N

Alarm handling 7 7
This section describes how to respond to ven tilator al arm s. It al so l ists, in al phabetic order,
m essages displ ayed by the venti lator wh en it detects al arm conditions.

7.1 Alarm classificat ions

Alarm s i n th e 840 Ventil ator are classi fied by urgency l evel ; th is cl assi fication determ in es h ow
the venti lator respon ds (Tabl e 7-1). Som e alarm s are triggered by a ventil ator settin g or
patient condition, and they can occur i n the usual course of patient care. Others are triggered
by the ven ti lator’s bui lt-i n background checks and may in dicate that the ventil ator requires
service; som e of these are called DEVICE ALERTs. W h en th e venti lator declares a DEVICE
ALERT, it not only displ ays a m essage an d w rites to the alarm l og, but it also places an
associated diagn osti c code into th e System Di agnostic Log.

Table 7-1: How the vent ilator responds to alarm condit ions

Urgency M eaning Displays Audible alarm Not es

High Requires immediate
attention to ensure
patient safety
Red high-urgency ! ! ! Sequence of 5 tones that If a high-urgency alarm
indicator flashes rapidly. repeats twice, pauses, goes away
Alarm message flashes at then repeats again spontaneously
top of upper screen. (autoresets), its indicator
remains lit (not flashing)
until you press the alarm
reset key.

Medium Requires prompt Yellow medium-urgency Repeating sequence of 3

attention ! ! indicator flashes tones
slowly. Alarm message
flashes at top of upper
screen.

Low There has been a change Yellow low-urgency ! 1 tone, non-repeating

in the patient-ventilator indicator lights. Alarm
system message flashes at top of
upper screen.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 7-1
7 Alarm handling

7.2 Responding t o alarms

1 Sil en ce th e audi bl e al arm for 2 m i nutes (where possible) by pressi ng the alarm sil ence
key.
2 Read the alarm m essage from th e top screen (Fi gure 7-1).
The base message identifies The analysis message gives the root
the alarm. Touch alarm cause of the alarm. May also include
symbol to view definition dependent alarms that have arisen
on lower screen. due to the initial alarm.

}
The two highest-
3VTE MAND 2 of last 4 mand breat hs ≤ set limit. Check for leaks, changes i n
patient's R& C. priority active
alarm messages
11:20 25 Jun 2000 are displayed here.

The remedy
message suggests
how to resolve the
alarm condition.

8-01197

Touch flashing more alarms

button to view messages for up
to six additional active alarms.

Figure 7-1. Alarm message format

3 Correct th e condi tion, if n ecessary, referri ng to Table 7-2. You can ch eck th e alarm log
(Fi gure 7-2). You m ay wan t to ch eck th e conten ts of th e System Di agnostic Log
(accessi bl e through the service men u, Section 4) for related di agnostic codes. The
troublesh ootin g procedures li sted are sequen ced to correct th e m ost probable
m alfunction or to present the m ost efficient corrective action first. The proposed fi xes
listed, h owever, m ay n ot al ways correct the particul ar problem.

NOTE:
• You can change alarm settings even when alarms are active.
• Completing a new patient setup or running EST clears the alarm log.
• When more than one alarm is active and their alarm messages vary in their degree of
seriousness, you should assume that the most serious message is applicable.

4 If necessary, cl ear the m essage or reset the al arm by pressing the al arm reset key.
For specifics about al arm operation, see th e 840 Ventilator System Operator’s and Technical
Reference Manual.

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Alarm handling 7

8-01198

Alarm log button Touch symbols to Touch scroll bar, then

(indicates that log see definition at turn knob to scroll
includes unread entries) bottom of lower through log
Question mark appears on button screen
if log includes event that has not
been viewed yet

Figure 7-2. Alarm log

"Lockabl e" al arm s incl ude all PATIENT DATA an d CIRCUIT DISCONNECT alarm s an d can be
silenced for two mi nutes by pressing the al arm si lence key. A n ew, h igh -urgency alarm
cancel s the si len ce. Each ti m e you press th e alarm silence key, th e sil ence peri od resets to two
m in utes. Each ti me you press the alarm si lence key (whether or n ot there is an active alarm ),
the keypress is recorded i n the alarm log.

Table 7-2: Alarm messages

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

AC POWER Operating on Power switch is on, and ac is not 1. Check integrity of ac

LOSS battery. available, so ventilator is power source.
operating on BPS. (BPS 2. Replace power supply.
operating indicator is on and
power indicator is off.) Resets
when ac power is restored.

Operational Prepare for Two minutes of battery power

time < 2 power loss. remain.
minutes.

APNEA The set apnea interval has Check patient and settings.
(lockable) elapsed without the ventilator,
patient, or operator triggering a
breath. Resets when patient
initiates 2 consecutive breaths.

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7 Alarm handling

Table 7-2: Alarm messages (cont inued)

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

CIRCUIT No Check patient/ Ventilator has recovered from 1. Check patient circuit con-
DISCONNECT ventilation. ventilator unintended power loss, detects nections.
(lockable) status. circuit disconnect, and switches 2. Run EST.
to idle mode; upper screen
displays elapsed time without
ventilator support. Resets when
ventilator senses reconnection.

Check patient. Ventilator detects circuit 1. Check patient circuit con-

Reconnect disconnect and switches to idle nections.
circuit. mode; upper screen displays 2. Run EST.
elapsed time without ventilator
support. Resets when ventilator
senses reconnection.

COMPLIANCE Compliance volume required to 1. Check patient circuit con-

LIMITED VT compensate delivery of a volume nections.
(lockable) controlled breath exceeds the 2. Run SST.
maximum allowed for 3 of the
last 4 breaths.

COMPRESSOR Compressor is not operating due 1. Check integrity of ac

INOPERATIVE to low ac. Resets when full ac is power source.
restored. 2. Check mains circuit
breaker.
3. Run EST.

DEVICE ALERT A background check or POST has Check System Diagnostic Log
detected a problem. Resets for any associated error codes.
when ventilator passes EST or Rerun POST/ EST.
POST.

1O2% The O2% measured during any Calibrate oxygen sensor.

phase of a breath cycle is 7%
(12% during the first hour of
operation) or more above the
O2% setting for at least 30 s.
(These percentages increase by
5% for 4 minutes following a
decrease in the O2% setting.)
Alarm updated at 1-s intervals.

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Alarm handling 7
Table 7-2: Alarm messages (cont inued)

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

1PCOMP 1PPEAK Check for Target pressure 1. Check for leaks.

(lockable) detected but leaks, tube ≥ (1PPEAK - 5 cmH2O) 2. Check for correct tube type
not 1PCOMP type/ I.D. and I.D. settings.
setting

Last spont
breath ≥ set
1PPEAK limit
Last 3 spont
breaths ≥ set
1PPEAK limit
Last 4 or more
spont breaths
≥ set 1PPEAK
limit

3VTESPONT Check patient Exhaled spontaneous tidal

& settings volume ≤ set limit

3VE TOT Check patient Total minute volume ≤ set limit

& settings

1fTOT Check patient Total respiratory rate ≥ set limit.

& settings

1PMEAN M easured airway pressure ≥ set 1. Run SST.

(lockable) limit. Ventilator truncates current 2. Run EST.
breath unless already in
exhalation.

1PPEAK Check patient, 1PPEAK detected and NOT

(lockable) circuit, & ET 1PCOMP.
tube.

1PVENT Inspiratory pressure > 100 1. Run SST.

(lockable) cmH2O and mandatory type = 2. Run EST.
VC. Ventilator truncates current
breath unless already in
exhalation.

1VTE Exhaled tidal volume ≥ set limit. 1. Run SST.

(lockable) Alarm updated whenever 2. Run EST.
exhaled tidal volume is
recalculated.

1VE TOT Expiratory minute volume ≥ set 1. Run SST.

(lockable) limit. Alarm updated whenever 2. Run EST.
an exhaled minute volume is
recalculated.

1VTI MAND Delivered inspiratory volume ≥ Check patient and settings.

(lockable) high inspiratory volume limit
(breath type = VC+)

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7 Alarm handling

Table 7-2: Alarm messages (cont inued)

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

1VTI SPONT Delivered inspiratory volume ≥ 1. For TC: Check for leaks,
(lockable) high inspiratory volume limit tube type/ I.D. setting.
(breath type = TC or VS) 2. For VS: Check patient and
settings.

1fTOT Total respiratory rate ≥ set limit. 1. Run SST.

(lockable) Alarm updated at the beginning 2. Run EST.
of each inspiration. Reset when
measured respiratory rate falls
below the alarm limit.

INOPERATIVE BPS installed but not Run EST.

BATTERY functioning. Resets when BPS is
functional.

INSPIRATION Inspiratory time for spontaneous 1. Run SST.

TOO LONG breath ≥ IBW-based limit. 2. Run EST.
(lockable) Ventilator transitions to
exhalation. Resets when TI falls
below IBW-based limit.

LOSS OF Power switch is on, but there is Turn power switch off to reset
POWER insufficient ac and BPS power. alarm. Restore ac power.
There may not be a visual
indicator for this alarm, but an
independent audio alarm sounds
for at least 120 s.

LOW AC Ventilator Power Mains (ac) power has dropped 1. Check integrity of ac
POWER currently not interrupt below 80% of nominal for 1 s. power source.
affected. possible. Ventilator continues operation as 2. If ventilator software was
close to settings as possible. recently downloaded or if
Resets when there is no low ac ventilator was moved
power signal for 1 s. between locations with dif-
ferent voltages, check Ser-
vice Mode Setup
NOTE: configuration.
Compressor operation 3. Check connections of ac
may be disrupted during power distribution compo-
low ac events. nents.

LOW BATTERY Operational Replace or Resets when BPS has more than 1. Check integrity of ac
time < 2 allow approximately 2 min of power source.
minutes. recharge. operational time remaining. 2. Check connections of ac
power distribution compo-
nents.

LOW INSP Inspiratory target pressure 1. Check patient.

PRESSURE < (PEEP + 5cmH2O) when 2. Check target volume.
(lockable) mandatory type is VC+

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Alarm handling 7
Table 7-2: Alarm messages (cont inued)

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

3O2% M easured Check patient, The O2% measured during any 1. Calibrate oxygen sensor.
O2% < set gas sources, phase of a breath cycle is 7% 2. Run EST.
O2%. O2 analyzer & (12% during the first hour of 3. Replace oxygen sensor.
ventilator. operation) or more below the 4. Inspect oxygen PSOL
O2% setting for at least 30 s, or (PSOL1).
below 18%. (These percentages
increase by 5% for 4 minutes
following an increase in the O2%
setting.) Alarm updated at 1-s
intervals.

3VTE MAND 2 of last 4 Check for Exhaled mandatory tidal volume Run SST.
(lockable) mand. breaths leaks, changes ≤ set limit. Alarm updated
≤ set limit. in patient‘s whenever exhaled mandatory
RSTAT & CSTAT. tidal volume is recalculated.

3 of last 4 Check for

mand. breaths leaks, changes
≤ set limit. in patient‘s
RSTAT & CSTAT.

4 of last 4 Check for

mand. breaths leaks, changes
≤ set limit. in patient‘s
RSTAT & CSTAT.

3VTE SPONT Exhaled spontaneous tidal Run SST.

(lockable) volume ≤ set limit. Alarm
updated whenever exhaled
spontaneous tidal volume is
recalculated.

3V E TOT .
V E TOT ≤ set Check patient Total minute volume ≤ set limit. Run SST.
(lockable) limit for ≤ 20s. & settings. Alarm updated whenever
exhaled minute volume is
.
V E TOT ≤ set Check patient recalculated.
limit for > 20s. & settings.
.
V E TOT ≤ set Check patient
limit for > 40s. & settings.

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7 Alarm handling

Table 7-2: Alarm messages (cont inued)

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

NO AIR SUPPLY Ventilation Check air Ventilator delivers100% oxygen. 1. Check air inlet filter.
continues as source. Resets if air supply connected. 2. Check pressure switch con-
set. Only O2 nections.
available. 3. Run EST.

Compressor Check air Ventilator delivers100% oxygen. 1. Check air inlet filter.
inoperative. source. Resets if air supply connected. 2. Check pressure switch con-
Ventilation nections.
continues as 3. Run EST.
set. Only O2
available.

Ventilation Check patient Ventilator delivers 100% oxygen 1. Check air inlet filter.
continues as & air source. instead of set O2%. Resets if air 2. Check pressure switch con-
set except supply connected. nections.
O2% = 100 3. Run EST.

Compressor Check patient Ventilator delivers 100% oxygen 1. Check air inlet filter.
inoperative. & air source. instead of set O2%. Resets if air 2. Check pressure switch con-
Ventilation supply connected. nections.
continues as 3. Run EST.
set, except
O2% = 100.

No Provide Safety valve open indicator 1. Check inlet filters.

ventilation. alternate lights. Upper screen displays 2. Check pressure switch con-
Safety Valve ventilation. elapsed time without ventilator nections.
Open. Check both support. Resets if air and oxygen 3. Run EST.
gas sources. supplies are connected.

NO O2 SUPPLY Ventilation Check patient Resets if oxygen supply 1. Check oxygen inlet filter.
continues as and O2 connected. 2. Check pressure switch con-
set. Only air source. nections.
available. 3. Run EST.

Ventilation Check patient Ventilator delivers 21% oxygen 1. Check oxygen inlet filter.
continues as & O2 source instead of set O2%. Resets if 2. Check pressure switch con-
set, except oxygen supply connected. nections.
O2% = 21. 3. Run EST.

No Provide Safety valve open indicator 1. Check inlet filters.

ventilation. alternate lights. Upper screen displays 2. Check pressure switch con-
Safety Valve ventilation. elapsed time without ventilator nections.
Open. Check both support. Resets if air and oxygen 3. Run EST.
gas sources. supplies are connected.

O2 SENSOR O2 sensor out Oxygen sensor requires 1. Calibrate O2 sensor.

of calibration/ calibration or replacement. 2. Replace and calibrate O2
failure. Press Ventilation is unaffected. User sensor.
100% O2 may also disable FIO2 monitor. 3. Disable O2 sensor.
CAL, replace,
or disable.

PROCEDURE Patient Provide Ventilator begins safety Complete patient setup.

ERROR connected alternate ventilation. Resets when
before setup ventilation. ventilator startup procedure is
complete. Complete complete.
setup process.

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Alarm handling 7
Table 7-2: Alarm messages (cont inued)

Analysis Remedy
Base message Descript ion Correct ive act ion
message message

SCREEN BLOCK Possible Remove Possible blocked beam (GUI) or 1. Remove obstruction.
blocked beam obstruction or touch screen fault. 2. Service ventilator.
or touch service
screen block. ventilator.

SEVERE Little/ no Check patient. Ventilator enters occlusion status Run EST.
OCCLUSION ventilation. Provide cycling (OSC) and upper screen
alternate displays elapsed time without
ventilation. ventilator support.
Clear
occlusions;
drain circuit.

VOLUME NOT Last 2 mand Check patient Ventilator cannot deliver target Check patient and settings.
DELIVERED breaths, and setting for volume.
(This alarm pressure > 2PPEAK.
applies to VC+ max allowable
and VS level
breaths.)
Last 10 or
more mand
breaths,
pressure >
max allowable
level

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7 Alarm handling

Thi s page i ntentionall y blank.

7-10 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
 SECTION
S EC T I O N

Service and repair 8 8

8.1 How t o use t his sect ion
This section describes how to repai r th e m aj or ventil ator subassem bl ies and thei r
components. Th ese repair procedures i nclude removal, i nstal lati on , an d adj ustm ent, as
appl icable. Thi s section does not provide com pl ete breakdowns of all assem bl ies an d
complete disassem bly in form ation. Repair procedures are provi ded mostly for maj or
components. For a com plete i ll ustrated parts breakdown (IPB), refer to Secti on 9. Do not rely
exclusivel y on Secti on 9 for rem oval and in stal lati on of parts.

8.2 General repair safet y

• W h en servici ng the ventil ator, be sure to fam ili ari ze yoursel f wi th, an d adhere to all
posted and stated safety warni ng and cauti on l abels on the ventil ator and its com ponents,
an d on any service equipm en t and m ateri als used. Failure to adh ere to such warn ings and
cautions at all tim es may result in in jury or property damage.
• To prevent patien t inj ury, do not use a venti lator if it requi res repair.
• To prevent personal i nj ury or death, do n ot attem pt any ven til ator servi ce whi le a patient,
or oth er person, i s con nected to the venti lator.
• Use personal protective equi pm ent wh enever exposure to toxic fum es, vapor, dust
particles, blood pathogen s, an d oth er transm ittable di seases and hazardous m aterial can
be expected. If in doubt, consult an environ men tal, health, and safety special ist or an
industrial hygieni st before servicing th e venti lator.
• To prevent el ectrical shock hazard an d possible person al inj ury, al ways di scon nect
electrical power sources before servi ci ng th e ven tilator. Fol low accepted safety practi ces
for el ectrical equipm ent wh en testin g or m akin g equi pm ent, adj ustm ent, or repairs.
• To prevent possible person al in jury, al ways di sconn ect air and oxygen sources from th e
ventil ator before service.
• To prevent possible person al i nj ury, n ever attem pt to push or pul l a ven til ator th at i s
install ed on a cart, whi le th e brakes are set on the casters.
• To prevent possible person al in j ury and equipm ent dam age, m ake sure th e brakes on th e
casters are set to prevent inadverten t movem en t of the ventil ator during service.
• To prevent possible person al in jury and equi pm en t dam age, h ave som eone assist you
when li fti ng the ventil ator or any of i ts m aj or com ponen ts.
• Chem icals from a broken LCD panel are toxic when i ngested. Use caution when handl ing
a GUI with a broken displ ay pan el .
• Repl acing som e ven ti lator parts requi res the use of leak detector fluid to ensure a good gas
seal . Use extrem e caution when usin g l eak detector in th e vi ci ni ty of el ectroni cs.
Thoroughly dry all com ponents foll owi ng use of leak detector.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 8-1
8 Service and repair

8.3 General repair guidelines

Fol low th ese gen eral gui deli nes when servici ng the ven til ator.
• To preven t dam age to electrostatic di sch arge (ESD) sensitive com pon ents, alw ays fol low
ESD gui deli nes when servici ng the ventil ator. Adhere to ESD control techn iques when
repairing ESD sen si tive components.
• Damage to com pon ents may occur due to overtightenin g of screws. Care sh ould be taken
during reassem bl y n ot to overtighten screws where in structed.
• Use on ly recomm ended tools, test equipm en t, and servi ce m ateri als when servi cing the
ventil ator (Section 1).
• As you repair th e venti lator, perform any appli cable cl ean ing an d i nspection procedures
listed below.
• Visual ly in spect any rem oved ven ti lator parts, includin g those rem oved to gain access to a
suspected faul ty part. Inspect th e exposed area beh in d the rem oved parts as wel l. Cl ean
rem oved parts to facil itate further inspection as necessary.
• Investi gate and determ i ne the cause of an y detected abn orm ali ty. Repair the uni t or
con tact Puritan Ben nett Techni cal Support for help i n diagn osing unresolved sym ptom s.
• Replace or repai r all parts that are worn, m issing, damaged, cracked, corroded, burnt,
warped, bent, di sfi gured, or broken . Con sult Secti on 9 for parts avai labili ty.
• Leak-test pneum atic parts where i ndicated, followin g procedures i n Section 8.7.
• Puritan Bennett recom men ds th at custom ers or tech nical servi ces personnel foll ow local
governin g ordi nances an d recycl in g instructions regardi ng disposal or recycli ng of battery
or other devi ce com ponents.
• The repair sections assum e the patient system , flex arm, oxygen, and hum i difi er are
already removed from th e ven ti lator.

8.4 Repair-relat ed cleaning

The fol lowi ng clean in g gui deli nes pertain to parts that requi re cl eani ng whi le servi cin g th e
venti lator. For procedures on peri odic cleanin g and steril ization of the ventil ator and
accessories, refer to the 840 Ven til ator System Operator's and Techni cal Reference M anual.
For periodic cl eani ng and inspection procedures th at are required during a ven tilator's
perform ance verifi cati on, refer to Section 5 in th is m an ual . Replace al l parts th at can not be
cl eaned.
• Cl ean venti lator exterior surfaces before disassem bl y. Table 1-5 in Secti on 1 of this
m anual l ists acceptable cl ean ing and disinfecti ng agen ts. Use a clean, l int-free cotton
cloth. Allow cl eaned venti lator parts and surfaces to air-dry.
• Vacuum ventil ator in terior usin g ESD safe equi pm ent. Do not cl ean th e ventil ator interior
or exteri or surface wi th hi gh-pressure air.
• Cl ean or polish el ectrical contacts wi th a very fin e abrasi ve paper or with a special tool
designed for such purposes. Do not bend contacts.

8-2 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Service and repair 8
8.5 Elect rical cables and pneumat ic t ubing
• To ensure proper reassem bl y, note or label wi re and tube posi tions before disconn ectin g
parts.
• To avoi d shreddin g a sil icone tube when rem ovi ng from a fi tting, gently pull the tube
whi le turni ng. Do n ot attem pt to rem ove si li cone tubing from barbed fitti ngs i n
inspi ratory modul e. Removal of tubing from non-barbed fitti ngs onl y i s permi ssi bl e.
• M ake sure al l tubes, and harnesses or cabl es, are installed usi ng tie wraps, as specified.
M ake sure wiring does not i nterfere w ith, an d cannot be dam aged by, hi nged or m ovi ng
venti lator parts.

8.6 Adhesive use

• For l ubri cants and resin-based adhesi ves, always veri fy th e sh elf-li fe expi rati on date h as
not passed.
• W h en instal li ng a part to be attach ed with adhesive, first rem ove the adhesi ve resi due
using a sui tabl e scrapin g tool that won 't scratch the ven til ator surface. Clean scraped
surfaces thoroughly wi th isopropyl alcohol . Be sure the appli cation area i s free of dust and
grease; then appl y pressure, ensuri ng adhesive contact an d bonding. Elim i nate any
trapped ai r bubbl es.
• Be careful when using any clean ers an d solven ts, as these m ay cause person al i njury or
damage to venti lator surfaces. Use in a well-ventil ated area.
• Repl ace an y dam aged w arn ing and caution label s usin g the rem oval and in stal lation
techn iques described above.

Warning
The failure to replace damaged warning, caution, and identification labels may result in
personal injury or equipment/property damage.

8.7 Leak t est ing

Caution
Replacing some ventilator components requires the use of leak detector fluid to ensure a
good gas seal. Use extreme caution when using leak detector in the vicinity of electronics.
Thoroughly dry all components following use of leak detector.

1 Connect compressed gas sources to ventilator.

2 Using sm al l brush , apply leak detector flui d (P/N 4-004489-00) to pn eum atic
conn ections.
3 If a connecti on leaks, repai r and retest m odule.
4 Dry all leak detector fl uid from chassi s.

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8 Service and repair

8.8 Elect rost at ic discharge cont rol

It is im portan t to follow ESD control procedures wh enever the ventil ator is repaired.
Electrostatic discharge can perm an ently dam age ESD sen sitive m icroelectroni c compon ents
or assem bli es wh en they are h andled, an d even wh en no di rect contact i s m ade with th e
com pon en t or assem bly. ESD dam age may not be i mm edi ately detectable; however, ESD
damage will show up at a l ater tim e. It can m ani fest as a prem ature catastrophi c fail ure of a
com ponen t or assem bl y, or as an in term ittent fai lure, al l of whi ch can be difficul t an d costly
to l ocate.

8.8.1 ESD procedures and precautions

Follow th ese procedures and precauti on s to prevent ESD dam age to th e ESD-sensitive
m icroelectroni c compon ents and assem bl ies in the 840 Ven til ator System .
• Use a personn el-groun din g system . Before open ing the ventilator li d or removing i ts
en cl osure pan els, en sure th at a person nel groundin g system such as P/N 4-018049-00
(wrist strap, stati c-dissipate m at, and ground cord) i s worn correctly and is properly
con nected to a reli able ground.
• Foll ow correct procedures when usi ng an an tistati c mat. Place tool s, test equi pm ent, and
the ESD sensi tive device on the m at before starting repairs. Conduct all w ork on the m at.
Never place nonconductin g i tem s, i .e. foam cups, on the mat.
• Handle ESD sensi ti ve com ponents properly. Do not handl e ESD sen sitive compon en t
con nection poi nts, con nector pi ns, l eads, or term i nals.
• Keep nonconductin g m ateri als away from the work area. Static charges from
noncon ducting m aterial , (i .e. plastic contain ers, foam cups, syn thetic cl othi ng,
cell ophane tape, etc.) cann ot be rem oved by groundi ng. Th ese item s m ust be kept away
from the work area when handl ing ESD sen sitive devices.
• Fol low correct procedures for use of static-shielding bags. Store and tran sport al l ESD
sensitive devi ces i n stati c-shi el di ng bags at al l tim es, except when being worked on . Never
place more than one ESD sensi tive devi ce i n a stati c-shi el din g bag. Never pl ace stati c-
generatin g noncon ductin g m aterial inside a static-shiel ding bag wi th an ESD sensi tive
devi ce. Place any faulty ESD-sensiti ve device in a static-shieldin g bag im m ediatel y after
rem oval , to prevent addi tion al damage. Cl ose th e bag to ensure that th e sh ield i s effective.

8.9 Replacement part ordering

Ordering correct parts requires that you properl y i denti fy th e venti lator version an d part. To
replace a part that is not stocked or that is un avail abl e, order the n ext hi gh er assembly. Retain
the part to be repl aced unti l the repl acemen t part i s obtain ed, an d com pare the two for
com pati bi lity, if possi bl e.

8.10 Test ing, calibrat ion, and ot her post -service procedures
After you com pl ete the ventil ator repair, do th e foll ow ing before pl acing th e ventil ator on a
patient:
• Visual ly verify th at all pn eum ati c and electrical parts are properly con nected an d th at all
parts are properly i nstalled. Then, wi th a l ight tug, verify th at connecti ons are secure an d
that parts are securely attached. Li sten for any un characteristic soun ds (pn eum atic
leaki ng, vi brations, gri ndi ng, squeakin g, or others).
• Perform th e addi ti on al service, testin g, and cal ibrati on activities li sted i n Tabl e 8-1. The
num bers in the colum ns i ndi cate the sequence in whi ch to perform these activi ties.
• Keep a m ain ten an ce l og of all repai rs. M ake sure servi ce records and other docum en tation
are com pleted.

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Table 8-1: Test ing and calibration requirement s

verification test ing (PVT)

Test or calibrat ion

Ext ended self t est (EST)

t ransducer calibrat ion
At mospheric pressure

Oxygen sensor (OS)

Short self t est (SST)
Vent ilat or w arm-up

Expirat ory valve

Vent inop t est

Performance
Flow sensor
calibrat ion

calibrat ion

calibrat ion
Download
Soft ware
cycle1
Type of service

Ventilator installation 1 -- 2 3 4 5 6 7 8 92

Software update or software 1 2 3 4 5 6 7 8 9 --3

option installation

10,000-hour preventive 1 -- 2 3 4 5 6 7 8 9
maintenance (ventilator or
compressor)

Oxygen sensor 2 1

PSOL1, PSOL2, flow sensors, 1 -- 2 3 4 5 6 7 8 9

expiratory valve, safety valve,
SOL1, SOL2, AI PCB, inspiratory
electronics PCB, exhalation
transducer PCB, regulators‘,
power supply, BPS PCB, battery
pack, alarms, motherboard, all
blindmate cables, BDU and GUI
LED PCBs, touchframe PCB, LCD
panels, backlight inverters,
keyboard, knob

Compressor 15,000 hour 1 24

preventative maintenance

Compressor, compressor PCB, -- -- -- -- -- 1 -- -- -- --

keyboard assembly, LED panel,
VGA controller PCB, backlight
inverter PCB

BD CPU PCB or GUI CPU PCB 1 2 3 4 5 6 7 8 9 10

replacement

6 month ventilator check 1 -- -- -- -- 2 -- -- -- --

Yearly ventilator check 1 -- 2 3 4 5 6 7 8 --

1. Warm-up must be done in the service mode.

2. Perform the electrical safety test only.
3. Performance verification testing (PVT) is not required for simple software updates, provided all of the following conditions exist:
The ventilator passes the Extended Self Test before the software is updated.
The reason for service is software update or software option installation only.
There are no events or entries in the ventilator’s diagnostic logs that indicate a need for hardware repair.
No functional hardware repairs are conducted or required during the software update service call.
Unless the ventilator meets all of these requirements, PVT must be performed following the repair.
4. Perform EST and electrical safety testing only.

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8 Service and repair

8.11 Pat ient syst em and accessories

To service the pati ent system and accessories, con sult th e 840 Ventilator System Operator' s and
Technical Reference Manual or appli cabl e accessory m anuals.

Warning
Connectors and tubes with the proprietary Bennett barbed cuff fittings are intended for use
only with like fittings. They are not interchangeable with ISO-standard cone and socket
fittings. A leak-tight connection cannot be ensured if these two fitting types are combined.
Adapters may be used to connect Bennett barbed cuff fittings to ISO-standard cone and
socket fittings.

8.12 Graphic user int erface (GUI)

Caut ion
Chemicals from a broken LCD panel are toxic when ingested. Use caution when handling a
GUI with a broken display panel.

There are two confi gurations of the GUI in th e field: the older 9.4-in ch GUI an d the newer
10.4-inch GUI. The table below li sts the m ajor differences between the two versions.

Table 8-2: Differences betw een 9.4-inch and 10.4-inch GUI

Feat ure Original Color GUI New Color GUI

Screen size 9.4 inch 10.4 inch

Communication Ports Single null port Single null port and two serial ports

GUI Status LEDs visible? No Yes

Configurable keyboard? No Yes

Minimum software level required? No Yes; H or higher

EST changes? No Yes, port test

Print Screen function? Yes; S/ W revision H (US only or Yes; S/ W revision H (US only or
equivalent) and higher equivalent) and higher

The GUI, shown in Fi gure 8-1, is a detachable m odule that can be m ounted on the opti onal
cart or shelf. W hen the ventilator is m ounted on a sh el f, an optional cabl e all ows you to place
the GUI up to 10 ft from the BDU.

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Touch screen
interface

Rotary
encoder
knob

Keyboard 8-00189

Figure 8-1. GUI

Table 8-3: GUI part replacement chart

GUI rear
GUI replacement part GUI mount ed GUI det ached housing
removed

Bezel and gasket (9.4-inch) X

Window and gasket (9.4-inch) X

Alarm assembly X X

GUI LED PCB X X

Backlight inverter PCB X X

Video controller PCBs X X

GUI CPU PCB X X

Touchframe PCB X X

Liquid crystal display (LCD) panels X X

Backlight tube (9.4-inch) X X

Keyboard assembly X

Cooling vent filters (9.4-inch) X X

Rotor housing assembly X

The service and repair procedures that fol low are organi zed i nto procedures for th e
10.4-i nch GUI, fol lowed by procedures for th e 9.4-inch GUI.

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8 Service and repair

8-01299 8-01297

Figure 8-2. 10.4-inch GUI front and back

8.13 Repairing t he 10.4-inch GUI

8.13.1 Removing or inst alling the 10.4-inch GUI

1 Di sconn ect GUI i nterface cabl e from side of BDU (Figure 8-3).
2 If GUI is mounted to opti onal cart, detach cabl e from cabl e gui de at rear of cart.
3 Rem ove GUI from its m oun t:
a. Grasp handl e at back of GUI.
b. Push GUI release kn ob to right to di sengage rotor housin g from m oun ti ng pl atform .
c. W hil e holding knob to ri ght, l ift m odul e up and away from m oun ting platform .
d. Release knob an d i t wi ll snap back to l eft, l ocked position .
4 Place GUI face down on flat ESD-protected work surface.
5 To i nstal l GUI, position it over GUI mount. Push GUI release kn ob to ri ght to disengage
rotor h ousi ng from m oun tin g platform ; then push knob to l eft to engage h ousi ng.
6 Connect GUI cable to th e si de of BDU.

M ounting Cable
M oun tin g guide
bracket
bracket
Cable
guide

GUI
interface Release
Release knobkn ob
cable GUI
in terface
con n ect ion
8-01328 8-00182

Figure 8-3. 10.4-inch GUI mounting plat form

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8.13.2 Removing the 10.4-inch GUI cable assembly
1 Using a Phi lli ps screwdriver, rem ove the screw securi ng the outer h andl e. (Refer to
Figure 8-4.)
2 Rem ove th e top handl e and set aside.
3 Using a sm al l flat blade screwdri ver, unscrew the capti ve screws securi ng the GUI cable.
Gently rem ove the GUI cable and set i t aside.

Top handle

GUI
interface cable

Bottom
Diagnostic handle
LED array

8-01218

Figure 8-4. Removing and replacing 10.4-inch GUI cable assembly

8.13.3 Replacing the 10.4-inch GUI cable assembly

1 Al ign the GUI PCB cable end with th e con nector on the rear of th e GUI. Press fi rm ly i nto
pl ace and ti gh ten the capti ve screws with a sm al l straight blade screwdri ver.

Caution
Use care not to overtighten captive screws.

2 Align the tabs on the top h andl e i nto the slots in the bottom h andle. Press h andl e into
pl ace.
3 In sert screw and gentl y ti gh ten un ti l snug.

8.13.4 Removing 10.4-inch GUI rear housing

1 Rem ove th e two Phi lli ps screws that secure th e bottom handl e to the rear housi ng
(Figure 8-5.)
2 Rem ove th e lower handl e an d set asi de wi th th e two screws.
3 Remove the rem aini ng 12 screw s that secure the rear panel to the GUI and set th em
aside.

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4 Gen tly separate the rear panel from the front housing and set aside. If necessary, a sm all
flat-bladed screwdriver m ay be used to separate the GUI rear panel from the fron t.

Caut ion
If you use a small flat-blade screwdriver to separate the rear and front housings, take care
not to damage the GUI front and rear panels.

8-01223

Figure 8-5. Removing 10.4-inch GUI rear housing

8.13.5 Replacing 10.4-inch GUI rear housing

1 Foll ow the in structions for rem ovin g the handle, cable, and rear housi ng from th e GUI.
2 Rem ove the rear pan el warni ng label from th e old rear h ousi ng by gen tly peelin g i t from
the housin g to expose the serial n um ber tag.
3 Careful ly peel th e serial n um ber tag from th e housing and set asi de.
4 Install th e n ew GUI rear h ousi ng.
5 Position the ol d serial num ber tag on th e rear housing and apply a new rear panel
warn ing label over i t.
The serial n um ber sh ould be visible through th e clear wi ndow i n th e l abel .
Warning
Serial number tag
label

8-01324

Figure 8-6. 10.4-inch GUI rear warning label and serial number tag

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8.13.6 Rem oving t he 10.4-inch CPU shield
1 Using a Phi lli ps screw driver, rem ove the 11 screws th at secure the CPU shi eld to the
LCD/GUI bracket (Figure 8-7).

NOTE:
Remove only those screws that go through the shield and not those located in a
cutout.

2 Lift the shield from th e bottom and ti lt up.

3 Gently rem ove the shield from th e GUI assem bly and set aside.

CPU shield

GUI LED
cable PCB
RS-232
shield

Keyboard
PCB cable
Alarm
speaker cable
(not shown)
Touchframe 8-01217
PCB cable

Figure 8-7. Removing the 10.4-inch CPU shield and GUI PCB

8.13.7 Removing t he 10.4-inch GUI backlight inverter PCBs

1 Rem ove th e rear housing panel (Secti on 8.13.5).
2 Rem ove th e GUI protective shi eld (Secti on 8.13.6).
3 Using a sm al l Phil li ps screwdri ver, rem ove the two nylon screws an d wash ers securi ng
each of the two backli ght inverter PCBs to th e GUI CPU.

Caution
To maintain an isolated ground system, ensure the nylon washer is placed between the
inverter PCB and the standoff on the GUI CPU PCB when mounting the backlight inverter
PCBs on the GUI CPU PCB.

4 For each of th e backli ght in verter PCBs, di sconn ect th e h arn ess that connects the LCD to
the backli ght in verter an d the cable from th e backl ight i nverter to the GUI CPU PCB
(Figure 8-8).
5 Rem ove each of the PCBs an d place i nto a con ducti ve bag.

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backlight inverter/
CPU harness

LCD/backlight Backlight
driver harness driver PCB
(one of two)

Standoffs (2)

Figure 8-8. Removal of a 10.4-inch backlight invert er PCB

8.13.8 Rem oving the 10.4-inch GUI CPU PCB

1 Di sconn ect th e followi ng cabl es from th e CPU PCB (Figure 8-7):
• keyboard PCB cable (J20)
• touchfram e PCB cabl e (J19)
• al arm speaker cabl e (J7)
• GUI LED PCB cable (J3)
2 Usin g a 3/ 16" n ut driver, rem ove th e four fem ale screw-lock screws that secure the RS-232
shi eld (Figure 8-9).
3 Rem ove RS-232 shi eld and set aside. Gentl y rem ove th e RS-232 fl ex circuit cable and set
asi de.

Caut ion
Handle the flex circuit cable with extreme care to prevent damage to the flex circuit
connectors.

RS-232 shield

Screw-lock screws

RS-232 flex circuit

Figure 8-9. RS-232 shield and flex circuit

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Service and repair 8
4 Using a Phill ips screwdriver, rem ove th e 10 screws securi ng th e PCB to th e GUI housing.
5 Gentl y ti lt the GUI CPU PCB to th e right and disconn ect the LCD pan el fl ex cables (2)
from the board (J2, J11).
6 Rem ove th e GUI CPU PCB an d place i nto a con ducti ve bag. Set the PCB asi de.

NOTE:
If installing a new 10.4-inch CPU PCB, ensure the touch panel jumpers are set to
the 10.4-inch touchframe style, “ MKG TOUCH.” The five jumpers are located on
the lower left side of the PCB (Figure 8-10).

Jumpers

Figure 8-10. GUI CPU PCB touch panel jumpers

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8 Service and repair

8.13.9 10.4-inch GUI support bracket

The GUI support bracket secures the GUI CPU PCB on on e si de and the LCD panels on the
other. The bracket m ust be rem oved to access the LCD panel s, th e touch fram e PCB, an d the
i nside fron t of the GUI housin g. Refer to Figure 8-11 for parts identi fication.

LCD
shield

EM I Harness from
gaskets backlight
inverter to
LCD panel

LCD
mounting
screws CPU
(4 ea.) shield

8-01325

Figure 8-11. 10.4-inch LCD panels and LCD shield

8.13.9.1 Removing t he 10.4-inch GUI support bracket

1 Rem ove the si x rem aini ng screws that secure th e support bracket to the front housi ng.
2 Rem ove the bracket from the GUI housing and place upon a protected w ork surface with
the LCD pan els facing up.
3 Usin g a Phi lli ps screwdriver, rem ove the four (4) screws that secure the LCD sh ield i n
place.
4 Set th e sh iel d an d screws asi de.

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8.13.10 10.4-inch LCD panels

Caution
• The LCD panels are easily soiled or damaged. Use caution not to touch the surface of the
LCD panel or the inside of the GUI window as fingerprints will result.
• Do not allow the LCD panels to be exposed to the ambient environment any longer than
necessary as dirt and debris will be deposited on the LCD panels. Should this occur, use
an ESD-protected air source to gently blow away any dust or debris.

8.13.10.1 Removing t he 10.4-inch LCD panels

1 With the LCD panel s exposed, rem ove the four screws th at secure the each of th e two
LCD panel i n place. Set screw s aside (Figure 8-11).
2 Gentl y l ift each LCD pan el wh ile routi ng the cables through the pan el.

8.13.11 10.4-inch t ouchframe PCB (M KG Touch)

Caution
The touchframe PCB should not be flexed or bent as damage will occur. Use caution when
handling and avoid touching emitters or receptors mounted on the board.

8.13.11.1 Removing t he 10.4-inch t ouchframe PCB

1 Di sconnect th e touchfram e cable and set aside (Figure 8-12).
2 Using sm all pl iers or thumbnail pressure to rem ove the el even (11) pl asti c ri vets th at
secure the touchfram e PCB to the front housi ng. Set plastic rivets aside.
3 Rem ove th e touch frame PCB an d pl ace i nto a conducti ve bag. Set PCB asi de.

GUI LED
PCB

GUI LED
cable

Touchframe
GUI
PCB
alarm

8-01157

Touchframe Keyboard
cable cable

Figure 8-12. 10.4-inch GUI t ouchframe PCB and GUI LED PCB locat ions

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8 Service and repair

8.13.12 Replacing t he 10.4-inch t ouchframe PCB

1 Orien t th e touch frame PCB with the cable connector facin g th e bottom in side of the
front GUI h ousin g.
2 Al ign the rivet hol es of th e touch fram e over th e standoffs located on th e i nside of the
front housing.
3 Insert the eleven (11) plastic rivets through the mounting h ol es in the touchfram e PCB
and l ock i nto place.
4 Ensure th at the ri vets are full y seated.
5 Connect the touch fram e PCB cable

8.13.13 10.4-inch GUI LED PCB

8.13.13.1 Removing t he 10.4-inch GUI LED PCB

1 Di sconn ect the GUI LED cable from the GUI LED PCB (J3) (Fi gure 8-12).
2 Usin g a sm al l Phil lips screwdri ver, rem ove the four screws that secure the GUI LED PCB
to the fron t housing (Fi gure 8-13). Set screws aside.
3 Rem ove the GUI LED PCB an d place into a con ductive bag. Set PCB aside.

8-1220

Figure 8-13. Removal of t he 10.4" GUI LED PCB

8.13.13.2 Replacing t he 10.4-inch GUI LED PCB

1 Al ign the GUI LED PCB on the four standoffs i nsi de the GUI front housin g.
2 Use the four screws to secure the GUI LED PCB to the fron t housing (Fi gure 8-13).
3 Connect the GUI LED cable to th e GUI LED PCB.

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8.13.14 10.4-inch GUI alarm assembly
The GUI alarm i s located beh in d the GUI fron t pan el and can on ly be accessed by rem oving
the rear GUI h ousi ng.

Caution
When handling the GUI alarm assembly, be careful not to damage the speaker element.

8.13.14.1 Removing t he 10.4-inch GUI alarm assembly

1 Rem ove th e GUI rear h ousi ng as descri bed above.
2 Di sconnect th e alarm h arn ess from the GUI CPU PCB (J7).
3 Grasp th e al arm assembly by the si des and pul l up on the alarm body to remove i t from
the slots in the GUI fron t housing (Fi gure 8-14).

8.13.14.2 Replacing t he 10.4-inch GUI alarm assembly

1 Grasp the alarm assem bl y by the sides and al ign i t with the slots in the GUI fron t
h ousi ng.
The speaker elem ent should be faci ng th e bottom of th e front housing (Figure 8-14).
2 Gentl y push the al arm assembly in to position.
3 Con nect the alarm h arn ess to the GUI CPU PCB (J7).

Speaker
harness

Speaker
element

GUI front
housing

8-01221

Figure 8-14. Removing the 10.4-inch GUI alarm

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8 Service and repair

8.13.15 10.4-inch GUI keyboard assembly

The 10.4-i nch GUI keyboard assembly can be repl aced with out accessin g th e GUI CPU PCB
an d wi thout openi ng the GUI housing.

8.13.15.1 Replacing t he 10.4-inch GUI keyboard assembly

1 Orien t the fron t h ousi ng assem bly so th at th e keyboard i s facin g up.
2 Sli de a fl at tool under one edge of the keyboard and gen tly li ft to break the adh esive
bond with the front h ousi ng.
3 Once th e adhesi ve h as been broken , disconn ect the keyboard cabl e from th e keyboard.
Rem ove the keyboard.
4 Clean th e surface of the GUI housin g w ith alcoh ol to rem ove an y adhesive resi due.
5 Prepare th e new keyboard for install ation by connecting th e ribbon cable to th e
keyboard and rem ovi ng the adhesive cover stri p.
Verify th at th e ribbon cable is in the upper row of th e conn ector and i s fi rm ly latched
into place.
6 Al ign the keyboard with th e open ing, sl idi ng the PCB as far up as possibl e on the front
housing. Press fi rm ly i nto place.

8.13.16 10.4-inch GUI front housing

The wi ndow, bezel, and fron t housi ng are al l lam inated together to form on e part.

Caut ion
Do not touch the inside (coated side) of the GUI window. If necessary, use finger cots or
protective gloves. The window is treated for glare resistance and touching it creates
smudges, which cannot be removed without damaging the window.

8.13.16.1 Replacing t he 10.4-inch front housing

1 Foll ow the preceding procedures to disassemble the GUI to the touchfram e PCB.
2 Rem ove the touchfram e PCB.
3 Rem ove th e GUI LED PCB.
4 Rem ove the GUI alarm assem bly.
5 Rem ove the keyboard usi ng care not to dam age the adhesi ve.
6 Install a new fron t housin g.
7 Reinstall or replace the keyboard assem bl y.
8 Reinstall the GUI LED PCB, the alarm assem bly and th e touchframe PCB.
9 Con tin ue rei nstal li ng the GUI compon ents that were rem oved to access the front
housing.
10 Install the GUI alarm graph i cs label.

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8.13.17 10.4-inch rot or housing
The rotor h ousi ng is easi ly replaced without disassembli ng the GUI h ousi ng.

8.13.17.1 Replacing t he 10.4-inch rot or housing

1 Rem ove the GUI from the cart.
2 Using a Phill ips screwdriver, rem ove th e two screws that secure the fascia panel in pl ace.
Set the bezel an d the screws aside.
3 Using pl iers, careful ly pull the spring away from th e rotor brake shoes. Let the sprin g
h ang from th e base.

Fascia
panel

GUI rear
panel
Rotor

Rotation
spring

Brake shoes

8-01337

Figure 8-15. 10.4-inch GUI rotor housing

4 Remove th e brake shoes from the rotor.

5 Rem ove the rotor an d di scard.
6 In stall the new rotor i nto the groove and sl ide i nto place.
7 In stall the two brake shoes an d align th e spri ng to fit in th e brake sh oe groove.
8 Align the fascia panel over the rotor and secure with the two screw s. Tigh ten until snug.
9 Rein stal l the GUI onto the cart.

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8 Service and repair

8.14 Repairing t he 9.4-inch GUI

The fol lowi ng repair and i nstal lati on i nstructions are specifi c to the 9.4-in ch color GUI.

8.14.1 Removing the 9.4-inch GUI t ouch screen bezel

The bezel surrounds the GUI wi ndow an d holds i t i n pl ace. To repl ace th e window, you m ust
first rem ove the bezel.
1 Di sconn ect GUI cabl e from side of BDU (Figure 8-19). If venti lator is m oun ted on
opti onal cart, detach cable from cabl e guide at rear of cart.
2 At top left corner of touch screen, posi tion blade of a sm all flat-bladed screwdriver
(poin ti ng up) between bezel an d w indow (Figure 8-16). Gently wedge bl ade (do not
twi st) between bezel and window.
3 Without pl aci ng blade in di rect contact wi th wi ndow, carefull y apply negative pressure
to bezel to dislodge from GUI housin g.
4 Gen tly pull each si de of bezel (do not twist) until it sn aps out of housin g. Rem ove gasket.
5 Inspect bezel . Repl ace if h eavi ly scratched or i f tabs are broken.

Caut ion
Be careful not to touch the inside (coated side) of the window. If necessary, use finger cots
or protective gloves. The window is treated for glare resistance and touching it creates
smudges which cannot be removed without damaging the window.

Bezel

Gasket

Screwdriver
placement
Window

Window
gasket

LCD
panels

8-00176

8-00104

Figure 8-16. 9.4-inch t ouch screen bezel and w indow

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8.14.2 9.4-inch GUI window

Caution
• Be careful not to touch the inside (coated side) of the window. If necessary, use finger cots
or protective gloves. The window is treated for glare resistance and touching it creates
smudges which cannot be removed without damaging the window.
• Avoid cleaning the coated side of the window. If necessary, gently blow off dust or debris
using compressed air.

The window serves as the GUI touch screen; it i s held i n place by th e bezel .

8.14.2.0.1 Removing 9.4-inch GUI window

1 Carefull y slide blade of a sm all, flat-bl aded screw driver under wi ndow at lower left and/
or ri gh t corn ers (Figure 8-16).
2 Gentl y apply negative pressure to unseat bottom of window.
3 Carefull y rem ove win dow and its gasket.
4 Pl ace w indow on fl at surface wi th coated si de faci ng up.

8.14.2.0.2 Inst alling 9.4-inch GUI window

Caution
Be careful not to touch the inside (coated side) of the window. If necessary, use finger cots
or protective gloves. The window is treated for glare resistance and touching it creates
smudges which cannot be removed without damaging the window.

NOTE:
When installing the window, be sure the coated-side (with the painted black strip)
is facing to the inside of the unit.

1 Til t GUI to its rear-m ost position (Figure 8-17).

2 M akin g sure gasket i s in pl ace an d coated side of win dow is facing GUI, careful ly set
win dow in to window fram e (Figure 8-16).
3 Carefull y i nsert window gasket i nto groove aroun d uncoated (front) side of win dow.
4 Gentl y press edges of window un ti l it full y seats in to front housin g.

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GUI tilt
positions

8-01339

Figure 8-17. 9.4-inch GUI tilt posit ions

8.14.3 Inst alling t he 9.4-inch bezel

NOTE: The top of the bezel is narrower than the bottom. When replacing the bezel,
position the narrower end at the top.

1 M ake sure window gasket i s i n place (Figure 8-16).

2 Careful ly i nsert bezel gasket i nto groove around bezel fram e.
3 With narrow side of bezel on top, carefull y place bezel into bezel fram e.
4 M ake sure gasket is n ot exposed or pinched; then startin g at top, press edges of bezel
unti l it is fully in serted an d securel y seated in frame.

8.14.4 The 9.4-inch keyboard assembly

The keyboard assem bl y is a field-replaceabl e un it (FRU), consisti ng of a keyboard l am i nate, a
keyboard PCB, and a rotary en coder. The keyboard can be removed with the GUI m ounted on
the venti lator.

8.14.4.1 Removing 9.4-inch keyboard assembly

1 Orien t front h ousi ng assem bl y so keyboard l am inate i s faci ng up (Figure 8-18).

Caut ion
Carefully remove the keyboard assembly to avoid damaging the GUI front housing.

2 Slide a flat tool under one edge of keyboard l am in ate and pull up to break keyboard's
adhesive bond to fron t h ousi ng.
3 Once th e adhesi ve has been broken , disconn ect ribbon cable from keyboard.
4 Con tin ue to pull keyboard assem bly away from front housin g. Rem ove en tire assem bl y
includi ng keyboard lami nate, keyboard PCB, an d rotary encoder.

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5 Gently rem ove keyboard assem bly and place i n conducti ve bag or on ESD-protected m at.
6 Using al coh ol, clean an y rem ai ni ng adhesi ve from front housin g, being careful not to let
debri s fall i nto the GUI housin g.

NOTE: Do not attempt to reuse the 9.4-inch keyboard assembly after removal.

Keyboard
assembly

Keyboard
laminate

8-00189
8-00116

fig8-19c.tif
8-00262

Figure 8-18. Replacing t he 9.4-inch keyboard assembly

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8 Service and repair

8.14.4.2 Inst alling t he 9.4-inch keyboard assembly

Caut ion
The keyboard assembly is held in place by a quick bonding adhesive that surrounds the
inside perimeter of the keyboard laminate. Once the adhesive is exposed, it immediately
bonds to anything it touches. Therefore, use extreme care when removing the protective
strip concealing the adhesive, and while aligning the keyboard laminate to the GUI's front
panel.

1 Al ign keyboard over housing and connect keyboard PCB ribbon cable (dark stri pe goes to
pin 1 of GUI CPU PCB J20) (Figure 8-18). Verify that cable is positi vel y l ocked into pl ace.
2 On in si de of keyboard lamin ate, careful ly peel back protective strip th at con ceal s
adhesive.
3 Takin g care not to touch keyboard assem bly to GUI fron t housin g, al ign keyboard
lam i nate (starting with side contai nin g rotary encoder) with keyboard i nset on fron t
housing.
4 Carefully press keyboard i n pl ace by appl yin g pressure to perim eter of lami nate; th en,
check keyboard perim eter to ensure i t i s securely bonded to GUI h ousin g.

8.14.5 Removing or inst alling the 9.4-inch GUI

1 Di sconn ect GUI i nterface cabl e from side of BDU (Figure 8-19).
2 If GUI is mounted to opti onal cart, detach cabl e from cabl e gui de at rear of cart.
3 Rem ove GUI from its m oun t:
a. Grasp handl e at back of GUI.
b. Push GUI release kn ob to right to di sengage rotor housin g from m oun ti ng pl atform .
c. W hil e holding knob to ri ght, l ift m odul e up and away from m oun ting platform .
d. Release knob an d i t wi ll snap back to l eft, l ocked position .
4 Place GUI face down on flat ESD-protected work surface.
5 To install the GUI:
a. Posi tion the GUI over th e GUI m ount.
b. Push GUI release kn ob to right to di sengage rotor housin g from m oun ti ng pl atform .
c. Push knob to left to engage housing.
d. Connect GUI cable from si de of BDU.

M ounting Cable
Cable
M oun tin g guide
guide
bracket
bracket

GUI
interface
connection
Release
Release knobkn ob
GUI
in terface
con n ect ion
8-01328 8-00182

Figure 8-19. 9.4-inch GUI mounting plat form

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Service and repair 8
8.14.6 9.4-inch GUI rear housing

Caution
To prevent damage to ESD-sensitive components, always follow ESD guidelines when
disassembling the GUI.

8.14.6.1 Removing 9.4-inch GUI rear housing

1 Rem ove GUI (Secti on 8.14.5).
2 With GUI face down, rem ove screw that holds top porti on of h an dle assem bl y to GUI
rear housi ng (Fi gure 8-20). Rem ove top handle and set asi de.
3 Loosen two captive screw s that secure i nterface cabl e connector to GUI CPU PCB.
Di sconnect interface cable an d set asi de.
4 Rem ove th e two screws that secure bottom han dle to GUI rear housin g and set asi de.

Top handle

Interface cable

Bottom
handle

Captive screw
(2 PL)
Interface cable
connector

8-00321

8-00108

Figure 8-20. Removing 9.4-inch GUI handle assembly and int erface cable

5 Loosen th e two captive screws that retai n RS-232 port cover; rem ove cover.
6 Unplug nurse’s call port cover.
7 Rem ove 19 screws from GUI rear h ousi ng (Figure 8-21) an d set aside.
8 Gently separate GUI rear and fron t housi ng. If necessary, use a sm all fl at-bladed
screwdriver to separate the GUI rear pan el from the front.

Caution
If you do use a small flat-blade screwdriver to separate the GUI rear and front housings, use
care not to damage the GUI front or rear housing.

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8 Service and repair

1-1/2-in. screw
(13 PL)

3/ 4-in. screw

3/8-in. screw
(5 PL)

8-00109

Figure 8-21. Replacing 9.4-inch GUI rear housing

8.14.6.2 Inst alling 9.4-inch GUI rear housing

NOTE:
The screws that secure the GUI rear housing to the front housing come in three
lengths. Refer to Figure 8-21 for correct lengths.

1 With GUI front housi ng face down, ali gn rear and fron t housi ngs.
2 Feed rem ote alarm cover through rear housing.
3 Check perim eter of housin g to m ake sure cables are not being pi nched.
4 Gen tly press rear housin g in to front h ousi ng un ti l two enclosures full y seat.
5 Install GUI rear housin g (Secti on 8.14.6.1).

Caut ion
Ensure cables are not pinched between the front and rear housings. Otherwise, damage to
the cables may result.

6 Install and h and-tighten 19 screws; then , usin g a screwdriver, ti gh ten until sn ug. D o n o t
o vert igh ten .
7 Insert the bottom han dle into h andle seati ng on rear housing (Fi gure 8-20). Install and
han d-tighten two screws; then , using a screwdriver, tighten until snug. Do n o t
o vert igh ten .
8 Connect fem al e end of GUI in terface cable to GUI CPU PCB con nector located in si de
bottom han dle. Tighten two i nterface cable captive screws to GUI CPU PCB un ti l snug.
Do n o t o vert igh t en .
9 Position the i nterface cable into th e handl e sl ots.
10 Sn ap top han dle in to place. In stal l screw an d ti gh ten un til snug. Do n o t ov ert igh t en .
11 Install GUI (Section 8.14.5).

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Service and repair 8
8.14.7 9.4-inch GUI alarm assembly
The GUI alarm assem bl y is located behi nd the GUI front panel.

8.14.7.1 Removing 9.4-inch GUI alarm assembly

1 Rem ove GUI rear housing (Section 8.14.6).
2 Di sconnect al arm harness from GUI CPU PCB J9 (Fi gure 8-22).
3 Grasp assem bl y at si des and pul l up on alarm body; i t will sli de out of sl ots in GUI
h ousi ng (Figure 8-23).

J16

GUI CPU PCB

J6
J9
J7

Alarm
assembly

Backlight
inverter
PCB
J3
J2

8-00166

Figure 8-22. 9.4" GUI interior

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8 Service and repair

8.14.7.2 Inst alling 9.4-inch GUI alarm assembly

1 Orien t al arm assembly wi th harness toward GUI CPU PCB and speaker away from
backli gh t in verter PCB (Figure 8-23).
2 Sli de alarm side brackets in to sl ots on GUI housin g. M ake sure bracket is fully seated i n
sl ots.
3 Connect alarm h arn ess to GUI CPU PCB J9 (Fi gure 8-22).
4 Install GUI rear housin g (Secti on 8.14.6.2).

Alarm
assembly

8-00110

Figure 8-23. Replacing t he 9.4-inch GUI alarm assembly

8.14.8 9.4-inch GUI backlight invert er PCB and GUI LED PCB
The backli ght i nverter PCB, whi ch is part of th e LCD backl igh t control circui t, con trols th e
bri ghtn ess of both LCD panels.
The GUI LED PCB i nterface lets th e GUI m i croprocessor con trol th e di screte diagnosti c LEDs
on the LED PCB.

8.14.8.1 Removing 9.4-inch GUI backlight invert er PCB

1 Rem ove GUI rear h ousi ng (Section 8.14.6).
2 Di sconn ect backli ght in verter PCB ribbon cable from GUI CPU conn ector J7 (Figure
8-22).
3 Di sconn ect two LCD harn esses from backl i gh t in verter PCB conn ectors J2 an d J3.
4 Rem ove four screws that secure backlight i nverter PCB to standoffs (Figure 8-24).
5 Lift backlight inverter PCB off stan doffs and pl ace in to conducti ve bag or on
ESD-protected m at. If you are i nstal lin g a n ew backlight in verter PCB, rem ove backl ight
inverter PCB/ GUI CPU PCB ribbon cabl e and save for rei nstal lation.

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Service and repair 8
8.14.8.2 Inst alling 9.4-inch GUI backlight invert er PCB
1 If appl icable, in stal l backli ght in verter PCB/ GUI CPU PCB ribbon cable to backli ght
i nverter PCB con nector J1.
2 With ribbon cable facing GUI CPU PCB an d com ponents facin g up, ali gn backlight
i nverter PCB to four stan doffs (Figure 8-24).
3 M anuall y in stall and tigh ten four screws; then, usi ng a screwdriver, tigh ten until snug.
Do n o t o v ert igh ten .
4 Connect backli ght inverter PCB/ GUI CPU PCB ribbon cable to GUI CPU PCB con nector
J7 (Fi gure 8-22).
5 Con nect two LCD panel cabl es to backl igh t inverter PCB conn ectors J2 and J3.
6 In stall GUI rear h ousi ng (Secti on 8.14.6.2).

J2
J3
Backlight inverter
PCB

Standoff
(4 PL)

GUI LED
PCB

8-00111

Figure 8-24. Replacing 9.4-inch backlight invert er and GUI LED PCBs

8.14.8.3 Removing 9.4-inch GUI LED PCB

1 Rem ove backlight inverter PCB (Section 8.14.8.1).
2 Di sconnect GUI LED PCB ribbon cable from GUI CPU PCB con nector J3 (Figure 8-22).
3 Using 1/ 4-in . nutdriver, rem ove four standoffs th at secure GUI LED PCB to front h ousi ng
(Figure 8-24).
4 Rem ove GUI LED PCB and pl ace i nto conductive bag or on ESD-protected m at. If you are
i nstall in g new GUI LED PCB, rem ove GUI LED PCB/GUI CPU PCB ri bbon cable and save
for rei nstal lati on .

8.14.8.4 Inst alling 9.4-inch GUI LED PCB

1 If appl icable, in stal l GUI LED PCB/GUI CPU PCB ri bbon cable to GUI LED PCB.
2 With ri bbon cable faci ng GUI CPU PCB, align GUI LED PCB to four standoff screwh ol es
(Figure 8-24).
3 M anual ly i nstall an d tighten four standoffs; then usi ng a 1/4-in. nutdri ver, tighten unti l
sn ug. Do n ot ov ert igh t en .
4 Con nect GUI LED PCB ribbon cabl e to GUI CPU PCB conn ector J3 (Figure 8-22).
5 In stal l backli ght inverter PCB. Secti on 8.14.8.2

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8 Service and repair

8.14.9 GUI EM I shield

8.14.9.1 Removing t he GUI EM I shield

1 Rem ove the 11 screws from the rear of the GUI EM I shi eld and set asi de (Fi gure 8-25).
2 Di sconn ect the touch fram e PCB cabl e (J19) and keyboard cable (J20).
3 Rem ove the GUI EM I sh ield an d set aside.

CPU
Screw (13 PL) protective
shield

GUI CPU PCB

J20
J19

Keyboard
cable

Touch
frame
cable
8-00112

Figure 8-25. Removing 9.4-inch GUI EM I shield

8.14.9.2 Inst alling t he 9.4-inch GUI EM I shield

1 Al ign GUI EM I sh ield to 13 screwh oles on CPU bracket (Figure 8-25). Install and h and-
tigh ten 13 screws; then, usi ng a screwdriver, tigh ten until snug. Do n o t o v ert igh t en .
2 Connect these cabl es to bottom of GUI (Fi gure 8-21):
• Touch fram e PCB ri bbon cable to GUI CPU PCB connector J19
• Keyboard ribbon cable to GUI CPU PCB con nector J20

8.14.10 9.4-inch video cont roller and VGA LCD cont roller PCBs
Later version s of th e 9.4-in ch GUIs use a CPU PCB that is com mon to both 9.4-inch and
10.4-inch GUIs. This l ater PCB design incl udes two bui lt-in VGA control lers th at i nterface
with the LCD panels. If replaci ng an older GUI CPU PCB in a 9.4-in ch GUI with the newer
PCB, discard the VGA controll ers.

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Service and repair 8
8.14.10.1 Removing 9.4-inch VGA LCD cont roller PCBs (older CPU PCB)
1 Rem ove GUI rear housing (Section 8.14.6).
2 Rem ove CPU EM I shield (Secti on 8.14.9.1).
3 Grasp sides of desired VGA LCD controller PCB and pul l up to di sengage pi ns from GUI
CPU PCB con nectors (Figure 8-26). Place i n conducti ve bag or on ESD-protected m at.

VGA LCD
controller
PCBs

J5
J4
J15
J14

8-00113

Figure 8-26. Removing 9.4-inch video cont roller PCBs

8.14.10.2 Inst alling 9.4-inch VGA LCD cont roller PCBs (older CPU PCB)

NOTE:
The two plug-in IP interface VGA LCD controller PCBs are identical and can be
mounted at either GUI CPU PCB location (J14/ J15 or J4/J5). The pin sets at each
end of the video controller PCBs are different, preventing the video controller
PCBs from being mounted backward on the GUI CPU PCB.

1 Ori en t pins on video control ler PCB so they ali gn wi th correspondin g connectors on GUI
CPU PCB (Fi gure 8-26).
2 Gently press vi deo control ler PCB un ti l ful ly seated.
3 Install GUI EM I sh ield (Section 8.14.9.2).
4 In stall GUI rear h ousi ng (Secti on 8.14.6.2).

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8 Service and repair

8.14.11 9.4-inch GUI CPU PCB

8.14.11.1 Removing t he 9.4-inch GUI CPU PCB

1 Rem ove GUI rear h ousi ng. (Secti on 8.14.6.1).
2 Rem ove the GUI EM I shi el d (Section 8.14.9.1).
3 Di sconn ect th ese cables from GUI CPU PCB (Figure 8-22):
• Two LCD harnesses from J6/ J8 an d J16/J18
• Backli ght inverter PCB ribbon cabl e from J7
• GUI LED PCB ribbon cabl e from J3
• GUI al arm harness from J9
4 Di sconn ect the backl igh t extender cable assem bli es from th e backli ght inverter PCB
conn ectors J2 and J3.
5 Di sconn ect these cabl es from bottom of GUI (Figure 8-22):
• Touch fram e PCB ri bbon cable to GUI CPU PCB connector J19
• Keyboard ribbon cable to GUI CPU PCB con nector J20
6 Rem ove th e eleven (11) screws th at secure GUI CPU PCB/ bracket assembly to the
stan doffs i n front h ousi ng.
7 Lift th e CPU bracket assem bl y off stan doffs.

Caut ion
When removing the GUI CPU PCB, be careful not to damage surface components. Do not
flex t he PCB.

8.14.11.2 Inst alling t he 9.4-inch GUI CPU PCB

W h en i nstall ing a later generation CPU PCB i n a 9.4-i nch GUI, be sure to set the five touch
panel j um pers on the l ower l eft side of the GUI CPU PCB TO “ Carrol l Touch .”

Jumpers

Figure 8-27. GUI CPU PCB t ouch panel jumpers

1 Al ign GUI CPU PCB to el even (11) screwholes in mountin g bracket (Figure 8-22). Install
and hand-ti ghten 11 screws. Th en use a screwdri ver to tigh ten the screws un ti l snug. D o
n o t o ver tigh ten .
2 Connect the backl igh t extender cable assem bl ies from the backli ght inverter PCB
conn ectors J2 and J3.

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Service and repair 8
3 Con nect these cables to GUI CPU PCB:
• LCD h arn esses (2) to J6 and J16
• Backl igh t i nverter PCB ri bbon cable to J7
• GUI LED PCB ri bbon cabl e to J3
• GUI al arm harness to J9
4 Align CPU EM I sh ield to 13 screwholes on CPU bracket (Figure 8-25). Install an d h and-
tighten 13 screws. Then , use a screwdri ver to tighten th e screws unti l snug. Do n o t
o vert igh t en .
5 Con nect these cables to bottom of GUI (Figure 8-22):
• Touchfram e PCB ribbon cable to GUI CPU PCB connector J19
• Keyboard ribbon cabl e to GUI CPU PCB conn ector J20
6 In stall GUI rear h ousi ng (Secti on 8.14.6.2).

8.14.12 9.4-inch touchframe PCB (Carroll Touch)

Caution
• Handle the touchframe PCB with care: do not flex the assembly, damage any of the
surface components, or touch emitters or receivers.
• Take care when disconnecting the LCD harnesses; do not pull on wires. These harnesses
are delicate.

8.14.12.1 Removing t he 9.4-inch t ouchframe PCB

1 Rem ove GUI rear housin g (Section 8.14.6.1).
2 Rem ove th e GUI EM I shi eld (Section 8.14.9.1).
3 Rem ove th e GUI CPU PCB/bracket assem bly (Section 8.14.11.1):
4 Turn the CPU bracket assem bl y (LCD panels up) an d place on an ESD-protected m at.
5 Rem ove th e two screws that secure touchfram e PCB to CPU bracket (Figure 8-28).
6 Gentl y l ift off touchfram e PCB and place i n conducti ve bag or on ESD-protected mat.

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8 Service and repair

Touchframe PCB
LCD
Backlight
adapter
extender cable
cable
assemblies
LCD
panels

LCD
harnesses
LCD
adapter
cable
CPU bracket
assembly
8-00114
LCD
harnesses

Figure 8-28. Replacing t he 9.4-inch t ouchframe PCB and LCD panel assembly

8.14.12.2 Reinst alling t he 9.4-inch t ouchframe PCB

1 Al ign the touch fram e PCB to two screwh ol es on CPU bracket (Figure 8-28).
2 Turn th e CPU bracket assem bly over (LCD panels down ) and place on an ESD-protected
m at.
3 Route the backl igh t extender cable assem blies as shown in Fi gure 8-29. Ensure that th e
foam si de of th e cabl e assem bl ies are facing away from th e LCD pan els.

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Service and repair 8

Short
cable

Long
Foam cable
side

Standoff

Plastic spacer
8-00364

Figure 8-29. Routing the backlight ext ender cable assemblies

4 In stall GUI CPU PCB/ bracket assembl y (Secti on 8.14.11.2).

5 In stall GUI EM I shi el d (Section 8.14.9.2).
6 In stall GUI rear housin g (Section 8.14.6.2).

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8 Service and repair

8.14.13 9.4-inch backlight panels and LCD panels

The 10,000 hour preventati ve m ai ntenan ce ki t for th e m on ochrome LCD is n o lon ger
avai lable. The uni t m ust be upgraded to th e 9.4-in ch col or display.

Caut ion
• Avoid touching the front of the LCD panels. Smudges are difficult to remove.
• Use care not to scratch the front of LCD panels.

8.14.13.1 Removing a 9.4-inch backlight panel and LCD pane

1 Rem ove GUI rear h ousi ng (Section 8.14.6).
2 Rem ove the GUI EM I shi el d (Section 8.14.9.1).
3 Rem ove GUI CPU PCB (Secti on 8.14.11.1).
4 Rem ove touchfram e PCB (Secti on 8.14.12.1).
5 Di sconn ect the adapter cabl e from on e LCD (Figure 8-28). Leave the cable in pl ace.
6 Rem ove the four screws th at secure th e LCD panel to the CPU bracket assem bl y.

NOTE:
LCD panels are not interchangeable due to backlight wire lengths. Do not reverse
displays. Complete the backlight replacement for one LCD panel first, then
complete the second backlight replacement.

7 Gen tly li ft the LCD panel from the bracket an d place the panel face down on an
ESD-protected m at.
8 Rem ove the LCD in terface PCB (wi th LCD harnesses attach ed) from th e rear of th e LCD
panel and set asi de (Fi gure 8-30).
9 Rem ove the backli gh t pan el (Figure 8-30):
a. Using a sm al l flat-bl aded screwdriver, strai ghten the smal l m etal tabs around the
perim eter of th e LCD panel.
b. Carefull y rem ove the backl ight panel .
c. Di scard i f replaci ng the panel .

8.14.13.2 Reinst alling a backlight panel and LCD panel

1 Rem ove the repl acement backl igh t panel from the ESD bag. Pl ace it over th e LCD panel.
2 Gently press th e backli ght pan el i nto position. Using a flat-blade screwdriver, bend the
sm al l m etal tabs around the perim eter of the pan el to hold i t in pl ace.
3 Reattach th e LCD interface PCB (with cabl es attached) to the LCD panel .
4 Al ign th e LCD panel (face up) with the four screw holes in the m ounting bracket (Fi gure
8-30).
5 Reattach the backl igh t exten der cabl e assem bly, then veri fy that it i s properly connected.
6 Install an d h and-tigh ten the four screws. Then , usi ng a screwdriver, ti ghten the screws
unti l they are snug. Do n ot o ver t igh t en .
7 Verify backl igh t extender cabl e assem bl y is firm l y connected.

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Service and repair 8

LCD
interface
PCB
Detail:
Bottom of LCD
Backlight interface PCB
panel

Reattach to
backlight cable
extender assembly
(not shown)

Bend and
straighten metal
tabs and secure
backlight panel

LCD panel

8-00374

Figure 8-30. LCD panel and backlight panel assembly

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8 Service and repair

8.14.14 9.4-inch GUI cooling vent filt ers

The GUI rear housi ng cooli ng vents are covered with foam fi lters as shown in Fi gure 8-31.
These filters col lect debris that enter through the GUI cool ing ven ts and must be repl aced
when di rty.

Caut ion
To prevent damage to filter-retaining studs, do not attempt to remove the pushnuts that
hold the foam filters in place.

1 Rem ove GUI rear h ousi ng (Section 8.14.6.1).

2 Rem ove di rty fi lter by tearin g all rem n ants of foam away from retain ing posts an d ven t.
Do not remove existing pushnuts; you will install the new foam and pushnuts directly over the
existing pushnuts (Figure 8-31).
3 Vacuum ven t area to rem ove any rem aini ng fil ter debri s.
4 Al ign n ew foam fi lter over ven t an d press on to posts. Secure foam fi lter wi th n ew
pushn uts, m aki ng sure each pushn ut is ful ly seated.
5 Repeat steps for each foam fi lter.
6 After all fil ters are replaced, gen tly bl ow dry, com pressed air over in side of rear housing
to rem ove any foam residue.
7 Install GUI rear housin g (Secti on 8.14.6.2).

Caut ion
Ensure cables are not pinched between the front and rear housings as you reassemble the
GUI unit. Otherwise, damage to the cables may result.

Pushnut

Foam
filter

Foam
filter Pushnut

8-00263

8-00117

Figure 8-31. Replacing the 9.4-inch GUI cooling vent filters

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Service and repair 8
8.14.15 9.4-inch rot or housing
The blue rotor h ousi ng supports the GUI. W hen th e GUI's rel ease knob is sli d to th e right, th e
rotor housin g opens and the m odule is released.

8.14.15.1 Removing t he 9.4-inch rot or housing

1 Rem ove GUI from m ountin g pl atform (Secti on 8.14.5).
2 Rem ove two screws th at secure fasci a panel to rotati on assembly (Figure 8-32). Remove
fascia panel.
3 Pull retai nin g spring out of groove and lift off brake shoes; release spring.
4 Sli de out rotor housing.

8.14.15.2 Inst alling t he 9.4-inch rot or housing

1 Sli de blue rotor h ousin g in to place i n base of GUI rear housin g (Fi gure 8-32). Positi on i t
so th at on e of the three proj ections faces forward.
2 Sli p on two brake shoes as shown. Secure by position ing spring into brake shoes’ groove.
3 Posi tion fasci a pan el; then in stall and hand-ti ghten two screws. Usin g a screwdri ver,
tighten unti l snug. D o n o t o v ert igh t en .
4 In stall GUI (Secti on 8.14.5).

Fascia
panel

GUI rear
panel

Blue rotor
housing

Spring
8-00077

Brake
shoes

Figure 8-32. 9.4-inch rot or housing assembly

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8 Service and repair

8.15 Breat h delivery unit (BDU)

The BDU, shown in Figure 8-33, includes the followi ng m aj or assem blies:
• Inspiratory m odule
• Exh alation m odul e
• Power suppl y
• ac pan el
• BDU alarm
• AI and BD CPU PCBs wi th correspondin g cablin g and i ntercon nect devi ces

8-0131 9 8-01298

Front view Rear view

Figure 8-33. BDU

The BDU is a removabl e uni t that can be m oun ted to the opti on al cart or shel f (using th e
shelf-m oun t kit).
M any BDU parts can be repl aced with out rem oving the uni t from i ts m ounti ng platform .
Table 8-4 in dicates th e l evel of di sassem bl y required for al l BDU fi eld-replaceabl e uni ts
(FRUs).
As you con duct th e foll owi ng repl acement and in stall ati on procedures for the BDU, you m ay
fi nd it useful to refer to Tabl e 2-2, and Fi gure 2-11 in Secti on 2 of th is manual.

Caut ion
To prevent damage to ESD-sensitive components, always follow ESD guidelines when
servicing the BDU.

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Service and repair 8

Table 8-4: BDU part replacement chart

M odules removed
BDU
replacement part Pow er Inspirat ory Exhalat ion BDU Card cage
BDU BPS
supply module m odule housing PCBs

Card cage r eplacement part s

AI PCB X

BD CPU PCB X

Pow er replacem ent part s

Power supply X
assembly

Power switch (S1) X

Power indicator X X X X X X X

Inspirat or y mod ule replacement p art s

Air inlet filter (F2)

Oxygen filters (F1/

F3)

Pressure switches
(PS1/ PS2)

PSOL cartridges X
(PSOL1/ PSOL2)

Inspiratory X
electronics PCB

Oxygen sensor X

Flow sensors (Q1/ X

Q2)

Safety valve X

Inspiratory check X
valve (CV3)

Regulators (REG1/ X
REG2)

Inspiratory X
pressure
transducer
autozero solenoid
(SOL1)

Exhalat ion module rep lacement part s

Exhalation valve
(EV)

Exhalation flow
sensor (Q3)

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8 Service and repair

Table 8-4: BDU part replacement chart (continued)

M odules rem oved

BDU
replacement part Pow er Inspirat ory Exhalat ion BDU Card cage
BDU BPS
supply module module housing PCBs

Exhalation X
transducer PCB

Filter seal

Expiratory X
pressure
transducer
autozero solenoid
(SOL2)

Exhalation heater X

Exhalation check X
valve (CV5)

Sample port X

Ot her replacement p art s

M otherboard PCB X X X X X X X

BDU alarm X X X X X X
assembly

Alarm blindmate X X X X X X X
cable

Inspiratory X X X X X X X
blindmate cable

dc power supply X X X X X X X
blindmate cable

ac power supply X X X X X X X
blindmate cable

ac panel X

Humidifier X
receptacle

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Service and repair 8
8.15.1 Removing BDU

Warning
To prevent personal injury, take appropriate measures when removing the BDU from its
mounting platform as the unit weighs 18.2 kg (40.1 lb) when fully loaded.

1 M ake th ese di scon nection s (Fi gure 8-34):

a. Venti lator power cord from facil ity power (Section 8.15.2.)
b. Ventil ator from pressuri zed gas source
c. Com pressor uni t power cord from BDU, if appl icabl e
d. Com pressor un it data cable from BDU, if appl icabl e
e. GUI cable from BDU
f. BPS cable from BDU [use 1/8-i n. (3-mm ) flat-bl aded screwdriver to loosen capti ve
screw s]

Caution
Use extreme care when moving the BDU. Do not jar or drop the unit.

2 Pull out BDU release handle (Fi gure 8-36) to di sengage BDU locking bracket; whi le
hol din g handle out, sli de BDU off bracket whil e resti ng it on edge of m ounting platform .
Release h andle.
3 Carefull y lift BDU off platform from rear of venti lator, and pl ace on a fi rm , clean surface.

Air Oxygen
Compressor hose hose
hose

GUI cable

Compressor
power cord
BDU
release
handle
8-00264 8-00265

Figure 8-34. BDU connect ions

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8 Service and repair

8.15.2 BDU pow er cord and ret ainer

There are two styles of the BDU power cord and retai ner combin ation. Th e later version uses
the cord an d the retain er togeth er to positively lock the power cord to the ventil ator. Parts are
n ot interchan geable between the old an d th e new power cords an d retain ers.

Figure 8-35. Sure-Lock™ ret ainer and pow er cord

Older field un its can be retrofi tted wi th th is new com bi nati on , usi ng a FRU ki t versi on. (Refer
to Section 9 for part num bers.)
1 Rem ove the two screws securing the current bracket to ac receptacl e of the BDU.
2 Install the Sure-Lock retain er over the receptacle and secure with th e two screws
provi ded.
3 Insert th e power cord and ensure that it clicks firml y into place.

Figure 8-36. BDU release handle

8.15.3 Inst alling BDU

1 Lifting BDU from rear, rest front of BDU on edge of BDU m ounti ng platform .
2 Sl i de BDU onto m ounti ng bracket.
3 M ake sure BDU is locked in place by pushin g and pulli ng it on sli de.
4 Con nect cables to GUI, BPS, com pressor, and ac power, as requi red (Figure 8-34).

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8.15.4 Analog int erface (AI) PCB and breat h delivery (BD) CPU PCB
The AI and the BD CPU PCBs (Fi gure 8-37) reside i n the card cage of the BDU.

Data
key

BD CPU PCB AI PCB

Figure 8-37. BD CPU PCB and AI PCB

Lookin g i nto th e card cage, the AI PCB sits in th e far right sl ot (toward the fron t of the
ven til ator), and the BD CPU PCB sits in second sl ot from the ri gh t (behind the AI PCB). Refer
to Fi gure 8-37.

Caution
The data key is matched to each ventilator. Ventilator is inoperable without the correct data
key installed. Do not lose the data key.

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8 Service and repair

Card
cage

BD CPU
PCB

2 PL

AI PCB

8 PL 8-00120

I/ O panel

Figure 8-38. BD card cage and PCBs

8.15.4.1 Removing AI PCB or BD CPU PCB

1 Rem ove two screws that retai n data key cover; rem ove cover. Rem ove data key.
2 Di sconn ect cables attach ed to card cage I/O pan el (Figure 8-39).
3 Usin g 3/ 16-i n. nutdri ver, rem ove two latchi ng post screws that secure panel to PTS2000
connector (Figure 8-38).
4 Usin g #0 Phi ll ips screwdriver, loosen eight screws that secure panel to BDU ch assi s and
to GUI and com pressor data con nectors. Rem ove panel.
5 Place your thum bs on backsi de of upper and l ower ej ector clips of PCB being i nstalled.
Si m ul taneously apply negative pressure to di sengage cl ips. (W hen the cli ps sn ap open,
the PCB is rel eased.)
6 Gently pul l PCB out of card cage, detachi ng it from m oth erboard PCB. Pl ace PCB in a
conducti ve bag or on ESD-protected m at.

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Service and repair 8

Test button
PTS 2000
connector

Data key

GUI
connector data connector

Figure 8-39. BDU I/ O panel connections

8.15.4.2 Inst alling AI PCB or BD CPU PCB

1 Ori ent PCB (Figure 8-38) with com ponen t si de toward fron t of ven tilator.
2 Al ign PCB to upper and l ower card guides an d gentl y slide PCB al on g guides in to card
cage.
3 Gently press PCB into card cage until i t seats to m otherboard PCB conn ector at back;
then, sim ultan eously press ejector cli ps closed unti l they latch.
4 Using #0 Phil li ps screwdri ver, i nstall eight screws that secure card cage I/ O panel to BDU
ch assis an d to GUI and compressor data con nections. Tighten screws un ti l snug. Do n o t
o vert igh t en .

Caution
Grounding of the BDU can be compromised is the I/ O panel is incorrectly installed.

5 Using a 3/16-i n. nutdri ver, in stal l two latch in g post screws that secure panel to PTS2000
conn ector, and tigh ten until snug. Do n o t o v er tigh t en .
6 Insert data key, i nstall data key cover, and con nect cables to panel.

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8 Service and repair

8.15.5 Power supply assembly

Caut ion
To prevent electrical shock hazard, always unplug the power cord from facility power and
disconnect the BPS cable from the power supply before servicing the power supply.

8.15.5.1 Removing power supply assembly

1 Di sconn ect BPS cabl e by fi rst openin g spring-loaded cover that shields power supply
connector, th en loosenin g conn ector’s two captive screws with 1/8-in. (3-m m ) flat-
bl aded screwdri ver.
2 Rem ove two screws that secure pow er supply assem bl y to BDU chassi s. Gently pull out
power suppl y assem bly, unseating it from conn ectors (Fi gure 8-40). Set assem bly on fi rm
surface.

Power supply assembly

8-00169

Figure 8-40. Replacing power supply assembly

8.15.5.2 Inst alling power supply assembly

1 Orien t power supply assem bly wi th slanted h eatsin k portion at top (Figure 8-40).
2 Gen tly sl ide power supply assem bl y i nto BDU ch assis until i t i s full y in serted.
3 Install two screws, and tighten unti l snug.
4 Connect BPS cabl e to power suppl y by openin g sprin g-l oaded cover that shields power
suppl y connector, conn ecti ng cabl e, and usin g 1/8-in. (3-m m ) fl at-bl aded screwdri ver to
tigh ten conn ector's two capti ve screws until snug. Do n o t o vert igh t en .

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Service and repair 8
8.15.6 Pow er swit ch (S1)

Warning
To prevent electrical shock hazard, always unplug the power cord from facility power and
disconnect the BPS cable from the power supply assembly before servicing ac components.

8.15.6.1 Removing power swit ch (S1)

1 Rem ove power supply assem bly (Section 8.15.5.1).
2 Reachi ng in to power supply com partm ent from rear, di scon nect h arness from power
swi tch (Figure 8-41).
3 If you are installi ng a new power switch , rem ove actuator and save for rei nstal lati on.
Power switch

8-00154

Figure 8-41. Replacing power sw it ch (S1)

8.15.6.2 Inst alling power swit ch (S1)

1 If you are i nstal li ng a new power switch , snap on actuator, ori enti ng it so that I is at top.
2 From front of BDU, orient power switch so that I is at top of switch , and sl ide switch i nto
sl ot.
3 From i nside power supply com partm ent, connect harn ess to power switch (Fi gure 8-41).
4 In stal l power supply (Section 8.15.5.2).

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8 Service and repair

8.15.7 Humidifier receptacle (100 – 120 V models only)

8.15.7.1 Removing humidifier recept acle

1 Rem ove power suppl y assembly (Secti on 8.15.5.1).
2 Reach in g i nto power supply compartm ent from rear, disconn ect h arness from receptacle
(Fi gure 8-42).
3 If hum idi fier receptacle cover is attached to front of ventil ator, rem ove four flat-head
screws that hol d cover in place.
4 From front of ven ti lator, rem ove two flat-h ead screw s that secure hum idi fier receptacl e
to chassi s. Feed receptacl e through power suppl y cavity. Rem ove receptacle assem bly
from chassis.

8-01161 8-00154

Figure 8-42. Replacing humidifier receptacle

8.15.7.2 Inst alling humidifier recept acle

1 From in si de power supply com partm ent, align receptacle to two screw l ocati on s on fron t
of ch assis (Figure 8-42). W hen faci ng front of venti lator, the ground socket shoul d be on
your left. Install two flat-head screws.
2 From i nsi de power suppl y com partment, connect harness to receptacl e.

Caut ion
Route the humidifier cables so they do not obstruct the ac power supply harness and
blindmate bracket, located at the bottom rear of the power supply compartment.

3 If desired, i nstall humi di fi er receptacl e cover w ith four fl at-head screws.

4 Install power supply assem bly (Section 8.15.5.2).

NOTE:
Consult this manual or the humidifier vendor for the appropriate bracket model
when mounting a humidifier to the ventilator.

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Service and repair 8
8.15.7.3 ac panel
8.15.7.3.1 Removing ac panel
1 Rem ove i nspi ratory m odule (Section 8.15.8.8). Th is is n ecessary to provide access to th e
panel .
2 If con nected, disconnect venti lator an d compressor (i f in stal led) power cords from ac
panel , and BPS cabl e from BDU.
3 Rem ove six screw s that secure panel (Figure 8-43) to BDU chassi s. (Two screws also secure
BPS con nector cover to pan el .)
4 Taki ng care n ot to disturb electrical conn ections on i nside of ac panel , gently separate
panel from chassi s.
5 To provide better access to com pon ent con necti on s, cut ti e wrap that secures wi res to
wal l of ac power di stri buti on com partment.
6 Using n eedlenose pl iers, disconnect th e wires from the ac panel com pon ents:
• red wire from termi nal 10 of relay
• bl ack wire from term inal 12 of relay
• bl ue wi re from top l eft-han d termi nal of ac fil ter PCB
• brown wire from top righ t-hand term inal of ac fil ter PCB
• brown wire from m i ddle left-h and term i nal of compressor ac receptacl e
• bl ue wi re from m iddle ri ght-h and term in al of compressor ac receptacl e
7 Using 5/ 16-in . nutdriver, di sconn ect ground wires from ground stud of ac panel .
8 Rem ove ac pan el.

Relay Ground stud ac filter PCB

8-00161 Compressor ac receptacle 8-00246

Figure 8-43. ac panel

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8 Service and repair

8.15.7.3.2 Inst alling ac panel

1 Usin g needl en ose pl iers, conn ect w ires to ac panel com ponents (Fi gure 8-43):
• red wire to termi nal 10 of rel ay
• black wi re to term in al 12 of relay
• blue wire to top left-hand term in al of ac fi lter PCB
• brown wire to top righ t-h and term in al of ac fi lter PCB
• brown wi re to m iddl e left-h an d term i nal of compressor ac receptacl e
• blue wi re to middl e ri ght-han d term i nal of compressor ac receptacl e
2 Usin g 5/ 16-in . nutdri ver, conn ect th e two green groun d wires to top l eft-hand ground
stud of ac panel .
3 Secure wi res to wal l of ac power di stributi on com partm ent usin g sm al l ti e wrap.
4 Install pan el to BDU ch assis using six screws. (Two screws al so secure BPS con nector
cover to panel.) Take care not to pinch wires between panel and chassis.
5 Connect ven ti lator and com pressor power cords to ac pan el, an d BPS cable to BDU.
6 Install in spiratory m odule (Secti on 8.15.8.10).

8.15.8 Inspiratory module

Warning
Replacing key inspiratory module components requires the use of leak detector fluid to
ensure a good gas seal. Use extreme caution when using leak detector in the vicinity of
electronics. Thoroughly dry all components following use of leak detector.

8.15.8.1 Inspiratory module modificat ions

Earli er inspiratory m odules used threaded air an d oxygen inl ets. Later versi on s use a com mon
m an ifold that all ows th e modul e to be easily con fi gured for each style of connection.
W h en orderin g a repl acem ent in spi ratory m odule, you m ust order two addi tional parts: th e
i nlets (ai r an d oxygen ), and th e m ounti ng brackets. There are five uni que confi gurations
avai lable to support the needs of vari ous countri es. Refer to Secti on 9 of thi s m anual for part
n um bers.
If repl aci ng the i nl et mani fol d on ly on an ori ginal m odule, refer to Section 9 to determ ine th e
replacem ent parts required.

8.15.8.2 Addit ional noise suppression (ferrit e cores)

Additi on al noise suppression has been added to th e 840 ven tilator, in form of th ree ferrite
cores on th e ai r fl ow tran sducer harn esses. Th e cores are now stan dard on n ew venti lators.
W h en configuri ng a fi el d unit for th e NeoM ode option, you m ust add these ferrite cores to
the uni t.
Add the ferrites to th e i nspi ratory m odul e i n accordance with the followin g instructions.
1 Rem ove the inspiratory m odule fascia panel . (Section 8.15.8.5.1)
2 Place the first of two l atchi ng ferrite cores around the l ower thi rd of the air fl ow
tran sducer harn ess (Fi gure 8-44).
3 Place the secon d l atchi ng ferrite core aroun d the upper third of th e ai r flow transducer
harness, al lowin g a m ini m um of 0.75 i nch es distan ce between the two cores.

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Service and repair 8

Figure 8-44. Adding ferrites to air and oxygen t ransducer harnesses

4 Pl ace th e thi rd core in the mi ddl e of the oxygen tran sducer h arn ess, usin g care not to
pi nch or damage th e wi res.
5 Vi suall y i nspect the cabl es and ensure that both of the latches are secure an d th at n o
stress is bein g placed on any discrete wires.
6 Rein stal l the fasci a pan el . (Secti on 8.15.8.5.2)

8.15.8.3 Inspirat ory module O-rings

Caution
When replacing damaged O-rings, carefully remove and install to prevent damage to the
manifold ports.

Check for damaged O-rings as you disassemble th e in spi ratory m odul e. If O-rings are
dam aged, pry them off of the ports. Lubricate replacem en t O-rings wi th Krytox grease, th en
gently stretch O-ri ng over base of th e port an d positi on i n place.
Allow replaced O-rin gs to settle i n place; then verify their i ntegrity.

8.15.8.4 Air inlet filt er (F2)

NOTE:
Replace the air inlet filter (F2) and O-ring every 10,000 hours. They are part of the
10,000-hour preventive maintenance kit.

8.15.8.4.1 Removing F2
1 M ake sure ai r source is di sconn ected from venti lator.
2 Drai n any con densate from ai r inlet fil ter bowl by unscrew ing captive drai n plug at
bottom (Figure 8-45). Ti gh ten pl ug.
3 Unscrew bowl.
4 Unscrew fil ter.

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8 Service and repair

Bowl
Top

Groove

Filter

Air filter
assembly Drain
(F2) plug
O-ring 8-00212
8-01118

Figure 8-45. Replacing F2

8.15.8.4.2 Inst alling F2

1 M ake sure O-ri ng is seated i n unthreaded groove atop F2 (Figure 8-45).
2 Screw fil ter in pl ace unti l snug. M ake sure O-ring m akes con tact with BDU chassi s.
3 Screw clear bowl in pl ace over fi lter unti l sn ug.
4 Usin g l eak detector fluid (P/N 4-004489-00), verify that bowl does not l eak.

8.15.8.5 Fascia panel

8.15.8.5.1 Removing fascia panel
Rem ove th e fascia panel that houses th e i nspi ratory modul e by rem oving two screws
(Figure 8-46).

Fascia
panel

8-00213

Figure 8-46. Removing inspirat ory module fascia panel

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Service and repair 8
8.15.8.5.2 Inst alling fascia panel
1 Insert l ip, at top of fascia panel, under ri m of BDU pl asti c h ousi ng and gently press fascia
panel in place (Fi gure 8-46).
2 Install two screws th at secure fascia pan el to BDU ch assis and tighten unti l snug. Do n o t
o vert igh t en .

NOTE:
Replace the oxygen impact filter (F1), oxygen inlet filter (F3) with a new O-ring
and spring every 10,000 hours. (These items are part of the 10,000-hour
preventive maintenance kit.)

8.15.8.5.3 Removing oxygen filt er assembly

1 Rem ove fascia panel (Secti on 8.15.8.5.1).
2 Pl aci ng adj ustabl e wrench on hexagon al part of cl ear fil ter bowl, loosen bowl
(Figure 8-47). Fin ish unscrewi ng i t by h and.
3 Unscrew oxygen i nlet filter (F3) el em en t.
4 Rem ove sin tered m etal oxygen i m pact fi lter (F1) and sprin g.

Oxygen
filter
assembly

Air pressure Oxygen

switch (PS2) pressure
switch (PS1)

8-00214

Oxygen Oxygen inlet

Bowl
impact filter filter (F3)
(F1)

8-00219 Spring 8-00220 8-00221

Figure 8-47. Oxygen filt er assembly and pressure swit ches

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8 Service and repair

8.15.8.5.4 Inst alling oxygen filt er assembly

1 Install spring into threaded cavi ty (Figure 8-47).
2 With rough si de down, place sin tered m etal fi lter (F1) over spri ng and make sure it i s
lyi ng fl at.
3 Insert threaded base of fi lter elem ent over metal fil ter, and screw it in to place unti l snug.
4 M ake sure O-ring on threaded base of bowl i s in pl ace an d fully seated i nto groove.
5 Place bowl over fil ter and screw into place until sn ug.
6 Usin g l eak detector fluid (P/N 4-004489-00), verify that bowl does not l eak.
7 Install fascia panel (Secti on 8.15.8.5.2).

8.15.8.6 Oxygen and air pressure swit ches (PS1 and PS2)
8.15.8.6.1 Removing PS1 and PS2
1 Rem ove fascia pan el (Section 8.15.8.5.1).
2 Rem ove oxygen fi lter assem bly (Secti on 8.15.8.5.3).
3 Di sconn ect harness from term inals at top of appli cabl e swi tch (Figure 8-47).
4 Usin g 9/16-in . open-en d wren ch , loosen pressure swi tch (Figure 8-48). Rem ove.

8-00222

Figure 8-48. Pressure sw itches

8.15.8.6.2 Inst alling pressure swit ches (PS1 and PS2)

The pressure switch l ocated di rectl y behin d the oxygen fil ter m ust be i nstal led first.
1 M ake sure O-ring i s properly seated at top of threaded base on pressure switch
(Fi gure 8-48); then screw pressure swi tch in to place (Fi gure 8-47).
2 Usin g 9/16-i n. open -end wren ch, ti gh ten pressure swi tch unti l snug. Do n o t
o vert igh ten .
3 Connect h arn ess to top of sw itch. M ake sure conn ectors are tight and that th ey make
contact wi th swi tch.
4 Install oxygen fil ter assem bly (Section 8.15.8.5.4). Using l eak detector fl ui d
(P/N 4-004489-00), verify that bowl does not leak.
5 Install fascia panel (Secti on 8.15.8.5.2).

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8.15.8.7 PSOL cart ridge
8.15.8.7.1 Removing PSOL cart ridge
1 Rem ove fascia panel (Secti on 8.15.8.5.1).
2 Pull in spiratory m odule out to access PSOLs:
a. Remove two screws th at retain i nspi ratory m odul e.
b. Fi rm ly grasp bottom of i nspiratory module, by ai r and oxygen i nlet fi tti ngs. Pull
module out of BDU chassi s unti l nyl on l ine atop PSOL m ani fold is visi bl e (Figure
8-49).
3 At top of PSOL m ani fol d, in sert blade of sm all, flat-bl aded screwdri ver into etched notch
adj acen t to nyl on l ine. Sl ide bl ade un der nyl on l in e an d pull l in e up, creating a loop.
Grasp loop and pull li ne com pl etel y out.
4 Di sconnect appropriate PSOL harness from in spi ratory electroni cs PCB. PSOL at your left
i s air PSOL (PSOL2); PSOL at your right i s ox ygen PSOL (PSOL1).

Caution
Place the PSOL cartridge on a clean work surface. Do not drop the assembly.

5 Carefull y pul l cartri dge out of PSOL m ani fol d and set on a clean work surface. Veri fy th at
al l four O-rin gs are present and i n good condi ti on.

Nylon Nylon
line line

8-00223 8-00224

Oxygen
PSOL
(PSOL1)

Air PSOL
(PSOL2)

8-00225

Figure 8-49. Replacing PSOL cart ridge

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8 Service and repair

8.15.8.7.2 Inst alling PSOL cart ridge

If th e PSOLs were di ffi cult to rem ove, lubricate the o-rings wi th a very thi n appl ication of
Krytox grease before reinstalli ng.
1 Orien t body of PSOL cartridge (Figure 8-49) so that PSOL harn ess reaches inspiratory
electroni cs PCB con nector.
2 Insert cartridge i nto m an ifold base and gen tl y press unti l cartridge i s full y seated.
3 Con nect PSOL h arn ess to i nspi ratory el ectronics PCB connector (P5=oxygen, P6=air).
4 Insert both ends of nyl on li ne into slots on top of m anifol d. Gui de lin es i nto m an ifold
unti l on e end reach es bottom of slot. Feed an y rem ai nin g lin e i nto opposite sl ot.
5 Press nylon lin e i nto groove at top of slots unti l i t i s fl ush wi th PSOL m anifold surface.
6 Sl ide in spiratory m odule back in to BDU.
7 Install two m ounti ng screws that secure modul e to BDU ch assis. Tighten unti l snug.
8 Install fascia panel (Secti on 8.15.8.5.2).
8.15.8.8 Removing inspirat ory module
1 Rem ove fascia pan el (Section 8.15.8.5.1).
2 Rem ove two screws that secure i nspiratory m odule (Figure 8-50) to BDU chassi s.
3 Fi rm l y grasp bottom of in spiratory m odule, by ai r and oxygen i nlet fi ttings, an d pull
m odule out of BDU ch assis. Place m odule on fi rm , ESD-protected, work surface.

Inspiratory
8-00226 module 8-00163

Figure 8-50. Removing inspirat ory module

8.15.8.9 Leak t est ing inspirat ory module

Before i nstalli ng the i nspiratory m odul e, leak-test it as fol lows, referri ng to Fi gure 8-50.
1 Place in spiratory m odule on fi rm surface.
2 Con nect com pressed air an d oxygen sources to in spi ratory m odul e.
3 Usin g sm all brush, appl y l eak detector fluid (P/N 4-004489-00) to th ese l ocation s.
• Base of air an d oxygen fl ow sensors
• Tran sfer tubes
• Check valve assem bl y
• Regul ator inl et/outl et ports
• Oxygen/air i nlets
If a conn ecti on leaks, repair and retest m odul e.
4 Dry al l l eak detector flui d from chassis.

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Service and repair 8
8.15.8.10 Inst alling inspirat ory module
1 Leak-test in spiratory m odule (Secti on 8.15.8.9).
1 Firm ly grasp bottom of i nspi ratory m odul e, by air an d oxygen in let fittings an d al ign
i nspi ratory m odul e wi th sl ots in inspiratory com partmen t (Figure 8-50).
2 Carefull y slide m odul e i nto i nspi ratory com partm ent and to back of BDU chassi s.
3 In stal l two screws that secure inspi ratory modul e to BDU chassis and tighten un ti l snug.
Do n o t o v ert igh ten .
4 In stall fasci a pan el (Section 8.15.8.5.2).

8.15.8.11 Oxygen sensor (OS)

The oxygen sensor should be replaced every two years or as often as n ecessary.
Newer 840 BDU covers have an access port located on the top ri ght edge of the BDU. Th is
access port facilitates conveni en t access to the oxygen sensor for the purpose of repl acem en t
by m edi cal staff. (Refer to Section 8.15.8.11.1 for replacement i nstruction s.)
Replacem ent of the oxygen sensor on venti lators without th is access port requires removal of
the in spiratory m odul e. (Refer to Section 8.15.8.11 for replacem en t in structi on s.)

8.15.8.11.1 Oxygen sensor replacement w it h access port

1 Locate the flexible oxygen sen sor access cover on the top ri ght edge of the BDU h ousing.
2 Firm ly push the center of the lower fl ap of th e access cover unti l the lower flap i s
di slodged from th e h ousi ng.

8-01329

Figure 8-51. Opening oxygen sensor access port

3 Pi nch the bottom and top fl aps of the access cover firm ly together and pul l the access
cover aw ay from the housing to remove.

NOTE:
The access cover is permanently attached to the instrument by an retaining strap.

4 Press wi re retai ner tab away from the connector to release th e sen sor cable connector.
an d gentl y rem ove the conn ector from the oxygen sensor.

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8 Service and repair

Access port
cover

Cover
retaining
strap
Sensor Check Valve
harness Housing

Wire retainer tab

Sensor Oxygen
harness sensor 8-01332
connector

Figure 8-52. Detail of oxygen sensor

5 Rem ove th e oxygen sen sor from ch eck valve housing.
6 Sli de the new O-rin g onto th e threaded end of the replacem ent oxygen sensor. Seat th e
O-rin g snugl y against the sensor base above the threads.

Caut ion
Ensure that the oxygen sensor O-ring is properly seated on the sensor before installing in the
ventilator. Failure to properly seat the O-ring may result in leaks.

7 Insert the th readed end of th e oxygen sensor i nto the cavi ty on th e check valve h ousi ng
and fin ger-tighten the sensor w ith out usin g excessi ve force. As th e sensor is in stal led,
ensure that it i s not cross-threaded.

Caut ion
To prevent cracking of the sensor body, do not overtighten as you screw it into place on the
check valve housing.

8 Connect the sensor harn ess connector to the oxygen sensor wi th th e ri dge on the cabl e
connector orien ted tow ards th e wire retainer tab on the oxygen sensor.
9 Repl ace the access port cover by fi rst sl idi ng i ts top flap i nto the openin g on the top of
the BDU housi ng.
10 Usin g both th um bs, seat the port cover in th e port by press the two outside corn ers of
the lower fl ap at the j uncture of th e housing edge, fittin g the in to the h ousi ng openi ng.
11 Contin ue using both th um bs and firm ly press th e lower flap i nto pl ace, workin g aroun d
the flap from the outside corners to the bottom center to seal th e access cover. Be sure
that th e cover properly seals th e h ousin g openin g.
12 Cali brate oxygen sensor by pressin g 100% O 2/CAL 2 m i n key. Veri fy that the calibrati on
passes.
13 Run an SST to check the system before placi ng the venti lator i n service.

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8.15.8.11.2 Removing oxygen sensor (no access port )
If your BDU unit does not have an access port on the top right edge of the h ousi ng, use the
fol lowin g i nstructi on s to replace the oxygen sensor.
1 Rem ove i nspiratory m odul e (Section 8.15.8.8).
2 Di sconnect oxygen sensor h arn ess from the sensor (Figure 8-53). Be sure to press the wi re
retai ner tab i nside the recess of th e oxygen sen sor to rel ease the connector.
3 Unscrew oxygen sen sor from PSOL m anifol d.

Oxygen
sensor

8-00153

Figure 8-53. Replacing oxygen sensor

8.15.8.11.3 Inst alling oxygen sensor (OS)

1 M ake sure O-ri ng is properl y seated at top of threaded base on oxygen sensor (Figure
8-53).

Caution
Ensure that the oxygen sensor O-ring is properly seated on the sensor before installing in the
ventilator. Failure to properly seat the O-ring may result in leaks.

2 In sert th e threaded end of th e oxygen sensor i nto th e cavity on th e ch eck valve housing
an d finger-ti gh ten the sensor with out using excessi ve force. As the sensor is install ed,
ensure that it is not cross-th readed.

Caution
To prevent cracking of the sensor body, do not overtighten as you screw it into place on the
check valve housing.

3 Con nect oxygen sensor h arness to sen sor.

4 Install in spi ratory m odul e, as needed. (Section 8.15.8.10).
5 Cali brate oxygen sensor by pressi ng 100% O2/ CAL 2 mi n key.
6 Run an SST to check the system before placi ng ven t in service.

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8 Service and repair

8.15.8.12 Inspirat ory check valve (CV3)

8.15.8.12.1 Removing inspirat ory check valve
1 Rem ove i nspi ratory m odul e (Section 8.15.8.8).
2 Di sconn ect harness from oxygen sensor.
3 Rem ove ch eck valve housin g (Fi gure 8-54) from PSOL m ani fol d by rem oving four screws.
Rem ove CV3 fl ap and seal.

Figure 8-54. Inspirat ory check valve (CV3) assembly

8.15.8.12.2 Inst alling inspirat ory check valve

NOTE:
If replacing an earlier version of the inspiratory check valve assembly (silver) with a
newer version (black), ensure the proper fit of the inspiratory filter. Otherwise, the
patient circuit may leak.

1 Reassem bl e CV3 in to housing, referrin g to Figure 8-54.

2 Install CV3 housing to PSOL m ani fol d wi th four screws.
3 Connect h arness to oxygen sen sor.
4 Install in spi ratory m odule, as n eeded (Section 8.15.8.10).

8.15.8.13 Right -side plat e

This i s the plate with the inspiratory electroni cs PCB attached.

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8.15.8.13.1 Removing right -side plat e
1 Rem ove i nspiratory m odul e (Section 8.15.8.8).
2 Di sconnect th ese from in spiratory electron ics PCB:
• Ai r PSOL (PSOL2) harness from P6
• Ai r fl ow sensor (Q2) harness from P4
• Pressure swi tch harness from P7
• Oxygen fl ow sensor (Q1) harness from P3
• Oxygen PSOL (PSOL1) harn ess from P5
• Oxygen sensor harn ess from P1
• Safety val ve h arn ess from P9 (adjacent to P1)
• Inspi ratory pressure tran sducer autozero solenoid (SOL1) harness from P10
• Tube from i nspiratory pressure transducer (PI) port
3 Ori en t in spi ratory m odule with ri ght-si de pl ate on top.
4 Rem ove six screws th at secure righ t-si de pl ate to ch assis (Figure 8-55):
• Th ree flat-head screws on flat side of pl ate
• One screw at fron t of pl ate
• Two screws at rear of pl ate
5 Rem ove righ t-side pl ate, wi th in spiratory electronics PCB attached, an d place on ESD-
protected m at.

8-00227

Figure 8-55. Removing inspirat ory module right-side plat e

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8 Service and repair

8.15.8.13.2 Inst alling right -side plat e

1 Al ign pl ate to right side of in spi ratory m odul e an d press i nto pl ace (Figure 8-55).
2 Install th ree fl at-h ead screws on si de, one pan-head screw on fron t, and tw o pan-head
screws on back.
3 Con nect these to i nspi ratory electronics PCB:
• Tube from si de of i nspi ratory pressure tran sducer autozero solenoi d (SOL1) to pressure
transducer port (port farth est from PCB edge)
• SOL1 h arness to P10
• Safety valve harness to P9 (adjacen t to P1)
• Oxygen sensor harness to P1
• Oxygen PSOL (PSOL1) harness to P5
• Oxygen fl ow sensor (Q1) harness to P3
• Pressure switch h arn ess to P7
• Air flow sensor (Q2) h arn ess to P4
• Air PSOL (PSOL2) h arness to P6
4 Install in spiratory m odule (Secti on 8.15.8.10).

8.15.8.14 Inspirat ory elect ronics PCB

The in spiratory electron ics PCB i s mounted to the righ t-si de pl ate.

8.15.8.14.1 Removing inspirat ory elect ronics PCB

1 Rem ove ri ght-si de plate (Secti on 8.15.8.13.1).
2 Rem ove si x screws that secure in spiratory electron ics PCB to right-si de plate.
3 Careful ly l ift in spi ratory electronics PCB off plate. Place PCB in a con ductive bag or on
ESD-protected m at.

8.15.8.14.2 Inst alling inspirat ory elect ronics PCB

1 Al ign in spi ratory electron ics PCB six screw locati ons to ri ght-side plate. Install six screws
that secure PCB to right-side plate.
2 Install ri gh t-si de pl ate (Section 8.15.8.13.2).

8.15.8.15 Left -side plat e

The left-side pl ate i s opposi te the inspi ratory el ectroni cs PCB m ounting plate.

8.15.8.15.1 Removing left -side plat e

1 Rem ove i nspi ratory m odul e (Section 8.15.8.8).
2 Rem ove th ree flat-head screws from side of left-si de plate (Figure 8-56).
3 Takin g care n ot to con tam inate seal adhesive, carefull y peel seal away from l eft-side
plate. If seal is dam aged, refer to Section 9 for replacem ent adhesi ve tape.
4 Rem ove one screw from rear of pl ate.
5 Rem ove two screws from fron t of plate. One screw is under seal.
6 Careful ly lift left-side plate off in spiratory m odule.

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Service and repair 8

3 screws on
left side of
left-side plate

1 screw at front
of left-side plate
2 screws at rear
of left-side plate
Th is p h o t o w ill
b e rep la ced w it h n ew sh ot .
8-00152

Figure 8-56. Replacing inspirat ory module left -side plate

8.15.8.15.2 Inst alling left -side plat e

1 Al ign plate (Figure 8-56) to left side of in spi ratory m odule and press in to pl ace.
2 Install and sligh tly ti gh ten two pan -head screws on fron t, one pan-h ead screw on rear,
an d th ree fl at-h ead screws on si de. Tigh ten all screws un til snug. D o n o t o ver tigh ten .
3 Rein stal l adhesive seal wh ere it was peeled back.

NOTE:
If seal is damaged, refer to Section 9 for replacement adhesive tape.

4 Install i nspi ratory m odul e (Section 8.15.8.10).

8.15.8.16 PSOL manifold

8.15.8.16.1 Removing PSOL manifold
1 Rem ove i nspiratory m odul e (Section 8.15.8.8).
2 Rem ove four fl at-h ead screws th at retain PSOL m an ifold, from both righ t- and left-si de
pl ates (Fi gure 8-57).
3 Di sconnect harnesses from i nspi ratory electron ics PCB, as required.
4 Di sconnect SOL1/PSOL m ani fol d in terconn ect tube from PSOL m an ifold.
5 Gentl y pull m an ifold aw ay from i nspi ratory m odul e. Th e flow sen sors sh ould be
attached to the manifol d.
6 Pl ace m anifold on cl ean work surface.

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8 Service and repair

PSOL
manifold Th is p h o t o w ill b e rep la ced .
Remove
(4 PL)

8-00172

Figure 8-57. PSOL manifold ready for removal

8.15.8.16.2 Inst alling PSOL manifold

NOTE:
The PSOL manifold slides between the left- and right-side plates. If the fit is too
tight, loosen the flat-head screw on the left side plate, allowing the plate to be
lifted slightly to provide sufficient clearance for the manifold.

1 Ali gn flow sensor tubes on PSOL m ani fol d to vents on air sen sor m ani fol d and gentl y
press m anifold until tubes ful ly seat in to vents.
2 Install four flat-head screws that secure PSOL m ani fol d to right- an d l eft-side pl ates
(Fi gure 8-57). Tighten screws. Do n o t o v er tigh t en .
3 If thi rd flat-head screw on left-side pl ate was l oosened to in stal l PSOL m an ifold, tigh ten
unti l sn ug.
4 Connect tube attach ed to top of SOL1 to beneath PSOL man ifold body.

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Service and repair 8
5 M ake these con nection s to inspiratory el ectroni cs PCB:
• Safety val ve harn ess to P9 (th is conn ector i s located between P1 and P10)
• Oxygen sensor harn ess to P1
• Ai r PSOL (PSOL2) harness to P6
• Ai r fl ow sensor (Q2) harness to P4
• Pressure swi tch (PS1 and PS2) h arness to P7
• Oxygen fl ow sensor (Q1) harness to P3
• Oxygen PSOL (PSOL1) harn ess to P5
6 Install i nspi ratory m odul e (Section 8.15.8.10).

8.15.8.17 Oxygen and air flow sensors (Q1 and Q2)

If you are i nstal li ng a pair of new flow sen sors, the sensors are in terchan geable. However, if
you are rei nstal lin g a flow sensor, you m ust install it in i ts previ ous posi ti on (air or oxygen) to
preven t contam ination of the oxygen system . Alw ays note whi ch sen sor is whi ch before
rem oving the pair.
The flow sen sor wi th the longer harness an d tw o ferrites is Q2.

8.15.8.17.1 Removing oxygen and air flow sensors

1 Rem ove PSOL m anifold (Section 8.15.8.16.1).
2 Gentl y pull sen sor from PSOL m an ifold (Figure 8-58). Pl ace on a cl ean surface to preven t
contam ination.
3 If you are installi ng a new flow sen sor, do th e foll owi ng:
a. Disconnect harn ess from existi ng sensor and tran sfer to new sensor.
b. Remove end caps from new sensor tube, an d transfer to exi sting fl ow sensor tube.

PSOL
manifold

Safety
valve

Air flow
sensor
(Q2)

Oxygen
flow
sensor
(Q1)

8-00177

Figure 8-58. Replacing oxygen and air flow sensors (Q1 and Q2) and safet y valve

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8 Service and repair

8.15.8.17.2 Inst alling oxygen and air flow sensors

1 M ake sure O-rin gs are properly seated at each end of flow sensor tube (Fi gure 8-59).
2 Orien ti ng flow sensor body as shown i n Figure 8-58, gently push sen sor into PSOL
m ani fol d.
3 Install PSOL m ani fol d (Secti on 8.15.8.16.2).
4 Applyi ng leak detector fluid (P/ N 4-004489-00) to bottom of fl ow sen sor only, veri fy that
sensor does not leak.

O-ring

O-ring

8-01184

Figure 8-59. Oxygen and air flow sensors (Q1 and Q2)

8.15.8.18 Safet y valve

8.15.8.18.1 Removing safet y valve (SV)
1 Rem ove oxygen and air fl ow sensors (Section 8.15.8.17.1).
2 Rem ove two flat-head screws that secure safety val ve (Figure 8-58) to PSOL m ani fol d.
Gently pul l safety valve (Figure 8-60) out of mani fol d.

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Service and repair 8

8-00269

Figure 8-60. Safety valve

8.15.8.18.2 Inst alling safet y valve

1 M ake sure O-ri ng i s properly seated in groove at base of safety val ve (Fi gure 8-60).
2 Before i nserti ng valve into manifold, route safety valve cabl e un der plate that seats to
m ani fold, toward oxygen sensor.
3 Al ign safety valve to two screw locations on PSOL m ani fol d (Figure 8-58). Careful ly press
base of safety val ve into m anifold until ful ly seated. M ake sure safety valve cabl e i s not
pi nch ed between valve an d manifold.
4 In stall two flat-head screws th at secure safety val ve to PSOL manifold. Ti gh ten until
sn ug. Do n ot ov ert igh t en .
5 In stall oxygen and air fl ow sensors (Section 8.15.8.17.2).

Caution
To prevent component damage when installing the safety valve, do not apply leak detector
fluid.

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8 Service and repair

8.15.8.19 Check valve assembly, regulat or assembly, and flow sensor manifold
8.15.8.19.1 Removing check valve assembly, regulat or assembly, and flow sensor
manifold
1 Rem ove ri ght-si de plate (Section 8.15.8.13.1) and left-side plate (Section 8.15.8.15).
2 Rem ove PSOL m ani fol d (Secti on 8.15.8.16.1).
3 Rem ove four in set screws that secure ch eck valve assem bly an d fl ow sensor m an ifold to
inspiratory fl oor (Fi gure 8-61).
4 Disconn ect oxygen vent tube from inspiratory floor.
5 Pull in g i n direction of check valve assem bly, rem ove fl ow sensor m anifold/regulator
assem bly/ check valve assembly from plate.
6 Pull fl ow sensor m anifold/regulator assem bl y/ check valve assem bly apart i nto three
pieces as shown.

8.15.8.19.2 Inst alling check valve assembly, regulat or assembly, and flow sensor
manifold
1 M ake sure four O-ri ngs on ch eck val ve assem bl y (Figure 8-61) are presen t an d properly
positi on ed (two O-rings on air and ox ygen ports and two O-rings in tran sfer tube port
cavities).
2 Al ign air an d oxygen ports (on ch eck val ve assem bl y) to ai r and oxygen ports on
regulator assem bly.
3 Gently press ch eck val ve assem bl y again st regul ator assem bly until it reach es stop post.

NOTE:
It may be necessary to flex the inspiratory floor plate down in order to seat the
check valve assembly to the regulators.

4 Install two screws that secure check val ve assem bl y to fl oor. Tigh ten screws un til snug.
Do n o t o vert igh t en .
5 Install PSOL m ani fol d (Secti on 8.15.8.16.2).
6 Install ri gh t-si de pl ate (Section 8.15.8.13.2) and left-side plate (Section 8.15.8.15.2).

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Service and repair 8

Regulator
assembly

Check
valve
assembly

Flow
sensor
manifold
Inspiratory
plate 8-00229

Inspiratory
floor plate

8-00230

Regulator
Check assembly
valve
assembly Flow
sensor
manifold

8-00231

Figure 8-61. Disassembling flow sensor manifold/ regulat or assembly/ check valve assembly

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8 Service and repair

8.15.8.20 Oxygen and air regulat ors (REG1 and REG2)

8.15.8.20.1 Removing REG1 and REG2
1 Rem ove regulator assem bly wi th plate (Section 8.15.8.19.1).
2 Usin g 7/16-in. socket or open -end w rench , rem ove retain in g nut that secures appl icable
regulator (REG1 or REG2) to regul ator plate (Fi gure 8-62). Rem ove regulator.
3 If you are rem ovin g REG1, disconnect ven t tube from REG1 output port. Save for
rei nstal lati on.

REG1 REG2
REG2

REG1 SOL1

fig8-51a.tif

Regulator
plate
SOL1

8-00232 8-00233

Regu la t or a ssem b ly Regu la t o r a ssem b ly co m p o n en t s

Figure 8-62. Removing REG1 and REG2

8.15.8.20.2 Inst alling REG1 and REG2

NOTE:
REG1 and REG2 are not interchangeable and must be installed in their appropriate
locations. REG1 has an output port, which distinguishes it from REG2.

1 Insert regul ator in appropri ate cutout i n regulator plate, and ali gn m ounti ng screw to
plate (Figure 8-62). Usi ng 7/16-in. socket or open -end wren ch, i nstall retaini ng nut and
tigh ten until snug.
2 If you are instal li ng REG1, con nect vent tube to REG1 output port, at bottom of
inspiratory fl oor pl ate.
3 Instal l regulator assem bly with pl ate (Secti on 8.15.8.19.2).

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Service and repair 8
8.15.8.21 Inspirat ory pressure t ransducer aut ozero solenoid (SOL1)

Caution
To prevent damage to tubing, do not attempt to remove silicone tubing from solenoid
barbed fittings. Solenoid FRUs have tubing pre installed.

8.15.8.21.1 Removing SOL1

1 Rem ove right-side plate (Section 8.15.8.13.1) and l eft-side plate (Secti on 8.15.8.15).
2 Rem ove PSOL m anifold (Section 8.15.8.16.1).
3 Di sconnect vent tube from REG1 output port.
4 Using 7/ 16-in . socket or open-end wrench, rem ove two nuts that secure pl ate to
regulators (Fi gure 8-62). Rem ove pl ate.
5 Rem ove two screws th at secure SOL1 to regul ator assem bl y pl ate. Rem ove SOL1 wi th
tubes.

8.15.8.21.2 Inst alling SOL1

1 Align repl acem ent SOL1 (with tubes attached) to two screwh ol es on regul ator plate
(Figure 8-62). In stal l two screws and tighten un til snug. D o n o t o vert igh ten .
2 Using 7/ 16-in. socket or open-en d w rench , install two n uts th at secure plate to
regul ators. Rem ove pl ate.
3 Con nect vent tube to REG1 output port.
4 In stall PSOL m anifold (Secti on 8.15.8.16.2)
5 In stall right-si de plate (Section 8.15.8.13.2) and left-si de plate (Secti on 8.15.8.15.2).

8.15.8.22 Inspirat ory floor assembly

The inspiratory fl oor assem bly consi sts of three subassem blies: gas in let m anifold, ai r filter
h ead, and inspiratory floor pl ate. This section covers repl acement of the dam aged O-rin gs. To
replace th e oxygen or air fil ter, refer to Secti on 8.15.8.4 or Secti on 8.15.8.6. To replace the
pressure switches, refer to Section 8.15.8.6.

8.15.8.22.1 Disassembling inspirat ory floor assembly

1 Rem ove flow sen sor m an ifold/regul ator assem bl y/ check val ve assem bl y from i nspiratory
fl oor assembly (Section 8.15.8.19.1).
2 Rem ove two screws th at secure gas inl et m an ifold to floor plate. Lower fl oor plate to
unseat gui deposts that i nsert in to bottom of gas in let m ani fold. Gentl y pul l gas i nl et
m an ifold away from air fi lter head, peel in g away adhesi ve seal as requi red.

8.15.8.22.2 Reassembling inspirat ory floor assembly

1 Carefull y slide ai r fil ter head inl et port in to cavity on gas in let m anifold. Press gas i nlet
m an ifold un ti l it seats flush agai nst ai r fi lter h ead.
2 Hol d fl oor with guide posts pointi ng up, l ower air fi lter head in to hole on m oun ting
pl ate. Al ign two gui de posts to m oun ting h ol es on bottom of gas i nlet m ani fol d. Seat
fl oor until it is flush with m ani fol d. In stal l seal.
3 From top of gas i nl et m anifol d, i nstall two screws that secure floor to m ani fol d. Tighten
screws un til snug. Do n o t o vert igh t en .
4 Install flow sensor m an ifold/ regulator assembl y/ch eck val ve assem bly to in spi ratory
fl oor assembly (Section 8.15.8.19.2).

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8 Service and repair

8.15.9 Exhalation module

8.15.9.1 Exhalat ion collect or vial (ECV) and expirat ory filt er (F9)
1 Push the bl ue latch up to release coll ector vial/ expi ratory fi lter.
2 Rem ove assem bly, and di sassem ble as required. For com pl ete detail s on usin g the
collector vial and expi ratory filter, consul t th e 840 Operator’s and Technical Reference
Manual.

NOTE:
To ensure that all patient circuit connections are leak-tight, perform a circuit leak
test by running SST every time you install the filter on a ventilator. Consult the 840
Operator’s and Technical Reference Manual.

8.15.9.2 Removing exhalat ion module cover

1 Rem ove collector vial an d expiratory fil ter (Section 8.15.9.1).
2 Rem ove four screws that secure the cover to the exh alati on m odul e (Fi gure 8-63).
3 Sl ide cover off from fron t, making sure i nside top bracket disen gages from BDU chassis.

Remove
screw

8-00160
8-01171 8-00160

8-01318

Figure 8-63. Removing exhalat ion module cover

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Exhalation heater
Heater
harness
Fascia panel

Exhalation
Expiratory pressure check valve
transducer autozero (CV5)
solenoid (SOL2)

Ferrites

Exhalation
flow sensor
(Q3)

Exhalation
valve (EV) Exhalation port
tube
Exhalation
module
harness

Exhalation
transducer PCB

Figure 8-64. Exhalat ion module disassembled

8.15.9.2.1 Inst alling exhalat ion module cover

1 M ake sure exhaust port is in pl ace (Figure 8-67).
2 Align exh al ation m odul e cover (Fi gure 8-63) di rectly in front of exhalati on
com partm ent. Slide cover straigh t back, allowi ng head screw to drop in to sl ot of
al ignm ent bracket.
3 Al ign cover screw locations to BDU ch assi s (three on front an d one on rear); th en ti ghten
screws un til snug. Do n o t o vert igh ten .
4 Install col lector vi al an d expiratory fil ter (Section 8.15.9.1).

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8 Service and repair

8.15.9.3 Removing exhalat ion module

1 Rem ove exhalati on m odule cover (Section 8.15.9.2).
2 Di sconn ect exhal ation m odul e harn ess from exhal ation I/O cable conn ector (Fi gure
8-65).
3 Loosen si x capti ve flat-head screws that secure exhalation m odule to BDU chassis (three
beneath collector vial/ expi ratory fil ter, one at bottom of exhalati on valve, on e behind
flow sensor Q3, and on e at bottom front of exhal ation m odul e).
4 Sl ide bottom of exhalation module out from chassi s; then careful ly lower un it to clear
top of m odule. Place exh alati on module on a clean work surface.

Exhalation
module
harness

Exhalation I/ O cable
Exhalation connector
module

8-01172

Figure 8-65. Replacing exhalation m odule

8.15.9.4 Inst alling exhalat ion module

1 Ti lt top of exhal ati on m odul e (Fi gure 8-65) back, an d i nsert in to top of exhal ation
compartm en t; then sli de bottom of m odule i nto compartm en t whi le ali gni ng
(ali gnment) tab (on BDU ch assis) to slot in exhal ation m odule back panel . (Th is
ali gnm en t al igns the capti ve screws to the screw locations on the BDU chassi s.)
2 Ti ghten si x captive screws unti l snug (three beneath coll ector vial/expi ratory fil ter, one
at bottom of exhal ation valve, one behi nd flow sen sor Q3, and one at bottom front of
exhal ation m odul e). D o n ot o vert igh t en .
3 Connect exh alati on m odule harness to exhalati on m odule I/O cable. Be sure cl ips on
each si de of cable latch into pl ace.
4 Install exhal ation m odule cover (Section 8.15.9.2).

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8.15.9.5 Exhalat ion valve (EV)
8.15.9.5.1 Exhalat ion met abolic sample port
The 800 Seri es ven til ators were ini tial ly equipped wi th a m etaboli c sample port, located on
the fron t fasci a panel of the exhal ation m odul e (Figure 8-66). This sam pl e port h as si nce been
el im in ated and a di fferen t styl e exhalation val ve has been im plem ented.
This n ew exhal ati on valve can be used on origin al 840 ventilators with the metaboli c sam ple
port, but a m in or m odifi cati on to th e exhal ati on m odule is requi red. W hen replaci ng an
exh alation valve wi th a m etabol ic port, you must first elim i nate th e m etabol ic port from the
unit, as descri bed in the fol lowing i nstruction s.

8.15.9.5.2 Eliminat ing t he exhalat ion met abolic sample port

1 Rem ove exh alati on m odule (Section 8.15.9.3).
2 Rem ove two flat-head screw s that secure sam ple port fascia panel (Figure 8-66) to
exhalati on m odule.
3 Unseat fasci a panel and di scon nect tube from sam ple port.
4 Using n eedlenose pl iers, loosen plastic nut that secures sam pl e port to fascia panel.
Rem ove n ut, luer fitting, an d green ri ng.

Fascia
panel

Exhalation
sample
port

Figure 8-66. Exhalat ion sample port

5 Rem ove and di scard the sam pl e port tubing and the Luer fittin g com ponents.
6 Cover the sam pl e port open ing in the fasci a panel with the l abel provi ded wi th the new
exhalation valve FRU.
7 Remove exhal ation valve from the ex hal ation m odule. (Section 8.15.9.5.3)
8 Install new exh alation valve. (Section 8.15.9.5.4)
9 Install exhal ation m odule in BDU. (Secti on 8.15.9.4).

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8.15.9.5.3 Removing exhalat ion valve

Caut ion
• To prevent equipment damage, do not attempt to disassemble the exhalation valve. It is
factory-tested as an assembly.
• When removing the exhalation valve, take care not to damage the flow sensor that sits
atop the exhalation valve. Do not drop or jar the valve.

1 Rem ove exhalati on m odule cover (Section 8.15.9.2).

2 Unlatch an d di sconnect exhal ati on m odul e harn ess (Figure 8-67) from exhalation I/O
cable conn ector.
3 If necessary, gentl y pul l top of exhaust port away from exh alation valve port; th en sli de
exhaust port down port guide and off exhalati on valve.
4 Rem ove four screws th at secure exhalati on val ve to exhalation com partm ent side pan el .
5 W h ile h ol din g exhalati on fl ow sensor (Q3) in pl ace, m aneuver exh al ation valve to
disconn ect it from Q3.
6 Disconn ect exhalation m odul e harness from valve.
7 Rem ove exhal ation valve.

Expiratory Exhalation
pressure heater
transducer assembly
autozero
solenoid (SOL2)

Exhalation
flow sensor
(Q3)

Exhalation
valve (EV)

Exhaust
port and tube Exhalation
module
harness

Exhalation
transducer PCB

8-01163

Figure 8-67. Replacing exhalat ion module components

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8.15.9.5.4 Inst alling exhalat ion valve (EV)

Caution
• When installing the exhalation valve, take care not to pinch or damage the O-ring at the
bottom of the flow sensor tube.
• Note that improperly installing the exhaust port can result in oxygen accumulation in the
exhalation compartment.

NOTE:
If replacing the exhalation valve with the newer version, note the absence of the
metabolic port. Refer to Section 8.15.9.5.1 for details regarding the elimination of
the metabolic port.

1 Con nect exhal ation m odul e harn ess to con nector on exhal ati on val ve (Fi gure 8-67).
2 With exhalati on valve port facin g out, careful ly m aneuver exhal ation val ve so it sl ides
up onto bottom of flow sensor tube.
3 Con nect sam pl e port tube to top of val ve.
4 Al ign four exh alation valve screwholes to exhal ati on m odule side pan el .
5 W h ile holding exhalati on valve in pl ace, m anually in sert and tigh ten four screws to hold
valve in pl ace; th en usi ng screwdri ver, ti gh ten screws until sn ug. D o n o t o vert igh t en .
6 In stal l exhaust port by sliding grooved portion of exhaust port onto plastic guide; th en
sl ip top of exh aust port over exhalati on port. M ake sure port is firm ly i n place.
7 Con nect exhal ation m odule harness to exh alation I/ O cable con nector.
8 Install exhal ation m odule cover (Section 8.15.9.2.1).

8.15.9.5.5 Cleaning exhalat ion valve

Although the exhalation filter assembl y i s designed to protect the exh alati on val ve from
contamin ates, certai n particulate are sm all enough to pass th rough the fi lter el em en t. Over
tim e, these parti culate can coll ect on th e seal ing surfaces. Th is bui ld-up can even tual ly lead to
l eak fail ures in EST.
The functi onal ity of th e exh alation valve can be ful ly restored by clean in g th e sealin g
surfaces.
Have th e foll owi ng avail able:
• Cotton sw abs, 6-in ches l on g
• Isopropyl alcohol
• Sterile water
• Can of com pressed ai r or equivalent
• Protecti ve gl oves
1 Rem ove the exh alati on m odule cover. (Section 8.15.9.2)
2 Rem ove th e exhal ation exhaust port tube.
3 Using two cotton swabs at a ti m e, wet the swabs with a 50% m ixture of i sopropyl al cohol
an d steril e water.

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4 Insert the cotton swabs between th e poppet seal and the m etalli c seat of the exhalation
valve. Wi th your in dex finger, l igh tly touch the poppet to preven t rotati on whi le
cleanin g.

Caut ion
Do not attempt to remove the seal from the poppet for cleaning. Otherwise, permanent
damage to the seal may result.

5 Cl ean th e m etall i c seat in a ci rcular pattern.

6 Clean the poppet i n a crosswise and circul ar pattern.
7 Repeat steps 3-6 again usin g two n ew cotton swabs.
8 Repeat steps 4-6 again using two n ew dry cotton swabs.
9 Bl ow the poppet and th e seat lightly with a can of com pressed ai r (or equival ent) to
ensure rem oval of l int or other particul ate.

Caut ion
Care should be taken to prevent dislodging the seal from the popet while blowing.

10 Reinstall the exhaust port tube.

11 Reinstall the exhalati on m odule cover. (Secti on 8.15.9.2.1)
12 Perform Exhalati on Cal ibration.

8.15.9.6 Exhalat ion flow sensor (Q3)

8.15.9.6.1 Removing Q3

Caut ion
When disconnecting Q3, be careful not to jar or drop it.

1 Rem ove exhal ation valve (Secti on 8.15.9.5.3).

2 W h ile h ol din g Q3 (Fi gure 8-68), disconnect attached cabl e (Fi gure 8-67).
3 Gently pul l Q3 down to unseat i t from heater body.
4 If you are instal li ng a new Q3, remove caps from new flow sensor, and in stall th em on
flow sensor th at you j ust rem oved.
5 Set Q3 on a cl ean surface to preven t con tam in ation .
6 Inspect O-rin gs.

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8-00236

Figure 8-68. Exhalat ion flow sensor (Q3)

8.15.9.6.2 Inst alling exhalat ion flow sensor (Q3)

1 If you are install in g a new Q3 (Fi gure 8-68), rem ove caps from both ends.
2 M ake sure O-ri ngs at both ends of Q3 tube are in place.
3 Ori ent body of Q3 with harness con nection facing up (Figure 8-67).
4 Gently i nsert longer portion of tube into heater port.

Caution
Ensure that no damage to the O-ring occurs during installation of Q3.

5 Con nect cable to conn ector on Q3.

6 In stal l exhalation valve (Secti on 8.15.9.5.4).

8.15.9.7 Exhalat ion t ransducer PCB

8.15.9.7.1 Removing exhalat ion t ransducer PCB
1 Rem ove exh alati on m odule (Section 8.15.9.3).
2 Di sconnect tran sducer cabl e from exhal ation tran sducer PCB (Figure 8-69).
3 Di scon nect tube from PCB transducer port.
4 Rem ove three screws th at secure exhalation transducer PCB to exhalation m odul e pl ate.
Rem ove PCB and pl ace in con ducti ve bag or on ESD-protected mat.

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8 Service and repair

Exhalation
transducer
PCB
8-01169

Figure 8-69. Replacing exhalat ion t ransducer PCB

8.15.9.7.2 Inst alling exhalat ion t ransducer PCB

1 Al ign exhal ation transducer PCB to three screwh ol es on exhal ation m odule plate (Fi gure
8-69). Install three screws that secure PCB to pl ate and tigh ten until snug. Do n o t
o vert igh ten .
2 Connect tube to tran sducer port.
3 Connect exh alati on tran sducer PCB cable to exhal ation transducer PCB.
4 Install exhal ation m odule (Secti on 8.15.9.4).

8.15.9.8 Expirat ory pressure t ransducer aut ozero solenoid (SOL2)

Caut ion
To prevent damage to tubing, do not attempt to remove silicone tubing from solenoid
barbed fittings. Solenoid FRUs have tubing pre installed.

8.15.9.8.1 Removing SOL2

1 Rem ove exhal ation m odule (Secti on 8.15.9.3).
2 Di sconn ect SOL2 tubes from exh alati on m odule connector and ex hal ation transducer
PCB (Fi gure 8-67).
3 Di sconn ect harness from SOL2.
4 Rem ove two screws that secure SOL2 to exhalati on m odule plate. Rem ove SOL2.

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8.15.9.8.2 Inst alling SOL2
1 Ori ent SOL2 so th at con nector on side faces downward (Figure 8-67). Install SOL2 to
exhalati on m odule plate using two screws. D o n o t o v er t igh t en .
2 Con nect exhal ation m odul e harn ess to SOL2.
3 Con nect tube from top of SOL2 to conn ector n ear top of exh alation modul e. Conn ect
tube from side of SOL2 to transducer on exhalati on transducer PCB.
4 Install exhal ation m odule (Section 8.15.9.4).

8.15.9.9 Exhalat ion heat er (EXH HTR) and check valve (CV5)

Caution
The exhalation heater may be hot. Be careful when removing it.

8.15.9.9.1 Removing exhalat ion heat er (EXH HTR) and check valve (CV5)
1 Rem ove exh alati on m odule (Section 8.15.9.3).
2 Di sconnect exhal ati on heater (Fi gure 8-70) cabl e from exhalation m odul e harn ess.
3 Loosen th ree screws that secure heater to module.
4 Gently l ift heater to separate i t from flow sen sor tube. Place heater on flat surface.
5 Gently rem ove ch eck val ve from ori fice on exhalati on m odul e.

Exhalation
heater

Exhalation heater

8-00239

8-00238 Exhalation check valve (CV5) 8-00240

Figure 8-70. Replacing exhalat ion heater (EXH HTR) and check valve (CV5)

8.15.9.9.2 Inst alling exhalat ion heat er (EXH HTR) and check valve (CV5)
1 Inspect seal surroun din g orifice that supports exhal ation check valve for cracks or
damage. Replace CV5 assem bl y if required (seal is part of assem bly).
2 M ake sure leaf is lyi ng fl at, then pl ace check valve (Fi gure 8-70) (l eaf side up) i nto groove
of seal surroun din g ori fice.
3 M ake sure O-ri ng at top of fl ow sensor tube is in pl ace.

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8 Service and repair

4 Al ign h eater over fl ow sensor tube and gentl y press heater assembly onto tube wh il e
ali gni ng three screw locati ons to exhal ati on m odule.
5 Ti ghten three screws unti l sn ug. Do n o t o vert igh t en .
6 Con nect h eater cable to exh al ation m odule harness.
7 Install exhal ation m odule (Secti on 8.15.9.4).

8.15.10 BDU housing

8.15.10.1 Removing BDU housing

The BDU housin g m ust be rem oved from the chassi s to access the motherboard PCB, al arm ,
h um idi fier receptacl e, and bli ndm ate cable assem bli es. Remove the h ousi ng from the ch assis
as foll ows, referring to Fi gure 8-71.
1 Rem ove BDU (Secti on 8.15.1).
2 Rem ove power suppl y assembly (Secti on 8.15.5.1).
3 Rem ove i nspi ratory m odul e (Section 8.15.8.8).
4 Rem ove exhal ation m odule (Secti on 8.15.9.3).
5 Di sconn ect BDU LED PCB cable from PCB con nector on top inside pl ate of exhalati on
com partm en t.
6 Sl ip BDU LED PCB cabl e through sl ot to i nsi de of chassi s.
7 Reach i nsi de power supply cavity, and discon nect harnesses from power i ndi cator an d
power swi tch.
8 From in side exh al ation com partment, remove two screws an d locking bl ocks that secure
exhal ation I/O cabl e conn ector to chassi s.
9 Stretch sil icone gasket over and off of exh alation I/O cable con nector.
10 Rem ove these 11 screws th at attach BDU pl astic h ousin g to BDU ch assis:
• Four flat-h ead screws that attach h um i difi er plate to BDU chassis
• One screw at vent insi de inspiratory com partm ent
• Two screws on l eft si de of ac panel
• One screw from cei ling of power supply com partm ent
• Two fl at-h ead screws above card cage
11 From rear of BDU, lift plastic h ousi ng up and til t i t forward over fron t of chassis.
12 Sl ide exhal ati on I/ O cable conn ector back in to ch assis. To accom pli sh this, it i s hel pful to
sl ide your han d between card cage body and plastic rear housing of exh al ati on
compartm en t. Th is al lows you to maneuver pl asti c housin g when posi tioni ng con nector
to sl ide through slot.

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Power
switch
Power
indicator

8-00154

Gasket ac panel
Exhalation
I/ O cable
connector

8-00241 8-00242

Figure 8-71. Removing BDU housing

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8.15.10.2 Inst alling BDU housing

1 From front of BDU, align plastic housing to front of BDU. Route exh alation I/ O an d BDU
LED PCB cables through open ings. Place pl asti c h ousi ng over ch assis.
2 Install th ese el even screws:
• One screw at vent insi de inspiratory com partm ent
• One screw and wash er i nside power suppl y com partment
• Two fl at-h ead screws above card cage
• Two screws on l eft si de of ac panel
• Four flat-h ead screws that attach h um i difi er plate to BDU chassis
3 Stretch si licone gasket over exh alation I/ O cable and posi tion in pl ace.

Warning
To reduce the risk of fire hazard due to oxygen enrichment in the power supply
compartment, make sure the gasket forms a complete seal between the exhalation module
and power supply compartment.

4 From in si de exhalati on com partm en t, install two screws and standoffs th at secure
exhal ation I/O cabl e conn ector to chassi s. M ake sure l atch ing block “ barbs” are facing
out.
5 Reach i nside power supply com partm ent and conn ect h arn ess to power i ndi cator and
power swi tch.
6 Con nect BDU LED PCB cable to PCB.
7 Install exhal ation m odule (Secti on 8.15.9.4).
8 Install in spiratory m odule (Secti on 8.15.8.10).
9 Install power supply assem bly (Section 8.15.5.2).
10 Install BDU (Section 8.15.3).

8.15.10.3 M ot herboard PCB

8.15.10.3.1 Removing mot herboard PCB
1 Rem ove BDU housi ng (Section 8.15.10.1).
2 Rem ove upper an d l ower card guides from insi de card cage (Figure 8-72). Gen tl y pry end
of guide to snap conn ectin g tab out of i nsert.

Caut ion
Be careful not to damage the upper and lower card guides.

3 Usin g 1/8-in. (3-mm ) flat-bladed screwdri ver, loosen two capti ve screws on each of four
bl indm ate cabl es con nected to m oth erboard PCB (Figure 8-73). Disconn ect cabl es.
4 Usin g 3/16-i n. n utdriver, rem ove ei ght stan doffs th at secure motherboard PCB
connectors to ch assis.
5 Rem ove seven screws that secure m otherboard PCB to back pan el of card cage (Fi gure
8-72). Gently remove m otherboard PCB th rough card cage open in g.
6 Place PCB in a con ductive bag or on ESD-protected m at.

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Screw
(7 PL)

Card
guide

8-00243
8-00244 8-00245
Motherboard

Figure 8-72. Removing motherboard PCB

8.15.10.3.2 Inst alling mot herboard PCB

1 Carefull y insert m otherboard PCB i nto card cage (Figure 8-72 and Figure 8-73) and ali gn
D-sub connectors with cutouts i n chassi s.
2 Using a 3/ 16” nutdriver i nstall eight standoffs but do not tighten.
3 Install seven screw s that secure m otherboard PCB to back pan el of card cage. Ti gh ten
unti l sn ug. Do n ot o vert igh t en .
4 Using a 3/ 16” nutdri ver tighten eight standoffs un til sn ug. Do n o t o ver tigh ten .
5 Con nect four bl indmate cables to m oth erboard PCB. Usi ng 1/8-in. (3-m m ) fl at-bl aded
screwdriver, ti ghten two captive screws (per cabl e) to each of four con nectors. D o n o t
o vert igh t en .
6 Install card guides.
7 In stall BDU housi ng (Section 8.15.10.2).

8.15.10.4 BDU alarm assembly

8.15.10.4.1 Removing BDU alarm assembly
1 Rem ove BDU h ousi ng (Secti on 8.15.10.1).
2 Rem ove two screws th at secure harness to BDU alarm assem bly (Figure 8-73).
3 Unscrew ring at fron t of al arm. Remove alarm from mounting bracket.

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8 Service and repair

BDU alarm
assembly

Alarm
blindmate
cable

Standoff
(8 PL)
Inspiratory
blindmate
cable
dc power supply
blindmate cable

Exhalation
I/ O cable

8-00173

Figure 8-73. BDU alarm and mot herboard PCB cable connections

8.15.10.4.2 Inst alling BDU alarm assembly

1 Position BDU al arm assem bl y so that speaker portion i s i nserted through bracket facin g
back of BDU and so th at pol arity notch is al ign ed with bracket (Fi gure 8-73).
2 Screw alarm ring onto th readed base. Tighten unti l snug. D o n o t o vert igh ten .
3 Usin g two screws, con nect harness to alarm .
4 Install BDU housing (Section 8.15.10.2).

8.15.11 Power indicator

Warning
To prevent electrical shock hazard, always unplug the power cord from facility power and
disconnect the BPS cable from the power supply assembly before servicing ac components.

8.15.11.1 Removing power indicat or

1 Rem ove BDU housi ng (Section 8.15.10.1).
2 Rem ove screw th at secures sleeve to in dicator (Fi gure 8-41). Rem ove in sert and sl eeve;
save for rei nstallation. Push indicator through open ing.

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Power indicator

8-00154

Figure 8-74. Replacing pow er indicat or

8.15.11.2 Inst alling power indicat or

1 From front of BDU, in sert in dicator (Fi gure 8-41). Place sl eeve over i ndi cator. Pl ace in sert
over sleeve an d secure with screw.
2 In stall BDU housi ng (Section 8.15.10.2).

8.15.11.3 Alarm blindmat e cable

8.15.11.3.1 Removing alarm blindmat e cable
1 Rem ove BDU h ousi ng (Secti on 8.15.10.1).
2 Rem ove four screws th at retain ac panel to chassis from rear of ac panel.
3 Cut ti e wraps used to bun dle this harness w ith other h arn esses or to secure it to chassi s.
4 Detach harness from BDU al arm assem bl y (Figure 8-73) by rem oving two screws.
5 Detach harn ess from power relay (Figure 8-75) by usi ng needl enose pli ers to di sconn ect
two fast-on connectors. Pul l these two wi res back through grom met and through
blindm ate cable open in g at rear of power suppl y com partm ent cavity.
6 Using 1/8-in. (3-m m ) flat-bl aded screwdriver, loosen two captive screws th at secure cable
to m oth erboard PCB conn ector (Fi gure 8-73). Discon nect cabl e.

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ac filter PCB M ain circuit

Power breaker (CB1)
relay (K1)

Auxiliary
(compressor/ humidifier)
circuit breaker (CB2)

8-00246

Figure 8-75. Cable connect ions t o ac panel

8.15.11.3.2 Inst alling alarm blindmat e cable

1 Con nect cabl e to m otherboard PCB. Usi ng 1/8-in . (3-m m ) fl at-bladed screwdriver,
tigh ten two capti ve screws until sn ug (Fi gure 8-73).
2 Connect cabl e to power relay (Fi gure 8-75):
a. Route cl ear pl asti c tube con tain in g black an d red wi res through open ing i nto power
supply com partm en t an d th rough grom m et i nto ac power di stributi on area.
a. Using needl en ose pli ers, conn ect two fast-on connectors to relay. The red wire goes to
term i nal 10. The black wire goes to term in al 12.
3 Connect cabl e to BDU alarm assem bl y with two screws (Figure 8-73).
4 Install four screws that retai n ac pan el to chassis from rear of ac panel. Tigh ten until
snug. D o n ot ov ert igh t en .
5 Install BDU housing (Section 8.15.10.2).

8.15.11.4 Inspirat ory blindmat e cable

Repl acing th e i nspi ratory bl indmate cabl e requires an 11/ 32-in. nutdri ver with a
6-i n. (15.2-cm) sh aft or a socket w rench wi th a 6-i n. (15.2-cm ) extensi on.

8.15.11.4.1 Removing inspirat ory blindmat e cable

1 Rem ove BDU housi ng (Section 8.15.10.1).
2 Usin g 1/ 8-in . (3-m m ) flat-bladed screwdriver, loosen two captive screws th at secure
inspiratory bli ndm ate cable to m oth erboard PCB conn ector (Fi gure 8-73). Disconn ect
cable.
3 Usin g 11/ 32-in. nutdriver or socket wren ch, remove three nuts that secure cable to
chassi s (Fi gure 8-76).
4 Gen tly feed fi rewal l gasket in to in spi ratory com partm en t. Feed rest of cable through
power supply m odul e compartm ent into i nspiratory m odule, an d rem ove.

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To inspiratory
module
Inspiratory
blindmate
cable

To motherboard PCB

8-00179 8-00154

Figure 8-76. Replacing inspiratory blindmat e cable

8.15.11.4.2 Inst alling inspirat ory blindmat e cable

1 Feed cable’s D-sub con nector through i nspi ratory and power supply com partm ents.
2 Con nect cable to m otherboard PCB. Usin g 1/ 8-i n. (3-m m ) flat-bladed screwdriver,
tighten captive screws until snug (Figure 8-73). D o n o t o vertigh t en .
3 Seat gasket firml y in firewall to create a complete seal. Th e h ole for th e cable shoul d be
towards the bottom of the gasket.

Warning
To reduce the risk of fire hazard due to oxygen enrichment in the power supply
compartment, make sure the gasket forms a complete seal between the inspiratory module
and power supply compartment.

4 Pl ace bracket over ch assi s studs and secure wi th three locknuts. Usi ng 11/32-i n.
n utdriver or socket wrench, tighten until snug (Figure 8-76). D o n o t o v er tigh t en .
5 In stall BDU housi ng (Section 8.15.10.2).

8.15.11.5 dc power supply blindmat e cable

Replaci ng the dc power bli ndm ate cabl e requi res #1 Ph il lips screwdri ver w ith a m i nim um 6-
i n. (15.2-cm ) sh aft.

8.15.11.5.1 Removing dc pow er supply blindmat e cable

1 Rem ove BDU h ousi ng (Secti on 8.15.10.1).
2 Using 1/ 8-in . (3-mm ) flat-bladed screwdri ver, loosen two capti ve screws that secure dc
power supply bli ndm ate cable to motherboard PCB con nector (Fi gure 8-73). Discon nect
cabl e.
3 Al low for access to dc power supply bl indmate cabl e retain ing screws:
a. Remove in spi ratory bl indmate cabl e (Section 8.15.11.4.1).
b. Remove four chassi s-retaini ng screws from rear of ac panel.
4 Rem ove two screws that secure cabl e (Figure 8-77) to ch assis. Feed both conn ectors i nto
power supply com partm ent, and rem ove cable.

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To
power
supply
dc power
supply
blindmate
cable

To
motherboard PCB

8-00180 8-00154

Figure 8-77. Replacing dc pow er supply blindmat e cable

8.15.11.5.2 Inst alling dc pow er supply blindmat e cable

1 Feed cabl e's D-sub con nector through power supply com partm ent.
2 Con nect cabl e to m otherboard PCB. Usi ng 1/8-in . (3-m m ) fl at-bladed screwdriver,
tigh ten two capti ve screws un til sn ug (Fi gure 8-73). Do n o t o vert igh t en .
3 Al ign bracket end of cabl e with m oun tin g holes an d secure with two flat-h ead screws,
on e th rough i nspiratory m odul e and on e th rough ac power distributi on com partm ent.
Ti ghten until snug. Do n ot o vert igh ten .
4 Install in spi ratory bl indm ate cable (Section 8.15.11.4.2).
5 Install four ch assis-retai nin g screws at rear of ac pan el .
6 Install BDU housing (Section 8.15.10.2).

8.15.11.6 ac power supply blindmat e harness

8.15.11.6.1 Removing ac power supply blindmat e harness
1 Rem ove BDU housi ng (Section 8.15.10.1).
2 Rem ove four chassis-retaini ng screws from rear of ac panel.
3 Cut tie wraps th at secure h arness to chassi s or to oth er h arnesses, as required.Cut ti e
wraps that secure th e harness to th e ch assis or to oth er h arn esses, as required.
4 Di sconn ect harness from ac filter PCB an d ground stud i n ac pan el.
5 Rem ove two flat-head screws securi ng harn ess bracket to fron t of ch assis. Rem ove
harness (Figure 8-78) through power supply com partm en t.

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To Bracket
power
indicator ac power
supply
To ac
blindmate
receptacle
harness
To power
supply

To ac panel
ground stud 8-00178 8-00154

Figure 8-78. Replacing ac pow er supply blindmat e harness

8.15.11.6.2 Inst alling ac power supply blindmat e harness

Warning
To reduce the risk of fire hazard due to oxygen enrichment in the power supply
compartment, make sure the gasket forms a complete seal between the inspiratory module
and power supply compartment.

1 In sert harness in to power suppl y com partm ent (Figure 8-78).

2 Route blue, brown, and green wires through roun d grom m et in to ac power distribution
com partm ent.
3 Install harness bracket to chassi s with two flat-h ead screws.
4 Route pow er i ndi cator LED cabl e (wi th black sleevi ng) behi nd bli ndm ate cables an d
through top of chassi s.
5 Using two small tie wraps, secure power i ndicator LED cable and oth er wires to power
supply wall at two pl aces. Cut tie wrap ends flush with the ti e wrap body.
6 Con nect bl ue wi re to top left-han d termi nal of ac fi lter PCB (PCB viewed from back,
righ tside up) (Figure 8-75). Conn ect brown wi re to top right-h and termin al of ac fil ter
PCB. Connect green wire to top l eft-han d ground stud.
7 Verify that wires m ove freely in bracket and are not obstructed by oth er wi res in area.

Caution
The obstruction of the harness within the bracket could prevent proper alignment of power
supply contacts.

8 Using two sm all ti e wraps, rebun dle wires on ei ther side of roun d grom m et. Cut ti e wrap
ends fl ush with the ti e wrap body.
9 Install four chassi s-retaini ng screws at rear of ac panel.
10 In stal l BDU h ousi ng (Section 8.15.10.2).

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8.15.12 Release handle

8.15.12.1 Removing release handle
1 Rem ove BDU. (Section 8.15.1)
2 Sl ide BDU out from its m ounti ng bracket an d l ay unit, face up, on a fi rm work surface.
3 Rem ove three flat-head screws that secure latch sli de mount to bottom of chassis.
4 Sl ide loop portion of rel ease han dle out of bracket and remove han dle an d slide m ount.

8.15.12.2 Inst alling release handle

1 Sl ide loop portion of rel ease han dle in to bracket slot. Ensure spri ng is on inside of
bracket.
2 Al ign l atch sl ide m ount to th ree screw l ocati on s at bottom of ch assis.
3 Install three flat-head screws and tighten unti l snug. D o n o t ov ert igh t en .
4 Install BDU (Section 8.15.3).

8.16 806 compressor unit

NOTE:
The 806 compressor is the replacement for the 804 compressor assembly.

The 806 compressor un it i s a detachabl e m odul e consistin g of th e com pressor, com pressor
PCB, accum ul ator, and heat exchanger. Th e compressor uni t is m ountable on ly when used
with the opti onal cart.
M ost routi ne repairs and preventive m ai nten ance to th e com pressor uni t requi re th at th e
com pressor be removed from th e cart. This section descri bes how to perform service an d
repai rs on the 806 com pressor, as well as perform an ce veri fi cati on.
To ensure th at reassem bly is correctly done, label al l w ires and tube positi on s before you
begin discon necti ng parts. Take precaution s to prevent dirt an d oth er particl es from enterin g
the interi or of th e com pressor. Always properl y dispose of the ori gin al parts that have been
replaced by new parts.
Repl acem en t parts for th e origi nal com pressor, model 804, are no longer avai labl e. Contact
Puritan-Ben nett Techni cal Support for additional i nform ati on .
Be su re to r ea d a ll a p p lica b le in str u ct io n s com p let ely b efore d isa ssem b ly.

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8.17 Servicing t he 806 compressor

NOTE:
To disconnect a pneumatic hose held in place by a compressible clip, use flat-
nosed pliers to compress the nubs on the clamp. Slide the clamp up the hose 1 to
2 inches.

Accessory
drawer

Compressor
handle

Compressor
Casters module
(facing out) (slide forward)
8-01335

Figure 8-79. 806 compressor mounted on cart

8.17.1 Compressor inlet filt er

The compressor i nl et fi lter provides pre-fi ltration for the com pressor inlet sil encer fil ter. The
i nlet fil ter i s l ocated in the top front panel of th e com pressor.
Remove and cl ean the fi lter m ore often than the recom m ended PM (Preventative
M ai ntenance) schedul e of every 250 hours if n ecessary. Som e environ men ts can cause
particulate to coll ect more quickly.

8.17.2 Removing and installing the compressor inlet filt er

1 To rem ove inl et fil ter, gentl y pull at one corner.
2 Wash th e fi lter in a m ild soap soluti on.
3 Ri nse filter well an d dry th orough ly to ensure an un restricted flow of ai r th rough th e
compressor com partm ent. Repl ace fil ter if dam aged.
4 To install the i nlet fi lter, al ign th e cl ean dry filter over th e open ing i n the front panel of
the com pressor. Gen tl y tuck in the edges of the fi lter.

8.17.3 Removing compressor from cart

8.17.3.1 Disconnect ing compressor from BDU
1 Di scon nect th e ven tilator power cord from the wall outlet.
2 Di sconnect th e hi gh pressure hoses.
3 Di sconnect th e foll owi ng:
• compressor power cabl e
• compressor data cabl e
• compressor supply hose

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8.17.3.2 Removing compressor from cart

1 Di sconn ect th e ven tilator power cord from the wall outlet.
2 Di sconn ect the hi gh pressure h oses.
3 Con firm th e compressor i s fully di scon nected from the BDU.
4 Rem ove the cart accessory drawer to al low room for the com pressor data cabl e to clear
the cart.
5 Orien t th e cart with the fron t casters facin g out. Lock front casters i n place.
6 Loosen the two capti ve screws under the bottom shel f at th e rear of the cart. (These
screws secure the com pressor to the cart.)
7 Sl i de the com pressor to the fron t of the cart.
8 Grasp th e handl es on both si des of the com pressor an d gentl y l ift.

Warning
To prevent personal injury and equipment damage, have someone assist you when lifting
the heavy ventilator and its components.

9 Place com pressor on a strong, firm work surface.

8.17.4 Removing t op cover

1 Rem ove the top cover assem bl y from the compressor.
2 Loosen , but do not rem ove, the four (4) Phil lips screws that secure the cover to th e rear
panel .
3 Loosen the four (4) screws (two on each side) th at secure the cover to th e si de panels.
4 Lift the top cover assem bly off the com pressor an d set aside.
5 Rem ove the m ain i nlet fi lter an d support baffle by li fting them out of the un it.

8-01259

Figure 8-80. Top cover removed from compressor

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8.17.5 Inst alling t op cover
1 Pl ace th e m ai n in let fil ter and support baffl e i nto position at top of front panel.
2 Pl ace th e top cover assembly on th e compressor.
3 Tighten th e four (4) screws (two on each si de) to secure the cover to the side panel s.

8.17.6 Cooling fans

The cooling fans provide a source of am bient air to cool both the heat exchanger and the
exh aust heat from the com pressor.

8.17.6.1 Removing a cooling fan

1 Rem ove th e top cover and pan els (Secti on 8.17.4).
2 Using diagon al cuttin g pl iers, cut and discard the ti e wraps securin g th e fan cable to the
fan ’s upper i nsi de m oun ti ng screws.

Caution
When removing the fan hardware:
• Be careful not to drop the screws or washers into the plenum assembly and onto the heat
exchanger.
• Be careful not to misplace the star washers as they provide ground to the fans.

3 Facin g th e front of the com pressor, rem ove the four (4) Phil li ps screws and star w ashers
that secure the fan to th e top of th e pl enum assembly.
4 Di sconnect th e electrical cable from the fan.
5 Rem ove th e fan .

8-01256

Figure 8-81. Fans installed in compressor

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8.17.6.2 Inst alling a fan

Caut ion
Verify the flow direction of the fan prior to installing the fan in place. The flow should be
directed into the compressor compartment.

1 Based on fl ow direction, properl y orien t th e replacem en t fan and place over the hole in
the pl enum assem bl y.
2 Connect the fan cord to the fan and place the fan on the fan-support panel .
3 Reinstall the four (4) screws and star washers.
4 Secure th e fan cable to the fan’s m oun ti ng screw with a cabl e ti e.
5 Reinstall the baffle and in take fi lter.
6 Reinstall top cover an d secure screw s.

8.17.7 Removing the back panel

1 Rem ove the top cover an d set aside (Secti on 8.17.4).
1 Rem ove the six (6) Phill ips screws from the si des of th e rear panel an d set them aside.
2 Lean the top of th e back panel away from the com pressor (Fi gure 8-82).
3 W h ile supporting the back panel, sli de the com pressibl e h ose clam p back and disconnect
the hose from th e accum ul ator intake port.
4 Rem ove the accum ulator and back panel from th e com pressor. Set asi de.

8.17.8 Reinst alling t he back panel

1 W hil e supporting the back panel, reconn ect the hose to th e accum ul ator i ntake port.
2 Repositi on the hose cl am p to secure th e h ose to the accum ulator in take port.
3 Position the back panel on rear of com pressor.
4 Repl ace the six (6) Phi lli ps screws from the si des of the back panel.
5 Reinstal l the top cover (Section 8.17.5).

Four (4) nuts

Fitting
and Accumulator
O-ring (4) intake port 8-01270

Figure 8-82. Removing t he back panel of the compressor

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8.17.9 Replacing an accumulator fitt ing and O-ring
Each of the four accumulators has a fitti ng with an O-ri ng that conn ects the accum ul ator to
the accumulator intake port.
1 Rem ove back panel (Secti on 8.17.7).
2 W h ile supportin g th e back pan el, disconn ect th e hose from the accumulator i ntake port.
3 Using a nut driver, rem ove th e four (4) nuts that secure the bottl es to th e rear panel.
4 Rem ove th e accum ul ator assem bly from th e back pan el .
5 Rem ove the compressible hose clam ps and disconnect the hoses from either si de of the
accum ulator.
6 Unscrew the accumulator fittin g and rem ove from th e bottle.
7 Replace th e accum ulator fittin g, applyi ng a sm al l am ount of Krytox grease to the O-ri ng
before reinstalli ng on th e accum ul ator.
8 Resecure the hoses to the accum ulator wi th the com pressible hose clam ps.
9 Rein stal l the accum ulator assem bly and place the accum ulator cover over the four (4)
studs.
10 Secure the accum ulator assembly to the back panel usi ng four (4) nuts. Hand tighten.

8.17.10 Pneumat ic hoses

NOTE:
• To prevent the shredding of the silicone hoses when disconnecting from barbed fittings,
gently pull while turning the hose.
• Use a flat-nosed pliers to compress the nubs on compressible clamp.

8.17.10.0.1 Disconnect ing pneumat ic hoses

1 Rem ove top cover (Section 8.17.4).
2 Rem ove rear panel assem bl y (Section 8.17.7).
3 Using a 3/16" flathead screwdri ver, loosen th e screw on the h ose clam p that secures the
pressure tran sducer to th e compressor PCB.
4 Disconnect th e tube from th e PCB. (See Figure 8-85.)
5 Di sconnect th e m ai n suppl y h ose at th e solen oi d fi lter outl et port. (See Fi gure 8-83.)

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8 Service and repair

M ain supply hose

Solenoid filter
outlet port

0.3 micron filter (F10)

8-01271

Figure 8-83. Disconnect ing filter out let port from main supply hose

6 Di sconn ect the hose at the heat exchanger i nlet conn ecti on that runs from the
compressor outl et (Figure 8-84).

Disconnect
inlet connection
here

8-01334

Figure 8-84. Disconnect ing heat exchanger inlet connect ion

7 Di sconn ect the hose at the water trap outl et that runs to the air dryer inl et port.
8 Loosen the two (2) Ph il lips screws that secure the i ntern al pl enum panel to th e left an d
ri ght panels.
9 Loosen the two (2) Ph il lips screws that secure the external pl enum pan el th e l eft and
ri ght panels.

8.17.11 Plenum assembly

The plenum assem bly contai ns the cool ing fans, heat ex changer, ac and dc cabl es, and the
com pressor air supply hose. The pl enum assem bl y is accessed by rem ovi ng the top cover an d
accum ulator assem bly, wh ich is m oun ted to the back panel, and th e electri cal con necti on s
from the com pressor PCB.

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Service and repair 8
8.17.11.1 Removing t he plenum assembly
1 Rem ove top cover (Section 8.17.4).
2 Rem ove rear panel assem bl y (Section 8.17.7).
3 Di sconnect th e electri cal cabl es from the com pressor PCB as foll ows (Fi gure 8-85):
• solenoid cabl e at J1
• two (2) fan cables at J2 an d J3.
• ac in put cord at J6
• m otor cabl e at J5
4 Release th e data cable by sl idi ng the l ock bracket up an d careful ly disconnecti ng the
cabl e.
5 Use a 11/32" n ut dri ver to rem ove the nut securin g the ground cable to th e grounding
l ug. (Locate the ground con nection on the pl en um base, adj acent to the com pressor
PCB.)
6 Di sconnect th e groun din g cable an d reinstall the nut for recon necting th e groun d l ater.
7 Di sconnect th e pn eum ati c h oses (Section 8.17.10.0.1).

Data cable connector

Pressure transducer
hose

Solenoid cable connector

Power cord connector

Fan connectors

M otor
cable 8-01272

Figure 8-85. 806 printed circuit board (PCB)

8 Facin g th e rear of the com pressor, place your thumbs under the edge of the plen um
assem bl y top pan el and li ft th e panel free from the si de panel .
9 Sli gh tl y l ift (or prop open) the pl enum assem bly enough to gain access to th e h eat
exch anger ports.
10 Di sconnect th e hose at th e heat exch an ger outlet port that runs to the w ater trap i nlet.

11 Taki ng care not to dam age the heat exch an ger fin s, carefull y l ift th e plenum assem bly
from the top of th e com pressor an d set assem bl y aside.

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8.17.12 Heat exchanger (HE)

8.17.12.1 Replacing t he heat exchanger

1 Rem ove the plenum (Secti on 8.17.11.1).
1 Rem ove the four (4) screws an d th e two (2) heat exchan ger straps that secure the h eat
exchanger plate to the plenum .
2 Install the n ew heat exch anger assem bly.
3 Secure th e heat exchanger plate to the plenum with the two (2) straps and four (4)
screws. Do n ot o vert igh ten t h ese fo u r sc rew s.

8.17.13 Removing and replacing the ac power cord

The ac an d dc cables are accessed by rem ovin g th e rear access panel assem bly. Verify power is
di sconnected before performi ng this operation.
1 Rem ove the back cover (Section 8.17.7).
1 Di sconn ect the power cord from th e com pressor PCB (Fi gure 8-85).
2 Usin g di agon al cutters, cut th e cable tie near the pl en um assem bl y.
3 Sever th e power cord.
4 Loosen th e strain rel ief and rem ove and discard both halves of the cable.
5 Install a new power cord by feeding th e loose pi ns th rough the strain rel ief.
6 Insert the power cord conn ector onto loose pin s by pl acing the con nector on to th e PCB
and con firmi ng the ori en tation.
7 Insert the brown wire into th e m i ddle socket.
8 Insert the blue wi re i nto the ri ght socket.
9 Rem ove the connector from the PCB an d veri fy the wires are full y i nserted.
10 Install a sm al l cable tie on to the power cord j ust bel ow th e strai n relief.
11 Reinstall the power cord onto the PCB.
12 Ti ghten strain reli ef.

8.17.14 Removing and replacing t he data cable

1 Rem ove the back cover (Section 8.17.7).
2 Di sconn ect the data cable from the com pressor PCB (Figure 8-85).
3 Cut the ti e wrap that secures the data cabl e to the plenum assem bl y.
4 Usin g a screwdri ver, rem ove the four (4) screws that secure th e strain reli ef to the top
panel.
5 Di sconn ect th e data ground cabl e from the pl en um assem bl y.
6 Gen tly rem ove th e data cabl e from the compressor.
7 Feed the new data cable en d th rough the top of th e pl enum .
8 Secure th e strain rel ief wi th four (4) screws and han d tighten.
9 Secure th e data ground cable to th e pl enum and tighten th e n ut.
10 Attach th e data cabl e to th e PCB an d sli de its lock i nto pl ace.
11 Attach th e cabl e to the plenum assem bl y wi th a ti e wrap.

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8.17.15 Compressor PCB
The rem oval of th e com pressor PCB requires the partial or com plete rem ove of the pl enum to
gai n n eeded access.

8.17.15.1 Removing and replacing t he compressor PCB

1 Rem ove top cover (Section 8.17.4).
2 Rem ove rear panel (Secti on 8.17.7).
3 Rem ove plenum (Section 8.17.11.1), as n eeded
4 Di sconnect th e electrical cables from the com pressor PCB as fol lows:
• solenoid cabl e at J1
• two (2) fan cables at J2 an d J3.
• ac in put cord at J6
• m otor cabl e at J5
5 Release th e data cable by sl idi ng the l ock bracket up an d careful ly disconnecti ng the
cabl e.
6 Di sconnect th e pressure tran sducer hose from th e PCB.
7 Rem ove the three screws th at secure th e PCB to the si de panel. Set asi de th e screws.
8 Rem ove th e com pressor PCB by leanin g the board away from the side panel an d sliding
the board up toe rem ove it from its board retai ner.

NOTE:
If you are installing a new PCB, it is necessary to transfer the compressor serial
number and operational hours information by removing the EEPROM from the
old board and transferring it to the new board.

Caution
Verify the polarity of the EEPROM before installing on the new PCB: When transferring the
EEPROM, ensure that the notch on the EEPROM matches the notch on the 806 PCB before
installing.

9 Rein stal l the new board by first ali gn ing the board with th e si de panel an d pl aci ng the
bottom of the board i nto the board retain er.
10 Reattach the cable con necti on s to th e PCB as foll ows:
• solenoid cabl e at J1
• two (2) fan cables at J2 an d J3.
• ac in put cord at J6
• m otor cabl e at J5
11 Attach the data cable to th e PCB and sli de i ts lock i nto place.

8.17.16 Air dryer (dryer) and solenoid valve assembly

The air dryer assem bly rem oves water vapor from the com pressed gas suppl y . The solenoi d
valve assem bl y open s to all ow the com pressor m otor to start. The air dryer assem bly is
accessed by removi ng the back pan el assem bly an d di scon necti ng the suppl y tubin g. The
fi lters are n orm all y repl aced as part of the 15,000 hour PM kit.

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8 Service and repair

8.17.16.1 Removing and reinst alling t he air dryer and solenoid valve assembly and
replacing filt ers
1 Rem ove th e top cover assem bly an d set aside (Section 8.17.4).
2 Rem ove th e rear panel and set aside (Section 8.17.7).
3 Cut the cable ti e securi ng the air dryer assem bly to the clam p (Fi gure 8-86).

Solenoid
outlet
Air
dryer filter
hose Air dryer
muffler/filter

Solenoid
purge outlet
hose

Cable tie

8-01263

Figure 8-86. Air dryer/ solenoid valve assemblies inst alled

4 Di sconnect hose to the air dryer.

5 Grasp th e ai r dryer an d solenoid valve assem bl y at the top and firml y pul l up to detach
from the cl am p th at holds the assem bly i n place.
6 Rem ove the assem bl y from the compressor and pl ace on a work surface.
7 Di sconnect the short hose at th e solen oid purge outlet port.
8 Unscrew th e ai r dryer fil ter/m uffler and discard.
9 Sl ightly rotate the sol enoid valve assem bl y away from the ai r dryer to rem ove the
solenoi d outl et fil ter.
10 Unscrew th e sol enoid outlet fi lter. Set th e ai r dryer/solenoid valve assem bl y asi de.
11 Unscrew the barbed fittin g from the en d of th e sol en oi d outlet fil ter. Set barbed fitti ng
asi de and di scard the fil ter.
12 Rem ove the Teflon tape from the th readed en d of th e barbed fi tti ng.
13 Apply a new l ayer of Teflon tape.
14 Install the n ew solen oid outlet fil ter on the solenoi d by screwin g i t i n pl ace.
15 Reattach th e barbed fi tti ng to the outlet fil ter by screwin g i t i n place.
16 Rotate the solenoi d val ve assem bl y back to its origin al positi on (paral lel w ith th e ai r
dryer assem bly).
17 Apply Teflon tape to the threaded end of the new ai r dryer filter/m uffl er.
18 Install the n ew fil ter by screw ing i t in place. on the ai r dryer assem bl y.

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19 Recon nect th e short h ose from th e ai r dryer to the solen oi d purge outl et fittin g.
Use a flat-nose pli ers to sli de th e hose clam p over the fitti ng to hold the h ose i n place.
20 Rein stal l the ai r dryer and solenoi d val ve assem bly in the compressor.
21 Secure th e assem bl y wi th a cable ti e (Fi gure 8-86) by sli din g th e cable tie under th e
bracket and aroun d the air dryer assem bl y.
22 Tighten cable tie and cut off excess.
To accumulator
To pressure
Unloading transducer (PC)
Solenoid
solenoid valve
To solenoid (SOL3) Filter (F10)
assembly

From heat
Air dryer exchanger
assembly
Air dryer Filter/muffler 8-01266

Figure 8-87. Air dryer and solenoid valve assemblies

8.17.17 Compressor assembly

The compressor assem bly com prises th e m otor/ com pressor, m otor starti ng capacitor, th e
m otor m oun ts, an d the m ounti ng plate. Th e com pressor/m otor i s on ly avai lable as part of
the 15,000 hour PM ki t. Refer to th e PM ki t i nstructi on s.

8.17.17.1 Removing t he compressor assembly

1 Rem ove th e top cover assem bly an d set aside (Section 8.17.4).
2 Rem ove th e rear panel an d set asi de (Secti on 8.17.7).
3 Rem ove th e ai r dryer assem bl y and set aside (Section 8.17.16.1).
4 Using a magneti c Phi ll ips screwdriver, rem ove the four (4) Phi ll ips screws that secure th e
com pressor assem bl y to th e base of the com pressor (Fi gure 8-88). A pai r of screws are
l ocated to th e left and to the right of th e com pressor. Set th e screws asi de.
5 Grasp the com pressor assem bl y at th e top and sli ght l ift and m ove the assem bly toward
the rear of the un it.
6 Lift th e compressor assem bl y out of th e com pressor com partm en t.

Warning
To prevent personal injury and equipment damage, have someone assist you when lifting
the heavy compressor assembly.

7 Rein stal l the com pressor assem bl y by ori enti ng the com pressor assembly wi th the
com pressor i ntake fi lter on the left.
8 Carefull y l ower th e com pressor in to the com partm ent. Sl ightl y ti lt th e com pressor
forward to posi ti on i n pl ace.

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8 Service and repair

9 Usin g a m agn etic Phi lli ps screwdriver, rei nstall th e four (4) ori gin al screws that secure
the com pressor assem bl y to th e base of the uni t.
Water

8-01260

Figure 8-88. 806 compressor motor

8.17.17.2 Replacing t he coalescing filt er element

1 Rem ove the back panel assem bl y (Secti on 8.17.7) and set asi de.
2 Rem ove the air dryer assem bly (Section 8.17.16.1) and set aside·
3 Rem ove the plenum assem bl y (Section 8.17.11.1) and set aside.
4 Rem ove h ose to outl et si de of the coal escing fi lter. (Figure 8-88).

Coalescing
filter
element

Water
trap

Figure 8-89. Wat er t rap assembly

5 Usin g a m agn eti c Phi lli ps screwdriver, rem ove the two (2) screws that secure the water
trap bracket to the base of the m odule. Set the screws aside.
6 Place the water trap assem bly on a work surface.

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Service and repair 8
7 Unscrew the ri ng th at secures th e water trap bowl to the fil ter head.
8 Rem ove th e bowl and ring and set aside.
9 Unscrew the fi lter elem ent retainer and set aside.
10 Verify that the O-ri ng i s in place aroun d th e filter h ead.
11 In stall the new coalesci ng filter elem ent.
12 Replace th e ori gin al fil ter elem ent retai ner.
13 Rein stal l the water trap bowl and hold it i n place by rein stal li ng the original rin g.
14 Using a m agnetic Phi lli ps screwdriver, rem oun t th e water trap assem bl y bracket to th e
base of the compressor usin g th e ori gi nal two (2) screws.
15 Reinstall hose on outl et si de of coalescin g filter.
16 Rein stal l ai r dryer (Section 8.17.16.1).
17 Rein stal l the back panel assem bl y (Secti on 8.17.8) an d the pl enum assem bl y (Section
8.17.11.1).

8.17.18 Replacing t he compressor panels

The in divi dual panels of 806 com pressor encl osure are repl aceabl e. The fron t an d side panels
are attached to th e base assem bly. Th e base assem bly i s replaced as a single uni t. The pan els
are accessed by first rem ovin g th e rear panel, the plenum , th e com pressor, and the water trap
assem bli es.
1 Remove th e panel s by first rem ovi ng th e foll owin g com pon ents. See the appropriate
i nstructions i n th is m anual for thei r rem oval .
• Top cover assem bl y
• Back pan el/ accum ulator assem bl y
• Plen um assem bl y
• Air dryer assembly
• Com pressor m odul e
• Air dryer assembly
• PCB (on ly replacin g the righ t panel )
2 Rem ove th e respective panel by loosen ing all of th e socket h ead screws an d sliding the
panel out.
3 Rein stal l the panel by sl iding the new panel under the hardware.
4 Tighten th e socket head screw usi ng an Allen driver. D o n o t o ver t ig h t en .
5 In stall the appropriate labels.
6 Rein stal l all the above removed com pon en ts.

NOTE:
If replacing a side panel, use the spare piece of foam in the foam kit to configure
the panel to match the panel removed. Install the Tinnerman clips to the rear of
the panel.

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8 Service and repair

8.17.19 Reinst alling the plenum assembly

W h ile facin g the rear of the com pressor, lower th e pl enum assem bly onto the com pressor
whi le ali gni ng the ri m (at the front of the pl enum assem bl y) to th e top of the front pan el.
1 Ti lt the plen um assembly up en ough to reconnect th e h ose run nin g from the water trap
inl et to the heat exchanger outl et port.
2 Usin g a flat-nosed pl iers, slide the hose cl am p over th e port to hold the h ose in pl ace.
3 Reconn ect the hose run ni ng from th e com pressor outlet to th e h eat exch anger inl et
port.
4 Usin g a flat-nosed pl iers, sl ide th e h ose clam p over th e exch anger in let port to hold the
hose i n place.
5 Reconn ect the pressure transducer hose to the port on the compressor PCB.
6 Sl ide the hose clamp over th e PCB port an d tighten the cl am p screw to hol d the hose i n
place.
7 filter
Al ign the pl en um assembl y to the side panel mountin g screws and press the assembl y
down i n place.
Do not tighten screws at this time.
8 Reconn ect pn eum ati c hoses (Section 8.17.16.1).

8.17.20 Reconnect ing electrical cables

1 Reconn ect the data cable to the com pressor PCB.
2 Push th e locking bracket up to lock in pl ace.
3 Recon nect th e followin g electri cal cables to the compressor PCB:
• Two (2) fan cables at J2 an d J3
• ac i nput cord at J6
• M otor cabl e at J5.
4 Reconn ect the ground wire con nector to the ground lug at the base of the m odule. Use
an 11/32-inch nutdri ver to ti ghten the nut.

NOTE:
The solenoid electrical cable also connects to the PCB at J1. Refer to reinstallation
instructions for the air dryer and solenoid valve assemblies in (Section 8.17.16).

8.17.21 Replacing t he Tinnerman clips

1 Rem ove the Ti nn erm an cl ips by sli din g th em off th e rear pan el m oun ting h ol es.
2 With th e fl at-side of the cli p facin g out, i nstal l th e new cl ip by sl idi ng it over th e rear
panel moun tin g h ol es.

8.17.22 Reinst alling the back panel/ accumulat or assembly

1 Repl ace the plenum assem bl y on the top of the com pressor m odule.
2 Sl ightly ti ghten the four (4) Phi ll ips screws th at secure the pl enum assem bl y to the ri gh t
and l eft pan els.
Do n ot full y tigh ten th e four Phi ll ips screws in order to leave enough space to allow for
cl earance when rei nstal lin g th e rear panel /accum ulator assem bl y.

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Service and repair 8
3 W h ile resti ng the bottom of th e rear pan el on th e base of the uni t.
4 Take th e h ose that connects th e solen oi d outlet to the accum ulator in let port and route
thi s h ose beh in d th e m ai n supply hose.
5 W h ile supporti ng the rear panel i n place, reconnect the h ose runn in g from the m ain
supply tee to the accum ul ator inl et port.
6 Reposi tion the hose cl am p over th e i nlet port to h ol d th e hose in pl ace.
7 Taki ng care n ot to crim p h oses or cabl es, press th e back pan el in to pl ace and secure to th e
unit usi ng the original si x (6) Phi lli ps screws.
8 Once the rear panel/ accumulator assembly is secured i n place, fi ni sh tigh ten in g th e four
(4) Phi lli ps screws th e secure the plenum assem bl y to th e si de panel s.

8.17.23 Replacing t he main inlet filt er and reinstalling t he t op

1 Rein stal l the support baffle by settin g on the inside slot at the top of the fron t panel .
It sh ould fi t easily in to the slot; i f n ot, turn th e baffle over and try th e other si de.
2 Rein stal l th e com pressor top cover assem bly and secure in pl ace by tighteni ng th e ei ght
(8) captive screws.
3 Once the top cover assem bly is in place, i nstall the n ew m ain in let fil ter by pressi ng it
i nto th e slot between the supportin g baffle an d the rear pan el .
Ensure al l fi lter edges are i n place.

8.17.24 Reinst alling t he compressor m odule

Warning
To prevent personal injury and equipment damage, have someone assist you when lifting
the heavy ventilator and its components.

1 Rein stal l the com pressor onto the cart and secure usi ng the captive hardware on th e cart.
2 Reattach and secure the com pressor data cabl e.
3 Reattach the compressor power cord.
4 Secure th e power cord usi ng the power cord retainer. Secure the retai ner with two (2)
screws.
5 Reattach the compressor supply tube.

8.17.25 Running performance verificat ion t est

It is necessary to run a Perform ance Verifi cation on th e enti re ventil ator, as descri bed in
Section 5 of thi s m anual .

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8 Service and repair

8.18 Backup power source (BPS)

The BPS consi sts of a +24 V battery pack and correspondi ng chargin g circui try on its PCB
assem bl y. Th e battery an d related com ponen ts are en cl osed i n a sturdy alum in um chassi s and
m oun ted to the (optional ) cart.

8.18.1 Removing BPS

1 Loosen two captive screws that secure battery cabl e to conn ector on side of power supply
assem bly. Disconnect cabl e.
2 Loosen two captive screws at rear of BPS.
3 Sli de BPS forward off sli de m ounts and pl ace unit on a firm work surface (Fi gure 8-90).

GUI mount

BPS

Rear caster
(2 PL)

Front caster
(2 PL)
8-01208

Figure 8-90. BPS and cart

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Service and repair 8
8.18.2 Inst alling BPS
1 From fron t of cart, sl ide brackets at top of BPS onto rail s, then push BPS to back (Fi gure
8-90). Secure BPS to rai ls wi th captive screws.
2 Open protective cover on BDU con nector, and conn ect BPS cabl e to BDU (Figure 8-91).
Tighten capti ve screws.

Back of BPS
BPS
cable
8-00038

Figure 8-91. Connecting BPS t o BDU

8.18.3 Batt ery pack

Caution
To prevent damage to ESD-sensitive components, always follow ESD guidelines when
disassembling the BPS.

8.18.3.1 Removing bat t ery pack

1 Rem ove BPS (Section 8.18.1).
2 Rem ove two flat-head screw s that secure fascia panel to BPS front plate (Figure 8-92).
3 Rem ove four fl at-h ead screws th at secure BPS front plate to unit.
4 Just in si de unit, discon nect battery cable connector from PCB.
5 Grasp pull loop and sl ide battery pack (attached to plate) out of enclosure.

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8 Service and repair

2 PL

Fascia
panel

4 PL

Front
panel

J1 Floor
assembly

Battery
J3 pack
Chassis

Nut
(4 PL)

BPS
PCB

Enclosure

8 PL

8-00134

Figure 8-92. Replacing batt ery pack and BPS PCB

8.18.3.2 Inst alling bat t ery pack

1 Sl i de battery onto plate and conn ect battery cable to PCB (Figure 8-92).
2 Al ign fron t pl ate to four screw l ocati on s on fron t of BPS housing. Install four fl at-head
screws an d tighten unti l sn ug.
3 Al ign fascia pan el to two screw locations on front pl ate. Instal l two flat-head screws and
tigh ten until snug. Do n ot ov ert igh t en .
4 Orien t battery pack housing wi th two LEDs toward front of cart, and sli de uni t onto slide
m ounts l ocated un der BDU pl atform
5 Install BPS (Section 8.18.2).

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Service and repair 8
8.18.4 BPS PCB

8.18.4.1 Removing BPS PCB

1 Rem ove battery pack (Section 8.18.3.1).
2 Rem ove ei ght fl at-h ead screws th at secure floor assembly of BPS (Figure 8-92).
3 Di sconnect battery cabl e conn ection s from PCB at J1 an d J3.
4 Using a 5/16-in. nutdriver, rem ove four retainin g nuts th at secure PCB to BPS chassi s.
Rem ove PCB.

8.18.4.2 Inst alling BPS PCB

1 Ori ent PCB to four retaini ng screws m ounted to BPS chassis and set PCB i n place .
2 Using 5/ 16-in . nutdri ver, i nstall four retaini ng nuts and tighten un ti l snug. Do n o t
o vert igh ten .
3 Con nect battery cable conn ection s to PCB at J1 and J3.
4 Pl ace BPS enclosure on fl at surface w ith two m oun ting guides on top.
5 Lift battery plate with pl ate down an d battery cable connecti on toward you.
6 Align bottom of plate un der brackets of BPS en closure and sli de uni t in to housing.
7 In stal l eight flat-h ead screws th at secure BPS bottom pl ate to uni t. Ti ghten un ti l sn ug.
8 Install battery pack (Secti on 8.18.3.2).

8.19 Cart

8.19.1 Cast ers

8.19.1.1 Removing cast ers

1 Rem ove GUI (Secti on 8.14.5).
2 Rem ove BDU (Secti on 8.15.1).
3 Rem ove com pressor uni t from cart (Section 8.17.3.2).
4 Rem ove BPS (Section 8.18.1).
5 Lay cart on n onabrasive surface an d rem ove caster usi ng caster wren ch (Fi gure 8-93).

Figure 8-93. Removing caster

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8 Service and repair

8.19.1.2 Inst alling cast ers

1 Insert caster through bum per and th read caster i nto ch assi s. Tigh ten with caster wrench
unti l sn ug.
2 Install BPS (Section 8.18.2).
3 Install com pressor uni t onto cart (Secti on 8.17.24).
4 Install BDU (Section 8.15.3).
5 Install GUI (Section 8.14.5).

8.19.2 Removing/ inst alling GUI mount

1 Rem ove GUI (Secti on 8.14.5) an d pl ace on flat work surface.
2 Rem ove three screws that retain GUI mount (Figure 8-94).
3 Lift en tire GUI h ousi ng assem bl y an d pl ace on fl at work surface.
4 Gently pul l cover away from release han dle.
5 Install assem bly by placi ng release cover upside down on work surface and i nstall in g
sprin g over boss (Fi gure 8-94).
6 Place release handle in to cover an d ali gn post with opposite en d of spring.
7 Place enti re assembly onto cart, al ignin g three m ountin g holes with cover. Instal l three
screws an d tighten unti l sn ug.
8 Verify release handle freel y return s to “ h om e posi ti on ” w hen released.
G

8-00259 8-00260 8-00261

Figure 8-94. Assembling GUI mount

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Service and repair 8
8.19.3 Rem oving/ inst alling flex arm inserts
On older style carts, rem ove and i nstall th e flex arm inserts as fol lows:
1 Rem ove flex arm or any item secured i n flex arm in sert (socket).
2 Remove flat-h ead screw from cart di rectl y beneath in sert in cart. Rem ove insert.

8-01402

Figure 8-95. Flex arm insert

3 Pl ace i nsert i nto cavi ty in cart, ali gni ng screwhol es i n cart and insert.
4 From beneath the cavity of the cart, i nsert fl at-head screw i nto insert and tighten unti l
sn ug. Verify insert is tigh t an d does n ot rotate.
On newer. ready to assem bl e (RTA) carts, rem ove an d i nstal the flex are i nserts as fol lows:
1 Sli de locki ng ri ng off the GUI m oun t.
2 Install new insert.
3 Rein stal l locki ng ring.

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8 Service and repair

Thi s page i ntentionall y blank.

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 SECTION
S EC T I O N

Parts list 9 9
9.1 How t o use t his part s list
Th is sectio n begin s by sh o win g th e en tire ven tilator system , in clu d in g accesso ries.
Su bseq uen t figu res sh o w ven tilato r sub assem b lies an d th eir com pon en t p arts.
Th is sectio n uses th e followin g co n ven tio n s:
• Two d ash es (-) in th e Part no. colu m n in d icate th at th e p art is n o t o rd erab le; it is sh o wn for
referen ce on ly.
• Bullets (• ) in th e descriptio n colum n in d icate levels o f in d en tation . For exam p le, a p art
with a n o n -b u lleted d escriptio n in clu d es all th e su bseq uen t sin gle-bu lleted p arts. A p art
with a sin gle-bulleted descrip tion in clu d es all th e su bseq u en t do u ble-bulleted p arts, an d
so on .
• Ab breviation s an d acron ym s used in th is section are listed in Tab le 9-1.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/ 03) 9-1
9 Parts list

Table 9-1: Abbreviations used in parts list

Abbreviat ion M eaning

A/ R As Required

BD Breath Delivery

BDU Breath Delivery Unit

BOC British Oxygen Company

BPS Backup Power Source

cmH2O Centimeters Of Water

DISS Diameter Index Safety System

EPROM Erasable Programmable Read-only Memory

EX LK External Lock

FIL Fillister-head

FH Flat-head

FRU Field Replaceable Unit

GUI Graphic User Interface

HEX Hexagonal

I/ O Input/ output

ID Inside Diameter

IN LK Internal Lock

NIST Non-interchangeable Screw Thread

NHA Next Higher Assembly

NOVRAM Nonvolatile Random-access Memory

OD Outside Diameter

PAN Panhead

PCB Printed Circuit Board

PEEP Positive End Expiratory Pressure

P/ N Part Number

SIS Sleeved Index System

SOC Socket

SR Split-ring

9-2 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9
9.2 840 Vent ilat or Syst em pat ient syst em and accessories

Patient system and accessories part s list

It em no.
Part no. Quant it y Description
(Figure 9-1)

-- -- -- 840 Ventilator System

1 4-032006-00
2 --
3 --
4 --
5 4-074600-00
1 • Flex arm assembly (See Section 9.3 for parts breakdown.)
1 • Power cord (See Section 9.3.3 for part numbers.)
1 • Hose assembly, oxygen (See Section 9.3.1 for part numbers.)
1 • Hose assembly, air (See Section 9.3.2 for part numbers.)
1 • Filter, inspiratory, reusable (Re/ FlexTM inspiratory bacteria filter,
with 22-mm ISO connectors) (F8)

4-074601-00 1 • Filter, inspiratory, single-patient use (D/ FlexTM inspiratory

6 4-076887-00
7 4-070305-00
8 4-074647-00
bacteria filter, with 22-mm ISO connectors) (package of 12)
(F8)
1 • Filter with collector vial, expiratory, single-patient use
(D/ X800) (carton of 12) (F9)
1 • Filter, expiratory, reusable (Re/ X800) (F9)
1 • Collector vial, exhalation, reusable (Re/X800) (ECV)

4-072311-00 1 • Seal (Re/ X800) (Not shown)

9 4-074613-00 1 • Drain cap
10 4-048493-00 1 • Tubing, drain bag, single-patient use (package of 10)
11 4-048492-00 1 • Clamp, reusable (carton of 5)
12 4-048491-00 1 • Drain bag, single-patient use (package of 25)
13 4-070311-00 1 • Seal, expiratory filter (Not shown)
14 -- 1 • Ventilator breathing circuit (Contact your Puritan Bennett
representative for ordering information.)
15 4-000612-00 1 • Test lung
16 4-075315-00 1 • Wall Air Water Trap kit, cart-mount, DISS male (Includes water
trap, bracket with mounting hardware, and interconnect hose)
(Not shown)
17 4-074636-00 1 • Plate, humidifier, blank
18 4-072623-00 4 • Screw, FH, 8-32 x 3/ 8 (Attach blank humidifier plate to BDU
chassis) (Not shown)
19 4-075313-00 1 • M ounting kit, Fisher & Paykel 480/ 730 humidifier, ventilator-
powered (120 V), cart-mount, English/ French

4-075659-00 • M ounting kit, Fisher & Paykel 480/ 730 humidifier, ventilator-
powered (120 V), cart-mount, Spanish/ Portuguese
20 -- 1 • • Plate with cutout, humidifier, English/ French
• • Plate with cutout, humidifier, Spanish/ Portuguese

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-3

9 Parts list

Pat ient syst em and accessories part s list (continued)

It em no.
Part no. Quant it y Descript ion
(Figure 9-1)

21 -- 1 • • Bracket assembly, Fisher & Paykel 480/ 730 humidifier, cart-

mount, English/ French
• • Bracket assembly, Fisher & Paykel 480/ 730 humidifier, cart-
mount, Spanish/ Portuguese
22 4-070141-00 4 • • Screw, FH, 8-32 x ½ (Attach bracket assembly/ plate to
ventilator)
23 4-074726-00 1 • • Cover, plug

24 4-070143-00 3 • • Screw, FH, 4-40 x 3/ 16 (Attach plug cover to bracket

assembly)
25 4-075314-00 1 • M ounting kit, Fisher & Paykel 730/ 850 humidifier with external
power source, cart-mount
26 -- 1 • • Bracket assembly, Fisher & Paykel 730/ 850 humidifier, cart-
mount
27 4-070141-00 4 • • Screw, FH, 8-32 x ½ (Attach bracket assembly/ plate to
ventilator)
28 4-075312-00 1 • M ounting kit, Hudson RCI ConchaTherm humidifier, cart-
mount (Not shown)
29 4-078008-00 1 • Connector lock, IEC-320, square (Not shown)

4-075172-00 • Connector lock, IEC-320, square (Not shown)

4-078009-00 • Connector lock, IEC-320, angled (Not shown)

30 4-070034-00 2 • Screw, PAN, 6-32 x 0.38, sems (Retain connector lock) (Not
shown)

-- T-T53204-00 2 • Screw (Secures mounting receptacle) (Not shown)

-- 4-078105-00 1 • M ounting, receptacle, clip-on style

31 4-018506-00 1 • Flex tube, 21 in. (53 cm) ("gold standard" test hose, for use with
EST) (Not shown)

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Parts list 9

25 15
(4 PL)

24

3
4

23

20 (4 PL) 2
Fisher & Paykel 480/ 730 humidifier,
ext ernally-powered (220-240 V) 6

8
22 (3 PL)
18 9
10
19
7

5
21
17

Fisher & Paykel 480/ 730 humidifier,

vent ilat or-pow ered (100-120 V)

12

13
8-00190

Figure 9-1. 840 Ventilator Syst em

pat ient system and
accessories

840 Ventilator System Service Manual 4-070496-00 Rev A (08/ 03) 9-5
9 Parts list

9.2.1 840 Vent ilat or Syst em NeoM ode pat ient syst em and accessories

NeoM ode pat ient syst em and accessories parts list

It em no.
Part no. Quant it y Descript ion
(Figure 9-2)

-- 4-076440-00 1 • Upgrade Kit, NeoM ode, English, Non-US

-- 4-076441-00 1 • Upgrade Kit, NeoM ode, English, US only

-- 4-076442-00 1 • Upgrade Kit, NeoM ode, German

-- 4-076443-00 1 • Upgrade Kit, NeoM ode, French

-- 4-076444-00 1 • Upgrade Kit, NeoMode, Italian

-- 4-076445-00 1 • Upgrade Kit, NeoM ode, Japanese

-- 4-076446-00 1 • Upgrade Kit, NeoM ode, Spanish

-- 4-076447-00 1 • Upgrade Kit, NeoM ode, Portuguese

1 307/ 6922 • Ventilator breathing circuit, neonatal, disposable (DAR)

7441-4S2 • Ventilator breathing circuit, neonatal, disposable, 4 feet

--
(Allegiance Healthcare Corporation )
2 4-076408-00 1 • Filter, expiratory, NeoMode

-- DAR part Box of 12 • Expiratory bacteria filter (DAR), disposable

number
351P19005
Order part
number
4-076408-00
3 4-074601-00 Box of 12 • Inspiratory bacteria filter, 22-mm ISO connectors, disposable,
D/ Flex
4 4-076405-00 1 • Adapter plate, NeoM ode

-- 4-076589-00 1 • Label, adapter, NeoMode

9-6 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9

2
3

8-00137

Figure 9-2. NeoM ode patient circuit and accessories

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-7

9 Parts list

9.3 Flex arm assembly

Flex arm assembly part s list

It em no.
Part no. Quant it y Descript ion
(Figure 9-3)

-- 4-032006-00 -- Flex arm assembly

1 4-032017-00 3 • Handle, button-head, large
2 4-032018-00 6 • Washer, Belleville
3 4-032019-00 3 • Washer, Delrin
4 4-021246-00 1 • Base assembly
5 4-032010-00 3 • Nut, mushroom
6 4-032011-00 3 • Ring, friction
7 -- 1 • Shaft with pivot, 0.34 m (13.55 in.) long
8 -- 1 • Shaft with pivot, 0.38 m (15.0 in.) long
9 -- 1 • Shaft, rotating
10 4-032025-00 1 • Bolt, carriage
11 4-032021-00 1 • Clamp, left
12 4-032022-00 1 • Clamp, right
13 4-032023-00 1 • Handle, button-head, small

9-8 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9

6 (3 PL)
5 (3 PL)

3 (3 PL)

8
2 (6 PL)

1 (3 PL)

10
7
11

12
13

8-01229

Figure 9-3. Flex arm assembly

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-9

9 Parts list
9.3.1 Oxygen hose assemblies
It em no.
Part no. Quant it y
(Figure 9-4)
1 4-001474-00
2 4-074710-00
3 4-074697-00
4 4-074711-00
5 4-074698-00
6 4-074715-00
7 4-074700-00
8 4-074702-00
9 4-074705-00
10 4-074708-00
9-10 4-070496-00 Rev. A (08/ 03)
Oxygen hose assemblies part s list
Descript ion
1 Hose assembly, oxygen, DISS female x DISS female, clear, 3-m (10-ft) (for
USA) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, DISS female x DISS male, 3-m (10-ft) (for
Canada) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, Air Liquide female x Air Liquide female, 3-m (10-
ft) (for France) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, SISfemale x SIS female, 3-m (10-ft) (for Australia,
New Zealand) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, NIST female x BOC male, 3-m (10-ft) (for United
Kingdom, Ireland) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, DISS female x Dräger male, 3-m (10-ft) (for
Germany) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, NIST female x NIST female, 3-m (10-ft) (for
Netherlands) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, DISSfemale x DISSfemale, green, 3-m (10-ft) (for
Israel, Japan, Saudi Arabia) (See Section 9.2 for NHA.)
1 Hose assembly, oxygen, DISSfemale x DISSfemale, white, 3-m (10-ft) (for
Egypt, India, Italy, Kuwait, Poland, Portugal, South Africa) (See Section 9.2
for NHA.)
1 Hose assembly, oxygen, DISS female x DISS female, blue, 3-m (10-ft) (for
Switzerland) (See Section 9.2 for NHA.)
840 Ventilator System Service Manual
Parts list 9

1 (clear)

8 (green)

9 (white)

10 (blue)

6 8-00073

Figure 9-4. Oxygen hose assemblies

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9 Parts list
9.3.2 Air hose assemblies
It em no.
Part no.
(Figure 9-5)
1 4-006541-00
2 4-074709-00
3 4-074696-00
4 4-074712-00
5 4-074713-00
6 4-074714-00
7 4-074701-00
8 4-074703-00
9 4-074706-00
10 4-074707-00
-- --
9-12 4-070496-00 Rev. A (08/ 03)
Air hose assemblies part s list
Quant it y Descript ion
1 Hose assembly, air, DISS female x DISSfemale, clear, 3-m (10-ft) (for USA)
(See Section 9.2 for NHA.)
1 Hose assembly, air, DISSfemale x DISSmale, 3-m (10-ft) (for Canada) (See
Section 9.2 for NHA.)
1 Hose assembly, air, Air Liquide female x Air Liquide female, 3-m (10-ft) (for
France) (See Section 9.2 for NHA.)
1 Hose assembly, air, SIS female x SIS female, 3-m (10-ft) (for Australia, New
Zealand) (See Section 9.2 for NHA.)
1 Hose assembly, air, NIST female x BOC male, 3-m (10-ft) (for United
Kingdom, Ireland) (See Section 9.2 for NHA.)
1 Hose assembly, air, DISS female x Dräger male, 3-m (10-ft) (for Germany)
(See Section 9.2 for NHA.)
1 Hose assembly, air, NIST female x NIST female, 3-m (10-ft) (for
Netherlands) (See Section 9.2 for NHA.)
1 Hose assembly, air, DISS female x DISS female, black, 3-m (10-ft) (for
Israel, Japan, Kuwait, Poland, Portugal), 3-m (10-ft) (See Section 9.2 for
NHA.)
1 Hose assembly, air, DISS female x DISS female, white/ black, 3-m (10-ft)
(for Egypt, India, Italy) (See Section 9.2 for NHA.)
1 Hose assembly, air, DISS female x DISS female, yellow, 3-m (10-ft) (for
Switzerland) (See Section 9.2 for NHA.)
1 Common module for the following: DISS male, DISS female, Air Liquide,
NIST, CIG (See Section 9.4.7.2 for details.)
840 Ventilator System Service Manual
Parts list 9

1 (clear)

8 (black)

9 (white/black)

10 (yellow)

6 11 (white)
8-00074

Figure 9-5. Air hose assemblies

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-13

9 Parts list

9.3.3 Power cords

Pow er cords parts list

It em no.
Part no. Quant it y Descript ion
(Figure 9-6)

1 4-078107-00 1 Power cord, , latching, for North America (See Section 9.2 for
NHA.)

-- 4-078107-SP 1 FRU, ac power cord, latching, North America

2 4-078109-00 1 Power cord, for Japan (See Section 9.2 for NHA.)

-- 4-078109-SP FRU, ac power cord, latching, Japan

3 4-078110-00 1 Power cord, for Australia (See Section 9.2 for NHA.)

-- 4-078110-SP FRU, ac power cord, latching, Australia

4 4-078108-00 1 Power cord, for continental Europe (See Section 9.2 for NHA.)

-- 4-078108-SP 1 FRU, ac power cord, latching, Europe

5 4-071422-00
6 4-071423-00
7 4-031323-00
8 4-031325-00
9 4-031322-00
10 4-071421-00
1 Power cord, for India/ South Africa (old, British-style plug with
round prongs) (See Section 9.2 for NHA.)
1 Power cord, for Israel (See Section 9.2 for NHA.)
1 Power cord, for Italy (See Section 9.2 for NHA.)
1 Power cord, for Switzerland (See Section 9.2 for NHA.)
1 Power cord, for United Kingdom (See Section 9.2 for NHA.)
1 Power cord, for Denmark (See Section 9.2 for NHA.)

T-T53204-00 Screw (secures receptacle clamp for latching power cord)

9-14 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9

1 2

3 4

5 6

7 8

8-00070
9

Figure 9-6. Pow er cords

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-15

9 Parts list

9.4 Vent ilat or major assemblies

M ajor assemblies part s list

It em no.
Part no. Quant it y Descript ion
(Figure 9-7)

-- -- -- 840 Ventilator (See Section 9.2 for NHA.)

1 -- 1 • Graphic user interface (GUI): 10.4-inch
(See pages 9-28–9-31 for parts breakdown.)
• Graphics user interface (GUI): 9.4-inch
(See pages 9-35–9-41 for parts breakdown.)
2 -- 1 • Breath delivery unit (BDU) (See (Section 9.4.7) for parts
breakdown.)
3 -- 1 • Data key (Contact your Puritan Bennett representative for
ordering information.)
4 4-071634-00 1 • Cover, data key
5 4-075234-00 2 • Screw, PAN, 4-40 x 0.312, sems (Attach data key cover)
6 4-070520-00 1 • 802 Backup Power Source (BPS) (See (Section 9.4.9) for parts
breakdown.)
7 -- 1 • 806 Compressor Unit (optional) (See Figure 9.4.8 for parts
breakdown.)1
8 4-074608-00 1 • Cart assembly (optional) (See Figure 9-29.)

1. Contact your Puritan Bennett representative to obtain 806 compressor unit ordering information.

9-16 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9

3
4
5

8-01204

Figure 9-7. Vent ilator major assemblies

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-17

9 Parts list

9.4.1 Label kit s

Label kit s part s list

It em no.
Part no. Quant it y Descript ion
(Figure 9-8)

-- 4-075143-00 1 Label kit, ventilator, 100 V, 50/ 60 Hz, Japanese (See Section 9.4 for
NHA.)

4-075413-00 Label kit, ventilator, 120 V, 60 Hz, English, US (See Section 9.4 for
NHA.)

4-071559-00 Label kit, ventilator, 120 V, 60 Hz, English/ French (See Section 9.4
for NHA.)

4-075099-00 Label kit, ventilator, 120 V, 60 Hz, Spanish/ Portuguese (See Section
9.4 for NHA.)

4-071590-00 Label kit, ventilator, 220-240 V, 50 Hz, English/ French (See Section
9.4 for NHA.)

4-075436-00 Label kit, ventilator, 220-240 V, 60 Hz, English (See Section 9.4 for
NHA.)

4-075059-00 Label kit, ventilator, 220-240 V, 50 Hz, German (See Section 9.4 for
NHA.)

4-075400-00 Label kit, ventilator, 220-240 V, 50 Hz, Portuguese (See Section 9.4
for NHA.)

4-075072-00 Label kit, ventilator, 220-240 V, 50 Hz, Spanish/ Italian (See Section
9.4 for NHA.)

4-075086-00 Label kit, ventilator, 220-240 V, 60 Hz, Spanish/ Portuguese (See

Section 9.4 for NHA.)
1 -- 1 • Label, gas output, BDU, English

-- • Label, gas output, BDU, English/ French

-- • Label, gas output, BDU, German

-- • Label, gas output, BDU, Japanese

-- • Label, gas output, BDU, Portuguese

-- • Label, gas output, BDU, Spanish/ Italian

-- • Label, gas output, BDU, Spanish/ Portuguese

2 -- 1 • Label, exhaust information, BDU, English, US

-- • Label, exhaust information, BDU, English/ French

-- • Label, exhaust information, BDU, German

-- • Label, exhaust information, BDU, Japanese

-- • Label, exhaust information, BDU, Portuguese

-- • Label, exhaust information, BDU, Spanish/ Italian

-- • Label, exhaust information, BDU, Spanish/ Portuguese

9-18 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9
Label kits parts list (cont inued)

It em no.
Part no. Quant it y Description
(Figure 9-8)

3 -- 1 • Label, product information, GUI, English, US

-- • Label, product information, GUI, English/ French

-- • Label, product information, GUI, German

-- • Label, product information, GUI, Japanese

-- • Label, product information, GUI, Portuguese

-- • Label, product information, GUI, Spanish/ Italian

-- • Label, product information, GUI, Spanish/ Portuguese

4 -- 1 • Label, GUI ports, non-US

-- • Label, GUI ports, US

5 -- 1 • Label, product information, BDU, 100 V, 50/ 60 Hz, Japanese

-- • Label, product information, BDU, 120 V, 60 Hz, English, US

-- • Label, product information, BDU, 120 V, 60 Hz, English/ French

-- • Label, product information, BDU, 120 V, 60 Hz, Spanish/

Portuguese

-- • Label, product information, BDU, 220-240 V, 50 Hz, English/

French

-- • Label, product information, BDU, 220-240 V, 60 Hz, English/

French

-- • Label, product information, BDU, 220-240 V, 50 Hz, German

-- • Label, product information, BDU, 220-240 V, 50 Hz, Portuguese

-- • Label, product information, BDU, 220-240 V, 50 Hz, Spanish/

Italian

-- • Label, product information, BDU, 220-240 V, 60 Hz, Spanish/

Portuguese
6 -- 1 • Label, gas inlet, BDU, English, US

-- • Label, gas inlet, BDU, English/ French

-- • Label, gas inlet, BDU, German

-- • Label, gas inlet, BDU, Japanese

-- • Label, gas inlet, BDU, Portuguese

-- • Label, gas inlet, BDU, Spanish/ Italian

-- • Label, gas inlet, BDU, Spanish/ Portuguese

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-19

9 Parts list

Label kits part s list (continued)

It em no.
Part no. Quant it y Descript ion
(Figure 9-8)

7 -- 1 • Label, humidifier electrical, 100 V, Japanese

-- • Label, humidifier electrical, 120 V, English, US

-- • Label, humidifier electrical, 120 V, English/ French

-- • Label, humidifier electrical, 120 V, Spanish/ Portuguese

-- • Label, humidifier electrical, 220-240 V, English/ French

-- • Label, humidifier electrical, 220-240 V, German

-- • Label, humidifier electrical, 220-240 V, Portuguese

-- • Label, humidifier electrical, 220-240 V, Spanish/ Italian

-- • Label, humidifier electrical, 220-240 V, Spanish/ Portuguese

8 -- 1 • Label, I/ O disconnect warning, BDU, English/ French

-- • Label, I/ O disconnect warning, BDU, English, US

-- • Label, I/ O disconnect warning, BDU, German

-- • Label, I/ O disconnect warning, BDU, Japanese

-- • Label, I/ O disconnect warning, BDU, Portuguese

-- • Label, I/ O disconnect warning, BDU, Spanish/ Italian

-- • Label, I/ O disconnect warning, BDU, Spanish/ Portuguese

9 -- 1 • Label, gas connection, compressor, non-US

-- • Label, gas connection, compressor, US

10 -- 1 • Label, cooling vent, BDU, English/ French

-- • Label, cooling vent, BDU, English, US

-- • Label, cooling vent, BDU, German

-- • Label, cooling vent, BDU, Japanese

-- • Label, cooling vent, BDU, Portuguese

-- • Label, cooling vent, BDU, Spanish/ Italian

-- • Label, cooling vent, BDU, Spanish/ Portuguese

11 -- 1 • Label, BPS connection

9-20 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9
Label kits parts list (cont inued)

It em no.
Part no. Quant it y Description
(Figure 9-8)

12 4-075101-00 1 • Label kit, 806 Compressor, 100 V, 50/ 60 Hz, Japanese (Not
shown)

4-075424-00 • Label kit, 806 Compressor, 120 V, 60 Hz, English, US (Not

shown)

4-074015-00 • Label kit, 806 Compressor, 120 V, 60 Hz, English/ French (Not
shown)

4-075108-00 • Label kit, 806 Compressor, 120 V, 60 Hz, Spanish/ Portuguese

(Not shown)

4-075120-00 • Label kit, 806 Compressor, 220-230 V, 60 Hz, English (Not

shown)

4-075095-00 • Label kit, 806 Compressor, 220-230 V, 60 Hz, Spanish/

Portuguese (Not shown)

4-074019-00 • Label kit, 806 Compressor, 220-240 V, 50 Hz, English/ French

(Not shown)

4-075069-00 • Label kit, 806 Compressor, 220-240 V, 50 Hz, German (Not

shown)

4-075409-00 • Label kit, 806 Compressor, 220-240 V, 50 Hz, Portuguese (Not

shown)

4-075081-00 • Label kit, 806 Compressor, 220-240 V, 50 Hz, Spanish/ Italian

(Not shown)
13 -- 1 • Label, compressor lint filter, English/ French

-- • Label, compressor lint filter, English, US

-- • Label, compressor lint filter, German

-- • Label, compressor lint filter, Japanese

-- • Label, compressor lint filter, Portuguese

-- • Label, compressor lint filter, Spanish/ Italian

-- • Label, compressor lint filter, Spanish/ Portuguese

14 -- 1 • Label, compressor, 100 V, 50/ 60 Hz, Japanese

-- • Label, compressor, 120 V, 60 Hz, English, US

-- • Label, compressor, 120 V, 60 Hz, English/ French

-- • Label, compressor, 120 V, 60 Hz, Spanish/ Portuguese

-- • Label, compressor, 220-230 V, 60 Hz, English/ French

-- • Label, compressor, 220-230 V, 60 Hz, Spanish/ Portuguese

-- • Label, compressor, 220-240 V, 50 Hz, English/ French

-- • Label, compressor, 220-240 V, 50 Hz, German

-- • Label, compressor, 220-240 V, 50 Hz, Portuguese

-- • Label, compressor, 220-240 V, 50 Hz, Spanish/ Italian

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-21

9 Parts list

Label kits part s list (continued)

It em no.
Part no. Quant it y Descript ion
(Figure 9-8)

15 4-075124-00 1 Label kit, humidifier mount, English/ French (Not shown)

4-075106-00 Label kit, humidifier mount, Japanese (Not shown)

4-075130-00 Label kit, humidifier mount, Spanish/ Portuguese (Not shown)

16 -- 1 • Label, humidifier plate, English/ French (Not shown)

-- • Label, humidifier plate, Japanese (Not shown)

-- • Label, humidifier plate, Spanish/ Portuguese (Not shown)

17 -- 1 • Label, humidifier bracket, English/ French

-- • Label, humidifier bracket, Japanese

-- • Label, humidifier bracket, Spanish/ Portuguese

18 4-075427-00 1 Label, product information, BPS, English, US

4-072504-00 Label, product information, BPS, English/ French

4-075071-00 Label, product information, BPS, German

4-075146-00 Label, product information, BPS, Japanese

4-075412-00 Label, product information, BPS, Portuguese

4-075085-00 Label, product information, BPS, Spanish/ Italian

4-075098-00 Label, product information, BPS, Spanish/ Portuguese

19 4-071524-00 1 Label, alarm graphics, BDU, non-US

4-075428-00 Label, alarm graphics, BDU, US

20 4-073028-00 1 Label, alarm graphics, GUI, non-US

4-075429-00 Label, alarm graphics, GUI, US

21 4-072505-00 1 Label, display, BPS, non-US

4-075430-00 Label, display, BPS, US

9-22 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9

20

19

1 6 5
2

21
18

13

8-01181 8-0002

8-00298

Figure 9-8. Label kits (Sheet 1 of 2)

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-23

9 Parts list

Grap h ic u ser in terface (GUI)

14

8-00029
8-00030
8-01182 8-01183

10

11

8-00033 8-00034

Figure 9-8. Label kit s (Sheet 2 of 2)

9-24 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual
Parts list 9

Th is p age in ten tion ally blan k.

840 Ventilator System Service Manual 4-070496-00 Rev. A (08/03) 9-25

9 Parts list

9.4.2 10.4-inch GUI (graphic user int erface) assembly

10.4-inch GUI assembly part s list

It em no. Part no. Quant it y Descript ion

(Figure 9-9)
1 4-076672-SP 1 • Housing assembly, GUI front
2 4-076678-00 1 • Shield, CPU PCB
3 4-070034-00 42 • Screw, 6-32 X 0.38, sems, SQCN
4 4-075727-SP 1 • PCB, GUI CPU
5 4-076675-00 1 • Bracket, LCD panels and GUI CPU PCB
6 4-076656-00 2 • Cable assembly, GUI alarm
7 4-073500-SP 1 • PCB, GUI LED
8 4-076651-00 1 • Cable assembly, touchframe
9 4-079013-SP 1 • Speaker, GUI alarm, 16 OHM
10 4-076652-00 1 • Cable assembly, keyboard
11 4-076671-SP 1 • Housing assembly, GUI front
12 4-076687-00 4 • Screw, 2-56 X 1/ 4 PH, nylon
13 4-076653-00 2 • Driver, backlight PCB
14 4-076653-00 2 • Cable assembly, backlight driver
15 4-076658-00 11 • Screw. 6-32 X 1/ 4 PH sem
16 4-076689-SP 2 • Display, LCD, 10.4" color
17 4-076684-00 3 • Gasket, EM C, Chrometrics, 8.5"
18 4-076684-00 2 • Gasket, EM C, Chrometrics, 13"
19 4-076660-00 11 • Rivet, snap, H type
20 4-076676-00 1 • Shield, LCD
21 4-076530-SP 1 • PCB, touchframe
22 4-076686-00 1 • Gasket, EM C, Chrometrics, RS-232, 5"
23 4-076677-00 1 • Shield, RS-232
24 4-076665-00 6 • Screw, lock, fem, 4-40, 0.75L
25 4-071944-SP 2 • Cable, flex circuit assembly, RS-232
26 4-076856-SP 2 • Cable, flex circuit assembly, video
27 4-076688-00 4 • Washer, nylon

9-26 4-070496-00 Rev. A (08/ 03) 840 Ventilator System Service Manual