7800 International Ventilator Product Group Code CAX Service Manual ‘ABOC Health Care ‘Company. Critical Care | Worldwide |Ohmeda Service Manual 7800 International Ventilator Product Group Code CAX This document is not to be reproduced in any manner, nor are the contents here in to be disclosed to anyone, without the express authorization of the Product Service Department, Ohmeda. Copyright © 1992, The BOC Group Inc.Important The information contained in this service manual pertains only to those models of products which are marketed by Ohmeda as of the effective date of this manual or the latest revision thereof. This service manual was prepared for exclusive use by Ohmeda service personnel in light of their training and experience as well as the availability to them of parts, proper tools and test equipment. Consequently, Ohmeda provides this service manual to its customers purely as a business convenience and for the customer's general information only without warranty of the results with respect to any application of such information. Furthermore, because of the wide variety of circumstances under which maintenance and repair activities may be Performed and the unique nature of each individual's own experience, capacity, and qualifications, the fact that customer has received such information from Ohmeda does not imply in any way that Ohmeda deems said individual to be qualified to perform any such maintenance or repair service. Moreover, it should not be assumed that every acceptable test and safety Procedure or method, precaution, tool, equipment or device is referred to within, or that abnormal or unusual circumstances, may not warrant or suggest different or additional procedures or requirements. This manual is subject to periodic review, update and revision. Customers are cautioned to obtain and consult the latest revision before undertaking any service of the equipment. Comments and suggestions on this manual are invited from our customers. Send your comments and suggestions to the Manager of Service Education, Ohmeda, Ohmeda Drive, Madison, Wisconsin 53707. A\ caution: Servicing of this product in accordance with this service manual should never be undertaken in the absence of proper tools, test equipment and the most recent revision to this service manual which ie clearly and thoroughly understood. Technical Competence The procedures described in this service manual should be performed by trained and authorized personnel only. Maintenance should only be undertaken by competent individuals who have a general knowledge of and experience with devices of this nature. No repairs should ever be undertaken or attempted by anyone not having such qualifications. it is strongly recommended that genuine replacement parts manufactured or sold by Ohmeda be used for all maintenance, service and repair involving this product. Read completely through each step in every procedure before starting the Procedure; any exceptions may result in a failure to properly and safely complete the attempted procedure. Fr 1500-0034-000 12/25/921/Antroduction 1.1 Notes, Cautions and Warnings ‘Throughout this manual notes, cautions and warnings have special meaning: Note: Is used to stress a point. Important: Is similar to a note but used for greater emphasis. Axcavtiow: ts for procedures or information that must be closely followed to help prevent possible damage to equipment. Awwarninc: ts for procedures or information that must be closely followed to help prevent injury to people. 1.2 Symbols The following symbols are used on Ohmeda products and technical manuals. No one product or manual has every symbol listed. On (power) Off (power) Standby Standby or preparatory state for a part of the equipment “ON" only for part of the equipment | oO © o © oO “OFF only for part of the equipment Direct Current Alternating Current Protective earth ground Earth Ground Frame or chassis ground Alarm silence button I+ A \ +R © 2 Minus, negative polarity ‘Lamp, lighting, illumination ‘Movement in one direction ‘Movement in both directions a in an © vresnauvni KR type w equipment ) yrurcnen \~ Type CF equipment AX warning 180 7000-0085 BS ep ZA oeveation,consut accompany. ing documents, IEC 601-1 Equipotential I risway up Variability 4 pangerois Vottage Variabaity in steps Input Pius, positive polarity DQ outoue 1500-0034-000 12/28/82 TTTable of Contents 1.1. Note, Important, Caution and Warning. 1.2 Symbols 1.3. Standard Service Procedures. 1.4 7800 Ventilator Configurations. 2/Theory of Operation... 2.0 Ventilator overview. 2.1 Pneumatic Description. A. Gas Inlet Valve B. Pressure Regulatio} 2.2 Electronic Descriptions. A. Cordsets. B. Filter, Breaker, Selector, Transformet C. Power Supply Board. D. Multilayer Control Boar E. Front Panel Board... F. Pressure Transducer Board.. G. Header Board. H. EMC/Interface Board. 3/Post-Service Checkout. 1500-0004-000 12/2572 iitTable of Contents 4/Tests and Calibration. 4.0 Overview. 4.1 Bellows Assembly Tests A. Visual Inspection. B. Bellows Assembly Pressure Leak Tes C. Additional Bellows Assembly Tests.. 4.2 Control Module Tests.. A. Power Supply Test..... B. Checking User Parameters. ©. Service Calibration Mode. D. Touch Sense Test.. E. Leak Test. F. Ground Impedance Test. G. Leakage Current Test 5/Maintenance Schedule. 6/Troubleshooting .. 6.1 Troubleshooting Guidi 62 Ventilator Failure Messages 7/Repair Procedure: 7.0 General Information. 7.1 Control Module Removal. A. Shelf Mounting B Optional Arm Mounting. 7.2 Major Assembly Replacement A. Control Board and EPROM Replacement.. B. Front Panel Board Replacement. C. Pressure Transducer Board Replacement D. Power Supply Board Replacement... E, Header Board Replacement. F, EMC/Interface Board Replacement... G. Primary Regulator Replacement. H. Pneumatic Manifold Assembly and EEPROM Replacement iv 11500-0084-000 12/25/82Table of Contents 8/llustrated Parts List 8.0 General Information. Major Assemblies 8.1 Assemblies and Components Non-Autoclavable Bellows Assembl; Autoclavable Bellows Assembly. Primary Regulator and Gas Inlet Valve Pneumatic Manifold. Front Panel. ‘Transformer. Power Supply. Transformer Mounting Internal Pneumatic Enclosure Upper Control Module. Lower Control Module. Lower Control Module (Continued). Pneumatic Mounting Panel Solenoids and Pressure Transducer Board. Hoses TA1-TAS and Tube TAG. Tubes TA7 - TA13.. Pneumatic Chamber.. Control Board and Cables. EMC/Interface Board, Stand-Alone. EMC/Interface Board, Excel Mount. Bottom Shroud, Stand Alone Bottom Shroud, Excel Mount. Pneumatic Cover, Stand Alone. Pneumatic Cover, Excel Mount Cover and Knobs.. Gas Supply Filter (Air Supply Only). 11500-0034-000 12/25/02Table of Contents 9/Schematic: 8.3 Accessories ‘Sensor Related Parts. Drive Gas tube: Excel Interface: Mounting Options Gas Supply Hoses. Test Plug. 8.4 Related Manuals... Pneumatic Schematic. Filter, Breaker, Selector, Transformer. ‘Power Supply board. Control Board. Front Panel board. Pressure Transducer board. Header Board... EMC/interface board... Excel/Ventilator Interface Cable (Excel Mount only). Patient Interface Box and Internal Excel Machine (Excel Mount only). vi 11500-0034-000 12/25/02 een f1/Introduction 1.3. Standard Service Procedures Operation and Service Manuals You must have, and be familiar with, the the Operation and Maintenance manuals for this product. Study the Anesthesia System Operation and Maintenance manuals if you need further information about the operation of the system. You must determine where a problem is located before you can determine which service manual to use. Refer to the various service manuals or accessory manuals if you require more information. Autoclavable Bellows Assembly The Autoclavable Bellows Assembly is operator maintainable. For more information see the Ventilator Operation and Maintenance manual, or the Autoclavable Bellows Assembly, Operation and Maintenance Supplement. Stock Numbers for Replacement Parts Stock Numbers can be identified in the “8/Ilustrated Parts List" section of this manual. Parts can be obtained through Ohmeda offices/distributors. Ventilator tests Normal operational tests can be performed while the Ventilator is installed in, or attached to, an Anesthesia System. Calibration, troubleshooting or repair may require removing the Ventilator from the Anesthesia System. A.waRNinG: Section *4/Test and Calibration" must be performed whenever you remove a Ventilator cover, to verify that all critical parts of the Ventilator are still operational and within specification. Awanninc: After the Ventilator has been serviced, you must perform section “3/Post-Service Checkout" to verify the entire Anesthesia System before the system can be returned to clinical uso. Awwarnina: Do not perform testing or maintenance on this instrument while it is being used to ventilate a patient, possible injury may result. 12 11500-0034-000 127257821/Antroduction 1.4 7800 Ventilator Configurations The 7800 Ventilator (hereafter called Ventilator) is available in significantly different product packages. The easiest way to distinguish between the different Ventilators is by the extended pneumatic compartment that sticks out the back. This manual is exclusively for the Ventilator with the extended pneumatic compartment and Product Group Code CAX. Verify the Product Group Code before you proceed. Extended Pneumatic Compartment Figure 1-1 7800 Configuration 11600-0034-000 12/25/92 131/Introduction The Ventilator's two basic units: + the Bellows Assembly; which contains the Bellows and Bellows Housing, and ‘* the Control Module; containing the control valves, processing circuits, controls, monitors and display screen. The Ventilator is available in two configurations: * Excel Mount; as an integrated Ventilator in an Ohmeda Excel Anesthesia System, or as a * Stand-alone; for use with other Anesthesia Systems. Differences in these configurations include: * How the Control Module and Bellows Assembly are mounted. * Connections between the Control Module, Bellows Assembly and Anesthesia System. * Connection of the oxygen and volume sensors. 1-4 7600-0034-000 12/25/921/introduction A. Stand-alone The Control Module can be mounted on an optional amm, or stand. The Bellows Assembly can be mounted on top of the Control Module, or directly to an Ohmeda GMS absorber (using an interface manifold). A power switch on the lower front panel, controls Ventilator power up. Oxygen and volume sensors connect directly to the lower front panel of the Control Module. B. Excel Mount The Control Module can be mounted on an optional arm, or from the system shelf. On systems with flowmeters extending all the way to the top shelf, the Control Module can hang, by a bracket, from the shelf to the right side of the flowmeters. On systems with the lower shelf extending over the flowmeters, the Control Module can hang, by a bracket, directly from the shelf over the flowmeters. The Bellows Assembly can be mounted on top of the Control Module, on an optional am, or directly to an Ohmeda GMS absorber (using an interface manifold). The Anesthesia System On/Standby switch, controls Ventilator power up. Oxygen and volume sensor connections are located on the front left or right side of the Excel, below the table top. Figure 1-2 Stand-alone Figure 1-3 Excel Mount 1500-0034-000 12/28/922/Theory of Operation 2.0 Ventilator overview The Ventilator provides mechanical ventilation of patients during surgery. It is a microprocessor controlled pneumatic device. The Ventilator consists of two major parts: * The Bellows Assembly; which isolates the Driving Gas from the Breathing Gas. * The Control Module; which contains the electronic and pneumatic components, moves Breathing Gas via the Bellows Assembly, and monitors oxygen, pressures and volumes. '1500-0084-000 12/25/92 a12/Theory of Operation The Control Module ‘The Control Module is usually mounted inside the Anesthesia System, near the flowmeters. Knobs and switches on the front of the Control Module are used to select operational parameters. A Liquid Crystal Display shows current parameter information, alarms and error messages. The Front Panel also has an Alarm Silence Button with a red and a yellow alarm light (Light Emitting Diodes). The Control Module uses a compressed gas source (typically compressed oxygen) to pneumatically control patient ventilation. The gas is usually supplied by the Anesthesia System from either attached cylinders or a pipeline Gas Supply. A microprocessor controls the operation of the Control Module. The microprocessor performs all of the timing, monitoring and sequencing involved ‘n applying positive controlled pressure to the Bellows. The main program memory is an EPROM (Erasable Programmable Read Only Memory). This memory retains its contents when the power is turned OFF. The EPROM holds the permanent preprogrammed application software package. The software revision number can be displayed in a special subroutine called the "Setup Page.” Certain user set parameters are stored in an EEPROM (Electrically Erasable Programmable Read Only Memory) that can be altered under program control. These include operator selected parameters that may vary between sites, such as speaker volume or altitude setting, and are not likely to be changed during a case. The EEPROM also contains the factory set calibration parameters for the Flow Control Valve (part of the Pneumatic Manifold assembly). The calibration parameters can not be programmed in the field. Ventilator data can be communicated to another device through an RS232 connection. 2-2 1500-0034-000 12/25/922/Theory of Operation The Bellows Assembly The Drive Gas output of the Control Module is used to impress patient gas on the patient through a Bellows. The Drive Gas is on the outside of the Bellows and the patient gas is isolated on the inside. There is no direct connection between the two gas volumes. The Ventilator moves breathing gas to the patient by applying positive pressure on the breathing circuit. Exhalation occurs when the Ventilator releases the positive Drive Gas pressure to atmosphere. The Ventilator Drive Gas output is connected to the Bellows Assembly by a flexible hose. A small diameter pressure sensing tube connects the patient Breathing Circuit to the Control Module which monitors pressure in the Breathing Circuit. The operator can select an adjustable inspiratory pressure limit which limits the inspiration phase of ventilation when excess pressure is detected. An independent Pressure Relief Valve is located inside the Bellows. If excess gas accumulates during exhalation, this valve will open and exhaust the excess breathing gas. 1500-0034-000 12/25/922/Theory of Operation 2.1 Pneumatic Description TAIZ ‘Transducer SOL2(ON) ag ate 3 | jaw J ag E 1 1 | Flow Control Valve (exe ! = 1 7 ‘Tals I mas | : 72) |) Pneumatic E Manifold Gas Inlet Valve (ON) [| [] | Assembly ee = @ ||i------ -- im a le Gas Inlet Filter Supply Gas Figure 2-1 Block Diagram Pneumatic Circuit. High Pressure High Pressure ‘Transducer Limit Switch 2-4 1500-0034-000 12/28/92 a i2/Theory of Operation A. Gas Inlet Valve ‘The Gas Inlet Valve switches the Supply Gas entering the Control Module. The Gas Inlet Valve and Inlet Solenoid together form a valve that is normally OFF. The Supply Gas is tumed ON by the microprocessor at power up. If the electrical power ever fails, the Gas Inlet Valve shuts OFF. Inside the Gas Inlet Valve is a Shuttle (Spoppet). The Shuttle has a small control stop on one end which blocks or allows the flow of Supply Gas to the Primary Regulator. When the Inlet Solenoid is OFF, a pressure differential holds the Shuttle in the closed position. ‘The Inlet Solenoid must be activated (have current flow) in order for the Gas Inlet Valve to allow Supply Gas into the Control Module. When the Inlet Solenoid is tumed ON, the energized coil attracts a plug that blocks the inlet orifice. At the same time, the exhaust orifice is opened. The compressed gas at the large side of the Shuttle is vented through the Inlet Solenoid. The pressure on the small side of the Shuttle moves it, opening the Gas Inlet Valve. Inlet Solenoid Inlet Solenoid SOL2 (OFF) SOL2 (ON) Primary Regulator Supply Gas ‘Supply Gas Figure 2-2 Inlet Solenoid and Gas Inlet Valve, OFF and ON 11500-0084-000 12/25/92 2-52/Theory of Operation B. Pressure Regulation The Ventilator has a Primary Regulator and a Secondary Regulator. The Primary Regulator is mounted next to the Gas Inlet Valve. Supply Gas enters the Primary Regulator directly from the Gas Inlet Valve. The Primary Regulator output connects to the Pneumatic Manifold Assembly which contains the Flow Control Valve. The output of the Primary Regulator also goes to a Secondary Regulator that further reduces the pressure. The output of the Secondary Regulator is used to inflate the Exhalation Valve. Bleed ‘Secondary Secondary Regulator Regulator Output Gas Inlet Valve Primary Regulator || ~<— supply Gas Input Output Primary Regulator Figure 2-3 Primary Regulator and Secondary Regulator 2-6 11500-0034-000 12/25/92 meen2/Theory of Operation Cc. Flow Control Valve ‘The drive for Inspiration is an increase in pressure applied to the breathing circuit. Ventilation Drive Gas flow is supplied by the Flow Control Valve. ‘The precise amount and rate of Inspiration is accurately controlled by the microprocessor through a Digital to Analog converter. The microprocessor proportionally changes the Drive Gas flow by changing the current applied to the Flow Control Valve. If the power is removed the Flow Control Valve shuts OFF. Exhalation Valve (inflated) Drive Gas Gas In igh Pressure Sensor biti so Free Breathing valve Figure 2-4 Pneumatic Manifold Assembly Inspiration ‘The Flow Control Valve releases positive pressure into the Drive Chamber. As gas enters, the Drive Gas pressure builds up in the Drive Chamber, through the flexible hose, and increases the pressure in the Bellows Assembly. During the inspiratory phase of ventilation the Drive Gas increases the patient circuit pressure and, in combination with the duration, determines the tidal volume. 71500-0034-000 12/25/922/Theory of Operation D. Exhalation Valve The Pneumatic Manifold Assembly has an intemal Exhaust Chamber. The Exhaust Chamber is open to atmosphere through the back of the Control Module. Note the louvers above the Drive Gas output on the rear panel. Exhaust gas from the two solenoids and the Secondary Regulator, is connected to the Exhaust Chamber and relieve directly to the atmosphere. During the Exhalation phase, the Exhalation Valve is deflated and Drive Gas pressure is released to the atmosphere through the Exhaust Chamber. Flow Control Valve (Closed) Gas In Figure 2-5 Pneumatic Manifold Assembly Exhalation The Drive Chamber and Exhaust Chamber are separated by the Exhalation , Valve. The Exhalation valve inflates, like a balloon, to seal OFF the opening. | Exhalation Valve Louvers 1500-0034-000 12/25/922/Theory of Operation Exhaust Secondary Regulator -———— Exhalation Output Solenoid SOL1 (ON) (Low Pressure) — Regulated —» [| Proseure => Secondary Regulator } -kenalation Vaive Figure 2-6 Exhalation Valve Inflating During inspiration, positive pressure is held in the Drive Chamber by inflating the Exhalation Valve. Positive Pressure builds in the Drive Chamber, Drive Gas Hose and the outside chamber of the Bellows Assembly. The Flow Control Valve allows gas flow for the desired inspiratory time. Approaching the end of inspiration the Flow Control Valve is tumed OFF. If inspiratory pause (Typ) is ON, the Exhalation Valve will remain inflated for an additional 25% of the set inspiratory time. The Exhalation Valve is deflated at the end of inspiration. This relieves the positive pressure in the Drive chamber and allows the drive gas in the Bellows Assembly to be vented through the Exhaust Chamber to the atmosphere. 1600-0034-000 12/25/92 2-92/Theory of Operation 4-——— Exhaust Exhalation Solenoid SOL1 (OFF) Bleed 4 1 Regulated —>| I — : i Pressure cxan> TAIL g leo Secondary Regulator ez ~*~ Figure 2-7 Exhalation Valve Deflating AX”) Bahalation Valve E. Bellows The Bellows isolates the Drive Gas from the Breathing Gas supplied by the Anesthesia Systems. At no time does the Drive Gas enter the patient Breathing Circuit. During the inspiratory phase, the Control Module delivers Drive Gas into the area between the Bellows and the Bellows Housing. As the volume of gas increases, pressure is exerted on the Bellows which compresses. The Bellows in tum exerts pressure on the patient breathing circuit and the patient's Jungs. During the exhalation phase, the Drive Circuit Pressure is vented to the \ -tmosphere. This reduction in pressure allows gas to flow from the patient breathing circuit into the Bellows. The Bellows rises within the Bellows Housing. F. Pressure Relief Valve The Pressure Relief Valve is located within the Bellows. This valve remains closed during inspiration. When the Bellows cannot extend any further during exhalation, the Pressure Relief Valve opens and the excess gas is vented through the exhaust tube. This will happen when the pressure in the patient circuit during ezhalation exceeds the vented Driving Gas circuit pressure by 2.5 cm HO. 2-10 1600-0034-000 12/25/922/Theory of Operation G. Free Breathing The Free Breathing Valve acts as a check valve. Normally the pressure within the Drive Chamber and corresponding Bellows and Breathing Circuit is controlled by the Ventilator. If the patient attempts to inhale, a sudden drop in Breathing Circuit pressure occurs. If the Drive Gas flow is less than the demand, pressure within the Drive Chamber will drop, the Free Breathing Valve will open making up the additional volume with ambient air. This allows the patient to breathe spontaneously. Free Breathing valve Figure 2-8 Free Breathing Valve ¥500-0034-000 12/28/02 2112/Theory of Operation I. Filtering Ventilators may have a replaceable five (5) micron inlet filter and water trap located before the Gas Inlet Valve. A replaceable five (5) micron particulate filter is located between the Primary Regulator and Secondary Regulator. A permanent coarse (150 mesh) screen filter is located where the gas enters the Pneumatic Manifold Assembly. 5 micron Filter Nee ‘Secondary Regulator ME Er Pneumatic Manifold Assembly Gas Inlet Filter Figure 2-10 Pneumatic Manifold Assembly Filter '1500-0034-000 12/25/92 2-132/Theory of Operation 2-14 1500-0034-000 12/25/922/Theory of Operation 2.2 Electronic Descriptions Notation Within this Text Unless otherwise noted, all voltages are positive with respect to signal and supply ground. A */" indicates that for this signal is active (true) at a logic level of zero (0). Some examples are: /CS2, /RD, or /WR. This is often referred to as a “negative logic" or “active low" signal. All voltages are designated as Direct Current "V dc" or Alternating Current "Vac." Voltages are also designated as positive *+" or negative “minus (-).” Some examples are: "+ 4.37 V de," or “minus (-) 4.37 V de." Tolerances are expressed with an additional number: “5.25 40.01 V de.” Current values are designated as Ampere “A dc", milliampere “mA dc" or microampere as “A de." Component Designations Component numbers are separated from pin numbers by a “-." Like this: “U124-2" or “J2-15." Additional pins are separated by a comma “U8-2,3" or *J10-7,8." Typical Notation Part 2. c178 Capacitor R124 Diode F2 Fuse FLI Filter 51, J15 Connector; jumper, jack or plug K102 Relay L103 Inductor Pt Connector; jack or plug R102 Resistor; fixed or adjustable swi01 Switch ui24 Integrated Circuit "1500-0034-000 12/25/92 2-152/Theory of Operation Flow High Control Pressure Inlet__Exhalation Valve Limit Switch Solenoid Solenoid Ventilator . INPUT ___ Switch Stand - alone only igure 2-11 Block Diagram Electrical Connections. 16 1500-0034-000 12/28/922/Theory of Operation A. Cordsets Cordsets vary according to local requirements. The cordsets have an IEC 320 style connector at the Control Module end. The cordset is secured to the «Control Module to prevent accidental disconnect. Filter, Breaker, Selector, Transformer The line cord connects directly to the power inlet electromagnetic interference filter, FLTR. The device filters interference going to and coming from the Control Module. ‘The output of the filter goes to a 0.5 A double pole circuit breaker, BKR. Excess line current, or neutral current, can cause this circuit breaker to open, disconnecting both inputs. The transformer windings are selected by a multiple pole voltage selector switch (VSC). The combinations of windings provide for different selectable primary voltages (100, 120, 220, 240 V ac). ‘The transformer has internal thermal protection and will open the primary winding if the temperature reaches 150°C. The secondary of the transformer steps down to a center tapped 32 V ac. '1500-0034-000 12/25/92 2-172/Theory of Operation C. Power Supply Board The Power Supply Board converts a de or ac input, to a +5.2 V de, 3A de power supply, using a step-down switching regulator configuration. The ac input is supplied by a transformer secondary with a center tap connection. The input voltage range is from 28.8 V ac (center tapped) minimum, to 48.0 V ac (center tapped) maximum, for a transformer rated at 42 VA. Fuses F1, F2, and F3 provide fault protection in the event of a component failure on the Power Supply board... Ut is an adjustable output, 3A dc step-down switching voltage regulator. ‘he combination of resistors R6 and R8 and potentiometer R7 provide a typical output voltage adjustment range of from +4.3 to +5.8 V de. U2 is a power supply supervisory circuit, used to monitor over and under voltage fault conditions. When a dc output voltage exceeding +6.17 V de (typical) is detected for a period exceeding 125 microseconds (typical), U2-1 will go to logic 1, and cause crowbar SCR CRS to conduct. Once SCR CRS is tured ON, it will remain ON as long as input power is applied to connector J1; the voltage at J2-1 and J2-2 will be reduced to the forward drop of CRS (0.8 V dc typical). When an unregulated voltage exceeding +36.6 V dc (typical) is detected for a period exceeding 1.25 milliseconds (typical), the open collector output U2-6 will turn OFF, and be pulled to a logic 1 by R11. Resistors R3 and R4 provide a high impedance path from de ground, to chassis ground. Capacitor C6, provides a high frequency path from de ground to chassis ground, for electrical noise and electrostatic discharge. Chassis ground | 7 tied to this circuit board through the heatsink on U1 . Connector J3 supplies power to an LED whenever ac power is supplied to the Power Supply board. This LED may be used to indicate to the user that the Ventilator is energized by mains voltage. 2-18 1600-0034-000 12/25/022/Theory of Operation D. Multilayer Control Board 1. Power Source Selection [Sheet 5 of schematic] ‘The + 5 Vdc power supply voltage is connected to the Control Board via J3-1,2 (+) and J3-3,4 (-). Fuse F102 limits current to 4A dc. On the 7800, a backup battery pack is connected via J2-1 (+) and J2-3 (-). Output U145-1 (PS OK) is high if the external supply voltage is greater than +4.58 £0.09 V de . If it drops below +4.58 +0.09 V de, K102 will switch ventilator supply voltage from the external supply to the battery. Output U145-7 (BAT_OK) will be high if the battery voltage is above +4.37 40.06 V de. Headers J14 and J15 (jumpered, 7850 only) provide the capability of using the ventilator without an internal battery pack. 2. Auxiliary Supply [Sheet 5] U138 is a step-up switching regulator that generates 9.65 +0.39 V de which is used for the battery charger and the TVX heater. 3. Battery Charger [Sheet 5] U139 is an adjustable linear voltage regulator which provides current to charge the NiCad battery pack connected between J2-1 and J2-2 . R229 and R282 limit the current delivered to the battery when it is fully charged. 1500-0034-000 12/25/82 2-192/Theory of Operation 4. TVX Heater Source Voltage [Sheet 5] The TVX heater (external) consists of two 272 (¥% Watt) resistors in series — located in the TVX clip. The TVX heater can be connected to the Front Panel board or J18 on the Control Board. When connected to the Front Panel board, the TVX heater is powered from the +5 V dc, the heater current is sensed on the Front Panel board, and a sense signal is supplied to the Control Board through J1-9 (TVX SEN). When the TVX heater is connected to J18-1,2 on the Control Board, it receives its power from the auxiliary supply (U138) and the heater current is sensed on the Control Board. R131 and CR118 provide two power paths for the auxiliary supply (U138). Power is supplied through CR131 during normal operation and is supplied through CR118 during backup operation. 5. System Power Up Relay [Sheet 5] System power up relay K103 switches the VCC power source selected by K102, to the rest of the ventilator system. K103 can be energized by shorting jumper J4 on the Control Board or by connecting REMOTE+ to REMOTE- with a remotely located switch. VCC is routed to the digital circuits, to the flow, gas inlet, and exhalation valve control circuits, and also to the dc-dc converters. 6. +VA, -VA and VPPFLASH Switching Regulator [Sheet 5] U143 and the associated components generate +VA, -VA and VPPFLASH. +VA is regulated to +8.3 40.3 V de, -VA is regulated to minus (-) 8.3 40.6 V de, and VPPFLASH is regulated to +17.0 41.6 Vdc. The +VA and -VA supplies to the Pressure Transducer board are provided through connector J6. 7. \VPPFLASH-Post Regulated Flash Programming Supply [Sheet 5] ‘The flash memory programming power supply (VPPFLASH) generates 12.0 +0.6 V dc and delivers a minimum current of 30 mA. 8. E.L, Panel Driver [Sheet 5] 1108 is a de-to-ac converter which develops 80 +20 V ac at 700 +100 Hz with an electro-luminescent panel connected to its output. R114 provides a 1aeans for adjusting the output voltage to the EL panel, affecting its brightness. J11 is for de-energizing the EL panel. 2-20 1500-0034-000 12/25/922/Theory of Operation 9. Power Up RESET and Program Flow Watchdog Timer [Sheet 3] This watchdog circuit is designed to detect errant program execution as well as provide a watchdog time-out function. A negative reset pulse will occur at U128-3 if the circuit is not toggled in an appropriate time or if incorrect program execution is detected. The on-board audio alarm (BZ1) will sound when multiple consecutive errors have been detected. U127 monitors the power supply voltage level and forces a system reset ifa low VCC voltage error or out of limit condition is detected. The voltage trip point is set at 4.5 V de maximum (4.37 V dc typical). 10. Too-Fast, Too-Slow Watchdog Timer [Sheet 3] The watchdog timer U128 monitors the frequency of the microprocessor watchdog input U128-2 (WDOGIN) to detect processor too-fast or too-slow conditions. The watchdog timer will reset the microprocessor if either condition occurs. 11, 64x 16 EEPROM [Sheet 1] U114 is a 64 register by 16-bit Electrically Erasable Programmable Read Only Memory (EEPROM). All data transfer to and from the device is done serially. 12. Microcontroller Oscillator [Sheet 1] X101, C104-C105, and the oscillator circuit in U104 form a 12 MHZ oscillator which provides the master clock for the 80C31 Microcontroller. 13. RS-232 Interface [Sheet 1] U108 is a dual RS-232 receiver/transmitter. It contains two voltage converters which generate +10 V de and (minus) -10 V dc from +5 V de. U108 contains four 4-level translators. Two of the level translators are RS-232 transmitters and convert TTL/CMOS input levels into +9 V de and minus (-) 9 V de RS-232 outputs. The other two level translators are RS-232 receivers which convert RS-232 inputs to +5 V de TTL/CMOS output levels. A single transmitter and receiver are used. The output of the transmitter and the input of the receiver are connected to JS. 1500-0034-000 12/25/92, 2-212/Theory of Operation 14, Microcontroller [Sheet 1] U104 is a 80C31 CMOS 8-bit Microcontroller running at 12 MHz with: * 128 x 8-bit RAM, © 32 programmable I/O lines, © two 16-bit timer/counters, * 64K program memory space, * 64K external data memory space, * programmable serial port, and * 5 interrupt sources. Eight of the I/O lines are used for the multiplexed lower address/data bus and eight additional lines are used for the upper address bus. Lhe remaining port lines are used to: * receive the TVX transducer interrupt, * read the TVX transducer direction input, * control the 32-channel multiplexer, * send and receive data from the EEPROM, * maintain the watchdog timer, * send and receive serial communication, © determine when an A/D conversion is complete, * provide read and write signals for extemal data memory and mapped devices. 15, Address Decode [Sheet 1] The 80C31 Microcontroller has separate 64K address spaces for program memory and external data memory. /RD and /WR control access to external data memory. /PSEN controls access to program memory. U101 and U146 determine which circuits will be accessed by the Microcontroller by decoding address lines A4 through A15 and generating the individual chip select signals (/CS1 through /CS7). 2-22 11600-0034-000 12/25/922/Theory of Operation 16. 64K x 8 Program Memory [Sheet 1] U112 can be a 64K x 8-bit CMOS FLASH memory, or a 64K x 8-bit CMOS EPROM. The FLASH memory is a 32 pin Dual-Inline-Package (DIP); the EPROM is a 28 pin DIP. For compatibility, the EPROM must be placed in the 32-pin socket so that pin 1 of the IC is placed in position 3 of the socket. 17, BUS TRANSCEIVER [Sheet 1] U110 is an octal bus transceiver. It provides buffering and direction control. 18. 8K x 8 Static RAM [Sheet 1] U102 is an 8K x 8-bit CMOS static Random Access Memory. 19. Address Latch [Sheet 1] U111 is an 8-bit address latch used to de-multiplex the lower address lines from the address/data bus. 20. 8-BIT Output Port [Sheet 3] U132 is an 8-bit output port. Pin Signal Function U132-12 EE_CLK Clock for EEPROM U132-13 EEPCS Select line for EEPROM U132-14 TVXHTRON ‘TVX heater, control line U132-15 SUP_VAL Inlet Solenoid, control line U132-16 = YELLED Front Panel, Yellow LED, control line U132-17 REDLED Front Panel, Red LED, control line U132-18 EX_VAL Exhalation Solenoid, control line U132-19 CHRG Battery Charger, control line "1500-0034-000 12/25/92 2-232/Theory of Operation 21. 8-BIT Input Port [Sheet 3] U133 is an 8-bit input port. Inputs are from 7 DIP switches used to select feature options on the ventilator and an external alarm silence signal. U134 is an 8-bit input port Pin Signal Function 134-2 BRD_ID_O J102 not installed = 0, J102 installed = 1 134-3 BRD_ID_1 J103 not installed = 0, J103 installed = 1 134-4 BRD_ID_2 J104 not installed = 0, J104 installed = 1 U134-5 OVR_PRES —fault=1; pressure exceeded high limit U134-6 UDER_VLT _fault=0; VCC below 4.6 V de "J134-7 OVER_VLT —fault=0; VCC above 5.4 V de 134-8 TVXHTRON TVX=1, heater is ON; TVX=0, heater is OFF U134-9 PROT_REG = EEPROM protect register control line 22. Voltage Reference [Sheet 2] U120 is a precision reference that generates a +2.5 V dc reference for the VCC overvoltage/undervoltage monitor circuit (sheet 4) and the Flow Control Valve drive circuit calibration (sheet 4). U121-2,3,6 amplifies this reference to a +4.5 V dc reference used for A/D and D/A conversion. U113-8,9,10 forms a voltage follower circuit, which buffers the +4.5 V de and goes to J6-1 (Pressure ‘Transducer board). U115-8,9,10 provides a buffered reference for use on J1-11 (Front Panel board) and the Test Connector J10-7. 23. Patient Pressure Analog Output [Sheet 2] Jne half of dual 8-bit latched multiplying DAC U105 (DAC A) along with C118 and U113-1,2,3 generates a voltage which can be controlled by the Microcontroller. The circuit is designed so that a 0 code latched into DAC A will generate 0 V dc, while an 8CH code (140 decimal) will generate +1 V dc (One LSB = 1 cm H,0). 2-24 1500-0034-000 12/25/922/Theory of Operation 24. Flow Control Valve [Sheet 2 & 4] The second half of DAC U105 (DAC B) along with U113-5,6,7 and related components generates another voltage which can be controlled by the Microcontroller. The signal at U137-1 can be varied between 44.2 mV dc and 0.0 mV dc with a 0 code input to U105, DAC B and varied between +245 mV dc and +409 mV de with a OFFH code input to DAC B. 25. Flow Control Valve Drive / Sense [Sheet 4] U137-1 (DAC_FLOW) is tied to the input of the differential amplifier U137-6 The differential amplifier generates the difference between VCC and DAC_FLOW at U137-7. This voltage is applied to U137-10, the input of the voltage to current converter. The current to pass 100 L/min through the Flow Control Valve is nominally 1200 mA de. The output of U137-8 is connected to Front Panel switch SW108. This interlocks the Flow Control Valve drive circuit with the Mechanical Ventilation switch. If the switch is open, the Flow Control Valve is shut OFF regardless of the voltage at U137-8 . U137-12,13,14 amplifies the sense voltage. This voltage is connected to one channel of the A/D converter for sensing correct drive circuit operation. U135-4,5,6 provides an additional interlock which keeps the Flow Control Valve OFF if the Exhalation Valve is ON. 26. Oxygen Analog Output [Sheet 2] One half of dual 8-bit latched multiplying DAC U103 (DAC A) generates a voltage which can be varied by the Microcontroller. A 0 code latched into DAC A will generate 0 V de, while a C8H code (200 decimal) will generate +1 V dc on U115-1 (One LSB = 0.5% 0). | 27. LCD Contrast Driver [Sheet 2] One half of dual 8-bit latched multiplying DAC U103 (DAC B) generates a voltage which can be varied by the Microcontroller. The circuit is designed to generate 0 V dc to (minus) - 4.5 V de, depending on the value latched into DAC B. This output is connected to the Front Panel board and is. used to vary | the contrast of the Liquid Crystal Display. 1500-0034-000 12/25/92 2-252/Theory of Operation 28. A/D Converter [Sheet 2] U117 is a CMOS 10-bit Analog-to-Digital converter with a conversion time of 50 HS (typical). The full scale input voltage is set to +4.500 V de at U117-9 . 29. 32-Channel Multiplexer [Sheet 2] U116, U119, U122 and U123 are CMOS single 8-channel analog multiplexers. Together they form a 32-channel multiplexer. The Microcontroller uses signals /MUXI, /MUX2, /MUX3, MUX4, MUXA, MUXB, and MUXC to select a specific multiplexer channel. 30. System OK / Valve Interlock [Sheet 4] Gates from U131 and U135 form an interlock for the Exhalation Valve (which also interlocks the Flow Control Valve). RST (the watchdog circuit reset) must be low and PS_OK or BAT_OK from the power source selection circuit must be high in order for SYS_OK to be high. SYS_OK is also ANDed with EX_VAL and if SYS_OK is low, the Exhalation Valve will not tum ON. SYS_OK is also sent to the Front Panel board to force a system fail response if it goes low. 31. Exhalation Valve Drive and Sense [Sheet 4] Operational amplifier U136-1,2,3 and 0104 acts as a current limited high side driver. The voltage at Ui36-7 (EXHSENS) may be monitored by the controller through one channel of the A/D converter U117 (sheet 2). A normally open (NO) pressure sense switch is connected between J16-1,3 . If the pressure sensed by the switch rises to 105 +5 cmH20, the switch closes. ‘This de-energizes K101, disconnecting the Exhalation Solenoid valve. K101 will latch itself OFF until EX VAL is driven low. This provides a high pressure safety relief in the event that the patient pressure sensing circuit of the Ventilator is inoperative. | 32. Gas Inlet Valve Drive and Sense [Sheet 4] Operational amplifier U136-8,9,10 and MOSFET Q106 forms a current limited high side driver for the Gas Inlet Valve. It operates the same way as the Exhalation Valve. The Inlet Solenoid is normally ON throughout Ventilator operation. The voltage at U136-14 (GIVSENS) may be monitored by the controller through one channel of the A/D converter U117 (sheet 2). "1500-0034-000 12/25/92 i2/Theory of Operation E. Front Panel Board 1. System Fail Logic SYSOK is generated by the Control Board and is high if the Power Supply and watchdog circuits are functioning correctly. If a failure occurs, SYSOK tums OFF the red LED, and tums ON the yellow LED. The Liquid Crystal Display also goes blank and the audio alarm section activates. 2. LED Alarm Indicators The red LED (CR31) and the yellow LED (CR32) located on SW109 are driven by transistors Q6 and Q5 respectively. Transistor Q6 is controlled by REDLED and Q& is controlled by YELLED from the Control Board. 3. Liquid Crystal Display The Liquid Crystal Display Module is connected to the Front Panel board at JS. It is an intelligent device that receives commands and data from the microprocessor on the Control Board. VEE is the display drive voltage which is controlled by V_DISP, generated on the Control Board. Liquid Crystal Display contrast is related to the voltage difference between VCC (J5-2) and VEE (J5-3). Diodes CR1-CR4 and CR23- CR25 provide a voltage change with temperature of about minus (-)9.5 mV dc/°C. This closely matches and balances the temperature sensitivity of the Liquid Crystal Display. An electro-luminescent panel is contained in the Liquid Crystal Display. An ac voltage of 80 + 20 V ac mms at 700 Hz +100 Hz, powers the EL panel. The ac voltage comes from the Control Board (J1), and goes to the Liquid Crystal Display. 4. Front Panel board Input U110 functions as an 8 bit input port. The Front Panel switch matrix, touch detection circuit, and variable frequency audio alarm are input to the processor through this port. 1500-0034-000 12/25/92 2-272/Theory of Operation 5. Front Panel Switches ‘The following switches are wired in a 4 x 7 matrix: * Pushwheel Assembly (Low MV, Low Oz, High O; $W102-SW107 Alarm Reset switch Mechanical Ventilation switch Inspiratory Pause switch -—- Future Switch Expansion ~- ‘The pushwheel format is BCD (Binary Coded Decimal). 6. TVX (Volume) Transducer Input The TVX Volume Transducer (connected at J2) provides two input signals in the form of pulse trains PULSE A and PULSE B. The frequency of each signal ‘s proportional to the amount of gas passing through the transducer. When flow is in the expiratory direction (direction indicated on the label on the transducer clip), PULSE B leads PULSE A. When flow is in the opposite direction, PULSE B lags PULSE A. R106 is connected in the retum line of the TVX clip heater when the clip is plugged into J2. The voltage generated across R106 is used to sense if the TVX clip is plugged in. 7. Oxygen Sensor Input The oxygen sensor (connected at J2) generates a current which is proportional to the partial pressure of oxygen in the sample gas. Two cells may be present in the sensor but only a single cell, SENSOR_A input, is used. The load presented to this cell is 617 ohms at 25 °C. The other cell, SENSOR_B input, is shunted to ground. Note: The oxygen sensor should be shunted to ground through a load resistor at all times for proper operation. Leaving a sensor open-circuited causes oxide | to develop on the cells. When the cell is later reconnected it may take several hours before normal operation of the cell resumes. Calibration of the circuit is done via software using a gain value derived from the oxygen calibration potentiometer (R80) setting. 2-28 1500-0034-000 12/25/922/Theory of Operation 8. Control Potentiometers R101-R103 and R105 are the Front Panel potentiometers used to set values for tidal volume, respiratory rate, inspiratory flow, and inspiratory pressure limit used by the Ventilator. Each potentiometer has 270 degrees of mechanical travel range. Appropriate scaling is done in the software. 9. Audio Alarm Two sections of the quad op amp U112 are used to generate +0.95 V de and minus (-) 0.95 V dc voltages from the reference +4.500 V dc supply. These voltages are used in the audio alarm circuit. One half of the dual 8 bit DAC U111 controls th frequency of a square wave oscillator. The other half of DAC U111 controls the gain of the square wave signal. If SYSOK is low, this signal drives the speaker connected to J8. A CMOS 555 timer, configured as an oscillator, generates an approximately 1 kHz waveform. If SYSOK is high this signal, instead of the microprocessor generated signal, drives the speaker. 10, Touch Detection Circuit There are three identical touch detection circuits, one each for the Tidal Volume, Rate and Inspiratory Flow setting knobs on the Front Panel. The knobs have a conductive front surface which is electrically connected to the Front Panel circuit board. Capacitors dc isolate the knob from the rest of the circuit. A 500 kHz oscillator is connected to the detection circuit. The circuit operates by using body capacitance (about 30-100pF) to lower the impedance to ground and reduce the amplitude of the 500 kHz signal. The signal is fed to a peak detector which outputs a signal equal to the difference at its inputs as the knob is touched. This signal is amplified for maximum gain without false triggering from noise. The output signal is low when the knob is not being touched. The output signal is high when the knob is first touched. The signal falls low again after about 1 second, as the low pass filters respond. 11. Flow Control Valve Interlock One half of the mechanical ventilation ON/OFF switch (SW108) is connected so as to interrupt the control loop on the Control Board which drives the Flow Control Valve. If SW108 is OFF (open), the control signal is disconnected, forcing the Flow Control Valve OFF. '1500-0034-000 12/25/92 2-292/Theory of Operation F. Pressure Transducer Board 1. Power Supply Power is supplied to the board via connector J1-6 (+8.30 +0.35 V dc), J1-5 [minus (-) 8.3 £0.60 V dc], J1-7,8 (analog ground) and J2-1 (chassis ground). 2. Voltage References U7 is a +2.5 +0.005 V de voltage reference with a 25 ppm/"C maximum temperature coefficient. The +2.5 V de reference drives amplifiers U6A and U6B which generate the +5 V de and minus (-) 5 V dc references. These references are used as power supplies for pressure transducers U4 and US and their offset adjustment circuits. The +2.5 V de reference is also used to generate a fixed +0.872 40.03 V dc temperature output reference at J1-4. 3. Patient Pressure Circuit US is a temperature compensated silicon piezoresistive gauge pressure transducer. The offset adjustment R102 is used to set a positive zero pressure output voltage. This positive offset allows the circuit to measure negative pressures. The gain adjustment R101 is used to set the full scale output voltage. 4. Supply Pressure Circuit U4 is a temperature compensated silicon gauge pressure transducer (output, J1-3). Potentiometer R103, R18 and R19 provide an offset adjustment to compensate for circuit offsets. 2-30 1500-0034-000 12/25/922/Theory of Operation G. Header Board ‘The Header board is an interconnection between the cables coming from the Control Board and the cables for the components mounted on the Pneumatic Mounting Plate assembly. There are no active components on this board. H. EMC/Interface Board The EMC assembly is the interface between the Ventilator internal electronics and the sensors. The circuit includes EMI filters and bipolar transient suppressors (transorbs). The EMI filters attenuate electrical noise from Electrosurgical units or other electrical noise generators in the operating room environment. The transorbs protect the EMI filters and the signal input circuitry on the Control Board. The filters and transorbs use the chassis ground as common. High frequency noise is shunted away from the signal lines. '1500-0034-000 12/25/92 2-313/Post-Service Checkout 3.0 Post-Service Checkout After servicing the Ventilator, you must complete section "4/Tests and Calibration.“ You must also complete the Ventilator checkout procedure for the entire system, the Ventilator, the Anesthesia System, and all the accessories and options. Awwarninc: You must perform all post-service checks after maintenance or service of the Ventilator. Malfunctioning equipment can result in serious patient injury. A\warninc: aul components and accessories must be connected correctly. All hoses and cables must be properly connected before returning the Anesthesia System to clinical use. Failure to do so may result in patient injury. 1. Test the Ventilator. Perform section "4/Preoperative checkout procedure” found in the: 7800 Ventilator International Operation and Maintenance Manual Software revision 4.xx 2. Test the Anesthesia System. The Ventilator is an integral part of a complete Anesthesia System. To be certain the Ventilator is functioning perfectly it is necessary to test the entire system. Please refer to the Anesthesia System manuals. Important: If you have an Ohmeda Excel Anesthesia System, complete the system checkout procedure in the Excel Service Manual. 3. Test all Options and Accessories. Complete the checkout procedures for all options and accessories included with the Anesthesia System. 1500-0034-000 12/25/02 oT4/Tests and Calibration 4.0 Overview AAwarNtnc: Do not perform testing or maintenance on medical instruments while they are being used to ventilate a patient, possible injury may result. ‘This section includes failure identification tests and calibration procedures for the Bellows Assembly and the Control Module. Testing Requirements If you service only the Bellows Assembly, and do not remove the Control Module cover, it is not necessary to perform the Control Module Tests. Or, if you service only the Control Module, and do not disassemble the Bellows Assembly, it is not necessary to perform the Bellows Assembly tests. If you are performing routine maintenance it is necessary to complete the entire section. It is always necessary to perform section "3/Post Service Checkout" after this section. Awwarnine: Post-Service Checkout required after you complete this section. You must perform section * 3/Post-Service Checkout" after performing any maintenance, service or repair procedure. Patient injury could result. ‘Viewing Displays in Another Language This manual illustrates ventilator displays in English. The ventilator language selection will determine which language you will actually see. In most cases the displays will be in the local language. You may choose to view the displays in English (by changing the language selection) or you can view the displays in your own language. Change the language setting back to the original language after testing is complete. Note: The altitude and language selection are described in the Operation and Maintenance mamual. '1500-0034-000 12/25/92 4a4/Tests and Calibration 4.1 Bellows Assembly Tests ‘These tests can be used to test both the Autoclavable Bellows Assembly (ABA) and the Non-Autoclavable Bellows Assembly (Non-ABA). Autoclavable parts are identified with the 134°C" marking. Important: The ABA is completely customer maintainable. The end user can disassemble, repair, clean and test the ABA. However, service of the Non-ABA must be performed by a trained service representative. A. Visual Inspection 1. Disassemble the Bellows Assembly. For more information refer to the Operation and Maintenance manuals. A\warnine: On the ABA, do not remove the seat from the Diaphragm. 2. Carefully inspect each component for proper fit, signs of wear, deterioration or damage such as cracks, warpage, swelling or other physical changes, and replace as necessary. It is normal for the ABA Bellows and other rubber goods to change color somewhat from steam autoclaving. AAWARNING: Non-ABA components can not be autoclaved. Non-ABA components that have been autoclaved must be replaced before the system can be returned to clinical use. 3. Reassemble the Bellows Assembly and connect back into the Anesthesia System. 42 1500-0034-000 12/25/92 i4/Tests and Calibration B. Bellows Assembly Pressure Leak Test This test checks the Bellows Assemblies for leakage under pressure by using the Breathing System pressure gauge and the Anesthesia System flow meters. Tools Required: * Ohmeda approved Test Plugs, two (2) ‘* Anesthesia O2 flowmeter * Breathing System pressure gauge * Breathing System, complete Overview First, the entire Breathing System leakage is determined with the Bellows Assembly removed from the circuit. Then the test is repeated with the Bellows Assembly included. The difference between the readings is the Bellows Assembly leakage. The test is done at a pressure of 60 cm H2O. The Bellows Assembly leakage must not be more than 250 mL/min for ABA, and 300 mL/min for Non-ABA. Important: The Breathing System leakage rate may be less than the minimum 02 flow limit, particularly with new systems. Leakage, without Bellows Assembly 1, Set the Breathing System to bag mode, which bypasses the Bellows Assembly. If you have an Ohmeda GMS Absorber, move the switch to *Bag/APL.” 2. Remove the breathing bag and occlude the port. Remove any gas sampling adapters and tightly cap connections. 3. Close the APL valve. Turn OFF any other device that may cause this circuit to leak at 60 cm HO. If necessary consult your Breathing System operation manuals. 4. Turn ON the Anesthesia System and adjust Oz to the minimum flow. All other gasses OFF. 5. Watch the pressure gauge and occlude the patient connection port (*Y* piece). Quickly unplug the port if the pressure approaches 100 cm HO. Ignore or silence alarms. 1500-0034-000 12/25/92 43 -4/Tests and Calibration 6. Slowly increase the O2 flow until the pressure approaches 60 cm H20. Quickly reduce the flow until the flow equals the leak rate. Note the O2 flowmeter reading. This flow is the Breathing System leak rate without the Bellows Assembly. If you can not maintain the pressure at 60 cm HzO and the pressure continues to increase with the lowest flow setting, then the Breathing System leak rate is less than the minimum Oz setting. 7. Remove the patient connection port occlusion. Return the O2 flowmeter to minimum flow. Remove the breathing bag occlusion and attach the breathing bag. Leakage, with Bellows Assembly 8. Set the Breathing System to Ventilator mode (Bag/APL switch to "Ventilator"). Disconnect and occlude the 17 mm Drive Gas hose at the back of the Ventilator Control Module. 9. Watch the pressure gauge and occlude the patient connection port ("¥"piece). Quickly unplug the port if the pressure approaches 100 cm HO. Ignore or silence alarms. 10. Slowly increase the O2 flow until the pressure approaches 60 cm H20. Quickly reduce the flow until the flow equals the leak rate. 11. Note the O2 flowmeter reading. This reading must not be more than 250 mL/min for ABA (or 300 mL/min for Non-ABA) above the Breathing System leak rate. If the leak rate is too high correct the cause and repeat this test. A\cauTion: An unacceptable leak rate requires repair. Do not return the Bellows Assembly to clinical use until the leak is corrected. 12, Remove all occlusions made in the Breathing System during this test. Remove the patient connection port occlusion. Remove the Drive Gas hose occlusion and connect the hose to the Ventilator. Troubleshooting Leaks Disassemble the Bellows Assembly and check the fit of all of the components (except the Non-ABA Pop-off valve, which can not be repaired in the field). The U-cup seal, Waste Gas Valve, Base and tubing are the most likely parts to leak. Systematically replace these components until the leak is corrected. Perform the test again. a4 11500-0034-000 12/25/824/Tests and Calibration C. Bellows Retention Test This tests the Bellows retention, under pressure, by using the Breathing System pressure gauge and the Anesthesia System flow meters. 1. Occlude the patient connection port (*¥* piece) ,and exhaust (Gas Scavenger) outlet. 2. Use the Oxygen Flush button to inflate the Bellows to the top of the Housing. Using the Oz flow valve, increase the pressure to 15 cm HzO as read on the Breathing System pressure gauge. The Bellows must remain on the securing rim. If the Bellows slips off, the Bellows must be replaced. 3. Remove all occlusions and reconnect any hoses that have been removed. D. Additional Bellows Assembly Tests If you have not removed the Control Module cover, it is not necessary to perform the Control Module Tests. Go directly to section “3/Post Service Checkout” if you have NOT serviced the Control Module. A\warwine: Section *4/Test and Calibration" must be performed whenever you remove the Control Module cover, to verify that all critical parts of the Ventilator are still operational and within specification. Awarninc: You must perform section “3/Post-Servico Checkout" before returning the Ventilator to service. Failure to do so could result in injury to the patient. 1500-0034-000 12/25/82 a54/Tests and Calibration 4.2 Control Module Tests A. Power Supply Test ‘Tools Required: Multimeter (4-¥ digit) Preparation: Remove the cover and swing the Control Board up. 1. Power ON the Ventilator. 2. Locate J10, the "TEST" connector, on the Control Board. w10 Figure 4-1 Control Board, TEST Connector J10 3. Measure between J10, pin 12 and pin 2 (AGND) on the Control Board (45.20 V de, + 0.10, -0.15 V de). TEST J10 pin 12 (+5.20) pin 2(AGND) If out of range: a. Remove the Lower Shroud and adjust the voltage through the small hole in the power supply board box. b. Ifnot adjustable, replace the power supply board. 4-6 '1500-0034-000 12/25/924/Tests and Calibration 4, Measure between J10, pin 4 and pin 2 (AGND) on the Control Board (+8.30 + 0.35 V dc). TEST J10 pin 4 (+8.30) pin 2(AGND) If out of range: a. Disconnect the ribbon cable to Jé (on the Control Board) and check the voltage again. b. Ifnow correct, replace the Pressure Transducer Board. ¢. If still NOT correct, replace the Control Board. 6. Measure between J10, pin 6 and pin 2 (AGND) on the Control Board (-8.30 + 0.60 V dc). TEST J10 pin 6 (-8.30) pin 2 (AGND) If out of range: a. Disconnect the ribbon cable to J1 (on the Control Board) and check the voltage again. b. Ifnow correct, replace the Front Panel. ¢. If still NOT correct, replace the Control Board. 6. Measure between J10, pin 7 and pin 2 (AGND) on the Control Board (4.500 + 0.008 V dc). TEST J10 pin 7 (4.500) pin 2 (AGND) If out of range: replace the Control Board. '1500-0034-000 12/25/92 a74/Tests and Calibration B. Checking User Parameters Important: These settings are saved even when the system is powered OFF. It is necessary to set these parameters when the EEPROM has been replaced. To Check User Parameters Move the Mechanical Ventilation switch to OFF. Electrically power ON the Ventilator. Hold down the Alarm Silence button BX), and press the Inspiratory pause button. 7808 REV xx. xx 70 ENGLISH xxxx m Ifyou do not see this screen: check the Control Board DIP switch SW101. Switch 1 must be ON and 2, 3, and 4 OFF to access the user selected parameters. This is the setting for operational mode. ‘This screen includes the following information: The Ventilator Model: 7800 If not 7800: check the battery connector. The battery is not being recognized. The Software Revision Number: REV xx. xx The Supply Gas: 70 70 = Oxygen Supply Gas, “A = Air Supply Gas, and “E indicates an Error or no Supply Gas selection has been made. The Language Selection: ENGLISH The Altitude: xxxx m ‘The language selection and altitude selection are described in the Operation and Maintenance manual. 48 1500-0034-000 12/25/924/Tests and Calibration Record for future reference: * Ventilator Model 7800 % * Software Revision Number xxx *% a * Supply Gas selection 2 or AIR * Language * Altitude xox meters. Repeatedly press the Alarm Silence button &) and record for future reference: ‘+ Reverse Flow Alarm ON or OFF + SIGH ON or OFF * Contrast number x * Audio Volume number xx. Press the Alarm Silence button BJ. CHECK SETTINGS ee The Ventilator will retum to operational mode. 9 1500-0094-000 12/25/924/Tests and Calibration C. Service Calibration Mode Tools Required: Pressure Gauge, 0-150 cm H20 Pressure Gauge, 0-400 kPa Digital Multi-Meter, 4 1/2 digit Squeeze bulb and valve Stopwatch Respirometer Adjustable pressure source (135 + 5 cm H20) ‘The Service Calibration routines perform electronic and pneumatic checks on the Control Module. Each check begins with a special display screen. Not all screens require action. You must step through the checks sequentially. After completing each check, press the Alarm Silence button BJ to enter the next check in the sequence. Do not turn OFF the Ventilator during these routines. Service Calibration can only be started from step 1. 1. Check the Watchdog Timer a. Power ON the Ventilator if not already powered ON. b, Move the Control Board DIP switches (SW101) 1 OFF, 2 ON, 3 ON, 4 OFF. This reset sequence occurs: c. Press the Alarm Silence button BM). * You will hear a long (1kHz) beep, * followed by repeating short and long (1kHz) beeps. ‘The yellow LED also flashes this sequence. 4-10 '1500-0034-000 12/25/824/Tests and Calibration 2. Check the Contrast a. Note the initial "CONTRAST ¢ xx) * number. b. Tum the Inspiratory Flow knob. The display contrast should change. c. Reset to the initial value “(xx).* Ifno change, * check the ribbon cable between J1 (Control Board) and J1 (Front Panel board), or * replace the Front Panel board. 3. Check the Analog to Digital Conversion of Oxygen Output Signal "PASSED" = correct If "FAILED" appears, replace the Control Board. 6.4 11800-0034-000 12/25/92 an A4/Tests and Calibration 4. Check the Analog to Digital Conversion of the Pressure Output Signal. SYSTEM CHECK: AD: PRES PASSED "PASSED" = correct If “FAILED* appears, replace the Control Board. 5. Check the CPU. SYSTEM CHECK: EPROM PASSED If "FAILED" appears, replace the EPROM or Control Board. 412 '1500-0034-000_ 12/25/924/Tests and Calibration 7. Check the EEPROM = SS LF —S— any EEPROM PASSED =,0 a = _—— c QoS Sao “PASSED" = correct a cS a ——— If "FAILED" appears, replace the EEPROM | KOS eS (U114) or the Control Board. eet Important: The EEPROM and the Pneumatic Manifold Assembly must be replaced together. If "FAILED" appears, replace the Control Board. 9. Check the Mechanical Ventilation Switch. VENTILATOR yj SWITCH IS OFF | ‘Move the Mechanical Ventilation switch ON and OFF. The screen should correspond to the switch position. If not, * replace the 50 pin ribbon cable or * the Front Panel board. 4.XX 1600-0034-000 12/25/02 4-134/Tests and Calibra' ym 10. Check the Inspiratory Pause Button , INSPIRATORY | PAUSE IS OFF J; ——, Toggle the Inspiratory Pause button between ON and OFF. The screen should read “ON” when the Green LED is ON. “OFF* when the Green LED is OFF. If not, * replace the switch, * replace the 50 pin ribbon cable, or * replace the Front Panel board. 11. Check the DIP Switches ‘The display should match the switch bank (SW101). Important: Do not change the position of the switches while in Service Calibration Mode. “not, replace the Control Board. '1500-0034-000 12/25/024/Tests and Calibration 12, Check the Tidal Volume Knob 4.XX a. Rotate the Tidal Volume knob through its range. Resolution Table b. Set the Tidal Volume to 300. The pointer and display should correspond. If not, adjust the knob: Set the Tidal Volume to display 300. Loosen both set screws. Position the pointer to 300 (do not rotate the shaft). ‘Tighten one set screw. Set the display to 50. Does the pointer correspond? Set the display to 1500. Does the pointer comespond? Tighten the second set screw. NOT ENE 1500-0084-000 12/28/02 4154/Tests and Calibration Check the Rate Knob a. Rotate the Rate knob through its range. b. Set the Rate to 20. The pointer and display should correspond. Resolution Table 2 - 100 1B/min If not, adjust the knob. NOT REN ep Set the Rate to display 20. Loosen both set screws. Position the pointer to 20 (do not rotate the shaft). ‘Tighten one set screw. Set the display to 2. Does the pointer correspond? Set the display to 100. Does the pointer correspond? ‘Tighten the second set screw. 4-16 "1500-0034-000 12/25/924/Tests and Calibration 14. Check the Inspiratory Flow Knob a FLOW KNOB READS: | xxx L¢min ee) a. Rotate the Inspiratory Flow knob through its range. 4.XX Resolution Table 10 - 100 1 L/min b. Set the Inspiratory Flow to 10. The pointer and display should correspond. If not, adjust the knob. Set the Inspiratory Flow to display 10. Loosen both set screws. Position the pointer to 10 (do not rotate the shaft). Tighten one set screw. Set the display to 100. Does the pointer correspond? Tighten the second set screw. oo pene '1500-0034-000 12/25/92 4-17 i4/Tests and Calibration 15. Check the Inspiratory High Pressure Limit Knob soe HI PRES LIM KNOB xxx om HZ0 Note: To set the Inspiratory Pressure Limit, press in on the knob and tum. a. Rotate the Inspiratory Pressure Limit knob through its range. When you push and tum, the knob should move smoothly. Confirm that the displayed value does not change if you do not push in. Resolution Table 20 - 100 1om H20 b. Set the limit to 60. The pointer and display should correspond. If not, adjust the knob. Set the Inspiratory Pressure Limit to display 60. Loosen both set screws. Position the pointer to 60 (do not rotate the shaft). ‘Tighten one set screw. Set the display to 20. Does the pointer correspond? Set the display to 100. Does the pointer correspond? | Tighten the second set screw. | Confinm that the knob rotates freely and does not stick: * the setting should change when you push and tum, * the setting should not change when you do not push. 9. Ifthe knob sticks, do the adjustment again. PN OA ON a 4-18 1500-0034-000 12/25/92 i4/Tests and Calibration Pushwheel Checks The next three checks are for the pushwheel limit switches Low Vg, Low O; and High 02. Step the pushwheels through their least significant and most significant digits. The display should match the setting on the pushwheel. All pushwheels should move evenly in both directions. If not, replace the Front Panel board. 16. Check the Low Minute Volume Limit Pushwheels LOW Ue LIM KNOB: xx L¢min * Step the Low Vg tenths digit. * Step the Low Vg ones digit. 17. Check the Low Oxygen Limit Pushwheels Note: 18% is the minimum % shown. * Step the Low O; ones digit. * Step the Low O, tens digit. 1500-0034-000 12/25/82 4-194/Tests and Calibration 18. Check the High Oxygen Limit Pushwheels * Step the High O, ones digit. * Step the High O, tens digit. 19. Check the Back-Light [ ADJUST R114 TO ITS MIDPOINT The back-light should be visible. If not present adjust the intensity: 1, Tum R114 fully counterclockwise (20 tum pot). You will hear and feel a clicking sound. 2, Tum R114 ten (10) tums clockwise. This is the midpoint. The display back-light should be visible in normal light. If not adjustable, or there is no light, the probable cause is: * amissing jumper J11 (Control Board), the ribbon cable between J1 (Control Board) and J1 (Front Panel board), the Front Panel board, or the Control Board. 4-20 '1500-0034-000 12/25/924/Tests and Calibration 20. Check the Audio Volume — (= |( FLOW KNOB TO SET || AUDIO VOLUME: xx Qe: som a a. Note the initial “VOLUME: ¢xx)." b. Tum the Inspiratory Flow knob. The volume should change. value "(xx).” c. Reset to the i If the Volume does not change: * be sure the speaker is plugged into J8 (Front Panel board), * check the ribbon cable between J1 (Control Board) and J1 (Front Panel board), © replace the speaker, or * replace the Front Panel board. '1600-0034-000 12/25/92 421 4.XX4/Tests and Calibration 21, Check the Exhalation Solenoid EXHALATION VALUE )| TEST: PASS ! semen) Sansone ee AF a. The display should read @,@ Lvmin FHD-> * +2 L/mi b. Reverse the sensor clip direction. The arrows against the direction of flow. c. The display should now read "8. L/min <-REU" +2 L/min. If either flow detection doesn't work: * check the sensor, * check the Sensor Interface panel connections, * check the Excel interface cable, * check the EMC/Interface board, * check the 50 pin ribbon cable between J1 ( Front Panel board) and J1 (Control Board). d. Return the sensor assembly to the breathing circuit. 4-32 1500-0034-000 12/25/924/Tests and Calibration 31, Check the Analog to Digital Conversion of Flow Valve Drive “PASS” = correct. If "FAIL" appears, replace the Control Board. 32, High Pressure Limit Setup Connect an adjustable pressure source (135 + 5 cm HO) to the Ventilator Drive Gas outlet. 4 Figure 4-7. High Pressure Limit Setup "1600-0034-000 12/25/92, 4-33 4.XX4/Tests and Calibration 33. Check the High Pressure Limit HI_PRES LIMIT CKT TEST: FAIL “FAIL* is displayed upon entering this check. a. Raise the pressure slowly and check that the pressure drops sharply between 105 and 115 cm H20. The display should read "PASS" after the pressure drops. Note: The Flow Control Valve may have a small leak (within specification). If Supply Gas is connected and the Drive Gas outlet is blocked, this leakage can cause the pressure to slowly increase. If the pressure does not drop: * check the connections between J16 (Control Board), through the Header board, to the High Pressure Limit switch, * check the tubing, or * replace the High Pressure Safety switch. To repeat this check, move the Mechanical Ventilation switch to ON and press the Alarm Silence button & twice. ‘To exit, the Mechanical Ventilation switch must be OFF. b. Remove the test equipment. 4-34 1500-0034-000 12/25/02