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Flight Medical Innovations 60 DL, Service Manual

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Flight Medical Innovations 60 DL Service Manual Download Page 52

Removing and Reinstalling Modules 

Replacing the Manifold Assembly 

 

4-22

  |  FLIGHT 60 Service Manual 

 

 Replacing the Manifold Assembly  

4.12.1  Removing the Manifold Assembly 

  To remove the maniford assembly: 

1.

 

Remove the detachable battery (see section 4.3) and the internal battery (see 
section 4.4). 

2.

 

Remove the ventilator cover (see section 4.5). 

3.

 

Remove the front panel assembly (see section 4.8) 

4.

 

Remove the Power board (see section 4.6)  

5.

 

Remove the two Torx screws securing the inlet assembly.  

 

Figure 41 –Inlet assembly screws 

6.

 

Disconnect the Oxygen hose from the inlet assembly 

 

Figure 42 – Low Flow O

2

 hose 

Summary of Contents for 60 DL

Page 1: ...FLIGHT MEDICAL INNOVATIONS Ltd FLIGHT 60 VENTILATOR Service Manual Models SL DL iO2 LIT 0021 Rev A12 Aug 2016 ...

Page 2: ...TABLE OF CONTENTS FLIGHT 60 Ventilator II ...

Page 3: ......

Page 4: ...that the purchase and use of the equipment is restricted to trained professionals and that certain inherent characteristics of the ventilator are known to the operator Instructions warnings and caution statements are therefore limited to the specifics of the FLIGHT 60 Ventilator Federal law US restricts this device to sale by or on the order of a physician This Operator s Manual excludes reference...

Page 5: ...s Rubber and plastic components and materials which are guaranteed to be free of defects at time of delivery Any product which proves during the warranty period to be defective in workmanship or material will be replaced credited or repaired FLIGHT MEDICAL retains the discretion to select the most suitable of these options FLIGHT MEDICAL is not responsible for deterioration wear or abuse In all ca...

Page 6: ...vicing and providing troubleshooting assistance for the FLIGHT 60 and F60 Dual Limb Ventilators For information on how to use the FLIGHT 60 Ventilator see the FLIGHT 60 Ventilator Operator s Manual Style Conventions Convention Used for Verdana Regular text Arial Bold Names of labels buttons and other elements of the user interface Arial Italics Special terms the first time they appear Notes which ...

Page 7: ...EUMATIC DIAGRAM IO2 INTERNAL MIXER MODEL 3 12 ELECTRICAL DIAGRAM 3 13 ELECTRICAL DIAGRAM IO2 INTERNAL MIXER MODEL 3 14 4 REMOVING AND REINSTALLING MODULES 4 1 INTRODUCTION 4 1 REQUIRED EQUIPMENT 4 1 REPLACING THE DETACHABLE BATTERY 4 2 4 3 1 Removing the Detachable Battery 4 2 4 3 2 Installing the Detachable Battery 4 2 REPLACING THE INTERNAL BATTERY 4 2 4 4 1 Removing the Internal Battery 4 2 4 4...

Page 8: ...Installing the Oxygen Sensor 4 28 REPLACING THE O2 LEAK SENSOR IO2 INTERNAL MIXER MODEL ONLY 4 28 4 14 1 Removing the O2 leak sensor 4 28 4 14 2 Installing the O2 leak sensor 4 28 REPLACING THE OXYGEN MIXER IO2 INTERNAL MIXER MODEL ONLY 4 29 4 15 1 Removing the Oxygen mixer 4 29 4 15 2 Installing the Oxygen mixer 4 30 REPLACING THE O2 MIXER FILTERS IO2 INTERNAL MIXER MODEL ONLY 4 31 REPLACING THE ...

Page 9: ...ion 7 10 7 1 4 Oxygen Sensor Calibration 7 11 7 1 5 O2 Leak Sensor calibration iO2 Internal mixer model only 7 12 OPERATIONAL VERIFICATION PROCEDURE OVP 7 13 7 2 1 Standard Ventilator Settings STS 7 13 7 2 2 Front Panel Self Test 7 13 7 2 3 Circuit Test 7 14 7 2 4 Volume verification 7 15 7 2 5 Pressure Verification 7 15 7 2 6 PEEP 7 16 7 2 7 Pressure Trigger 7 17 7 2 8 Exhalation Valve Leak 7 18 ...

Page 10: ...le of Contents viii FLIGHT 60 Service Manual INTRODUCTION 9 3 ERROR MESSAGES 9 3 10 REPACKAGING AND SHIPPING 10 1 RGA RETURNS 10 1 11 SPARE PARTS 11 2 ELECTRONIC 11 2 MECHANICAL ASSEMBLIES 11 5 CABLES 11 8 ...

Page 11: ...entilator Intended Use The FLIGHT 60 Ventilator is intended to provide continuous or intermittent mechanical ventilation support for the care of individuals who require mechanical ventilation Specifically the FLIGHT 60 Ventilator is applicable for adult and pediatric patients greater than or equal to 10 kg 22 lbs Symbols Symbol Description Front Panel On Off Alarm Reset OK Enter Decrease Button In...

Page 12: ... Screen Nebulizer Port Rear Panel Caution consult accompanying documents Type BF applied part Temperature limitation Humidity limitation Atmospheric pressure limitation DC Direct Current AC Alternating Current USB Universal Serial Bus LAN Local Area Network High Pressure and Low Flow Oxygen Port ...

Page 13: ...sing AC power only connect to grounded receptacles Always disconnect the external power prior to servicing There is a risk of explosion if used in the presence of flammable anesthetics All settings and adjustments in the different ventilation modes must be made in accordance with a physician s prescribed therapy Do not use electrically conductive patient circuits Always use a clean disinfected pat...

Page 14: ...ree hours before powering the ventilator from the batteries This provides fully charged batteries During storage charge the batteries for a minimum of three hours every 30 days This provides charged batteries Always ensure that the green Ext Power LED is illuminated after connecting the FLIGHT 60 Ventilator to an external AC or DC power source If the LED is not illuminated check all power connecti...

Page 15: ...nce will not occur in a particular installation If this equipment does cause harmful interference with other devices which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving device Increase the distance between the equipment Connect the equipment into an outlet o...

Page 16: ...nal power Use standard antistatic techniques while working inside the ventilator or handling any electronic parts Clean all external accessories of the ventilator prior to servicing Water in the oxygen supply can cause equipment malfunction and damage Batteries contain Li Ion Do not discard them in an incinerator or force them open Batteries should not be disposed of with normal waste Use the tool...

Page 17: ... Panel Label Name Description 1 Patient Circuit Connector Composed of a gas outlet and quick connector 2 button Enables the user to adjust setting parameters 3 Panel Lock button Enables the user to lock the ventilator s control preventing accidental changes Pressing the button of a locked panel and then Enter unlocks the panel 4 On Off button Turns the ventilator on or off to start or stop ventila...

Page 18: ...0 cmH2O each notch equals 10 cmH2O 8 Display touch screen Enables the user to modify the ventilation alarm and technical settings and to view real time patient data alarms battery status and logs 9 LED Indicators Inform the user of various events 10 Primary Alarm LED Flashes red to indicate that there is a high priority alarm 11 Dual Limb Exhalation Valve DL model only Connects the patient circuit...

Page 19: ...ded Additional ventilation parameters screen 3 1 2 LED Indicators The LED indicators on the front panel inform the user of various events The following table describes the available LED indicators LED Indicator Description TRIG Green LED indicates a patient s breathing effort EXT PWR Yellow LED indicates that an external power source is being applied to the ventilator LOW BAT Red LED indicates tha...

Page 20: ... Red LED indicates low peak airway pressure Left Side Panel Figure 3 Left Side Panel Label Name Description 1 Emergency Air Intake Enables the patient to pull ambient air into the patient circuit in the event of a complete system failure The Air Intake opening pressure is approximately 3 cmH2O 3 mbar ...

Page 21: ...ver Environmental air enters through this 30 mm ID Fresh Gas Intake The air inlet particle filter is placed behind the Filter Cover to protect the patient as well as the ventilator s piston system from dirt and particles The Fresh Gas Intake also serves as the attachment socket for the optional FLIGHT 60 Ventilator Air Oxygen Entrainment Mixer or Oxygen Blending Bag ...

Page 22: ...th Fuses 100 240 V AC 50 60 Hz Fuses 2x8A time lag 3 DC Connector 12 15 V DC 4 RS 232 Serial Port COM2 Remote alarm connector Normally Open and Normally Closed options 5 RS 232 Serial Port COM1 Online output of events and error messages to the PC using a dedicated PCS2 protocol for authorized and qualified service technicians only 6 USB B type PC connector USB port for downloading the main applica...

Page 23: ...ory stick for authorized and qualified service technicians only 8 LAN RJ45 LAN for network logging currently not available 9 Mini RS 485 COM3 For connecting FLIGHT MEDICAL peripherals For future use 10 Low Flow Oxygen Port Low flow oxygen enrichment source 11 High Pressure O2 Port iO2 Internal mixer model only Connects to high pressure O2 ...

Page 24: ...sing the contacts to transmit an alarm Normally Closed Pin 8 opening the contacts to transmit an alarm The dry contacts current should not exceed 1mA The voltage on the contacts must be lower than 12 Volts Remote Alarm Electrical schematics The legal and regulatory responsibility for this integration of the Flight 60 device into any external system lays on the integrator and not the Flight 60 manu...

Page 25: ...ntilator Modules Component P N A Main board MB V60 60002 65 B Power board PB V60 21000 65 C Power supply PS V60 13000 65 D Manifold assembly V60 21000 60 E Solenoid board assembly V60 26000 65 F Solenoid assembly V60 21400 69 G Oxygen O2 Sensor V60 25000 29 H Purge board V60 23000 65 A C B C D F G E H ...

Page 26: ... Internal mixer model Figure 7 Ventilator Modules Internal Mixer Component P N A Main board MB V60 60002 65 B Power board PB V60 21000 65 C Power supply PS V60 13000 65 D Manifold assembly V60 21000 60 E O2 Mixer Neb board ELE 0001 F Inlet assembly V60 21400 69 G O2 leak sensor G60 25000 29 H Internal O2 mixer SUB 0101 ...

Page 27: ...Functional Description Pneumatic Diagram Flight 60 Service Manual 3 11 Pneumatic Diagram ...

Page 28: ...Functional Description Pneumatic Diagram iO2 Internal mixer model 3 12 FLIGHT 60 Service Manual Pneumatic Diagram iO2 Internal mixer model ...

Page 29: ...Functional Description Electrical Diagram Flight 60 Service Manual 3 13 Electrical Diagram ...

Page 30: ...Functional Description Electrical Diagram iO2 Internal Mixer model 3 14 FLIGHT 60 Service Manual Electrical Diagram iO2 Internal Mixer model ...

Page 31: ...t inside the ventilator Disconnect electrical power and oxygen sources before attempting any disassembly Remove watch and any jewelry Failure to do so may result in injury to service personnel or damage to the ventilator Required Equipment The following equipment is required to remove and replace FLIGHT 60 ventilator modules Antistatic wrist strap Phillips screwdriver PH1 Flat screwdriver 0 8x4 To...

Page 32: ... in the direction of the OPEN arrow Figure 8 Removing the Detachable Main Battery 2 Pull the battery out of the ventilator 4 3 2 Installing the Detachable Battery To install the detachable battery 1 Insert the detachable battery into the ventilator 2 Turn the lock dial clockwise in the direction of the CLOSE arrow until it is firmly locked Replacing the Internal Battery 4 4 1 Removing the Internal...

Page 33: ...talling the Internal Battery To install the internal battery Follow the above procedure in reverse order Removing the Ventilator Cover 4 5 1 Removing the Ventilator Cover The following procedure describes how to remove the ventilator cover In most cases the cover must be removed in order to access the ventilator modules To remove the ventilator cover 1 Remove the two Torx screws inside the ventila...

Page 34: ... Ventilator Cover 4 4 FLIGHT 60 Service Manual Figure 10 Removing Screws Inside Handle 2 Remove the two Torx screws connecting the ventilator cover to the back panel Figure 11 Removing Back Screws 3 Remove the two Torx screws from the bottom panel ...

Page 35: ... 60 Service Manual 4 5 Figure 12 Removing the Bottom Panel Screws 4 Remove the ventilator cover The modules of the ventilator are now exposed and accessible Figure 13 Removing the Ventilator Cover Cover screws are longer than the rest of the screws used in the ventilator ...

Page 36: ...oard 4 6 1 Removing the Power Board To remove the power board 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Disconnect the flat flex cable P3 from the power board Figure 14 Disconnecting Flat Flex Cable from Power Board 4 Disconnect the 8 pin P2 manifold cable connector from the power board by pressing the r...

Page 37: ...Disconnecting Manifold Cable Connector P2 from Power Board 5 Disconnect the 4 pin P6 power supply connector from the power board by pressing the release tab on the connector Figure 16 Removing Power Supply Connector P6 from Power Board 6 Remove the Torx screw connecting the power board to its bracket ...

Page 38: ...old the power board by its components To pull the board out hold the grooves Refer to the figure below for correct positioning Figure 18 Lifting Power Board from Ventilator Base 7 Holding the board by the grooves carefully pull the board out by lifting up slightly on one side and then the other continuing to alternate sides until the board is released from the socket ...

Page 39: ... pins 2 Slide the power board through the right and left guide tracks positioning the power board connectors over the sockets Figure 19 Power Board Slots and Tracks Figure 20 Inserting Power Board into Ventilator Base 3 Firmly push down the power board making sure that the power board connectors fit well into the sockets pin headers in the base of the ventilator Right Track Right Slot Left Track L...

Page 40: ...e Flight60 has either a Class I or a Class II Power Supply The Power Supplies are NOT interchangeable Class I Power Supply is obsolete and cannot be supplied by Flight Medical 4 7 1 Class I Power Supply To remove the power supply 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Release the manifold motor cable ...

Page 41: ...nual 4 11 Figure 22 Releasing the Motor Cable 4 Disconnect the power wiring total of seven wires by loosening the Phillips screws Figure 23 Power supply Wiring 5 Remove the 4 Torx screws that are securing the power supply bracket two on each end Figure 24 Power Supply Bracket screws ...

Page 42: ... securing the bracket Figure 25 Detaching the Power Supply from Its Bracket To install the power supply Follow the above procedure in reverse order paying attention to the following The Power Supply bracket fits under the power board bracket Figure 26 Bracket Positioning Be sure not to apply pressure to the solenoid assembly during this procedure Connect the wires according to the following diagra...

Page 43: ...erminal block including the unused ones 4 7 2 Class II Power Supply To remove the power supply 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Release the manifold motor cable from the cable clamps on the power supply 4 Disconnect the 2 cables from the Power Supply Figure 27 Power Supply cables Disconnect the ...

Page 44: ...r Supply Figure 29 Detaching the Power Supply from Its Bracket To install the power supply Follow the above procedure in reverse order Replacing the Front Panel Assembly 4 8 1 Removing the Front Panel Assembly To remove the front panel assembly 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Disconnect the fla...

Page 45: ...P16 4 On the underside of the ventilator unscrew the three Torx screws securing the bottom of the front panel Figure 31 Loosening the Torx Screws Under the Front Panel 5 Remove the Torx screws from the front panel brackets one on each side Carefully slide the front panel outwards to allow access to electrical cables and silicon tubes ...

Page 46: ...oard 7 Disconnect the nebulizer cable from the O2 mixer neb board 8 Disconnect the mixer cable from the O2 mixer neb board 9 Disconnect the O2 leak sensor cable from the O2 mixer neb board Figure 33 Disconnecting from O2 mixer neb board 10 Disconnect the 3 silicon tubes coming from the main board Note the color coding Disconnect them from the Y connectors and not from the board itself 11 Disconnec...

Page 47: ... above procedure in reverse order Replacing the O2 mixer Neb board iO2 Internal mixer model only 4 9 1 Removing the O2 mixer neb board To remove the O2 mixer neb board 1 Follow the procedures for removing the front panel assembly see section 4 8 2 remove the 3 screws securing the O2 mixer Neb board to the Main Board Figure 34 Securing screws 3 Pull the mixer board out of the connector 4 9 2 Instal...

Page 48: ...ed in chapter 8 4 10 1 Removing the Main Board To remove the main board 1 For iO2 internal mixer model Follow the procedure for Removing the O2 mixer neb board see section 4 9 2 Remove the 6 Torx screws holding the Main Board to the front panel 3 On the bottom side of the Main Board disconnect buzzer connectors LS1 and LS2 4 Disconnect the back light cable from connector P5 Do not pull the wires P...

Page 49: ... 60 Service Manual 4 19 Figure 36 Disconnecting LS2 connector 5 Disconnect the P13 flat cable by pressing hard on the locker and then pulling it out Figure 37 Disconnecting the P13 Flat Cable 6 Remove the six Philips screws securing the Main Board to the front panel ...

Page 50: ...n Board from the Front Panel 7 Remove the grounding screw at the top left of the board Figure 39 Detaching the Grounding Screw 8 Lift the Main Board Carefully detach the flat cables from the connectors on the main board 9 Remove the J3 flat cable by clicking the locker on the main board and then pulling out the cable ...

Page 51: ...ain board 1 Check that the main board sockets do not have any bent pins 2 Perform the removal procedure in the reverse order Replacing the Touch Screen The touch screen cannot be detached from the front panel When the touch screen needs replacement the Front Subassembly P N V60 70010 60 is to be replaced 1 Follow the procedures for removing the main board see section 4 10 2 Replace the front Subas...

Page 52: ...ly 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Remove the front panel assembly see section 4 8 4 Remove the Power board see section 4 6 5 Remove the two Torx screws securing the inlet assembly Figure 41 Inlet assembly screws 6 Disconnect the Oxygen hose from the inlet assembly Figure 42 Low Flow O2 hose ...

Page 53: ...e inlet assembly from the flex tube by pulling out the tube Figure 43 Pulling out the Flex Tube 8 Disconnect the O2 Mixer hose from the muffler 9 Cut the cable ties securing the muffler Figure 44 Cutting the Cable Ties 10 For iO2 model Disconnect the vertical silicon tube from the muffler Figure 45 Silicon tube ...

Page 54: ...the Manifold Assembly 4 24 FLIGHT 60 Service Manual 11 Gently pull the muffler out of the short flex tube and put it aside Figure 46 Removing the Muffler 12 Disconnect the flex tube between the manifold and the outlet assembly Figure 47 Flex tube ...

Page 55: ...48 Disconnecting the Flex Tubes 14 Release the Manifold power cord from the wire saddles 15 Remove the six Torx screws from the manifold base three on each side Figure 49 Detaching the Manifold Base 16 Carefully lift out the manifold assembly Don t apply any force on the piston drive mechanism Don t hold the manifold by the bearings or by the metal rods ...

Page 56: ...g flex tubing 4 12 2 Installing the Manifold Assembly To install a manifold assembly Perform the removal procedure in the reverse order with the following additional step after inserting the muffler assembly which is helpful for getting the cable ties through their slots Insert the detachable battery until it is almost completely in and then assemble the cable ties through the slots under the muff...

Page 57: ...ut an Oxygen sensor Refer to Flight Medical Service Notes for a list of approved Oxygen sensors 4 13 1 Removing the Oxygen Sensor To remove the oxygen sensor 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Remove the front panel see section 4 8 4 Disconnect the electrical cable from the oxygen sensor ...

Page 58: ...the above procedure in reverse order Replacing the O2 leak sensor iO2 Internal mixer model only 4 14 1 Removing the O2 leak sensor To remove the O2 leak sensor 1 Remove the ventilator cover see section 4 5 2 Disconnect the electrical cable from the O2 leak sensor 3 Turn the O2 leak sensor counterclockwise until it comes out 4 14 2 Installing the O2 leak sensor To install the oxygen sensor Follow t...

Page 59: ...e the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Remove the Power Supply and the power supply base plate the solenoid see section 4 7 4 Remove the muffler 5 Remove the O2 leak sensor 6 Remove the 2 silicon tubes and disconnect the Nebulizer O2 Mixer cables from the O2 mixer Neb board Figure 53 Electronic connectors an...

Page 60: ...model only 4 30 FLIGHT 60 Service Manual Figure 54 Pulling out the mixer 4 15 2 Installing the Oxygen mixer To install the oxygen mixer Follow the above procedure in reverse order Make sure the flat surface of the mixer is aligned with the metal bracket Figure 55 Mixer orientation ...

Page 61: ...filters 2 each at the O2 input and push all the way in 4 Push the O ring in verify it s in the groove securing the filters in place Figure 56 O2 regulator filter Replacing the Purge Board Assembly 4 17 1 Removing the Purge Board Assembly To remove the purge board assembly 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see sect...

Page 62: ...e connector on the solenoid board 4 17 2 Installing the Purge Board Assembly To install the purge board assembly Follow the above procedure in reverse order Replacing the Solenoid Board Assembly 4 18 1 Removing the Solenoid Board Assembly To remove the solenoid board assembly 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see ...

Page 63: ...noid board connectors 6 Remove the silicon tubes from the fittings on the redundancy solenoid Figure 59 Removing the Silicon Tubes 7 Remove the solenoid board assembly 4 18 2 Installing the Solenoid Board Assembly To install the solenoid board assembly 1 Insert the solenoid assembly 2 Insert the purge board assembly ...

Page 64: ...n tube connect the Solenoid assembly to the outer fitting on the redundancy solenoid Figure 60 Connecting the Silicon Tubes Replacing the Solenoid Assembly 4 19 1 Removing the Solenoid Assembly To remove the solenoid assembly 1 Remove the ventilator cover 2 For iO2 internal mixer model Remove the O2 leak sensor 3 Remove the 2 screws securing the O2 leak sensor bracket Remove the bracket Figure 61 ...

Page 65: ...the screws that secure the front panel and move the front panel so gain better access Figure 62 Solenoid Cable connector 5 Disconnect the 3 silicon tubes from the solenoid assembly Figure 63 Disconnecting Silicon Tubes 6 Unscrew the two adjacent Torx screws on the solenoid bracket Pull out the bracket with the solenoid carefully leading the solenoid cable making sure it is not being damaged ...

Page 66: ...verse order Replacing the Lower Board and D type Board 4 20 1 Removing the Lower Board and D type Board To remove the Lower and D type boards 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Remove the front panel assembly see section 4 8 4 Remove the Power board see section 4 6 5 Remove the Power Supply and it...

Page 67: ...utlet assembly 10 Disconnect connectors P5 P6 and P7 from the lower board Figure 66 Disconnecting P7 connector 11 Unscrew the 6 Philips screws securing the lower board and 2 Philips screws securing the D type board 12 Gently lift the back side of the lower board and pull the lower board with D type board out of the ventilator base ...

Page 68: ...anual Figure 67 Removing the Lower Board and D type Board 13 Disconnect the D type board from the Lower board Figure 68 D type and Lower boards 4 20 2 Installing the Lower Board and D type Board To install the Lower and D type boards Follow the above procedure in reverse order D type Board Lower Board ...

Page 69: ...ly in case of a problem 4 21 1 Removing the Fuse To remove the fuse 1 Pull out the plastic fuse housing at the back of the device with the aid of a flat screwdriver Figure 69 Removing the Fuse 4 21 2 Installing the Fuse To install the fuse Reposition the fuse housing flat edge on the left and press firmly to make sure that it is inserted completely Figure 70 Connecting the Fuse ...

Page 70: ...do not need regularly scheduled servicing Servicing is required only in case of a problem 4 22 1 Removing the Rubber Bumpers To remove bumpers 1 Use a Torx screwdriver to remove bumpers as needed Figure 71 Removing a Rubber Bumper 4 22 2 Installing the Rubber Bumpers To install a bumper Use a Torx screwdriver to attach the bumper and verify that it is fastened securely ...

Page 71: ...nable O2 mixer O2 Only Nebulizer is disabled O2 Neb Mixer Nebulizer OFF Universal Circuit ON OFF Flow sensor less patient circuit flow sensor is Integrated in the DL exhalation valve Purge Period 60 300 Time interval sec for purge pump operation Additional Config Quick Start Enable Disable quick start buttons Display C R Enable Disable lung mechanics values Japanese config Screen Intensity Value I...

Page 72: ...ersion Displays the SW version of each CPU Calibrate Pressure Activate pressure calibration Calibrate FIO2 Activate Oxygen sensor calibration Volume Factor Activate Volume factor calibration Displays the saved calibration value Calibrate Relief Activate Over pressure relief valve calibration SERVICE Change serial numbers and working hours Enter the code 2009 confirm by pressing Factory Defaults De...

Page 73: ...Service Technical Menu Service Screen Flight 60 Service Manual 5 3 Bar Intensity Single Full Number of lit LEDs in the ventilator s pressure gauge iO2 INTERNAL MIXER MODEL ONLY ...

Page 74: ...entilator powers up and a software update screen opens displaying the current version and the new version to update 6 Press OK on the touch screen 7 Once upgrade is done the ventilator displays Finished updating please remove DOK 8 Remove the USB storage device and press OK on the touch screen 9 Turn on the ventilator press Technical and press Show Info 10 Verify the new software version is displa...

Page 75: ... check Flight 60 Service Manual 6 5 Vti Within the 450 550 spec Pbase 5 1cm H2O O2 72 88 for External O2 Mixer 76 84 for Internal O2 mixer iO2 model 5 If any of those values is out of spec perform the appropriate calibration and check again ...

Page 76: ...on IO2 models Calibration 7 1 1 Pressure Relief Calibration To calibrate the pressure relief mechanism 1 Connect the ventilator to the test lung using a patient circuit 2 Set the test lung to minimum compliance 3 Press Technical and then press ADVANCED Screen 4 Enter the code 5844 and confirm by pressing 5 Press SERVICE SCREEN 6 Press Calibrate Relief and then Enter to start the motor 7 Verify tha...

Page 77: ... Check internal tubing connections 7 1 2 Pressure Sensors Calibration To calibrate the pressure sensors 1 Connect the ventilator to an external pressure meter using a reusable patient circuit 2 Connect the pressure meter to the test lung 3 Use the following settings for the test lung C 10 Rp 5 4 Press Technical and then press ADVANCED Screen 5 Enter the code 5844 and confirm by pressing 6 Press SE...

Page 78: ...pressure sensors 1 If the pressure on the external pressure meter is in the 50 75 cmH2O range continue to step 2 If the pressure is less than 50 cmH2O Press Cancel Press Calibrate Pressure again The calibration screen will come up with the following message You can set the solenoid and motor commands for pressure sensor and displays default values of 65 200 Use the UP and DOWN buttons to change th...

Page 79: ...the test fails 1 Replace patient circuit and redo calibration 2 Do one of the following If the external measurement lower than 50 Check internal tubing connections for air leaks Replace the solenoid and redo calibration If the external measurement higher than 75 Check internal tubing connections for blocking Replace the solenoid and redo calibration If the patient pressure outlet pressure differen...

Page 80: ... confirm by pressing 4 Press SERVICE SCREEN 5 Press Calibrate Volume Volume Factor and follow the instructions which appear on the display 6 After pressing Enter the ventilator will run volume factor calibration and display the volume factor value on the screen The volume factor value should be between 0 85 and 1 2 Press Enter 7 Repeat the calibration again and verify that in both cases the volume...

Page 81: ...ait 1 minute and press Enter 9 The ventilator switches to 100 automatically Verify the external Oxygen analyzer reads 100 wait 1 minute and press Enter For External mixer model 1 Connect the Air Oxygen Entrainment Mixer to an Oxygen source Install the Air Oxygen Entrainment Mixer on the ventilator s air inlet 2 Set the regulator on the oxygen source to 50 PSI 3 Connect a calibrated Oxygen Analyzer...

Page 82: ...e the O2 leak sensor 1 Connect a calibrated Oxygen Analyzer to the ventilator s outlet Don t connect a patient circuit 2 Press Technical and then press ADVANCED Screen 3 Enter the code 5844 and confirm by pressing 4 Press SERVICE SCREEN 5 Press Calibrate O2 Leak The system will be flushed with ambient air 6 Wait 2 minutes Use the UP and DOWN buttons to match the displayed value with the external O...

Page 83: ... cmH2O 7 2 2 Front Panel Self Test To run the self test 1 Connect the ventilator to AC power 2 Press the On Off button on the front panel 3 During the self test that begins automatically check for the following Short audible beep All LEDs on the LED indicator light up with the same intensity with the following colors Description Colour TRIG Pressure trigger Green EXT PWR External power Yellow LOW ...

Page 84: ...nal connectors to the front panel Some LEDs are on Replace the Main Board 7 2 3 Circuit Test Each time the Exhalation Valve or patient circuit is replaced or serviced it must be tested To test the patient circuit exhalation valve 1 Connect the patient circuit to a 0 5L test lung 2 Press Technical and then press Circuit TEST 3 Press Enter 4 The test is done automatically It includes the following 3...

Page 85: ...ation To test the device for pressure 1 Set the ventilator to STS settings 2 Activate the ventilator and verify that the volume is between 450 and 550ml If the test fails Repeat the Volume factor calibration 7 2 5 Pressure Verification To test the device for pressure 1 Set the ventilator to STS settings 2 Connect a pressure meter between the ventilator and the test lung 3 Use the following setting...

Page 86: ...basic pressure levels in the lung and in the ventilator display are 5 1 cmH2O 7 Raise the P trig level as needed until no auto triggering is observed 8 Verify that the P trig level is not more than 1 5 cmH2O and that the ventilator is not performing an auto trigger 9 Set PEEP to 10 10 After five breaths check that the basic pressure levels in the lung and in the ventilator display are 10 2 cmH2O 1...

Page 87: ...lation attempt by creating a negative pressure from the test lung 5 Verify that the green P trig LED flashes and a mandatory breath is forced each time the edge shoulder is raised 6 Change settings to SIMV PSV 20 Rate 5 7 Simulate inhalation attempt by creating a negative pressure from the test lung 8 Verify that the green P trig LED flashes and that the ventilator provides a mandatory breath foll...

Page 88: ... that the pressure level is over 72 cmH2O If pressure doesn t get to 72 cmH2O decrease the compliance or increase the resistance of the test lung If pressure becomes too high after changing compliance resistance reduce the set volume from 1400 until achieving the required pressure level 6 Check for air flow from the underside of the Exhalation Valve during inhalation If air flow is noticed there i...

Page 89: ...is triggered inhalation is interrupted 6 Set HIGH P to 99 cmH2O 7 Check that the following occurs the audible alarm is silenced automatically the visual alarm is displayed until the Alarm Reset button is pressed If the test fails 1 Replace the Main Board see 4 10 2 Perform the required calibrations see 7 3 Test table 7 2 10 Battery Charger Power Supply To test the power supply Verify that both bat...

Page 90: ...r is off the green EXT PWR is lit 7 2 11 Inlet Leak To test the inlet leak 1 Set the ventilator to STS settings 2 Connect the ventilator to a test lung using a patient circuit 3 Verify that the three screws securing the filter cover are tight to insure that air leakage is prevented 4 Connect a vacuum meter to the air inlet 5 Activate ventilation The vacuum reading should be at least 0 16 negative ...

Page 91: ...e 4 10 and perform the required calibrations see 7 3 Test table 7 2 13 Oxygen Calibration Test For non iO2 ventilator no internal O2 mixer Connect an external Air Oxygen Entrainment Mixer to an Oxygen source Install the Air Oxygen Entrainment Mixer on the ventilator s air inlet O2 settings are changed with the mixer dial For iO2 ventilator with internal O2 mixer Connect the ventilator to an Oxygen...

Page 92: ...Main Board see 4 10 and perform the required calibrations see 7 3 Test table 7 2 14 Nebulizer compensation test iO2 Internal mixer model only To test the Nebulizer compensation 1 Set the ventilator to STS mode 2 Connect a nebulizer circuit before the patient circuit s flow sensor Start ventilation 3 Verify that Vti is 450 550 4 Set O2 mixer to 50 Activate the Nebulizer 5 Verify that Vti remains in...

Page 93: ...let Pressure Pressure Relief Valve Calibration Relief Pressure Volume Factor Calibration Circuit Test N A Volume Verification Vti Vte Pressures Verification External gauge peak Pressure PPeak PEEP Set Tolerance PEEP Value Ptrig 5 5 1 10 10 2 20 20 2 Pressure Trigger test P trig N A Exhalation Valve leak Pressure level High Pressure Alarm N A Power Supply and Battery Charge N A Inlet Leak Alarm Buz...

Page 94: ... Table 7 24 FLIGHT 60 Service Manual Test Table The following table summarizes tests associated with each device module When a module is replaced All tests associated with the replacement must be performed before the ventilator is used again ...

Page 95: ...Press SERVICE 5 Enter the code 2009 and confirm by pressing 6 Press the displayed Compressor Serial Number use the numerical keyboard to type in the new number 7 Press the displayed Hour Meter use the numerical keyboard to change it to 0 AIR INLET FILTER Check the filter s condition whenever servicing the ventilator OXYGEN O2 SENSOR Replace once a year O2 LEAK SENSOR Replace once a year BATTERY Re...

Page 96: ...N The download icon will display 6 Wait for the download complete icon to display Note that It might take few minutes for download to complete depending on the size of the log files 7 Check the USB device on a computer and verify that 3 log files errors changes events were downloaded ...

Page 97: ...sonnel should operate the ventilator The FLIGHT 60 Ventilator is a restricted medical device designed for use by Respiratory Therapists or other properly trained and qualified personnel under the direction of a physician and in accordance with applicable state laws and regulations Error Messages Displayed error Potential Cause Suggested Action CHECK FiO2 SENSOR Oxygen sensor bad reading Oxygen sen...

Page 98: ...H Air leak Hardware problem Check internal hoses connections Replace Main Board MOTOR FAULT Motor control Motor Replace Power Board Replace manifold PRESS SENSOR Patient pressure sensor higher than outlet Perform Pressure sensors calibration Replace Main Board POWER FAULT Check log file to identify failed power 3 3V POWER FAULT Replace Main Board MAIN BOARD 10V POWER FAULT Check cables Replace Pow...

Page 99: ...eating Replace battery Replace Power Board MAIN BAT GAUGE Battery control Replace battery SEC BAT CHARGER Charger malfunction Replace battery Replace Power Board SEC BAT V HIGH LOW Out of range Replace battery Replace Power Board SEC BAT VOLTAGE Mismatch in Battery voltage reading Replace battery Replace Main Board SEC BAT TEMP HIGH Battery overheating Replace battery Replace Power Board SEC BAT G...

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Page 101: ...nly after an RGA number was provided by FLIGHT MEDICAL Copies of the RGA form and the Service Call should be included with the returned item RGA Returns Use the following guidelines to return a FLIGHT 60 ventilator Use the original box and packaging Remove both batteries and any accessories from the ventilator When returning a module place it in the original box and packaging If not available plac...

Page 102: ...ic Main Board SUB 0202 Connecting cables not part of the board 1 MB to SB cable V60 70100 29 2 O2 sensor cable V60 00130 29 3 FPC MB to PB cable V60 21000 29 Power Board V60 21000 65 Connecting cables not part of the board 1 FPC MB to PB cable V60 21000 29 Power Supply SUB 0174 ...

Page 103: ...Electronic Flight 60 Service Manual 11 3 Lower Board V60 22000 65 D Type Board V60 24000 65 Purge Board V60 23000 65 Solenoid Board V60 26000 65 Connecting cables not part of the board 1 MB to SB cable V60 70100 29 ...

Page 104: ...Spare parts Electronic 11 4 FLIGHT 60 Service Manual O2 Mixer Neb board ELE 0001 Detachable main battery V60 19000 67 Integral battery V60 19100 63 Keypad English V60 74000 68 Keypad Symbols SUB 0087 ...

Page 105: ...Mechanical Assemblies Front Subassembly SUB 0195 English Keypad SUB 0194 Symbols Keypad Connected items 1 Front right bracket V60 76023 03 2 Front Left bracket V60 76022 03 Manifold V60 21000 60 Solenoid V60 21400 69 1 Filter Cover V11 35001 63 2 O ring V11 36000 26 ...

Page 106: ...anical Assemblies 11 6 FLIGHT 60 Service Manual Oxygen Sensor Leak sensor G60 25000 29 Air Oxygen Entrainment mixer V13 00030 60 Inlet Assembly V60 15000 63 1 Silicon tube V60 32000 06 Internal Mixer Nebulizer SUB 0101 ...

Page 107: ...ight 60 Service Manual 11 7 Muffler MEC 0040 L connector G27 00017 27 Flex tube short V60 25010 06 Flex tube long V60 25020 06 For Dual Limb Ventilator 1 Dual limb Cap SUB 0088 2 Diaphragm 5 pcs V64 00050 90 3 Exhalation Valve DL MEC 0034 ...

Page 108: ...LIGHT 60 Service Manual Cables Internal AC Cable CBL 0053 Internal DC Cable V60 40200 29 FPC MB PB cable V60 21000 29 MB SB cable V60 70100 29 DC DC cable power supply Power board CBL 0054 Detachable Battery cable V60 00050 29 ...

Page 109: ...Spare parts Cables Flight 60 Service Manual 11 9 Internal Battery cable V60 50100 29 Oxygen Sensor cable V60 00130 29 O2 Leak sensor cable SUB 0010 ...

Page 110: ......

Page 111: ...rameters 3 2 Technical 3 3 Up Down 3 1 BUV LED Indicator 3 3 LED Indicator Back up ventilation 7 12 Buzzer Test 7 20 C Cable ties 4 1 Cancel button 3 3 Charger 7 18 9 4 9 5 Connector patient circuit 3 1 Ventilator Cover 4 3 4 5 4 6 Cutter 4 1 D DC connector 3 6 Decrease button 3 3 Detachable battery 3 6 Detachable Battery 4 2 Display touch screen 3 2 D type Board 4 36 Dual limb exhalation valve 3 ...

Page 112: ...onnector 3 1 PC connector 3 6 PEEP 6 3 7 12 7 15 Peripherals connector 3 7 Phillips screwdriver PH1 4 1 7 5 PLT1M M69 4 1 PLT4S M69 4 1 Power Board 4 6 4 7 4 8 4 9 4 10 9 3 9 4 9 5 Power board PB 3 9 3 10 Power Supply 4 7 4 10 4 12 4 14 7 18 Power supply PS 3 9 3 10 Pressure gauge 3 2 Pressure Relief Calibration 7 8 Pressure Sensors Calibration 7 5 9 3 Pressure Trigger 7 16 Pressure Verification 7...

Page 113: ...Flight 60 Service Manual 3 V60 25000 29 3 9 3 10 V60 26000 65 3 9 3 10 V60 60002 65 3 9 3 10 Verification 2 3 7 5 Volume Factor Calibration 7 9 ...

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