Puritan Bennett 840 User manual

Ventilator System
840 Service Manual
4-070496-00 Rev K
August 2010

Copyright information
Copyright 2010 Nellcor Puritan Bennett LLC. All rights reserved. The Puritan Bennett ™ 840 Ventilator System is
manufactured in accordance with Puritan Bennett proprietary information, covered by one or more of the following
U.S. Patents and foreign equivalents: 5,271,389; 5,319,540; 5,339,807; 5,390,666; 5,771,884; 5,791,339; 5,813,399;
5,865,168; 5,881,723; 5,884,623; 5,915,379; 5,915,380; 6,024,089; 6,161,539; 6,220,245; 6,269,812; 6,305,373;
6,360,745; 6,369,838; 6,553,991; 6,668,824; 6,675,801; 7,036,504; 7,117,438; and RE39225. 840, 800 Series,
DualView, SandBox, SmartAlert, and Flow-by, are trademarks of Nellcor Puritan Bennett LLC.
The information contained in this manual is the sole property of Nellcor Puritan Bennett LLC and may not be
duplicated without permission. This manual may be revised or replaced by Puritan Bennett at any time and without
notice. You should ensure you have the most current applicable version of this manual; if in doubt, contact the
Technical Support Department of Nellcor Puritan Bennett LLC. or your local representative. While the information
set forth herein is believed to be accurate, it is not a substitute for the exercise of professional judgment.
The ventilator should be operated and serviced only by trained professionals. Puritan Bennett’s sole responsibility
with respect to the ventilator, and its use, is as stated in the limited warranty provided.
Nothing in this manual shall limit or restrict in any way Puritan Bennett’s right to revise or otherwise change or
modify the equipment (including its software) described herein, without notice. In the absence of an express, written
agreement to the contrary, Puritan Bennett has no obligation to furnish any such revisions, changes, or
modifications to the owner or user of the equipment (including its software) described herein.
Manufacturer: Authorized Representative:
Nellcor Puritan Bennett LLC Tyco Healthcare UK Limited
4280 Hacienda Drive 154 Fareham Road
Pleasanton, CA 94588-2719 Gosport
USA PO13 0AS
UK
Phone: [phone]

Preface
ii Puritan Bennett 800 Series Ventilator System Service Manual
Definitions
This manual uses three special indicators to convey information of a specific nature.
They include:
Warning
Indicates a condition that can endanger the patient or the ventilator operator.
Caution
Indicates a condition that can damage the equipment.
NOTE:
Indicates points of particular interest that make operation of the ventilator more efficient or
convenient.
Warnings, cautions, and notes
Please take the time to familiarize yourself with the following caveats as they cover safety
considerations, special handling requirements, and regulations that govern the use of the
Puritan Bennett™ 840 Ventilator System.
• To ensure proper servicing and avoid the possibility of physical injury, only qualified
personnel should attempt to service or make authorized modifications to the ventilator.
• To prevent possible personal injury and equipment damage, make sure the brakes on the
casters are set to prevent inadvertent movement of the ventilator during service.
•
The user of this product shall have sole responsibility for any ventilator malfunction
due to operation or maintenance performed by anyone not trained by Puritan Bennett
staff.
• To avoid an electrical shock hazard while servicing the ventilator, be sure to remove all
power to the ventilator by disconnecting the power source and turning off all ventilator
power switches.
• To avoid a fire hazard, keep matches, lighted cigarettes, and all other sources of ignition
(e.g., flammable anesthetics and/or heaters) away from the Puritan Bennett 840 Ventilator
System and oxygen hoses.
Do not use oxygen hoses that are worn, frayed, or contaminated by combustible materials
such as grease or oils. (Textiles, oils, and other combustibles are easily ignited and burn
with great intensity in air enriched with oxygen.)
In case of fire or a burning smell, immediately disconnect the ventilator from the oxygen
supply, facility power, and BPS.
• When handling any part of the Puritan Bennett 840 Ventilator System, always follow your
hospital infection control guidelines for handling infectious material.
Puritan Bennett recognizes cleaning, sterilization, sanitation, and disinfection practices
vary widely among healthcare institutions. It is not possible for Puritan Bennett to specify
or require specific practices that will meet all needs, or to be responsible for the
effectiveness of cleaning, sterilization, and other practices carried out in the patient care
setting.
Puritan Bennett does recommend users of its products that require cleaning and
sterilization/disinfection consider the National Standards and Recommended Practices for
Sterilization published by the Association for the Advancement of Medical
Instrumentation (AAMI), as well as the following Center for Disease Control (CDC)

Preface
Puritan Bennett 800 Series Ventilator System Service Manual iii
publications: Guidelines for Maintenance of In-use Respiratory Therapy Equipment and
Guidelines for Prevention of Nosocomial Pneumonia.
• Patients on life-support equipment should be appropriately monitored by competent
medical personnel and suitable monitoring devices.
• The Puritan Bennett 840 Ventilator System is not intended to be a comprehensive
monitoring device and does not activate alarms for all types of dangerous conditions for
patients on life-support equipment.
• For a thorough understanding of ventilator operations, be sure to thoroughly read the
Puritan Bennett 800 Series Ventilator System Operator’s and Technical Reference Manual before
attempting to use the system.
• Before activating any part of the ventilator, be sure to check the equipment for proper
operation and, if appropriate, run SST (Short Self Test).
• Do not use sharp objects to make selections on the graphical user interface (GUI) display
or keyboard.
• Federal law (U.S.) restricts the sale of this device to, or by the order of, any physician.
• Check the ventilator periodically as outlined in this manual; do not use if defective.
Immediately replace parts that are broken, missing, obviously worn, distorted, or
contaminated.
• An alternative source of ventilation should always be available when using the Puritan
Bennett 840 Ventilator System.
Year of manufacture
The year of manufacture for ventilators whose serial numbers begin with 4200 is indicated on
the rear panel of the BDU as shown here. The two digit number following the year indicates
the month of manufacture.
For ventilators whose serial numbers begin with 3510, the year of manufacture is indicated by
the serial number’s 5th and 6th digits. In the example below, a ventilator with serial number
3510021223 was the 1223rd unit built in 2002.
2003 – 10
3510 02 1223
Year of manufacture
Sequential number

Preface
iv Puritan Bennett 800 Series Ventilator System Service Manual
Electromagnetic susceptibility
The Puritan Bennett 840 Ventilator System complies with the requirements of IEC 60601-1-2
(EMC Collateral Standard), including the E-field susceptibility requirements at a level of 10
volts per meter, at frequencies from 26 MHz to 1 GHz, and the ESD requirements of this
standard. However, even at this level of device immunity, certain transmitting devices
(cellular phones, walkie-talkies, cordless phones, paging transmitters, etc.) emit radio
frequencies that could interrupt ventilator operation if located in a range too close to the
ventilator. It is difficult to determine when the field strength of these devices becomes
excessive. Practitioners should be aware radio frequency emissions are additive, and that the
ventilator must be located a sufficient distance from transmitting devices to avoid
interruption. Do not operate the ventilator in a magnetic resonance imaging (MRI)
environment. Chapter 7 describes possible ventilator alarms and what to do if they occur.
Consult with your institution’s biomedical engineering department in case of interrupted
ventilator operation and before relocating any life support equipment.
Warning
Accessory equipment connected to the analog and digital interfaces must be certified
according to IEC 60601-1. Furthermore, all configurations shall comply with the
system standard IEC 60601-1-1. Any person who connects additional equipment to the
signal input part or signal output part of the Puritan Bennett 840 ventilator configures
a medical system, and is therefore responsible for ensuring the system complies with
the requirements of the system standard IEC 60601-1-1. If in doubt, consult
Puritan Bennett Technical Support at 1.800.255.6774 or your local representative.
Customer assistance
If you require further assistance, contact Nellcor Puritan Bennett LLC at 1.800.255.6774 or
your local Puritan Bennett representative.
Additional information
For online technical support, visit the SolvITSM Center Knowledge
Base at http://www.puritanbennett.com. The SolvIT Center provides
answers to frequently asked questions about the Puritan Bennett
840 Ventilator System and other Puritan Bennett products 24 hours a
day, 7 days a week.
About this manual
This manual provides information needed to service the Puritan Bennett 840 Ventilator
System. This manual is intended for use by certified biomedical engineering technicians or
personnel with equivalent experience and training in servicing this type of equipment. It is
recommended the user complete the Puritan Bennett training class geared specifically to the
Puritan Bennett 840 Ventilator System.
While this manual covers the ventilator configurations currently supported by
Puritan Bennett, it may not be all-inclusive and may not be applicable to your ventilator. You
should ensure you have the most current applicable version of this manual; if in doubt,
contact Puritan Bennett or visit the Puritan Bennett product manual Web page at
http://www.puritanbennett.com/serv/manuals.aspx
Some illustrations and photos are shown with a ready-to-assemble (RTA) cart, Puritan Bennett
800 Series Ventilator Compressor Mount Cart or a Puritan Bennett 800 Series Ventilator Pole
Cart. Please note these images are for illustrative purposes only, and regardless of which cart
you have, the required information is provided.
The term “RTA cart” refers to the ready-to-assemble cart and any earlier cart versions.
Within the USA, contact Puritan Bennett at 1.800.255.6774 for questions regarding the
applicability of the information.

SECTION
v
CONTENTS
1 General information
1.1 How to use this manual...............................................................................................1-1
1.2 General product description ........................................................................................1-1
1.3 Configuration information...........................................................................................1-2
1.4 Accessories ..................................................................................................................1-3
1.5 Specifications ..............................................................................................................1-4
1.6 Compliance and approvals ..........................................................................................1-9
1.6.1 Manufacturer’s Declaration ...............................................................................1-11
1.7 Technical information................................................................................................1-17
1.8 Range, resolution, accuracy, and new patient/default settings ..................................1-19
1.9 Tools, equipment, and service materials ....................................................................1-29
1.10 Periodic maintenance ..............................................................................................1-35
1.11 Service kits ..............................................................................................................1-37
1.12 Controls and indicators ..........................................................................................1-39
1.13 Onscreen symbols and abbreviations.......................................................................1-61
1.14 Ventilator serial numbers and software version ........................................................1-61
1.15 Service philosophy...................................................................................................1-61
2 Theory of operation
2.1 Major ventilator subassemblies ....................................................................................2-1
2.1.1 Breath delivery unit (BDU)...................................................................................2-2
2.1.2 Graphic user interface (GUI) ................................................................................2-3
2.1.3 806 Compressor Unit ..........................................................................................2-4
2.1.4 802 or 803 Backup Power Source (BPS)...............................................................2-4
2.1.5 Cart.....................................................................................................................2-5
2.1.6 Patient system .....................................................................................................2-6
2.2 Operational overview ..................................................................................................2-7
2.3 Pneumatic system .....................................................................................................2-11
2.3.1 Inspiratory module ............................................................................................2-16
2.3.1.1 Gas supply conditioning subsystem........................................................2-17
2.3.1.2 Flow control subsystem..........................................................................2-23
2.3.1.3 Safety valve and inspiration monitoring subsystem.................................2-26
2.3.1.4 Inspiratory module operation.................................................................2-32
2.3.2 Patient System...................................................................................................2-36
2.3.2.1 Patient system components....................................................................2-37
2.3.2.2 Patient system operation........................................................................2-38
2.3.3 Exhalation module.............................................................................................2-38
2.3.3.1 Exhalation module components.............................................................2-39
2.3.3.2 Exhalation module operation .................................................................2-40
2.3.4 806 Compressor Unit ........................................................................................2-43
2.3.4.1 806 Compressor unit components .........................................................2-43
2.3.4.2 806 Compressor unit operation..............................................................2-46
Puritan Bennett 800 Series Ventilator System Service Manual

Contents
vi Puritan Bennett 800 Series Ventilator System Service Manual
2.4.1 Summary of electrical components ................................................................... 2-48
2.4.2 Overview of electrical system operation ............................................................ 2-53
2.4.3 AC distribution components ............................................................................ 2-62
2.4.3.1 Power cord............................................................................................ 2-62
2.4.3.2 AC panel................................................................................................ 2-62
2.4.3.3 Power switch ......................................................................................... 2-65
2.4.4 Power supply .................................................................................................... 2-66
2.4.5 BPS ................................................................................................................... 2-68
2.4.6 Card Cage ........................................................................................................ 2-71
2.4.6.1 Motherboard PCB.................................................................................. 2-73
2.4.6.2 BDU CPU PCB........................................................................................ 2-76
2.4.6.3 Analog interface (AI) PCB....................................................................... 2-80
2.4.7 Data key subsystem .......................................................................................... 2-82
2.4.8 GUI................................................................................................................... 2-82
2.4.8.1 GUI CPU PCB ........................................................................................ 2-82
2.4.8.2 Touch frame PCB................................................................................... 2-90
2.4.8.3 Keyboard assembly with knob ............................................................... 2-91
2.4.8.4 GUI LED PCB ......................................................................................... 2-93
2.4.8.5 Backlight inverter PCB and LCD lamps................................................... 2-94
2.4.8.6 GUI alarm assembly............................................................................... 2-95
2.4.9 BDU LED PCB ................................................................................................... 2-97
2.4.10 Inspiratory electronics PCB.............................................................................. 2-97
2.4.11 Exhalation transducer PCB .............................................................................. 2-99
2.4.11.1 BD (continuous-tone) alarm assembly.................................................. 2-101
2.4.12 806 Compressor unit .................................................................................... 2-101
2.4.12.1 806 compressor unit AC power distribution components and motor ... 2-103
2.4.12.2 806 compressor PCB ........................................................................... 2-103
2.4.12.3 806 Compressor unit operation ........................................................... 2-107
2.5 Breath delivery........................................................................................................ 2-109
2.5.1 Inspiration....................................................................................................... 2-109
2.5.1.1 Pressure triggering............................................................................... 2-111
2.5.1.2 Flow triggering.................................................................................... 2-111
2.5.1.3 Time-cycling method........................................................................... 2-111
2.5.1.4 Operator triggering ............................................................................. 2-111
2.5.2 Exhalation....................................................................................................... 2-111
2.5.2.1 Time-cycling method........................................................................... 2-112
2.5.2.2 End-inspiratory flow method................................................................ 2-112
2.5.2.3 Airway pressure method ...................................................................... 2-112
2.5.2.4 Time limit ............................................................................................ 2-112
2.5.2.5 High circuit pressure limit .................................................................... 2-112
2.5.2.6 High ventilator pressure limit ............................................................... 2-112
2.6 Other hardware operations .................................................................................... 2-114
2.6.1 Gas supply and control ................................................................................... 2-114
2.6.2 Data monitoring ............................................................................................. 2-114
2.6.3 Pressure transducer autozero........................................................................... 2-115
2.6.4 Power monitoring and power fail handling ..................................................... 2-117
2.6.4.1 Loss of power source ........................................................................... 2-117
2.6.4.2 Supply voltage monitoring .................................................................. 2-118
2.7.1 Safety valve open (SVO) state.......................................................................... 2-118

Contents
Puritan Bennett 800 Series Ventilator System Service Manual vii
2.7.2 Occlusion handling .........................................................................................2-120
2.7.2.1 When the ventilator declares an occlusion............................................2-120
2.7.2.2 Occlusion detection and handling........................................................2-120
3 Self tests
3.1 Introduction ................................................................................................................3-1
3.2 How to enter Service Mode .........................................................................................3-1
3.3 Self tests and background checks ................................................................................3-1
3.3.1 POST (Power On Self Test) ..................................................................................3-1
3.3.2 SST (Short Self Test) ............................................................................................3-1
3.3.3 EST (Extended Self Test) .....................................................................................3-2
3.3.4 Background checks..............................................................................................3-2
3.3.5 When self tests are run ........................................................................................3-2
3.4 Power on self test (POST) ............................................................................................3-3
3.4.1 Safety .................................................................................................................3-8
3.4.2 POST characteristics ............................................................................................3-8
3.4.3 POST following power interruptions ....................................................................3-9
3.4.4 POST user interface .............................................................................................3-9
3.4.5 Structure of POST..............................................................................................3-10
3.5 SST (short self test)....................................................................................................3-13
3.5.1 When to run SST ...............................................................................................3-13
3.5.2 Hardware requirements .....................................................................................3-14
3.5.3 Running SST......................................................................................................3-15
3.6 EST (extended self test) .............................................................................................3-19
3.6.1 Description of EST .............................................................................................3-19
3.6.2 When to run EST ...............................................................................................3-19
3.6.3 Hardware requirements .....................................................................................3-20
3.6.4 How to run EST .................................................................................................3-20
3.6.5 How to run Single Test EST................................................................................3-28
4 Service mode
4.1 Accessing Service Mode...............................................................................................4-1
4.2 Service Mode functions ...............................................................................................4-3
4.2.1 SST RESULT: Displaying SST results......................................................................4-5
4.2.2 DIAG LOG: Displaying error and status logs.........................................................4-5
4.2.3 Alarm log: Displaying the alarm history ...............................................................4-7
4.2.4 VENT CONFIG: Displaying software revisions and serial numbers ........................4-7
4.2.5 OPERATION TIME: Displaying ventilator and compressor elapsed hours ..............4-7
4.2.6 TEST SUMMARY: Displaying results from EST and SST .........................................4-7
4.2.7 EST: Extended self test.........................................................................................4-7
4.2.8 DATE/TIME: Adjusting date and time...................................................................4-7
4.2.9 EXIT: Exiting Service Mode ..................................................................................4-8
4.2.10 Other screens ....................................................................................................4-8
4.2.10.1 Service Mode Setup .................................................................................4-9
4.2.10.2 External Test Control: Performing remote ventilator testing .....................4-9
4.2.10.3 Exp Valve Calibration ...............................................................................4-9
4.2.10.4 Vent Inop Test........................................................................................4-12
4.2.10.5 Flow Sensor Calibration..........................................................................4-13
4.2.10.6 Atmospheric Pressure Transducer calibration..........................................4-15

Contents
viii Puritan Bennett 800 Series Ventilator System Service Manual
4.2.10.7 Data key Update.................................................................................... 4-16
4.2.10.8 Serial Loopback Test .............................................................................. 4-16
4.2.10.9 Compact flash test................................................................................. 4-17
4.2.11 Automatically executed Service Mode functions.............................................. 4-17
4.2.11.1 Initialize Flow Sensor.............................................................................. 4-17
4.2.11.2 Cal Info Duplication............................................................................... 4-18
4.2.11.3 Serial number setup............................................................................... 4-18
4.2.12 Oxygen sensor calibration............................................................................... 4-20
5 Performance verification
5.1 Tools, test equipment, and service materials ............................................................... 5-1
5.2 When to run ............................................................................................................... 5-1
5.3 Preliminary ventilator cleaning and inspection ............................................................ 5-4
5.4 Preliminary ventilator setup......................................................................................... 5-4
5.5 Preliminary calibrations and tests ................................................................................ 5-5
5.6 Performance verification guidelines............................................................................. 5-7
5.7 Performance verification tests...................................................................................... 5-7
5.7.1 Electrical safety test ............................................................................................ 5-8
5.7.2 Ground isolation check ....................................................................................... 5-9
5.7.3 Extended self test (EST)....................................................................................... 5-9
5.7.4 Regulator setting verification............................................................................. 5-10
5.7.5 Serial loopback test (10.4-inch GUI only) .......................................................... 5-10
5.7.6 Performance verification using PTS 2000 Performance Test System
and BreathLab 840 VTS software....................................................................... 5-10
5.7.6.1 How to view the test results log............................................................. 5-11
5.7.7 Manual ventilator check using equipment other than PTS 2000
Performance Test System .................................................................................. 5-14
5.8 Regulator calibration hose repair instructions ............................................................ 5-15
6 Diagnostic codes
6.1 Introduction................................................................................................................ 6-1
6.2 Reference Tables ......................................................................................................... 6-1
6.3 Troubleshooting.......................................................................................................... 6-2
6.4 POST fault handling ................................................................................................... 6-2
6.5 Diagnostic CPU LED arrays.......................................................................................... 6-3
6.6 Diagnostic codes......................................................................................................... 6-4
6.6.1 How to interpret diagnostic codes ...................................................................... 6-4
6.7 Organization of diagnostic codes table ....................................................................... 6-5
6.8 System Diagnostic Log and BDU POST analog devices test ....................................... 6-60
6.9 Diagnostic codes for POST faults............................................................................... 6-62
6.9.1 POST interrupt errors and test failures............................................................... 6-70
6.10 SST and EST test sequences and diagnostic codes ................................................... 6-72
6.11 How to troubleshoot VGA LCD controller PCB faults (UT0002)
(9.4-inch GUI only) ................................................................................................. 6-108
6.12 How to troubleshoot GUI LCD screen messages ................................................... 6-109
6.12.1 Example 1: Missing data key information ...................................................... 6-109
6.12.2 Example 2: No communication between the GUI and BDU........................... 6-111
6.12.3 Example 3: POST or Background check errors ............................................... 6-112