Puritan bennett 840 User manual

Ventilator System

840 Service Manual

4-070496-00 Rev K

August 2010

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

Phone: +800.255.6774

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

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

Contents

Puritan Bennett 800 Series Ventilator System Service Manual ix

7 Alarm handling

7.1 Alarm classifications.....................................................................................................7-1

7.2 Responding to alarms..................................................................................................7-2

8 Service and repair

8.1 How to use this chapter...............................................................................................8-1

8.2 General repair safety....................................................................................................8-1

8.3 General repair guidelines.............................................................................................8-2

8.4 Repair-related cleaning................................................................................................8-2

8.5 Electrical cables and pneumatic tubing........................................................................8-3

8.6 Adhesive use................................................................................................................8-3

8.7 Leak testing.................................................................................................................8-3

8.8 Electrostatic discharge control .....................................................................................8-4

8.8.1 ESD procedures and precautions .........................................................................8-4

8.9 Replacement part ordering..........................................................................................8-4

8.10 Testing, calibration, and other post-service procedures..............................................8-4

8.11 Patient system and accessories...................................................................................8-6

8.12 Graphic user interface (GUI) ......................................................................................8-6

8.13 Repairing the 10.4-inch GUI ......................................................................................8-8

8.13.1 Removing or installing the 10.4-inch GUI when mounted on RTA cart...............8-8

8.13.2 Removing or installing the 10.4-inch GUI when mounted on Puritan Bennett

800 Series Ventilator Compressor Mount Cart or Puritan Bennett

800 Series Ventilator Pole Cart...........................................................................8-9

8.13.3 Removing the 10.4-inch GUI cable assembly ...................................................8-11

8.13.4 Replacing the 10.4-inch GUI cable assembly....................................................8-12

8.13.5 Removing the 10.4-inch GUI rear housing.......................................................8-12

8.13.6 Replacing the 10.4-inch GUI rear housing .......................................................8-13

8.13.7 Removing the 10.4-inch CPU EMI shield .........................................................8-13

8.13.8 Removing the 10.4-inch GUI backlight inverter PCBs.......................................8-14

8.13.9 Removing the 10.4-inch GUI CPU PCB ............................................................8-15

8.13.10 Replacing the 10.4-inch Non-TE GUI CPU PCB with the TE GUI CPU PCB......8-16

8.13.11 Replacing the 10.4-inch TE GUI CPU PCB with a new

10.4-inch TE GUI CPU PCB................................................................................8-19

8.13.12 Replacing the compact flash component (TE GUI CPU PCB only) ..................8-19

8.13.13 Replacing the real-time clock.........................................................................8-20

8.13.14 10.4-inch GUI support bracket ......................................................................8-20

8.13.14.1 Removing the 10.4-inch GUI support bracket.........................................8-21

8.13.15 10.4-inch LCD panels ...................................................................................8-21

8.13.15.1 Removing the 10.4-inch LCD panels ......................................................8-22

8.13.16 10.4-inch touchframe PCB (MKG Touch).......................................................8-22

8.13.16.1 Removing the 10.4-inch touchframe PCB...............................................8-22

8.13.17 Replacing the 10.4-inch touchframe PCB.......................................................8-23

8.13.18 10.4-inch GUI LED PCB .................................................................................8-23

8.13.18.1 Removing the 10.4-inch GUI LED PCB....................................................8-23

8.13.18.2 Replacing the 10.4-inch GUI LED PCB ....................................................8-23

8.13.19 10.4-inch GUI alarm assembly.......................................................................8-23

8.13.19.1 Removing the 10.4-inch GUI alarm assembly .........................................8-24

8.13.19.2 Replacing the 10.4-inch GUI alarm assembly..........................................8-24

8.13.20 10.4-inch GUI keyboard assembly .................................................................8-24

Contents

xPuritan Bennett 800 Series Ventilator System Service Manual

8.13.20.1 Replacing the 10.4-inch GUI keyboard assembly.................................... 8-25

8.13.21 10.4-inch GUI front housing ......................................................................... 8-26

8.13.21.1 Replacing the 10.4-inch front housing................................................... 8-26

8.13.22 10.4-inch rotor housing ................................................................................ 8-26

8.13.22.1 Replacing the 10.4-inch rotor housing................................................... 8-26

8.14 Repairing the 9.4-inch GUI...................................................................................... 8-28

8.14.1 Removing the 9.4-inch GUI touch screen bezel ............................................... 8-28

8.14.2 9.4-inch GUI window...................................................................................... 8-29

8.14.3 Installing the 9.4-inch bezel ............................................................................ 8-30

8.14.4 The 9.4-inch keyboard assembly ..................................................................... 8-30

8.14.4.1 Removing 9.4-inch keyboard assembly .................................................. 8-30

8.14.4.2 Installing the 9.4-inch keyboard assembly.............................................. 8-32

8.14.5 Removing or installing the 9.4-inch GUI.......................................................... 8-32

8.14.6 9.4-inch GUI rear housing............................................................................... 8-33

8.14.6.1 Removing 9.4-inch GUI rear housing ..................................................... 8-33

8.14.6.2 Installing 9.4-inch GUI rear housing....................................................... 8-34

8.14.7 9.4-inch GUI alarm assembly .......................................................................... 8-35

8.14.7.1 Removing 9.4-inch GUI alarm assembly................................................. 8-35

8.14.7.2 Installing 9.4-inch GUI alarm assembly .................................................. 8-36

8.14.8 9.4-inch GUI backlight inverter PCB and GUI LED PCB .................................... 8-36

8.14.8.1 Removing 9.4-inch GUI backlight inverter PCB ...................................... 8-36

8.14.8.2 Installing 9.4-inch GUI backlight inverter PCB........................................ 8-37

8.14.8.3 Removing 9.4-inch GUI LED PCB ........................................................... 8-37

8.14.8.4 Installing 9.4-inch GUI LED PCB............................................................. 8-37

8.14.9 GUI Electromagnetic Interference (EMI) shield ................................................ 8-38

8.14.9.1 Removing the GUI EMI shield ................................................................ 8-38

8.14.9.2 Installing the 9.4-inch GUI EMI shield .................................................... 8-38

8.14.10 9.4-inch video controller and VGA LCD controller PCBs ................................ 8-39

8.14.10.1 Removing 9.4-inch VGA LCD controller PCBs (older CPU PCB) .............. 8-39

8.14.10.2 Installing 9.4-inch VGA LCD controller PCBs (older CPU PCB)................ 8-39

8.14.11 9.4-inch GUI CPU PCB .................................................................................. 8-40

8.14.11.1 Removing the 9.4-inch GUI CPU PCB .................................................... 8-40

8.14.11.2 Installing the 9.4-inch GUI CPU PCB ...................................................... 8-40

8.14.12 Replacing the compact flash component (TE GUI CPU PCB only).................. 8-42

8.14.13 Replacing the real-time clock ........................................................................ 8-42

8.14.14 9.4-inch touchframe PCB (Carroll Touch)...................................................... 8-43

8.14.14.1 Removing the 9.4-inch touchframe PCB ................................................ 8-43

8.14.14.2 Reinstalling the 9.4-inch touchframe PCB .............................................. 8-44

8.14.15 9.4-inch backlight panels and LCD panels .................................................... 8-46

8.14.15.1 Removing a 9.4-inch backlight panel and LCD panel ............................. 8-46

8.14.15.2 Reinstalling a backlight panel and LCD panel......................................... 8-46

8.14.16 9.4-inch GUI cooling vent filters.................................................................... 8-48

8.14.17 9.4-inch rotor housing .................................................................................. 8-49

8.14.17.1 Removing the 9.4-inch rotor housing .................................................... 8-49

8.14.17.2 Installing the 9.4-inch rotor housing...................................................... 8-49

8.15 Breath delivery unit (BDU) ...................................................................................... 8-50

8.15.1 Removing BDU from RTA cart ......................................................................... 8-53

8.15.2 Removing BDU from Puritan Bennett 800 Series Ventilator

Compressor Mount Cart or Puritan Bennett 800 Series Ventilator Pole Cart..... 8-53

Contents

Puritan Bennett 800 Series Ventilator System Service Manual xi

8.15.3 BDU power cord and retainer..........................................................................8-54

8.15.4 Installing BDU onto RTA cart ...........................................................................8-55

8.15.5 Installing BDU onto Puritan Bennett 800 Series Ventilator

Compressor Mount Cart or Puritan Bennett 800 Series Ventilator Pole Cart.......8-55

8.15.6 Analog interface (AI) PCB and breath delivery (BD) CPU PCB...........................8-56

8.15.6.1 Removing AI PCB or BD CPU PCB ..........................................................8-57

8.15.6.2 Replacing the real-time clock .................................................................8-58

8.15.6.3 Installing AI PCB or BD CPU PCB ............................................................8-59

8.15.7 Power supply assembly....................................................................................8-59

8.15.7.1 Removing power supply assembly..........................................................8-59

8.15.7.2 Installing power supply assembly ...........................................................8-60

8.15.8 Power switch (S1)............................................................................................8-61

8.15.8.1 Removing power switch (S1)..................................................................8-61

8.15.8.2 Installing power switch (S1) ...................................................................8-62

8.15.9 Humidifier receptacle (100 – 120 V models only) ............................................8-62

8.15.9.1 Removing humidifier receptacle .............................................................8-62

8.15.9.2 Installing humidifier receptacle...............................................................8-63

8.15.9.3 AC panel................................................................................................8-64

8.15.10 Inspiratory module ........................................................................................8-65

8.15.10.1 Inspiratory module modifications ...........................................................8-65

8.15.10.2 Additional noise suppression (ferrite cores).............................................8-65

8.15.10.3 Inspiratory module o-rings .....................................................................8-66

8.15.10.4 Air inlet filter (F2) ...................................................................................8-66

8.15.10.5 Fascia panel ...........................................................................................8-67

8.15.10.6 Oxygen and air pressure switches (PS1 and PS2)....................................8-69

8.15.10.7 PSOL cartridge .......................................................................................8-70

8.15.10.8 Removing inspiratory module ................................................................8-71

8.15.10.9 Leak testing inspiratory module..............................................................8-71

8.15.10.10Installing inspiratory module .................................................................8-72

8.15.10.11Oxygen sensor (OS) ..............................................................................8-72

8.15.10.12Inspiratory check valve (CV3) ................................................................8-75

8.15.10.13Right-side plate .....................................................................................8-75

8.15.10.14Inspiratory electronics PCB ....................................................................8-77

8.15.10.15Left-side plate........................................................................................8-77

8.15.10.16PSOL manifold ......................................................................................8-78

8.15.10.17Oxygen and air flow sensors (Q1 and Q2).............................................8-80

8.15.10.18Safety valve ...........................................................................................8-81

8.15.10.19Check valve assembly, regulator assembly, and flow sensor manifold ....8-83

8.15.10.20Oxygen and air regulators (REG1 and REG2) .........................................8-85

8.15.10.21Inspiratory pressure transducer autozero solenoid (SOL1)......................8-86

8.15.10.22Inspiratory floor assembly......................................................................8-86

8.15.11 Exhalation module.........................................................................................8-87

8.15.11.1 Exhalation collector vial (ECV) and expiratory filter (F9)..........................8-87

8.15.11.2 Removing exhalation module cover .......................................................8-87

8.15.11.3 Removing exhalation module.................................................................8-90

8.15.11.4 Installing exhalation module ..................................................................8-90

8.15.11.5 Exhalation valve (EV)..............................................................................8-91

8.15.11.6 Exhalation flow sensor (Q3) ...................................................................8-94

8.15.11.7 Exhalation transducer PCB .....................................................................8-96

Contents

xii Puritan Bennett 800 Series Ventilator System Service Manual

8.15.11.8 Expiratory pressure transducer autozero solenoid (SOL2)....................... 8-97

8.15.11.9 Exhalation heater (EXH HTR) and check valve (CV5) .............................. 8-98

8.15.12 BDU housing................................................................................................. 8-99

8.15.12.1 Removing BDU housing......................................................................... 8-99

8.15.12.2 Installing BDU housing ........................................................................ 8-101

8.15.12.3 Motherboard PCB................................................................................ 8-101

8.15.12.4 BDU alarm assembly............................................................................ 8-102

8.15.13 Power indicator........................................................................................... 8-103

8.15.13.1 Removing power indicator................................................................... 8-103

8.15.13.2 Installing power indicator .................................................................... 8-104

8.15.13.3 Alarm blindmate cable......................................................................... 8-104

8.15.13.4 Inspiratory blindmate cable ................................................................. 8-105

8.15.13.5 DC power supply blindmate cable....................................................... 8-106

8.15.13.6 AC power supply blindmate harness.................................................... 8-107

8.15.14 Release handle ............................................................................................ 8-109

8.15.14.1 Removing release handle ..................................................................... 8-109

8.15.14.2 Installing release handle....................................................................... 8-109

8.16 806 compressor unit............................................................................................. 8-109

8.17 Servicing the 806 compressor ............................................................................... 8-110

8.17.1 Compressor inlet filter................................................................................... 8-110

8.17.2 Removing and installing the compressor inlet filter ....................................... 8-110

8.17.3 Removing compressor from cart ................................................................... 8-110

8.17.3.1 Disconnecting compressor from BDU .................................................. 8-110

8.17.3.2 Removing compressor from cart .......................................................... 8-111

8.17.4 Removing top cover...................................................................................... 8-111

8.17.5 Installing top cover ....................................................................................... 8-113

8.17.6 Cooling fans.................................................................................................. 8-113

8.17.6.1 Removing a cooling fan ....................................................................... 8-113

8.17.6.2 Installing a fan ..................................................................................... 8-114

8.17.7 Removing the back panel.............................................................................. 8-114

8.17.8 Reinstalling the back panel............................................................................ 8-114

8.17.9 Replacing an accumulator fitting and o-ring.................................................. 8-115

8.17.10 Pneumatic hoses ......................................................................................... 8-115

8.17.11 Plenum assembly ........................................................................................ 8-116

8.17.11.1 Removing the plenum assembly .......................................................... 8-117

8.17.12 Heat exchanger (HE)................................................................................... 8-118

8.17.12.1 Replacing the heat exchanger.............................................................. 8-118

8.17.13 Removing and replacing the AC power cord ............................................... 8-118

8.17.14 Removing and replacing the data cable ...................................................... 8-118

8.17.15 Compressor PCB ......................................................................................... 8-119

8.17.15.1 Removing and replacing the compressor PCB...................................... 8-119

8.17.16 Air dryer (dryer) and solenoid valve assembly.............................................. 8-119

8.17.16.1 Removing and reinstalling the air dryer, solenoid valve assembly,

and replacing filters ............................................................................. 8-120

8.17.17 Compressor assembly ................................................................................. 8-121

8.17.17.1 Removing the compressor assembly .................................................... 8-121

8.17.17.2 Replacing the coalescing filter element ................................................ 8-122

8.17.18 Replacing the compressor panels ................................................................ 8-123

8.17.19 Reinstalling the plenum assembly................................................................ 8-124

Contents

Puritan Bennett 800 Series Ventilator System Service Manual xiii

8.17.20 Reconnecting electrical cables ....................................................................8-124

8.17.21 Replacing the Tinnerman clips.....................................................................8-124

8.17.22 Reinstalling the back panel/accumulator assembly.......................................8-124

8.17.23 Replacing the main inlet filter and reinstalling the top .................................8-125

8.17.24 Reinstalling the compressor module ............................................................8-125

8.17.25 Running performance verification test .........................................................8-125

8.18 Backup power source (BPS) ...................................................................................8-125

8.18.1 Removing the 802 or 803 BPS.......................................................................8-126

8.18.2 Installing 802 BPS..........................................................................................8-127

8.18.3 Installing 803 BPS..........................................................................................8-127

8.18.4 Battery pack ..................................................................................................8-132

8.18.4.1 Removing 802 BPS battery pack...........................................................8-132

8.18.4.2 Installing 802 BPS battery pack ............................................................8-133

8.18.4.3 Removing 803 BPS battery pack...........................................................8-133

8.18.4.4 Installing 803 BPS battery pack ............................................................8-133

8.18.5 BPS PCB ........................................................................................................8-135

8.18.5.1 Removing 802 BPS PCB........................................................................8-135

8.18.5.2 Installing 802 BPS PCB .........................................................................8-135

8.18.5.3 Removing 803 BPS PCB........................................................................8-135

8.18.5.4 Installing 803 BPS PCB .........................................................................8-136

8.19 Cart.......................................................................................................................8-136

8.19.1 Removing and replacing the battery in the Puritan Bennett

800 Series Ventilator Compressor Mount Cart BPS ........................................8-138

8.19.1.1 Removing the four-hour battery...........................................................8-139

8.19.1.2 Replacing the four-hour battery ...........................................................8-140

8.19.1.3 Removing the one-hour battery ...........................................................8-141

8.19.1.4 Replacing the one-hour battery............................................................8-143

8.19.2 Removing and replacing the battery in the Puritan Bennett

800 Series Ventilator Pole Cart.......................................................................8-145

8.19.2.1 Four-hour battery removal ...................................................................8-146

8.19.2.2 Four-hour battery replacement.............................................................8-146

8.19.3 Charging circuit PCB removal and replacement for Puritan Bennett

800 Series Ventilator Pole Cart.......................................................................8-149

8.19.3.1 Charging circuit PCB removal...............................................................8-149

8.19.3.2 Charging circuit PCB replacement........................................................8-151

8.19.4 Cart Casters...................................................................................................8-151

8.19.4.1 Removing casters from RTA cart...........................................................8-151

8.19.4.2 Installing casters on RTA cart................................................................8-151

8.19.5 Removing casters from Puritan Bennett 800 Series Ventilator

Compressor Mount Cart or Puritan Bennett 800 Series Ventilator Pole Cart ...8-151

8.19.6 Installing casters on Puritan Bennett 800 Series Ventilator

Compressor Mount Cart or Puritan Bennett 800 Series Ventilator Pole Cart.....8-152

8.19.7 Removing/installing GUI mount on all carts...................................................8-152

8.19.8 Removing/installing GUI mount ...................................................................8-152

8.19.9 Removing/installing flex arm inserts on RTA cart............................................8-153

8.19.10 Removing/installing flex arm inserts on Puritan Bennett 800 Series Ventilator

Compressor Mount Cart and Puritan Bennett 800 Series Ventilator

Pole Cart .....................................................................................................8-153

Contents

xiv Puritan Bennett 800 Series Ventilator System Service Manual

9 Parts list

9.1 How to use this parts list ............................................................................................. 9-1

9.2 Puritan Bennett 840 Ventilator System patient system and accessories ....................... 9-3

9.2.1 Puritan Bennett 840 Ventilator System NeoMode patient system

and accessories ................................................................................................... 9-6

9.3 Flex arm assembly, oxygen and air hose assemblies, power cords .............................. 9-8

9.3.1 Flex arm assembly .............................................................................................. 9-8

9.3.2 Oxygen hose assemblies .................................................................................. 9-10

9.3.3 Air hose assemblies .......................................................................................... 9-12

9.3.4 Power cords ..................................................................................................... 9-14

9.4 Ventilator major assemblies ...................................................................................... 9-16

9.4.1 Major ventilator assemblies (Puritan Bennett 800 Series Ventilator

Compressor Mount Cart) .................................................................................. 9-18

9.4.2 Major ventilator assemblies (shown on Puritan Bennett 800 Series Ventilator

Pole Cart).......................................................................................................... 9-20

9.4.3 10.4-inch GUI (graphic user interface) assembly with Trending-enabled

(TE) GUI CPU PCB ................................................................................................. 9-30

9.4.4 10.4-inch GUI (graphic user interface) assembly ............................................... 9-34

9.4.5 10.4-inch GUI (graphic user interface) handle .................................................. 9-36

9.4.6 10.4-inch graphic user interface (GUI) rotor assembly ...................................... 9-38

9.4.7 10.4-inch GUI keyboards and speaker assembly ............................................... 9-40

9.4.8 9.4-inch graphic user interface (GUI) ............................................................... 9-43

9.4.8.1 9.4-inch GUI front housing assembly ..................................................... 9-46

9.4.8.2 9.4-inch GUI rear housing assembly....................................................... 9-48

9.4.9 Breath delivery unit (BDU) ............................................................................... 9-50

9.4.9.1 Exhalation module................................................................................. 9-54

9.4.9.2 Inspiratory module ................................................................................ 9-58

9.4.9.3 BDU cover ............................................................................................. 9-68

9.4.9.4 BDU chassis assembly ............................................................................ 9-70

9.4.9.5 BDU chassis kit ...................................................................................... 9-72

9.4.10 806 compressor unit ...................................................................................... 9-74

9.4.10.1 806 compressor base assembly.............................................................. 9-76

9.4.10.2 806 compressor unit enclosure assembly ............................................... 9-78

9.4.10.3 806 compressor unit plenum assembly.................................................. 9-80

9.4.11 Backup power source (802 BPS) ..................................................................... 9-82

9.4.12 803 Backup Power Source .............................................................................. 9-84

9.4.13 840 RTA (ready-to-assemble) Cart assembly ................................................... 9-86

9.4.14 Puritan Bennett 800 Series Ventilator Compressor Mount Cart assembly......... 9-88

9.4.15 Puritan Bennett 800 Series Ventilator Pole Cart assembly ................................ 9-91

SECTION

FIGURES

Figure 1-1. Remote alarm (nurse’s call) port pinout (view from back of GUI). . . . . . . . . . . . . . . . . . . . 1-7

Figure 1-2. Puritan Bennett 840 Ventilator System RS-232 serial port pinout. . . . . . . . . . . . . . . . . . . . 1-8

Figure 1-3. Monochrome GUI front view (showing all keys) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

Figure 1-4. 10.4-inch GUI rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

Figure 1-5. BDU front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

Figure 1-6. BDU I/O panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

Figure 1-7. BDU right-side panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Figure 1-8. BDU rear view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

Figure 1-9. GUI rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

Figure 1-10. 802 BPS controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Figure 1-11. 803 BPS controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Figure 1-12. Puritan Bennett 800 Series Ventilator Compressor Mount Cart charging status and

battery indicator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-58

Figure 1-13. Puritan Bennett 800 Series Ventilator Pole Cart charging status and

battery indicator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59

Figure 2-1. L-R Puritan Bennett 840 Ventilator shown on RTA cart, Puritan Bennett

800 Series Ventilator Compressor Mount Cart, and Puritan Bennett

800 Series Ventilator Pole Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Figure 2-2. BDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-3. 10.4-inch GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2-4. Compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-5. 802 BPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-6. 803 BPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-7. RTA cart, Puritan Bennett 800 Series Ventilator Compressor Mount Cart,

and Puritan Bennett 800 Series Ventilator Pole Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Figure 2-8. Patient system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-9. NeoMode patient system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-10. Puritan Bennett 840 Ventilator System block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Figure 2-11. Pneumatic system block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Figure 2-12. Pneumatic system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Figure 2-13. Inspiratory module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Figure 2-14. Inspiratory module in ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Figure 2-15. Inspiratory module gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Figure 2-16. Gas supply conditioning subsystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 2-17. Gas supply conditioning subsystem gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Figure 2-18. Gas supply conditioning subsystem components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Figure 2-19. Flow control subsystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Figure 2-20. Flow control subsystem gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Figure 2-21. Hot film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Figure 2-22. Flow control subsystem components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Figure 2-23. Safety valve and inspiration monitoring subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Figure 2-24. Inspiration monitoring subsystem gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Figure 2-25. Safety valve and inspiration monitoring subsystem components . . . . . . . . . . . . . . . . . . . 2-29

Puritan Bennett 800 Series Ventilator System Service Manual

Figures

xvi Puritan Bennett 800 Series Ventilator System Service Manual

Figure 2-26. Safety valve open gas flow diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Figure 2-27. Air flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Figure 2-28. Oxygen flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Figure 2-29. Patient system (minus exhalation collector vial and expiratory filter) . . . . . . . . . . . . . . . . 2-36

Figure 2-30. Patient system flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

Figure 2-31. Exhalation module (removed from BDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Figure 2-32. Exhalation module flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Figure 2-33. Exhalation module components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Figure 2-34. 806 compressor on Puritan Bennett 800 Series Ventilator Compressor Mount Cart . . . . . 2-43

Figure 2-35. 806 Compressor Pneumatic diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Figure 2-36. 806 components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Figure 2-37. Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Figure 2-38. 806 water trap assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Figure 2-39. Air dryer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Figure 2-40. 806 back panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Figure 2-41. 806 cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Figure 2-42. Electrical system block diagram (10.4-inch GUI—Trending-enabled CPU PCB shown) . . 2-55

Figure 2-43. Electrical system block diagram (10.4-inch GUI—Non-Trending-enabled

CPU PCB shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Figure 2-44. Electrical system block diagram (9.4-inch GUI—Trending-enabled CPU PCB shown) . . . 2-59

Figure 2-45. Electrical system block diagram (older 9.4-inch GUI shown) . . . . . . . . . . . . . . . . . . . . . . 2-61

Figure 2-46. AC panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Figure 2-47. Puritan Bennett 840 Ventilator System interconnect diagram – AC panel . . . . . . . . . . . . 2-64

Figure 2-48. Power switch (S1) and indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Figure 2-49. Power supply assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Figure 2-50. Puritan Bennett 840 Ventilator System interconnect diagram – Power distribution . . . . . 2-67

Figure 2-51. 802 BPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Figure 2-52. 803 BPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Figure 2-53. 802 BPS battery pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Figure 2-54. BPS PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Figure 2-55. Card cage with all PCBs installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Figure 2-56. Puritan Bennett 840 Ventilator System interconnect diagram – Card cage . . . . . . . . . . . 2-72

Figure 2-57. Motherboard PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

Figure 2-58. Motherboard PCB in place. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

Figure 2-59. Motherboard PCB block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75

Figure 2-60. BD CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Figure 2-61. AI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

Figure 2-62. Data key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

Figure 2-63. 10.4” Non-TE GUI CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

Figure 2-64. 10.4” TE GUI CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

Figure 2-65. 9.4” Non-TE GUI CPU PCB and backlight inverter PCB in place . . . . . . . . . . . . . . . . . . . . 2-84

Figure 2-66. 9.4” GUI TE GUI CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84

Figure 2-67. Puritan Bennett 840 Ventilator System interconnect diagram – GUI 10.4-inch

LCD panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Figure 2-68. Puritan Bennett 840 Ventilator System interconnect diagram – GUI 9.4-inch

LCD panels (Non-TE GUI CPU PCB P/N 4-073200-SP shown) . . . . . . . . . . . . . . . . . . . . 2-88

Figure 2-69. Puritan Bennett 840 Ventilator System interconnect diagram – GUI 9.4-inch

LCD panels (TE GUI CPU PCB shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

Figure 2-70. Touch Frame PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Figures

Puritan Bennett 800 Series Ventilator System Service Manual xvii

Figure 2-71. Keyboard assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92

Figure 2-72. GUI LED PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

Figure 2-73. 10.4” GUI LCD panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

Figure 2-74. 9.4-inch LCD panels and backlight tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95

Figure 2-75. GUI alarm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96

Figure 2-76. BDU LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97

Figure 2-77. Inspiratory electronics PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97

Figure 2-78. Puritan Bennett 840 Ventilator System interconnect diagram – Inspiratory module . . . . 2-98

Figure 2-79. Exhalation transducer PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

Figure 2-80. Puritan Bennett 840 Ventilator System interconnect diagram – Exhalation module . . . 2-100

Figure 2-81. BD alarm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

Figure 2-82. 806 compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

Figure 2-83. 806 Compressor fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

Figure 2-84. 806 compressor PCBA installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

Figure 2-85. 806 compressor PCB block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105

Figure 2-86. Puritan Bennett 840 Ventilator System interconnect diagram – Compressor unit . . . . . 2-106

Figure 2-87. Compressor operational sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108

Figure 2-88. Compressor unit start-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

Figure 2-89. Inspiration gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110

Figure 2-90. Exhalation gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113

Figure 2-91. Pressure transducer autozero mode gas flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

Figure 2-92. Power loss sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117

Figure 2-93. Safety valve open diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119

Figure 2-94. Pressure release, patient circuit occluded diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

Figure 3-1. Patient circuit setup for SST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Figure 3-2. EST setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Figure 3-3. EST screens during testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Figure 4-1. Service Mode screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Figure 4-2. Service Mode functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Figure 4-3. System diagnostic log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Figure 4-4. System Information Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 4-5. EST/SST Diagnostic Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 4-6. 100% O2/CAL In Progress indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Figure 5-1. Puritan Bennett 840 ventilator side view — PTS 2000 port . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Figure 5-2. How to access the test logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Figure 5-3. Report selection menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Figure 5-4. Puritan Bennett 840 Ventilator System PVT setup with PTS 2000 . . . . . . . . . . . . . . . . . . 5-12

Figure 5-5. Puritan Bennett 840 Ventilator System PVT setup with PTS 2000 and laptop computer. . 5-13

Figure 5-6. Regulator calibration hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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

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

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

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

Figure 8-2. 10.4-inch GUI front and back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Figure 8-3. 10.4-inch GUI mounting platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Figure 8-4. P-clip and GUI cable installed on Puritan Bennett 800 Series Ventilator Pole Cart . . . . . . 8-10

Figure 8-5. Removing and replacing 10.4-inch GUI cable assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Figure 8-6. Removing 10.4-inch GUI rear housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Figure 8-7. 10.4-inch GUI rear warning label and serial number tag . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Figures

xviii Puritan Bennett 800 Series Ventilator System Service Manual

Figure 8-8. Removing the 10.4-inch EMI shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Figure 8-9. Removal of a 10.4-inch backlight inverter PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Figure 8-10. RS-232 shield and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Figure 8-11. GUI CPU PCB touch panel jumpers configured for “MKG TOUCH” . . . . . . . . . . . . . . . . . 8-16

Figure 8-12. Socket savers and spacers installed onto RS-232 connectors . . . . . . . . . . . . . . . . . . . . . . 8-17

Figure 8-13. RS-232 shield with gaskets installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Figure 8-14. Thermal pad adhered to CPU heatsink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

Figure 8-15. How to replace the compact flash component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Figure 8-16. GUI CPU PCB real-time clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Figure 8-17. 10.4-inch LCD panels and LCD shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

Figure 8-18. 10.4-inch GUI touchframe PCB and GUI LED PCB locations . . . . . . . . . . . . . . . . . . . . . . . 8-22

Figure 8-19. Removal of the 10.4" GUI LED PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

Figure 8-20. Removing the 10.4-inch GUI alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

Figure 8-21. How to attach the grounding strap to the EMI shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

Figure 8-22. 10.4-inch GUI rotor housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Figure 8-23. 9.4-inch touch screen bezel and window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

Figure 8-24. 9.4-inch GUI tilt positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

Figure 8-25. Replacing the 9.4-inch keyboard assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

Figure 8-26. 9.4-inch GUI mounting platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

Figure 8-27. Removing 9.4-inch GUI handle assembly and interface cable . . . . . . . . . . . . . . . . . . . . . 8-33

Figure 8-28. Replacing 9.4-inch GUI rear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Figure 8-29. 9.4" GUI interior (TE GUI CPU PCB shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

Figure 8-30. Replacing the 9.4-inch GUI alarm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36

Figure 8-31. Replacing 9.4-inch backlight inverter and GUI LED PCBs . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

Figure 8-32. Removing 9.4-inch GUI EMI shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

Figure 8-33. Removing 9.4-inch VGA LCD controller PCBs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

Figure 8-34. GUI CPU PCB touch panel jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

Figure 8-35. Thermal pad adhered to CPU heatsink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-41

Figure 8-36. How to remove the compact flash component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Figure 8-37. GUI CPU PCB real-time clock (TE GUI CPU PCB shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

Figure 8-38. Replacing the 9.4-inch touchframe PCB and LCD panel assembly . . . . . . . . . . . . . . . . . . 8-44

Figure 8-39. Routing the backlight extender cable assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

Figure 8-40. LCD panel and backlight panel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

Figure 8-41. Replacing the 9.4-inch GUI cooling vent filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

Figure 8-42. 9.4-inch rotor housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

Figure 8-43. BDU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

Figure 8-44. BDU connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53

Figure 8-45. Sure-Lock™ retainer and power cord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54

Figure 8-46. BDU release handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55

Figure 8-47. BD CPU PCB and AI PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-56

Figure 8-48. BD card cage and PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57

Figure 8-49. BDU I/O panel connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

Figure 8-50. BD CPU PCB real-time clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58

Figure 8-51. Replacing power supply assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-60

Figure 8-52. Replacing power switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-61

Figure 8-53. Power switch actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-62

Figure 8-54. Replacing humidifier receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-63

Figure 8-55. AC panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-64

Figure 8-56. Adding ferrites to air and oxygen transducer harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . 8-66

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