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Service mode 4 4
The 840 Ventilator System operates in two modes: Patient Ventilation and Service Mode. The
Service Mode is intended for use by a trained service technician to aid in ventilator testing
and troubleshooting and to perform system calibrations.
This chapter details the Service Mode, including prompts and expected system responses. It
also includes how to calibrate the oxygen sensor, which is required during almost all service
operations, but occurs outside of Service Mode.
Warning
Do not enter the Service Mode while a patient or other person is connected to the
ventilator. To do so may cause patient injury or death. Normal ventilator operation is not
accessible while in the Service Mode.
NOTE:
During Service Mode startup, certain functions may automatically execute to
program data into BDU and/or GUI NOVRAM. Refer to Section 4.2.11 for details.
While in the Service Mode, normal ventilation is not allowed.
Function Purpose
Upper screen
SST RESULT Displays the latest SST test results, including test name, date and time
each test was last run, individual test results, and overall test outcome.
NOTE:
When reviewing SST results, be aware that not all of the results
for each SST test may be from the same date and time run.
DIAG LOG Displays the contents of System Diagnostic Log, System Information
Log, and EST/SST Diagnostic Log.
Alarm log Displays the history of most recent ventilator alarms for the previous
patient.
NOTE:
Running EST or selecting New Patient will erase this log.
VENT CONFIG Displays software revisions and serial numbers. Software revisions
displayed include: GUI and BDU boot PROM and application software
as well as GUI audible alarm subsystem (SAAS). Serial numbers
displayed are for BDU, GUI, and compressor unit (if installed); these
serial numbers are read from the data key and compressor (if
installed).
TEST SUMMARY Displays the latest EST and SST test results, including date and time
each was last run and overall test outcome.
Lower screen
EST Displays the details of the last EST run. Runs EST to thoroughly test the
operational integrity of the ventilator, both electronics and
pneumatics.
DATE/TIME Adjusts current date and time and allows the user to select a date
format.
UPPER SCREEN
Other
EST DATE/TIME EXIT
Screens
Atmospheric Serial
Service External Exp Valve Vent Inop Flow Sensor Pressure Data key Loopback
Mode Setup Test Control Calibration Test Calibration Transducer Update Test
Calibration (10.4 GUI only)
Compact
Flash Test*
External
Nominal Pressure
Control
Line Voltage Unit
Baud Rate
LOWER SCREEN
NOTE:
SST lets you exit and resume patient ventilation if required. Thus, the results shown are not
necessarily all from the same SST run. If a partial SST run is performed, the results of the first few
tests might be more recent than the results of later tests.
NOTE:
System Diagnostic Information and EST/SST Diagnostic logs can only be erased by
using the 840 VTS Breath Labs Software. The alarm log is automatically erased
each time a new patient is setup is selected and when EST is run.
This function lets you read the contents of the ventilator’s error and status logs. The logs are
as follows:
• The System Diagnostic Log (Figure 4-3) stores data on unexpected conditions detected
during POST, background checks. This includes alerts and failures.
• The System Information Log (Figure 4-4) stores data on ventilator events, including
details on GUI/BDU communication.
• The EST/SST Diagnostic Log (Figure 4-5) stores data on overall test outcomes and events
during SST and EST.
NOTE:
The performance verification, described in Chapter 5 of this manual, is a more
thorough test of the ventilator to verify it meets specifications.
Function Purpose
Service Mode Setup Lets you adjust nominal line voltage lower limit, baud rate for RS-232
port, and lets you choose the unit for display of pressures (cmH2O or
hPa).
External Test Control Lets you test the ventilator using a computer, 840 VTS Breath Labs
Software, and PTS 2000 tester, to run performance verification. Also
used to download new application software to the 840 ventilator.
Exp Valve Calibration Performs calibration. For use after a new exhalation valve, AI PCB, or
BD CPU PCB is installed, or as part of the performance verification.
Vent Inop Test Exercises ventilator inoperative circuitry during five test phases.
Flow Sensor Calibration Performs calibration. For use after a flow sensor replacement or as part
of the performance verification.
Data key Update Transfers the operational hours from the ventilator to the new data
key. For use after software options have been installed.
Serial Loopback Test (10.4-inch Tests the serial communication ports on the 10.4-inch GUI.
GUI only)
Compact Flash Test Only available if Trending software option is installed. Performs
internal diagnostics and functional tests of the compact flash memory
on the TE GUI CPU PCB.
Function Purpose
Nominal Line Voltage Nominal line voltage lower limit. This setting is used to detect low
power alarm conditions. It has no direct effect on power supply
function. Improper line voltage settings will cause a Device Alert,
preventing normal operation. You must run EST to reset this Device
Alert.
External Control Baud Rate For GUI RS-232 port. The baud rate takes effect when you restart the
ventilator in the Service Mode.
NOTE:
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in Service Mode before performing this calibration, to
ensure a successful calibration.
• Ensure that the ventilator has passed the Leak Test in EST prior to performing this
calibration.
This function builds the exhalation valve calibration table. This table lists exhalation valve
DAC commands versus exhalation pressure. The exhalation valve calibration requires a gold
standard test circuit and lasts approximately 3 minutes.
If the calibration fails, try rerunning it. If it continues to fail, refer to Table 4-4 to troubleshoot
any errors. Run EST to assist in troubleshooting.
NOTE:
A system leak is a common source of failure, particularly expiratory filter leaks.
Make sure the expiratory filter collector vial is secured tightly, the drain port is
capped, and the filter is mounted securely to the ventilator. Make sure the test
circuit is securely attached.
Bad exp valve loopback Failure Exhalation valve and/or analog 1. Clean the exhalation valve if
current interface PCB may be out of inspection warrants and re-run the
specification. calibration.
2. Replace the exhalation valve.
Both insp and exp Failure Analog Interface PCB may be out of 1. Replace the AI PCB.
autozero failed specification. 2. Replace the BD CPU PCB.
Calibration failed: current Failure Exhalation valve and/or analog 1. Verify that there are no leaks or
limit exceeded interface PCB may be out of occlusions.
specification. 2. Verify expiratory module connec-
tions.
3. Clean the exhalation valve.
4. Replace the exhalation valve.
Calibration failed: gain Failure Exhalation valve and/or analog 1. Verify that there are no leaks or
resolution interface PCB may be out of occlusions.
specification. 2. Verify expiratory module connec-
tions.
3. Clean the exhalation valve.
4. Replace the exhalation valve.
Calibration failed: Pressure Failure Verify that gold standard circuit is still 1. Verify that there are no leaks or
build time-out. connected and expiratory filter is occlusions.
locked in place. Verify that seal is 2. Run EST circuit pressure and leak
placed over collector vial drain and vial tests.
is securely fastened to expiratory filter. 3. Clean the exhalation valve.
4. Replace the exhalation valve.
5. Replace expiratory pressure trans-
ducer.
6. Replace inspiratory pressure trans-
ducer.
Exhalation valve pressure Failure Expiratory pressure transducer DAC 1. Verify that there are no leaks or
transducer autozero failed count at 0 cmH2O is out of range. occlusions.
2. Replace expiratory pressure trans-
ducer autozero solenoid.
3. Replace expiratory pressure trans-
ducer.
Exhalation valve Failure Exhalation valve temperature out of 1. Verify that the ventilator has
temperature out of range range. warmed up for at least 10 minutes
in Service Mode.
2. Replace exhalation valve.
3. Replace AI PCB.
Flow sensor cross-check: Failure Flow controller is not able to establish 1. Verify that there are no leaks or
unable to establish flow a 5 L/min test flow via the air flow occlusions.
sensor. 2. Swap air flow sensor (Q2) and oxy-
gen flow sensor (Q1). If calibration
passes, replace Q2.
3. Swap air PSOL (PSOL2) and oxy-
gen PSOL (PSOL1). If calibration
passes, replace PSOL2.
4. Replace expiratory flow sensor
(Q3).
Flow sensor cross-check Failure Expiratory air flow is out of range with 1. Verify that there are no leaks or
failed respect to the 5 L/min inspiration- occlusions.
controlled test flow. Verify gold circuit 2. Exit exhalation valve calibration
is connected. Check for expiratory and perform flow sensor calibra-
filter leaks. tion.
3. Swap air flow sensor (Q2) and oxy-
gen flow sensor (Q1). If calibration
passes, replace Q2.
4. Swap air PSOL (PSOL2) and oxy-
gen PSOL (PSOL1). If calibration
passes, replace PSOL2.
5. Replace expiratory flow sensor
(Q3).
Flow sensor info invalid Failure Flow sensor calibration table 1. Re-run flow sensor calibration.
checksum error occurred. 2. Replace expiratory flow sensor
(Q3).
3. Replace air flow sensor (Q2).
Inspiratory autozero failed Failure Inspiratory pressure transducer DAC 1. Verify that there are no leaks or
count at 0 cmH2O is out of range. occlusions.
2. Replace inspiratory autozero sole-
noid (SOL1).
3. Replace inspiratory pressure trans-
ducer.
No air connected Failure Wall and compressor air pressure 1. Verify air is connected.
switches detect no air connected. 2. Replace air pressure switch (PS2).
Pressure sensor cross- Failure Pressurization algorithm is unable to 1. Check for expiratory filter leaks.
check: unable to build pressurize system to one or more of 2. Replace inspiratory pressure trans-
pressure five test pressures via the inspiratory ducer.
pressure transducer.
Pressure sensor cross- Alert Pressure cross-check alert occurred at 1. Verify that there are no leaks or
check alert: approaching one or more of five test pressures, no occlusions.
spec limit cross-check failures occurred. 2. Replace inspiratory pressure trans-
ducer.
3. Replace expiratory pressure trans-
ducer.
Pressure sensor cross- Failure Pressure transducer cross-check failed 1. Verify that there are no leaks or
check failed at one or more of these five test occlusions.
pressures (5, 25, 50, 75, and 100 2. Verify adequate supply pressure.
cmH2O). 3. Replace inspiratory pressure trans-
ducer.
4. Replace expiratory pressure trans-
ducer.
Unable to establish flow Failure Flow controller is not able to establish 1. Verify that there are no leaks or
a 5 L/min test flow via the expiratory occlusions.
flow sensor. 2. Exit exhalation valve calibration
and perform flow sensor calibra-
tion.
3. Swap air PSOL (PSOL2) and oxy-
gen PSOL (PSOL1). If calibration
passes, replace PSOL2.
4. Swap air flow sensor (Q2) and oxy-
gen flow sensor (Q1). If calibration
passes, replace Q2.
5. Replace expiratory flow sensor
(Q3).
Unable to program flash Failure Unable to program calibration table 1. Check BDU +12 V supply and BD
into BDU NOVRAM. CPU PCB.
2. Replace power supply.
3. Replace BD CPU PCB.
4. Replace AI PCB.
If a test phase fails (“Vent Inop Test failed” message in lower screen), powering the ventilator
down and back up into Service Mode will invoke the normal Service Mode. Troubleshoot as
indicated in Table 4-6. You must repeat the Vent Inop Test and pass it with no failures before
ventilation is allowed.
GUI vent inop test phase BDU alarm (alone) Check BDU alarm or AI PCB.
NOTE:
The BD CPU PCB controls the
ventilator inoperative and safety
valve open LEDs on both the
BDU and GUI CPU PCBs,
sending the two LED signals to
the GUI via the BDU-GUI cable.
BDU alarm and ventilator inoperative Check BDU-GUI cable, GUI LED PCB,
and safety valve open LEDs or GUI CPU PCB.
Any other test phase Any Check BD LED PCB, BD alarm, BD CPU
PCB or AI PCB.
NOTE:
• If the ventilator has not reached operating temperature from recent usage, allow it to
warm up for at least 10 minutes in Service Mode before performing this calibration, to
ensure a successful calibration.
• It is very important that the ventilator passes the leak test during EST prior to running a
flow sensor calibration.
• A system leak is a common source of failure, particularly expiratory filter leaks. Make sure
the expiratory filter collector vial is secured tightly, the drain port is capped, and the filter
is mounted securely to the ventilator. Make sure the test circuit is securely attached.
• Use both air and oxygen gas sources to run Flow Sensor calibration. Ensure gas source is
capable of supplying 200 L/min.
This function builds a table of expiratory flow sensor (Q3) offsets. The flow sensor calibration
requires a gold standard test circuit.
If the calibration fails, make sure that the test circuit is attached and that the expiratory filter
is securely connected and free of leaks, then try rerunning it. If the calibration continues to
fail, refer to Table 4-7 to troubleshoot any errors.
4 Ensure that there are no leaks or occlusions by running EST and ensure that the
ventilator passes the EST Leak Test. Once this test has passed, exit EST.
5 Select the Other Screens button.
6 Select Flow Sensor Calibration.
7 Press the Start button and press ACCEPT.
The ventilator automatically starts the calibration. When the calibration is complete, press
the Other Screens button again to return to the Other Screens menu.
Air offset out of range Failure Determines maximum air flow 1. Monitor air pressure at TP2 with
capability in 500 ms. Measures regulator calibration hose,
inspiratory and expiratory flow offsets P/N 4-079050-00 to ensure ade-
at maximum flow, then decreases to quate supply pressure.
1 L/min in 1 L/min increments. 2. Swap air PSOL (PSOL2) and oxy-
gen PSOL (PSOL1). If calibration
passes, replace PSOL2.
3. Swap air flow sensor (Q2) and oxy-
gen flow sensor (Q1). If calibration
passes, replace Q2.
4. Try installing a known good
inspiratory module. If calibration
passes, replace inspiratory elec-
tronics PCB. If calibration fails,
replace inspiratory module blind-
mate cable.
5. Replace expiratory flow sensor
(Q3).
6. Replace AI PCB.
Cannot achieve Failure System cannot sustain a minimum 1. Monitor air pressure at TP2 with
minimum air flow 60 L/min flow. regulator calibration hose,
P/N 4-079050-00 to ensure ade-
quate supply pressure.
2. Swap air PSOL (PSOL2) and oxy-
gen PSOL (PSOL1). If calibration
passes, replace PSOL2.
3. Swap air flow sensor (Q2) and oxy-
gen flow sensor (Q1). If calibration
passes, replace Q2.
4. Try installing a known good
inspiratory module. If calibration
passes, replace inspiratory elec-
tronics PCB. If calibration fails,
replace inspiratory module blind-
mate cable.
5. Replace expiratory flow sensor
(Q3).
6. Replace AI PCB.
Cannot achieve Failure System cannot sustain a minimum 60 1. Monitor oxygen pressure at TP1
minimum O2 flow L/min flow. Check oxygen supply with regulator calibration hose,
pressure and REG1. P/N 4-079050-00 to ensure ade-
quate supply pressure.
2. Swap oxygen PSOL (PSOL1) and
air PSOL (PSOL2). If calibration
passes, replace PSOL1.
3. Swap oxygen flow sensor (Q1) and
air flow sensor (Q2). If calibration
passes, replace Q1.
4. Try installing a known good
inspiratory module. If calibration
passes, replace inspiratory elec-
tronics PCB. If calibration fails,
replace inspiratory module blind-
mate cable.
5. Replace expiratory flow sensor
(Q3).
6. Replace AI PCB.
No air connected Failure Wall air pressure switch (PS2) detects Verify air is connected.
no air connected.
No O2 connected Failure Oxygen pressure switch (PS1) detects Verify oxygen is connected.
no oxygen connected.
O2 offset out of range Failure 1. Replace oxygen flow sensor (Q1). 1. Monitor oxygen pressure at TP1
2. Replace expiratory flow sensor with regulator calibration hose,
(Q3). P/N 4-079050-00 to ensure ade-
3. Replace AI PCB. quate supply pressure.
2. Swap oxygen PSOL (PSOL1) and
air PSOL (PSOL2). If calibration
passes, replace PSOL1.
3. Swap oxygen flow sensor (Q1) and
air flow sensor (Q2). If calibration
passes, replace Q1.
4. Try installing a known good
inspiratory module. If calibration
passes, replace inspiratory elec-
tronics PCB. If calibration fails,
replace inspiratory module blind-
mate cable.
5. Replace expiratory flow sensor
(Q3).
6. Replace AI PCB.
NOTE:
When calibrating the atmospheric pressure transducer, make sure that the
pressure in the room is stable and not subject to pressure changes caused by door
closures, heavy foot traffic, or the startup of an air conditioning system. Any such
environmental changes will result in an incorrect adjustment being made to the
ventilator.
This function calibrates the atmospheric pressure transducer using an external barometer.
Refer to Table 1-10 for barometer accuracy specifications.
Allow the barometric pressure reading to stabilize, then touch the button and turn the knob
to enter the pressure (in mmHg) measured by this external barometer, as prompted.
(1 mmHg = 1.333 mbars = 133.33 Pa = 0.019 psia.)
If the calibration displays the Atmospheric Pressure Transducer OOR (out of range) message,
try rerunning it, making sure you correctly enter the barometric pressure. If the calibration
continues to fail, try rerunning EST, then replacing the inspiratory pressure transducer
autozero solenoid (SOL1), the inspiratory electronics PCB, and then the AI PCB.
NOTE:
If the data key is updated before calibrations have been run, the operational hours
will be lost or become corrupted.
NOTE:
If the compact flash component test fails, the Trending option will be disabled
until a functional component is installed. The ventilator’s performance is otherwise
unaffected.
Unable to read air flow sensor Error reading air flow sensor (Q2) serial EEPROM
data. Check Q2 and AI PCB.
Unable to read O2 flow sensor Error reading oxygen flow sensor (Q1) serial
EEPROM data. Check Q1 and AI PCB.
Unable to read the expiratory flow sensor Error reading expiratory flow sensor (Q3) serial
EEPROM data. Check Q3 and AI PCB.
Unable to receive flash data GUI did not receive all calibration data from BDU
within 10 s. Check BDU/GUI cable, BD CPU PCB, or
GUI CPU PCB.
Caution
When troubleshooting with a GUI not originally matched to the BDU, do not press the
ACCEPT key when prompted to match serial numbers. If you press ACCEPT, a software
download will be required to restore the original serial numbers.
Data key is not installed If a data key is installed but not being detected, try
inserting the key into a known good ventilator whose
serial numbers have already been initialized. Then
power the ventilator up into Service Mode and verify
that the ventilator sees an invalid data key (that is, the
message “Serial number(s) doesn’t match the data key”
is displayed). If the data key is still not detected, replace
it; otherwise, replace the AI PCB. Alternatively, try using
a known good data key in the suspect ventilator and
verify that it is detected.
NOTE:
If no data key is inserted, you can proceed with
Service Mode but ventilation is not allowed.
Serial number(s) doesn’t match the data key Press ACCEPT to confirm and proceed with Service
Mode.
NOTE:
If an invalid data key is inserted, you can proceed
with Service Mode but ventilation is not allowed.