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Service Manual - Flight Medical

1. Ba ws f P ng UN eh i ao ie C 3 moy PATIENT AN Y A cac a e j p Y La CS os j i 4 r ew A af HA 5 ms gt a gt an Se f ng j NG l e d F nG he i g Mg 4 SS Figure 1 Front Panel Name Description Composed of a gas outlet and quick connector Enables the user to adjust setting parameters Enables the user to lock the ventilator s control preventing accidental changes Pressing the button of a locked panel and then Enter unlocks the panel Turns the ventilator on or off to start or stop ventilation Flight 60 Service Manual 3 1 Functional Description Front Panel Label 10 11 12 Name Manual Breath button Audio Paused Alarm Reset button Pressure Gauge Display touch screen LED Indicators Primary Alarm LED Dual Limb Exhalation Valve DL model only Nebulizer Port iO Internal mixer model only 3 2 FLIGHT 60 Service Manual Description Delivers a user initiated manual inflation Toggle button Pressing Audio Paused temporarily silences the audible alarm pressing Alarm Reset clears lit alarm LEDs The pressure gauge is a visual indicator of breath activity which shows the dynamic movements of the breath pressures When a breath is being delivered the user can see the relative pressure and phase of the breath inspiration or expiration The pressure gauge is comprised of 29 LEDs From 10 to
2. 20 cmH20 each notch equals 2 cmH20 from 20 to 50 cmH 0 each notch equals 5 cmH20 above 50 cmH20 each notch equals 10 cmH50 Enables the user to modify the ventilation alarm and technical settings and to view real time patient data alarms battery status and logs Inform the user of various events Flashes red to indicate that there is a high priority alarm Connects the patient circuit expiratory limb Connects to the pneumatic nebulizer 3 1 1 Functional Description Front Panel Keypad Control Buttons Item 1 Parameters home 2 Manual Breath 3 Panel Lock 4 Cancel 5 Increase Button 6 Decrease Button 7 OK Enter 8 On Off 9 Alarm Reset 10 Technical 11 Extended Figure 2 Keypad Control buttons 56789 A Gaani ga U Description The Parameters screen is the Flight 60 s default screen Display switches automatically to Parameters from the other screens if not operated for 30 seconds Use the Parameters button to toggle between the numeric and the graphic displays Delivers a user initiated manual inflation Enables the user to lock the ventilator s control preventing accidental changes Pressing the button of a locked panel and then Enter unlocks the panel Enable the user to cancel parameters change Enables the user to adjust setting parameters upwards Enables the user to adjust setting parameters downwards Enable the u
3. Replace the O Regulator filters PROX LINE Problem in the proximal line Check internal hoses connections Pressure sensors is improperly Pressure Sensors Calibration calibrated or defective Replace Main Board FLOW SENSOR ERROR Processor defective Replace Main Board Processor communication problem EMPTY BAT Combined charge of both batteries Connect to AC charging for 3 hours is less than 30 Replace Power Board Flight 60 Service Manual 9 3 Troubleshooting Guide Error Messages Displayed error HIGH MV INS HIGH MV EXH HIGH LOW P BASE PCV NOT REACHED LOW MV EXH MOTOR FAULT PRESS SENSOR POWER FAULT MEMORY FAULT MAIN BAT CHARGER MAIN BAT V HIGH LOW 9 4 FLIGHT 60 Service Manual Potential Cause Air leakage Calibration problem Hardware problem Solenoid malfunction Calibration problem Hardware problem Air leak Hardware problem Motor control Motor Patient pressure sensor higher than outlet Check log file to identify failed power 3 3V POWER FAULT MAIN BOARD 10V POWER FAULT POWER BOARD 10V POWER FAULT 5V POWER FAULT Parameters mismatch Charger malfunction Out of range Suggested Action Check internal hoses connections Check internal hoses connections Perform Volume factor calibration Replace Main Board Replace manifold Check solenoid Perform Circuit Test Replace solenoid Perform Volume Factor calibration Replace manifold
4. errors changes events were downloaded 8 2 FLIGHT 60 Service Manual Troubleshooting Guide Introduction 9 Troubleshooting Guide 9 1 Introduction The FLIGHT 60 Ventilator is used in life support situations As such it is essential that all individuals using the FLIGHT 60 Ventilator including clinicians and support staff have a thorough understanding of its operation This should include a working knowledge of the ventilator s pneumatic and electronic systems The following practical troubleshooting section is provided as a training resource for individuals learning how to use the FLIGHT 60 Ventilator and as a reference tool for those already familiar with its use and operation It should be noted that this outline is not all inclusive and is intended only as a guide A Only properly trained personnel should operate the ventilator The FLIGHT 60 Ventilator is a restricted medical device designed for use by Respiratory Therapists or other properly trained and qualified personnel under the direction of a physician and in accordance with applicable state laws and regulations I I sn a Om Om Om Om Om Om BO BO Om Om Om Om BO Om BO Om BO BO nn ee 9 2 Error Messages Displayed error Potential Cause Suggested Action CHECK FiO SENSOR Oxygen sensor bad reading Run Oxygen sensor calibration Oxygen sensor defective Replace Oxygen sensor O SUPPLY FAILED O2 pressure is very low Check O source pressure is 30 90PSI
5. mo External pressure gauge 6 4 Pressure Sensors Calibration Patient Pressure acc Outlet Pressure Pressure Relief Valve Calibration Relief Pressure Volume Factor Calibration AY kol External gauge peak Pressure Pressures Verification 8xer a nee ts Tolerance PEEP Value 5 51 PEEP 10 2 20 2 GT m IE 1 ig COLECTA IS O CC f o TR s n m Io Tolerance i 20 9 29 32 48 6 16 O2 Sensor 52 68 12 88 92 100 7 24 FLIGHT 60 Service Manual 68 Pressures Pressures Verification Operation Verification Procedure OVP Test Table 7 22 Test Table The following table summarizes tests associated with each device module When a module is replaced All tests associated with the replacement must be performed before the ventilator is used again SEHE SI EI EI E E 2 2 IR is ar E H E i 5 a E H E i F ol 8 a TI WN HS Pa EA Ed PA PA NN EEE EEE LE EB HE HE EEE NB ii HE EEE BEE EM EEE EB EEE BE il SONG NG GB BB IE EEE a EB iH A PA PA LA B I PA LA LA PA PA PA PA PA SUN OOOO MM SUU NG NM MN PA PA E PA PA PA PA pa Flight 60 Service Manual 7 25 Maintenance Scheduled maintenance 8 Maintenance 8 1 Scheduled maintenance MANIFOLD The manifold should be replaced every 15 000
6. 4 1 7 1 Touch Screen 4 22 TRIG LED Indicator 3 4 LED Indicator Pressure trigger 7 2 Troubleshooting Guide 9 3 U Uploading log files 3 8 V V60 13000 65 3 10 4 10 V60 21000 60 3 10 4 22 V60 21000 65 3 10 4 6 V60 21400 69 3 10 4 34 V60 23000 65 3 10 4 31 V60 25000 29 3 10 Verification 2 3 7 1 V60 26000 65 3 10 4 32 Volume Factor Cal bration 7 1 7 6 7 7 V60 60002 65 3 10 4 18 Flight 60 Service Manual I 3
7. 4 6 Cutter 4 1 D DC connector 3 7 Decrease button 3 3 Detachable battery 3 7 Detachable Battery 4 2 Display touch screen 3 2 D type Board 4 37 Dual limb exhalation valve 3 2 E Electrical Diagram 3 12 Emergency Air Intake 3 5 Error Messages 9 3 Error Reference source not found Calibration 7 1 7 7 Exhalation Valve Leak 7 1 EXT PWR LED Indicator 3 4 LED Indicator External power 7 2 Extended button 3 4 F FAULT LED Indicator 3 4 9 4 LED Indicator Device malfunction 7 2 FILTER 8 1 Filter Cover 3 6 Flat screwdriver 4 1 7 1 Fresh Gas Intake 3 6 Front Panel 3 1 4 15 4 16 4 17 4 20 7 1 7 2 Front Panel Assembly 4 15 4 17 Front Panel Self Test 7 1 7 2 Fuse 4 40 4 41 H HIGH MV LED Indicator 3 4 9 3 9 4 LED Indicator High minute ventilation 7 3 High P LED Indicator High pressure 7 3 HIGH P LED Indicator 3 4 7 12 High Pressure Alarm 7 1 7 12 Flight 60 Service Manual 1 Index Home button 3 3 Increase button 3 3 Inlet Leak 7 1 7 13 Internal Battery 4 2 4 3 L LED indicator 3 2 LED Indicators 3 4 LOW MV LED Indicator Low minute ventilation 7 3 LOW BAT LED Indicator 3 4 LED Indicator Low battery 7 2 Low flow oxygen port 3 8 LOW MV LED Indicator 3 4 9 4 LOWP LED Indicator 3 4 9 4 LED Indicator Low pressure 7 3 Lower Board 4 37 Main board 3 10 Main Board 4 15 4 18 4 20 4 22 7 3 7 12 7 15 7 17 9 3 9 4
8. 9 5 Maintenance 8 1 MANIFOLD 8 1 Manifold Assembly 4 22 4 27 Manual breath button 3 2 3 3 N Network logging 3 8 O OK button 3 3 On Off 7 2 LED Indicator 7 3 On Off button 3 2 3 3 7 2 Oxygen O2 Sensor 3 10 Oxygen Blending Bag Kit 2 2 2 3 Oxygen Sensor 4 28 4 29 7 1 7 15 7 16 P Panel Lock LED Indicator 7 3 Panel lock button 3 1 3 3 Parameters button 3 3 Patient Circuit Reusable 7 1 Patient circuit connector 3 1 PC connector 3 8 l 2 FLIGHT 60 PEEP 7 1 7 2 7 9 7 10 Peripherals connector 3 8 Phillips screwdriver PHI 4 1 7 1 PLT1M M69 4 1 PLT4S M69 4 1 Power Board 4 6 4 7 4 8 4 9 4 10 9 3 9 4 9 5 Power board PB 3 10 Power Supply 4 7 4 10 4 12 4 13 7 1 7 13 Power supply PS 3 10 Pressure gauge 3 2 Pressure Gauge Verification 7 1 Pressure Relief Calibration 7 1 7 5 Pressure Sensors Calibration 7 1 7 3 9 3 Pressure Trigger 7 1 7 10 Pressure Verification 7 8 Primary alarm LED 3 2 Purge board 3 10 Purge Board Assembly 4 31 4 32 R Remote alarm connector 3 7 Removing and Reinstalling Modules 4 1 Repackaging 10 1 RGA number 10 1 Rubber Bumpers 4 41 4 42 S OXYGEN SENSOR Oxygen 8 1 Shipping 10 1 Solenoid Assembly 4 34 4 37 Solenoid Board Assembly 4 32 4 33 Standard Ventilator Settings STS 7 2 7 7 7 8 7 9 7 10 7 12 7 13 T Technical button 3 3 Test Table 7 19 Torx screwdriver BT10x200
9. INTERNAL MIXER MODEL ONLY 5 2 FLIGHT 60 Service Manual Software Upgrade Installing the SW upgrade 6 Software Upgrade Required equipment USB storage device with the SW version 6 1 Installing the SW upgrade 1 Turn on the ventilator connect a patient circuit perform circuit test see section 7 9 2 Connect the circuit to a Flight Medical test lung and start ventilation in the following parameters e ACMV e VCV 500 mL e PEEP 5 e Ptrig 5 0 e Rate 15 e Ti 1 e O 80 e Waveform Square press Technical A and press Show Info 4 Write down the System serial number Compressor serial number and Hour meter values 5 Go to the parameter screen and write down the measured values of the following parameters Vti also verify value is between 450 550 PIP Pbase 6 Turn off the ventilator disconnect from AC Copy the new SW version to a USB storage device and plug it to the vent USB port 8 Connect the ventilator to AC Flight 60 Service Manual 6 3 Software Upgrade Calibration integrity check 9 The ventilator identifies the USB storage device and launches the software upgrade sequence 10 A software update screen opens displaying the current version and the new version to update 11 Press OK on the touch screen 12 Once upgrade is done the ventilator displays Finished updating please remove DOK 13 Remove the USB storage device and press OK on the touch screen 14 Tur
10. Square For test lung a Rp 5 m C 50 mL cmH20 7 3 Front Panel Self Test Torun the self test 1 Connect the ventilator to AC power 7 6 FLIGHT 60 Service Manual Operation Verification Procedure OVP Pressure Sensors Calibration 2 Press the On or button on the front panel 3 During the self test that begins automatically check for the following m Short audible beep m All LEDs on the LED indicator light up with the same intensity with the following colors Description Colour TRIG Pressure trigger Green EXT PWR External power Yellow LOW BAT Low battery Red BAT Battery power Orange FAULT Device malfunction Red APNEA Red BUV Back up ventilation Red HIGH MV High minute ventilation Red LOW MV Low minute ventilation Red High P High pressure Red LOW P Low pressure Red Audio Paused Alarm Reset Orange On Off Green Panel Lock Orange m All LEDs between 60 100 on the pressure gauge light up If the test fails No LEDs are on Check the internal connectors to the front panel Some LEDs are on Replace the Main Board 7 4 Pressure Sensors Calibration To calibrate the pressure sensors 1 Connect the ventilator to an external pressure meter using a reusable patient circuit Flight 60 Service Manual 7 7 Operation Verification Procedure OVP Pressure Sensors Calibration N Connect the pressure meter to the test lung 3 Use the following settings for the test lun
11. Check internal hoses connections Replace Main Board Replace Power Board Replace manifold Perform Pressure sensors calibration Replace Main Board Replace Main Board Check cables Replace Power Board Replace Main Board Check cables Replace Power Board Replace Main Board Perform OVP Replace Main Board Replace battery Replace Power Board Replace battery Replace Power Board Displayed error MAIN BAT VOLTAGE MAIN BAT TEMP HIGH MAIN BAT GAUGE SEC BAT CHARGER SEC BAT V HIGH LOW SEC BAT VOLTAGE SEC BAT TEMP HIGH SEC BAT GAUGE Potential Cause Mismatch in Battery voltage reading Battery overheating Battery control Charger malfunction Out of range Mismatch in Battery voltage reading Battery overheating Battery control Troubleshooting Guide Error Messages Suggested Action Replace battery Replace Main Board Replace battery Replace Power Board Replace battery Replace battery Replace Power Board Replace battery Replace Power Board Replace battery Replace Main Board Replace battery Replace Power Board Replace battery Flight 60 Service Manual 9 5 Repackaging and Shipping RGA Returns 10 Repackaging and Shipping All returned items must have a Return Goods Authorization RGA number assigned by FLIGHT MEDICAL To obtain an RGA number email a completed RGA form filled in its entirely to support flight medical com A
12. Enable O2 mixer ON OFF Enable Disable the internal Oxygen mixer Enable MVG ON OFF Enable Disable MVG ventilation mode Display C amp R OFF Not in use Screen Intensity Value Increase decrease the screen intensity Language Choose the language Enable Sigh ON OFF Enable Disable Sigh ventilation mode Enable VG ON OFF Enable Disable VG ventilation mode RA Period OFF Not in use Saving Logs OFF Activate log files download Refer to Chap 8 Service SCREEN Move to the calibrations screen Flight 60 Service Manual 5 1 Service Technical Menu Service Screen 5 2 Service Screen SERIAL SW Calibrate Calibrate Volume Factor Calibrate Version Pressure FIO2 0 97 Relief Factory Neb Comp Calibrate Bar Intensity SERVICE Defaults 6 0 O2Leak SINGLE Button Options Description Serial OFF EGD JSON Serial port output format SW Version Displays the SW version of each CPU Calibrate Pressure Activate pressure calibration Calibrate FIO2 Activate Oxygen sensor calibration Volume Factor Activate Volume factor calibration Displays the saved calibration value SERVICE Change serial numbers and working hours Factory Defaults Default calibration parameters to recover from calibration data corruption Neb Comp Value Compensate for volume decrease when nebulizer is on Calibrate 02 Leak Leak sensor calibration Bar Intensity Single Full Number of lit LEDs in the ventilator s pressure gauge j0
13. Left Side Panel Label Name Description 1 Emergency Air Intake Enables the patient to pull ambient air into the patient circuit in the event of a complete system failure The Air Intake opening pressure is approximately 3 cmH 0 3 mbar Flight 60 Service Manual 3 5 Functional Description Right Side Panel 3 3 Right Side Panel Figure 4 Right Side Panel Label Name Description 1 Fresh Gas Intake and Environmental air enters through this 30 mm ID Fresh Gas Intake Filter Cover The air inlet particle filter is placed behind the Filter Cover to protect the patient as well as the ventilator s piston system from dirt and particles The Fresh Gas Intake also serves as the attachment socket for the optional FLIGHT 60 Ventilator Air Oxygen Entrainment Mixer or Oxygen Blending Bag 3 6 FLIGHT 60 Service Manual Functional Description Back Panel 3 4 Back Panel fa JM le j8 nme 2 SA P pe ES a y N Ei y 7 gr A To ensure proper grounding and prevent possible shock hazards this device should only be connected to grounded power receptacles Label Name Description 1 Detachable Battery Li Ion 14 8 VDC 2 AC Connector with Fuses 100 240 V AC 50 60 Hz Fuses 2x8A time lag 3 DC Connector 12 15 VDC 4 RS 232 Serial Port COM2 Remote alarm connector Normally Open and Normally Closed options 5 RS 232 Serial Port COM1 Online output of events and error messa
14. Remove the ventilator cover see section 4 5 Remove the front panel assembly see section 4 8 Remove the Power board see section 4 6 Remove the two Torx screws securing the inlet assembly Figure 36 Inlet assembly screws 6 Disconnect the Oxygen hose from the inlet assembly Figure 37 Low Flow O hose Flight 60 Service Manual 4 21 Removing and Reinstalling Modules Replacing the Manifold Assembly 7 Disconnect the inlet assembly from the flex tube by pulling out the tube pr Figure 38 Pulling out the Flex Tube 8 Disconnect the O Mixer hose from the muffler 9 Cut the cable ties securing the muffler Figure 39 Cutting the Cable Ties 10 For iO model Disconnect the vertical silicon tube from the muffler Figure 40 Silicon tube 4 22 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Manifold Assembly 11 Gently pull the muffler out of the short flex tube and put it aside Figure 41 Removing the Muffler 12 Disconnect the flex tube between the manifold and the outlet assembly Figure 42 Flex tube Flight 60 Service Manual 4 23 Removing and Reinstalling Modules Replacing the Manifold Assembly 13 Disconnect the silicon tubes from the solenoid Figure 43 Disconnecting the Flex Tubes 14 Release the Manifold power cord from the wire saddles 15 Remove the six Torx screws from the manifold base three on each
15. To remove the oxygen mixer 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 Remove the Power Supply and the power supply base plate the solenoid see section 4 7 4 Remove the muffler Remove the O leak sensor 6 Remove the 2 silicon tubes and disconnect the Nebulizer amp O2 Mixer cables from the O mixer Neb board Figure 48 Electronic connectors and silicon tubes 7 Gently pull out the O mixer 4 28 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Oxygen mixer i02 Internal mixer model only gt x af kaaa gt GA X a wi a F a Figure 49 Pulling out the mixer 4 15 2 Installing the Oxygen mixer To install the oxygen mixer m Follow the above procedure in reverse order Make sure the flat surface of the mixer is aligned with the metal bracket Figure 50 Mixer orientation Flight 60 Service Manual 4 29 Removing and Reinstalling Modules Replacing the O2 mixer filters i02 Internal mixer model only 4 16 Replacing the O mixer filters iO gt Internal mixer model only To replace the filters 1 Use twizers to remove the O ring that secures the filters 2 Use the twizers to pull out the filters 2 each 3 Place the new filters 2 each at the O input and push all the way in 4 Push the O ring in verify it s in the
16. V60 70100 29 PS PB cable V60 30100 29 Detachable Battery cable V60 00050 29 11 8 FLIGHT 60 Service Manual Internal Battery cable V60 50100 29 Oxygen Sensor cable V60 00130 29 O Leak sensor cable SUB 0010 Spare parts Cables Flight 60 Service Manual 11 9 Index A AC connector 3 7 ACMV 7 2 7 11 7 16 Air Oxygen Entrainment Mixer 2 2 2 3 3 6 7 15 7 16 Alarm connector 3 7 Alarm Reset button 3 2 3 3 Antistatic wrist strap 4 1 APNEA 3 4 LED Indicator 3 4 LED Indicator 7 3 Audio Paused button 3 2 Audio Paused Alarm Reset LED Indicator 7 3 B Back panel AC connector 3 7 DC connector 3 7 Detachable battery 3 7 Low flow oxygen port 3 8 Network logging 3 8 PC connector 3 8 Peripherals connector 3 8 Remote alarm connector 3 7 Uploading log files 3 8 BAT LED Indicator 3 4 7 13 9 3 9 4 9 5 LED Indicator Battery power 7 2 Battery 4 2 7 1 7 13 9 4 9 5 Button Alarm Reset 3 2 3 3 Audio Paused 3 2 Cancel 3 3 Decrease 3 3 Extended 3 4 Home 3 3 Increase 3 3 Manual breath 3 2 Manual breath 3 3 OK 3 3 On Off 3 2 3 3 Panel lock 3 1 Panel lock 3 3 Parameters 3 3 Technical 3 3 Up Down 3 1 BUV LED Indicator 3 4 LED Indicator Back up ventilation 7 3 Buzzer Test 7 1 7 14 C Cable ties 4 1 Cancel button 3 3 Charger 7 1 7 13 9 4 9 5 Connector patient circuit 3 1 Ventilator Cover 4 3 4 5
17. and Reinstalling Modules Replacing the Power Supply Figure 18 Pushing Power Board into Ventilator Base 4 Perform steps 1 to 6 of the removal procedure in the reverse order 4 7 Replacing the Power Supply 4 7 1 Removing the Power Supply To remove the power supply 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 3 Release the manifold motor cable from the cable clamps on the power supply Nee Te PAWANG a ote aec ACR CE E Ng ay Ca 0 RR LE CM Soe EN NG Soran ee Elf kh HAB Figure 19 Releasing the Motor Cable 4 10 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Power Supply 4 Disconnect the power wiring total of seven wires by loosening the Phillips screws AE Figure 20 Power supply Wiring 5 Remove the 4 Torx screws that are securing the power supply bracket two on each end Figure 21 Power Supply Bracket screws 6 Remove the power supply 7 Detach the power supply from its bracket by unscrewing the three Phillips screws securing the bracket Flight 60 Service Manual 4 11 Removing and Reinstalling Modules Replacing the Power Supply Wa e TAE agogo an ce se jil es 2 e Figure 22 Detaching the Power Supply from Its Bracket 4 7 2 Installing the Power Supply To install the power supply m Follow
18. as needed until no auto triggering is observed Verify that the P trig level is not more than 1 5 cmH O and that the ventilator is not performing an auto trigger 9 Set PEEP to 10 10 After five breaths check that the basic pressure levels in the lung and in the ventilator display are 10 2 cmH gt O 11 Raise the P trig level as needed until no auto triggering is observed 12 Verify that the P trig level is not more than 2 cmH 0 13 Set PEEP to 20 14 After five breaths check that the basic pressure levels in the lung and in the ventilator display are 20 2 cmH gt O 15 Raise the P trig level as needed until no auto triggering is observed 16 Verify that the P trig level is not more than 3 cmH50 If the test fails il Replace the patient circuit In case of a Flight60 DL replace the exhalation valve diaphragm Repeat Circuit test Replace the solenoid see section 4 14 and run the required calibrations see see section 7 21 7 16 FLIGHT 60 Service Manual Operation Verification Procedure OVP Pressure Trigger 7 13 Pressure Trigger 1 2 To test the pressure trigger Set the ventilator to STS Connect the ventilator to the test lung using a patient circuit Use the following settings for the test lung m C 50 m Rp 5 Activate ventilation Initiate inhalation by slightly raising the edge shoulder of the test lung to create negative pressure of at least 1 0 cmH20 Verify that the g
19. during the warranty period to be defective in workmanship or material will be replaced credited or repaired FLIGHT MEDICAL retains the discretion to select the most suitable of these options FLIGHT MEDICAL is not responsible for deterioration wear or abuse In all cases FLIGHT MEDICAL will not be liable beyond the original selling price Application of this warranty is subject to the following conditions m FLIGHT MEDICAL or its authorized representatives must be promptly notified upon detection of the defective material or equipment m Defective material or equipment must be returned to FLIGHT MEDICAL or its authorized representative m Examination by FLIGHT MEDICAL or its authorized representatives must confirm that the defect is covered by the terms of this warranty To ensure complete protection under this warranty the Warranty Registration Card must be returned to a FLIGHT MEDICAL authorized representative within ten 10 days of equipment receipt The above is the sole warranty provided by FLIGHT MEDICAL No other warranty expressed or implied is intended Representatives of FLIGHT MEDICAL are not authorized to modify the terms of this warranty In no way does this or any of FLIGHT MEDICAL policies training materials guidelines or instructions create an obligation for FLIGHT MEDICAL to perform any services Flight 60 Service Manual iii About this Document About this Document This document is a service manu
20. hours of operation or every 3 years whichever comes first For instructions on replacing the manifold see section 4 12 After replacing the manifold update the manifold serial number and zero the working hours 1 Press Technical A and then press ADVANCED Screen 2 Enter the code 5844 and confirm by pressing v 3 Press SERVICE SCREEN 4 Press SERVICE 5 Enter the code 2009 and confirm by pressing Y 6 Press the displayed Compressor Serial Number use the numerical keyboard to type in the new number 7 Press the displayed Hour Meter use the numerical keyboard to change it to 0 AIR INLET FILTER Check the filter s condition whenever servicing the ventilator OXYGEN O SENSOR Replace once a year O LEAK SENSOR Replace every 2 years BATTERY Recommended replacement every 2 years 8 2 Download Log Files To save log files use a FAT formatted USB mass storage device 1 2 3 Press Technical X and then press ADVANCED Screen Enter the code 5844 and confirm by pressing v Press SERVICE SCREEN Plug the USB storage device to the ventilator Flight 60 Service Manual 8 1 Maintenance Download Log Files 5 Change Auto Logs to ON The download icon ad will display 6 Wait for the download complete icon to display Note that lt might take few minutes for download to complete depending on the size of the log files 7 Check the USB device on a computer and verify that 3 log files
21. is in a working position on a horizontal surface m Place the ventilator on a table close to the edge m Rotate the ventilator in a way that the front left rubber pad deviates from the table the ventilator only rests upon 3 bumpers and the calibration screw is accessible from below Refer to figure 31 below m Break the RTV that secures the calibration screw m Use a Philips screwdriver to adjust the relief valve by tightening or loosening the calibration screw located on the underside of the outlet fitting 7 10 FLIGHT 60 Service Manual Operation Verification Procedure OVP Volume Factor Calibration Figure 66 Adjusting the Pressure Relief Valve 10 Press Enter to confirm the reading and to complete the calibration Press Cancel x to discontinue the calibration If the test fails m Check internal tubing connections 7 6 Volume Factor Calibration aa Volume Factor calibration must be performed only with an Rp50 resistor manufactured by Michigan Instruments Inc Ventilator might not deliver the correct volume if another Rp50 is used for this calibration To calibrate the volume factor l MA N Connect a patient circuit to the ventilator Connect the RP50 resistor to the patient circuit and leave the other end of the resistor exposed to the open air verifying that it is not blocked in any way Press Technical X and then press ADVANCED Screen Enter the code 5844 and confirm by pr
22. is replaced The ventilator performs 21 calibration Verify the external Oxygen analyzer reads 21 wait 1 minute and press Enter Ox The ventilator switches to 100 automatically Verify the external Oxygen analyzer reads 100 wait 1 minute and press Enter 9 7 12 FLIGHT 60 Service Manual Operation Verification Procedure OVP O2 Leak Sensor calibration i02 Internal mixer model only For External mixer model 1 Connect the Air Oxygen Entrainment Mixer to an Oxygen source Install the Air Oxygen Entrainment Mixer on the ventilator s air inlet 2 Set the regulator on the oxygen source to 50 PSI 3 Connect a calibrated Oxygen Analyzer to the ventilator s outlet Don t connect Press Technical A and then press ADVANCED Screen D 5 Enter the code 5844 and confirm by pressing Y 6 Press SERVICE SCREEN 7 Press Calibrate FiO2 8 Choose USED if calibrating the current sensor NEW if O2 sensor is replaced 9 Set the Entrainment Mixer dial to AIR 10 Once the external Oxygen sensor displays 100 wait 1 minute and then press Enter 9 11 Set the Entrainment Mixer dial to 100 12 Once the external Oxygen sensor displays 100 wait 1 minute and then press Enter 7 8 O Leak Sensor calibration iO Internal mixer model only p To calibrate the O leak sensor 1 Connect a calibrated Oxygen Analyzer to the ventilator s outlet Don t connect Press Technical X and then press ADVANCE
23. that both batteries are above 60 If not connect to external power and charge for at least 3 hours 1 Disconnect the ventilator from AC power 2 Verify that the following occur Flight 60 Service Manual 7 19 Operation Verification Procedure OVP Inlet Leak m the Power Switchover indicator is displayed m an audible beep is heard m the EXT PWR indicator is not lit external power m the battery BAT LED indicator is lit 3 Verify that the ventilator functions normally with no further alarms 4 After at least 90 seconds have passed reconnect to AC power 5 Verify that within 30 seconds of the connection time the ventilator indicates switching back to AC power 6 Verify that the following occur m the battery BAT LED indicator is off m the green EXT PWR is lit 7 17 Inlet Leak To test the inlet leak 1 Set the ventilator to STS settings p Connect the ventilator to a test lung using a patient circuit Use the following settings for the lung H C 20 nu Rp 5 3 Verify that the three screws securing the filter cover are tight to insure that air leakage is prevented A Connect a vacuum meter to the air inlet Activate ventilation The vacuum reading should be at least 0 16 negative 0 16 Bar atthe end of expirium a a a a aa aa a a a a aa a a a a a aa a aa a a a a a a aa a aa a a a a a a aa aa aa rr a a a a a a a a a a aa aa mm aa a a a a a a a aa aa a aa aaa a a a a aa a a mm mm ima N
24. the above procedure in reverse order paying attention to the following m The Power Supply bracket fits under the power board bracket run Figure 23 Bracket Positioning m Be sure not to apply pressure to the solenoid assembly during this procedure m Connect the wires according to the following diagram 4 12 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Front Panel Assembly DC Output V unused Yellow Green Yellow green 3 wires GND chassis a AC AU an i m After reconnecting the power wiring firmly tighten all 7 Phillips screws in the terminal block including the unused ones AA 4 8 Replacing the Front Panel Assembly 4 8 1 Removing the Front Panel Assembly To remove the front panel assembly 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 Disconnect the flat flex cable P16 from the Main Board Figure 24 Flat Flex Cable going to P16 4 On the underside of the ventilator unscrew the three Torx screws securing the bottom of the front panel Flight 60 Service Manual 4 13 Removing and Reinstalling Modules Replacing the Front Panel Assembly Figure 25 Loosening the Torx Screws Under the Front Panel 5 Remove the Torx screws from the front panel brackets one on each side Carefully slide the front panel outwards to allow access to
25. 0 3 7 VENTILATOR MODULES IO gt INTERNAL MIXER MODE Luvcceccscccuuceucceuveuuseuueauens 3 11 3 0 PNEUMATIC DIAGRAM ne ee a rede 3 12 3 9 PNEUMATIC DIAGRAM IO gt INTERNAL MIXER MODEL sennnnnnunnnnnnunn nn nun nun nun nn 3 13 9 0 JELECTRICALIDTAGRAM Eee ea Renee 3 14 3 11 ELECTRICAL DIAGRAM IO gt INTERNAL MIXER MODEL wecceccecccucceucceuveuusuunauees 3 15 4 REMOVING AND REINSTALLING MODULES uusunnnunnnnunnnnnunnnnunnnnnnnnn 4 1 Al INTRODUCTION ans rennen 4 1 4 2 REQUIRED EQUIPMENT ana nina 4 1 4 3 REPLACING THE DETACHABLE BATTER Ya ee 4 2 4 3 1 Removing the Detachable Battery 2222222220nnnenonnnnnn nun nn nn 4 2 4 3 2 Installing the Detachable Battery ccccccceeeseeeeeeeeeeeeeeneeees 4 2 4 4 REPLACING THE INTERNAL BATTERY a a ia 4 2 4 4 1 Removing the Internal Battery 22000000nnnnnnnnnnn nn Rn nn nn nn 4 2 4 4 2 Installing the Internal Battery 22ssesunnnnnonnenunnnnnnn nenn nn nn nenn nenn 4 3 4 5 REMOVING THE VENTILATOR COVER nnneennnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnennnnnnnn 4 3 4 5 1 Removing the Ventilator Cover ssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nun 4 3 4 5 2 Installing the Ventilator Cover zssssnnnnnnnnnnnnnnnnnnnnennnnnnnn nun 4 6 4 6 REPLACING THE POWER BOARD anG AGA ANG 4 6 4 6 1 Removing the Power Board zzz u0s0snnnnnnnnnnnnn aaa aaa 4 6 4 6 2 Installing the Power Board zussssssnnnnnnnnnnnnnnnnnnnn nn nnnnnn nun nn 4 9 Flig
26. 15 Folio We lee oe era ria 7 15 7 31 3 PRESSURE TRIGGER Sen een 7 16 Fila EXHALATION VALVE PEAK nennen 7 17 LES HIGH PRESSURE ALARM ke aaa Near 7 18 7 16 BATTERY CHARGER POWER SUPPLY cccecceeceeuceeceuueeueeuueeueeuueeueeauseueeauees 7 19 Trade INET WEAK ssl eae ads 7 20 JLo BUZZER VES Reese een a AA een a AA a 7 20 TAS OXYGEN CALIBRATION TEST us dde 7 21 7 20 NEBULIZER COMPENSATION TEST IO INTERNAL MIXER MODEL ONLY 7 22 tus i OVP TEST RESULTS ass 2 2 Me ee RM ee Hei 1 23 2222 EST ABE ANAN AA AA ANA AA Aa 7 24 MAINTENANCE u 8 1 Bil SCHEDULED MAIN TENANCE zitate 8 1 8 2 DOWNLOAD LOGFILES nn ee eines 8 1 TROUBLESHOOTING GUIDE us uunununnununnnunnnnununnnunnnnunnnnnnnnnnunnnnnnnnnnn 9 3 Flight 60 Service Manual vii Table of Contents Ol INTRODUCTION AA AA AA ee ee 9 3 9 2 ERROR MESSAGES nisse aa ns 9 3 10 REPACKAGING AND SHIPPING nuuunnuunnnnunnnnunnnnnunnnnunnnnnnnnnnnnnnnn 10 1 ROARETURNS trono essen 10 1 Ll SPARE PAR ES aid 11 2 Wd ELECTRONIC rennen 11 2 11 2 MECHANICAL ASSEMBLIES GES ie Balearen 11 5 HA GABLE SP ee ee 11 8 viii FLIGHT 60 Service Manual Introduction Intended Use 1 Introduction This Service Manual V60 00002 18 Rev A provides information for servicing the FLIGHT 60 Ventilator It is for use by authorized service personnel while installing servicing and repairing the ventilator 1 1 Intended Use The FLIGHT 60 Ventilator is intended to prov
27. 2 3 4 5 6 Press Technical A and then press O sensor Select ON Set the Low FiO and the High FiO alarm to OFF Connect the patient circuit via a calibrated Oxygen Analyzer to the test lung Set the ventilator to STS mode Start ventilation Change O settings according to the following test table Input pressure Mixer settings Acceptable Range 2 so o If the test fails 1 2 3 4 Check for an inlet leak see section 7 17 Replace the sensor cable Replace the sensor Replace the Main Board see section0 and perform the required calibrations see section 7 21 7 20 Nebulizer compensation test iO gt Internal mixer model only To test the Nebulizer compensation 1 2 3 4 Set the ventilator to STS mode Start ventilation Verify that Vti is 450 550 Set O mixer to 50 Activate the Nebulizer Verify that Vti remains in the 450 550 range If the test fails 1 Press Technical X and then press ADVANCED Screen 2 Enter the code 5844 and confirm by pressing V 7 22 FLIGHT 60 Service Manual Operation Verification Procedure OVP Nebulizer compensation test i02 Internal mixer model only 3 Press SERVICE SCREEN 4 Use the UP and DOWN buttons to change the Neb Comp value Increasing the value will decrease Vii Flight 60 Service Manual 7 23 Operation Verification Procedure OVP OVP Test Results 7 21 OVP Test Results e BEE le m m pour
28. D Screen Enter the code 5844 and confirm by pressing Y Press SERVICE SCREEN Press Calibrate O2 Leak The system will be flushed with ambient air Ch MT ak TO Wait 2 minutes Use the UP Q and DOWN O buttons to match the displayed value with the external Oxygen analyzer reading 7 Press Enter Flight 60 Service Manual 7 13 Operation Verification Procedure OVP Circuit Test 7 9 Circuit Test latas To test the patient circuit exhalation valve 1 Connect the ventilator to the test lung using a patient circuit Set the lung to um Rp 5 m C 20 2 Press Technical A and then press Circuit TEST Circuit Test Attach a 0 5L Test lung and press ENTER 3 Press Enter 4 The test is done automatically It includes the following 3 steps Testing the motor Finding Test Points 6 calibration points in descending values Verifying 3 verification points 20 2 10 2 5 2 If the test is successful the display reads Test completed If the test fails 1 Press Cancel Go 2 Replace the patient circuit In case of a Flight60 DL replace the exhalation valve diaphragm Perform the calibration again 4 Check internal tubing connections for air leaks Replace the solenoid see section 4 14 and perform the reguired calibrations see section 7 21 7 14 FLIGHT 60 Service Manual Operation Verification Procedure OVP Volume verification 7 10 Volume verification To test the devi
29. During expiration a decrease in the vacuum meter s negative pressure is normal If the test fails 1 Tighten the screws locking the filter cover 7 20 FLIGHT 60 Service Manual Operation Verification Procedure OVP Buzzer Test 2 Replace the filter 3 Remove the filter cover and check the O ring 4 Check the Inlet to muffler connection for a leak 7 18 Buzzer Test To test the buzzer Press Parameters and choose Screen ALARMS 5 Tap the Buzzer button 6 Choose HIGH and press Enter x Verify that a High buzzer sound is heard 7 Tap the Buzzer button 8 Choose LOW and press Enter 9 Verify that a Low buzzer sound is heard If the test fails m Check the buzzers cables Make sure they are connected to the Main Board and are intact m Replace the Main Board see section O and perform the required calibrations see section 7 21 7 19 Oxygen Calibration Test For non iO ventilator no internal O mixer Connect an external Air Oxygen Entrainment Mixer to an Oxygen source Install the Air Oxygen Entrainment Mixer on the ventilator s air inlet O settings are changed with the mixer dial For iO ventilator with internal O mixer Connect the ventilator to an Oxygen source O settings are changed by the 0 button on the touch screen Flight 60 Service Manual 7 21 Operation Verification Procedure OVP Nebulizer compensation test i02 Internal mixer model only 1
30. FLIGHT MEDICAL INNOVATIONS Ltd FLIGHT 60 VENTILATOR Service Manual Models SL DL 1O gt LIT 0021 Rev AO6 Dec 2013 CE Legal Notice Legal Notice Disclaimer FLIGHT MEDICAL INNOVATIONS Ltd FLIGHT MEDICAL provides this Service Manual in its commitment to help reduce patient risk and injury However this manual is not intended to in any way replace or substitute duty of care to a patient professional responsibility or professional judgment nor is it intended to provide any warranty promise guarantee assumption of risk or duty release or indemnity Physicians shall at all times maintain responsibility for patient treatment and outcomes and FLIGHT MEDICAL further assumes no liability for patient treatment or outcome or for physician s negligence breach of duty of care or malpractice The FLIGHT 60 Ventilator operator is solely responsible for selecting the appropriate level and method of patient monitoring Product modification or misuse can be dangerous FLIGHT MEDICAL disclaims all liability for the consequences of product alterations or modifications as well as for the consequences which might result from the combination of this ventilator with other products whether supplied by FLIGHT MEDICAL or by other manufacturers unless such a combination has been specifically endorsed by FLIGHT MEDICAL The design of FLIGHT 60 Ventilator the Operator s and Service Manuals and the labeling on the ventilator take int
31. FLIGHT MEDICAL approved exhalation valve can be used with the FLIGHT 60 Ventilator A This FLIGHT 60 Ventilator has been tested and found to comply with the EMC limits according to the EN60601 1 1 2 standard class B These limits are designed to provide reasonable protection against harmful interference in a typical medical installation The equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with these instructions may cause harmful interference to other devices in the vicinity However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference with other devices which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving device Increase the distance between the equipment Connect the equipment into an outlet on a circuit different from that to which the device s is connected Consult the manufacturer for help atan A Only use medical grade oxygen with the Air Oxygen Entrainment Mixer or Oxygen Blending Bag Kit a a aaa a a aa A Do not place liquid containers in the immediate vicinity or on top of the FLIGHT 60 Ventilator Liquids that get into the ventilator can cause equipment malfunction and damage a a a a a a a a a aa aa a a a a a a aa aa
32. Reposition the fuse housing flat edge on the left and press firmly to make sure that it is inserted completely 4 38 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Rubber Bumpers Figure 64 Connecting the Fuse 4 22 Replacing the Rubber Bumpers The six bumpers on the underside of the device do not need regularly scheduled servicing Servicing is required only in case of a problem 4 22 1 Removing the Rubber Bumpers To remove bumpers 1 Use a Torx screwdriver to remove bumpers as needed Flight 60 Service Manual 4 39 Removing and Reinstalling Modules Replacing the Rubber Bumpers ip s Pme 30929734 POZO AMY veado 90001011 Kae Figure 65 Removing a Rubber Bumper 4 22 2 Installing the Rubber Bumpers To install a bumper Use a Torx screwdriver to attach the bumper and verify that it is fastened securely 4 40 FLIGHT 60 Service Manual Service Technical Menu Advanced Screen 5 Service Technical Menu To enter the Service Technical menu 1 Press Technical A 2 Press ADVANCED Screen 3 Enter the code 5844 and confirm by pressing Y 5 1 Advanced Screen Enable B LEVEL Enable O2 mixer Enable MVG Display C amp R Screen Intensity ON ON OFF 100 Language Enable Sigh Enable VG RA Period Saving Logs English ON ON OFF OFF Button Options Description Enable B LEVEL ON OFF Enable Disable B LEVEL ventilation mode
33. aa aa aa a a aa a a a aa ir aa aa aa aa re a a aa AN After the FLIGHT 60 Ventilator is serviced it must completely pass an Operational Verification Procedure OVP before being returned to patient use Flight 60 Service Manual 2 3 Safety Instructions Cautions laten An authorized FLIGHT MEDICAL factory trained technician must do all service or repairs performed on the FLIGHT 60 Ventilator alain Do not open the ventilator or perform service on an open unit while connected to external power latas Use standard antistatic techniques while working inside the ventilator or handling any electronic parts A Batteries contain Li Ion Do not discard them in an incinerator or force them open Batteries should not be disposed of with normal waste a a a a aa a a a a aa a a a a a aa aa aa aa aaa a aa a aa Use the tools and equipment specified in this manual to perform specific procedures 2 4 FLIGHT 60 Service Manual Functional Description Front Panel 3 Functional Description 3 1 Front Panel The front panel contains the control buttons visual indicators display screen and patient circuit connection There are 2 types of keypad symbols or print fi 7 aa Fe Label 1 2 3 4 Patient Circuit Connector button Panel Lock button On Off button feas u ew Pa z man ma a TN TE Mr ur BR bb sb gt 5 5 Se S S amp S YS amp e I rs j s 6 N Y
34. acing the Detachable Battery Single battery configuration ventilators are not equipped with a detachable battery Le ee en a nn nn nn en nn nn ne nn nn en nn nn en nn nn nn nn nn nn nl 4 3 1 Removing the Detachable Battery To remove the detachable battery 1 Turn the lock dial counterclockwise in the direction of the OPEN arrow Figure 7 Removing the Detachable Main Battery 2 Pull the battery out of the ventilator 4 3 2 Installing the Detachable Battery To install the detachable battery 1 Insert the detachable battery into the ventilator 2 Turn the lock dial clockwise in the direction of the CLOSE arrow until it is firmly locked 4 4 Replacing the Internal Battery 4 4 1 Removing the Internal Battery To remove the internal battery 1 Remove the four Phillips screws that secure the battery panel to the bottom panel 4 2 FLIGHT 60 Service Manual Removing and Reinstalling Modules Removing the Ventilator Cover gt Figure 6 Removing the Internal Battery Panel 2 Remove the internal batteries from the battery compartment 4 4 2 Installing the Internal Battery To install the internal battery m Follow the above procedure in reverse order 4 5 Removing the Ventilator Cover 4 5 1 Removing the Ventilator Cover The following procedure describes how to remove the ventilator cover In most cases the cover must be removed in or
35. al for the FLIGHT 60 and F60 Dual Limb Ventilators ventilators that provide continuous or intermittent mechanical ventilation support for the care of individuals who require mechanical ventilation It is intended for technicians who are responsible for maintaining servicing and providing troubleshooting assistance for the FLIGHT 60 and F60 Dual Limb Ventilators For information on how to use the FLIGHT 60 Ventilator see the FLIGHT 60 Ventilator Operator s Manual Style Conventions Convention Verdana Arial Bold Arial Italics A Used for Regular text Names of labels buttons and other elements of the user interface Special terms the first time they appear Notes which offer an additional explanation or a hint on how to overcome a common problem Warnings which indicate potentially damaging user operations and explain how to avoid them iv FLIGHT 60 Service Manual Table of Contents Table of Contents 1 INTRODUCTION criar aia 1 1 Ll SINTENDEDEU Eee ee 1 1 132 SYMBOL ne een ea ae eae a a 1 1 2 SAFETY INSTRUCTIONS nen 2 1 dol GENERAL WARNINGS ee eis 2 1 2 2 CCRUTIONS aaa ee 2 3 3 FUNCTIONAL DESCRIPTION 3 1 Sal TERONT PAN Boda 3 1 3 1 1 Keypad Control BULLONS manada 3 3 Il 27 WE NCIC SEO nen ee 3 4 3 2 LEFT OIDE PANEL Rare 3 5 Bas RIGHT SIDE PANEL da ed 3 6 3 4 BACK PANEL aa rra 3 7 349 REMOTE ALARM CONNECTION soriana AA AAA 3 9 0 VENTILATOR MODULES Sarai ro een mar 3 1
36. alation If air flow is noticed check either by hearing or by feeling air flow on your palm there is a leak and the test fails If the test fails 1 Replace the patient circuit In case of a Flight60 DL replace the exhalation valve diaphragm Repeat the following m Pressure sensors calibration m Pressure relief calibration m Volume factor calibration m Circuit test Replace the solenoid see section 4 19 and perform the required calibrations see section 7 21 7 18 FLIGHT 60 Service Manual Operation Verification Procedure OVP High Pressure Alarm 7 15 High Pressure Alarm To test the high pressure alarm 1 Set the ventilator to STS settings 2 Connect the ventilator to a test lung using a patient circuit Use the following settings for the lung C 20 Bi Rp 5 3 Activate ventilation 4 Set HIGH P to 10 cmH 0 Check that when the pressure reaches 10 cmH50 the following occurs m the audible alarm is triggered m the visual alarm is triggered m inhalation is interrupted Set HIGH P to 99 cmH gt 0 Check that the following occurs m the audible alarm is silenced automatically m the visual alarm is displayed until the Alarm Reset AA button is pressed If the test fails 1 Replace the Main Board see section 0 2 Perform the required calibrations see section 7 21 7 16 Battery Charger Power Supply bp To test the power supply a a a aaa a a a a aa a a a a Aa N Verify
37. ance of equipment performance and ii FLIGHT 60 Service Manual Legal Notice patient condition However equipment surveillance should not replace direct observation of clinical signs The liability of FLIGHT MEDICAL is subject to and limited to the exclusive terms and conditions as set forth herein Said liability is limited whether arising out of or related to the manufacture and sale of goods their installation demonstration sales representation use performance or otherwise Any liability based upon product warranty is limited regardless of any fault attributable to FLIGHT MEDICAL and the nature of the action including breach of warranty negligence and strict liability The written warranties are in lieu of all other warranties expressed or implied including without limitation warranties of merchantability fitness for any purpose or non infringement FLIGHT MEDICAL shall not be liable for any special incidental or consequential damages incurred by the buyer to a third party The buyer shall not be entitled to make liability recoveries from FLIGHT MEDICAL due to such situations Warranty The FLIGHT 60 Ventilator warranty does not apply for in case of m Defects caused by misuse mishandling tampering or by modifications not authorized by FLIGHT MEDICAL or its representatives m Rubber and plastic components and materials which are guaranteed to be free of defects at time of delivery Any product which proves
38. anual Removing and Reinstalling Modules Replacing the Main Board Figure 33 Detaching the Grounding Screw 8 Lift the Main Board Carefully detach the narrow and wide flat cables J4 from their connectors on the main board Figure 34 Removing the J4 Flat Cables 9 Remove the J3 flat cable by clicking the locker on the main board and then pulling out the cable Flight 60 Service Manual 4 19 Removing and Reinstalling Modules Replacing the Touch Screen Figure 35 Removing the J3 Flat Cable 10 Remove the Main Board 4 10 2 Installing the Main Board To install the main board 1 Check that the main board sockets do not have any bent pins 2 Perform the removal procedure in the reverse order 4 11 Replacing the Touch Screen The touch screen cannot be detached from the front panel When the touch screen needs replacement the Front Subassembly P N V60 70010 60 is to be replaced 1 Follow the procedures for removing the main board see section 4 10 2 Replace the front Subassembly To reassemble the touch screen m Perform the above procedure in reverse order 4 20 FLIGHT 60 Service Manual 4 12 Removing and Reinstalling Modules Replacing the Manifold Assembly Replacing the Manifold Assembly 4 12 1 Removing the Manifold Assembly Ea soy gt To remove the maniford assembly Remove the detachable battery see section 4 3 and the internal battery see section 4 4
39. ce for pressure 3 Set the ventilator to STS settings 4 Activate the ventilator and verify that the volume is between 450 and 550ml If the test fails Repeat the following m Volume factor calibration 7 11 Pressure Verification To test the device for pressure 1 Set the ventilator to STS settings 2 Connect the ventilator to the a pressure meter using a patient circuit Connect the pressure meter to the test lung 3 Use the following settings for the test lung m C 50 4 Activate ventilation Set Ti 2 Verify that the external pressure meter reading and the PIP value displayed on the ventilator differ by no more than 2 cmH5 0 or 10 The higher of the two can be used for this determination If the test fails Repeat the following m Pressure sensors calibration m Pressure relief calibration m Volume factor calibration m Circuit Test Flight 60 Service Manual 7 15 Operation Verification Procedure OVP PEEP 7 12 PEEP To test the PEEP 1 Use the following settings for the test lung m C 50 um Rp 5 m If atest lung with analysis software is used configure the analysis software program to the same settings 2 Connect the ventilator to the test lung using a patient circuit 3 Set the ventilator to STS settings 4 Set PEEP to 5 5 Activate ventilation 6 After 5 breaths check that the basic pressure levels in the lung and in the ventilator display are 5 1 cmH 0 7 Raise the P trig level
40. d i Display Adapter Lower Board Keypad Solenoid Board Solenoid Assembly Purge Board D Type O2 Mixer board Sec Battery Oxygen Solenoid Nebulizer Solenoid Flight 60 Service Manual 3 15 Removing and Reinstalling Modules Introduction 4 Removing and Reinstalling Modules 4 1 Introduction This chapter provides detailed procedures on how to remove FLIGHT 60 Ventilator modules and assemblies that you suspect are worn damaged or performing improperly and how to install new or repaired modules and assemblies Make sure you are familiar with the FLIGHT 60 Ventilator s operation before attempting any service or maintenance laten e nn el aaa aa aaa aaa a aa aaa alain Remove watch and any jewelry Failure to do so may result in injury to service personnel or damage to the ventilator 4 2 Required Equipment The following equipment is required to remove and replace FLIGHT 60 ventilator modules m Antistatic wrist strap m Phillips screwdriver PH1 m Flat screwdriver 0 8x4 m Torx screwdriver BT10x200 m Cutter m Cable ties PLT1M M69 PLT4S M69 alada contact with the working surface place the ventilator on a cushioned surface while it is being serviced aaa Verification Procedure OVP chapter and perform the necessary Operation Verification Tests Flight 60 Service Manual 4 1 Removing and Reinstalling Modules Replacing the Detachable Battery 4 3 Repl
41. der to access the ventilator modules To remove the ventilator cover 1 Remove the two Torx screws inside the ventilator handle Flight 60 Service Manual 4 3 Removing and Reinstalling Modules Removing the Ventilator Cover Figure 7 Removing Screws Inside Handle 2 Remove the two Torx screws connecting the ventilator cover to the back panel Figure 8 Removing Back Screws 3 Remove the two Torx screws from the bottom panel 4 4 FLIGHT 60 Service Manual Removing and Reinstalling Modules Removing the Ventilator Cover Figure 9 Removing the Bottom Panel Screws 4 Remove the ventilator cover The modules of the ventilator are now exposed and accessible Flight 60 Service Manual 4 5 Removing and Reinstalling Modules Replacing the Power Board 4 5 2 Installing the Ventilator Cover To reattach the ventilator cover m Follow the above procedure in reverse order 4 6 Replacing the Power Board 4 6 1 Removing the Power Board To remove the power board 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 Disconnect the flat flex cable P3 from the power board Figure 11 Disconnecting Flat Flex Cable from Power Board 4 Disconnect the 8 pin P2 manifold cable connector from the power board by pressing the release tab on the connector 4 6 FLIGHT 60 Service Manual Remo
42. ee section 4 8 2 remove the 3 screws securing the O mixer Neb board to the Main Board 3 Pull the mixer board out of the connector 4 9 2 Installing the O mixer board To connect the O mixer board m Follow the above procedure in reverse order 410 Replacing the Main Board LA Record system S N manifold S N and motor hours prior to replacing the main board After replacing the board need to update the SW with those numbers AN as described in chapter 8 410 1 Removing the Main Board To remove the main board 1 For iO internal mixer model Follow the procedure for Removing the O mixer neb board see section 4 9 4 16 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Main Board 2 Remove the 6 Torx screws holding the Main Board to the front panel 3 On the bottom side of the Main Board disconnect buzzer connectors LS1 and LS2 4 Disconnect the back light cable from connector P5 AN Do not pull the wires Press the locker and then remove Figure 30 Disconnecting LS2 connector 5 Disconnect the P13 flat cable by pressing hard on the locker and then pulling it out Flight 60 Service Manual 4 17 Removing and Reinstalling Modules Replacing the Main Board N y reTetrittt S 221211181 Ri Zen Figure 32 Detaching the Main Board from the Front Panel 7 Remove the grounding screw at the top left of the board 4 18 FLIGHT 60 Service M
43. electrical cables and silicon tubes Figure 26 Removing Torx Screws from Front Panel Bracket For 10 gt Internal Mixer model Disconnect the 2 silicon tubes from the O mixer neb board Disconnect the nebulizer cable from the O mixer neb board Disconnect the mixer cable from the O mixer neb board Disconnect the O leak sensor cable from the O mixer neb board 4 14 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Front Panel Assembly Figure 27 Disconnecting from O mixer neb board 10 Disconnect the 3 silicon tubes coming from the main board refer to the following picture Disconnect them from the Y connectors and not from the board itself 11 Disconnect the solenoid board flat cable from connector P15 refer to the following picture 12 Disconnect the O sensor cable refer to the following picture Figure 28 Disconnections of the main board Flight 60 Service Manual 4 15 Removing and Reinstalling Modules Replacing the 02 mixer Neb board 102 Internal mixer model only 13 Remove the front panel from the ventilator 4 8 2 Connecting the Front Panel Assembly To connect the front panel assembly m Follow the above procedure in reverse order 4 9 Replacing the O mixer Neb board IO Internal mixer model only 4 9 1 Removing the O mixer neb board To remove the O mixer neb board 1 Follow the procedures for removing the front panel assembly s
44. es 4 35 REPLACING THE LOWER BOARD AND D TYPE BOARD cseeseeeeeeeeeeeeetteeesesgaaes 4 35 4 20 1 Removing the Lower Board and D type Board 4 35 4 20 2 Installing the Lower Board and D type Board 4 38 REPLACING THE USE ee ee 4 38 vi FLIGHT 60 Service Manual Table of Contents 4 21 REMOVIDO tne Else ni iris 4 38 2 21 2 IMStallina he FUSS nidad 4 38 4 22 REPLACING THE RUBBER BUMPERS ans aan 4 39 4 22 1 Removing the Rubber BumpersS s2222200nnnnnnnnnnn en nun nenn nn nn 4 39 4 22 2 Installing the Rubber Bumpers 2222220000nnnnnnnn nn nn nun 4 40 SERVICE TECHNICAL MENU ie 5 1 Sil ADVANCED SCREEN seen 5 1 342 SERVICE SCREEN aussehen e MARA NA el ANON 5 2 SOFTWARE UPGRADE curia eo 6 3 SL ANSTALEING THE SW UPGRADE naa ati im 6 3 6 2 CALIBRATION INTEGRITY CHECK aces vaya as nenn 6 4 OPERATION VERIFICATION PROCEDURE OVP uuunnuuunnnnnnnnnnnnnnnnnn 7 5 TL REQUIRED EQUIPMENT iaa 7 5 12 STANDARD VENTILATOR SETTINGS STS sn 7 6 73 PRONT PANEL ELE TEST act a aa 7 6 7 4 PRESSURE SENSORS CALIBRATION ana aaa 7 7 7 5 PRESSURE RELIEF CALIBRATION ais 7 10 7 6 VOLUME FACTOR CALIBRATION aa neuen 7 11 Lid OXYGEN SENSOR CALIBRATION copar NR 7 12 7 8 O LEAK SENSOR CALIBRATION IO INTERNAL MIXER MODEL OMLY 7 13 7 3 CIRCUIT TEST Er ee ei eek een 7 13 7410 VOLUME VERIFICATION nenn ein 7 14 Zall PRESSURE VERIFICATION rss een 7
45. essing V Press SERVICE SCREEN Press Calibrate Volume Volume Factor and follow the instructions which appear on the display Flight 60 Service Manual I 7 11 Operation Verification Procedure OVP Oxygen Sensor Calibration 6 After pressing Enter the ventilator will run volume factor calibration and display the volume factor value on thee reen The volume factor value should be between 0 85 and 1 2 Press Enter 7 Repeat the calibration again and verify that in both cases the volume factor values are the same If not repeat the test until 2 consecutive matching volume factor values are achieved The test may be repeated up to 10 times If the test fails 1 Check internal tubing connections for air leaks 2 Run the following tests m Pressure sensor calibration m Circuit test m Pressure relief calibration Volume factor calibration If Volume Factor is still out of spec Replace the manifold see section 4 10 Perform the required calibrations see section 7 21 7 7 Oxygen Sensor Calibration To calibrate the Oxygen sensor For iO internal mixer model 1 Connect a high pressure oxygen hose to the High Pressure O2 port Connect a calibrated Oxygen Analyzer to the ventilator s outlet Don t connect Press Technical X and then press ADVANCED Screen Enter the code 5844 and confirm by pressing Y Press SERVICE SCREEN Press Calibrate FiO2 Choose USED if calibrating the current sensor NEW if O2 sensor
46. essories 2 1 General Warnings a a a a aa a oa a a a a aa aa aa a a a aa a aa a aa a a a a a a a a a a aa aa aa aa aa a a a a aa a a a a a a aa aa aa aa aa aa a aa a a a aa aa a a a a a a a a aa aa i a at a aa a a a a aa aa aa aa aa aaa aa a a a a aaa a aa a a a an el en anhand External power connection To maintain grounding integrity when using AC power only connect to grounded receptacles Always disconnect the external power prior to servicing There is a risk of explosion if used in the presence of flammable anesthetics A All settings and adjustments in the different ventilation modes must be made in accordance with a physician s prescribed therapy Always use an outlet filter or equivalent at the Airway Pressure Connector to protect the internal sensors from moisture and other contaminants The ventilator is ready for operation only when 1 It is completely assembled 2 The OVP has been successfully completed e e u u i u E AASA HH HH HH HH AASA HH HH HH GH HH HH tt tk HH Y Flight 60 Service Manual 2 1 Safety Instructions General Warnings lala Ensure that the oxygen source is not empty before and during the use of the optional Air Oxygen Entrainment Mixer or Oxygen Blending Bag Kit Am mi aan As Li Ion batteries are charged and discharged over time their ability to hold a charge is decreased with use This can shorten the amount of time the ventilator can function while on battery p
47. front panel so gain better access N Figure 56 Solenoid Cable connector 5 Disconnect the 3 silicon tubes from the solenoid assembly Figure 57 Disconnecting Silicon Tubes 6 Unscrew the two adjacent Torx screws on the solenoid bracket Pull out the bracket with the solenoid carefully leading the solenoid cable making sure it is not being damaged 4 34 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Lower Board and D type Board Figure 58 Detaching the Solenoid Bracket 7 Remove the 2 screws securing the solenoid to the bracket Pull out the solenoid from the bracket Verify the sealant O ring is removed and is not attached to the bracket 4 19 2 Installing the Solenoid Assembly To install the solenoid assembly Follow the above procedure in reverse order 4 20 Replacing the Lower Board and D type Board 4 20 1 Removing the Lower Board and D type Board To remove the Lower and D type boards 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 Remove the ventilator cover see section 4 5 Remove the front panel assembly see section 4 8 Remove the Power board see section 4 6 Remove the Power Supply and its base plate see section 4 7 Remove the internal O2 mixer see section 4 15 Remove the Manifold assembly see section 4 11 Unscrew the 2 Torx screws plastic washers securing the Outlet assembly Remove the Out
48. g m C 10 m Rp 5 Press Technical X and then press ADVANCED Screen Enter the code 5844 and confirm by pressing Y Press SERVICE SCREEN Disconnect the patient circuit from the ventilator to verify there is no pressure buildup in the circuit Reconnect the circuit to the ventilator oe tS 8 Press Calibrate Pressure and then Enter The ventilator starts to build pressure 9 The following screen opens m a an r R ma NG i Patient Pressure Jue pa w A A A N e N El e or f AN J mat External measurement 10 Check the Patient Pressure and Outlet Pressure values verify the following m Values match the pressure measurement of the external pressure meter m Values are between 50 and 75 cmH5 0 m The difference between the Patient Pressure and Outlet Pressure values is no more than 0 1 If one of the conditions above is not met calibrate the pressure sensors 1 If the pressure on the external pressure meter is in the 50 75 cmH 0 range continue to step 2 If the pressure is less than 50 cmH50 e Press Cancel 9 e Press Calibrate Pressure again The calibration screen will come up with the following message You can set the solenoid and motor commands for pressure sensor and displays default values of 65 200 7 8 FLIGHT 60 Service Manual Operation Verification Procedure OVP Pressure Sensors Calibration Please make sure there is no pressure in the system and then p
49. ges to the PC using a dedicated PCS2 protocol for authorized and qualified service technicians only Flight 60 Service Manual 3 7 Functional Description Label Name 6 USB B type 7 USB A type 8 LAN RJ45 9 Mini RS 485 COM3 10 Low Flow Oxygen Port 14 High Pressure O Port O Internal mixer model only 3 8 FLIGHT 60 Service Manual Description PC connector USB port for downloading the main application from the PC using a dedicated PCS2 protocol for authorized and qualified service technicians only USB port for uploading LOG files to an external memory stick for authorized and qualified service technicians only LAN for network logging currently not available For connecting FLIGHT MEDICAL peripherals For future use Low flow oxygen enrichment source Connects to high pressure Op Functional Description Remote Alarm Connection 3 5 Remote Alarm Connection The Flight 60 ventilator can be connected to third party remote alarm system The remote alarm station displays all visible and audible alarms and alerts if the ventilator is shutdown Remote alarm cable should be connected to the COM2 RS232 RA port the lower port in the back of the ventilator The COM2 port provides a dry contact output both Normally Open NO and Normally Closed NC e Normally Open Pin 7 closing the contacts to transmit an alarm e Normally Closed Pin 8 opening the contacts to transmit an alarm The dr
50. groove securing the filters in place 4 17 Replacing the Purge Board Assembly 4 17 1 Removing the Purge Board Assembly To remove the purge board assembly 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 Remove the ventilator cover see section 4 5 Remove the front panel see section 4 8 4 Disconnect the two check valves at the ends of the silicon tubes from the purge board 4 30 FLIGHT 60 Service Manual a 6 Removing and Reinstalling Modules Replacing the Solenoid Board Assembly Figure 51 Disconnecting the Check Valves Remove the four Philips screws star washers and flat washers from the purge board Carefully remove the stand offs between the purge board and the solenoid board Carefully separate pull out the purge board from the connector on the solenoid board 4 17 2 Installing the Purge Board Assembly To install the purge board assembly Follow the above procedure in reverse order 4 18 Replacing the Solenoid Board Assembly 4 18 1 Removing the Solenoid Board Assembly SA SU au To remove the solenoid board assembly Remove the detachable battery see section 4 3 and the internal battery see section 4 4 Remove the ventilator cover see section 4 5 Remove the front panel see section 4 8 Remove the purge board see section 0 Disconnect connector P1 and the flat cable from the solenoid board Flight 60 Serv
51. ht 60 Service Manual v Table of Contents 4 7 4 8 4 9 4 11 4 12 4 16 4 17 4 20 4 21 REPLACING THE POWER SUPPLY acacia 4 10 4 7 1 Removing the Power Supply ccccccsscccessennneeeeeeeesensseeeauees 4 10 4 7 2 Installing the Power Supply ccc cc cccccceeee sees ence eee eeeeeeeeeaaaaees 4 12 REPLACING THE FRONT PANEL ASSEMBLY secceeceeeeeeeeeseeeeeeeeeeeettteeeseggaags 4 13 4 8 1 Removing the Front Panel Assembly ccc cece eee eeeeeeeeeeeees 4 13 4 8 2 Connecting the Front Panel Assembly cccccceeeeeeeeeeeeeeees 4 16 REPLACING THE O MIXER NEB BOARD IO INTERNAL MIXER MODEL OMLY 4 16 4 9 1 Removing the O mixer NED DOAM c cece cece eeeeeeeeeeees 4 16 4 9 2 Installing the O mixer DOAMI ccccesse cesses nnnnn nn nennen nn naaa 4 16 REPLACING THE MAIN BOARD ccccceessscceeeeeeeeeeeteeeeeessageeeeteeeeettteeesggagaags 4 16 4 10 1 Removing the Main Board zussssssenenonnnnnnnnnnnnnnnnnnnn nennen 4 16 4 10 2 Installing the Main Board zzzu2u2seeeennonunnn nn nnnnn nn nennen non nn nun nn 4 20 REPLACING THE TOUCH SCREEN Seren ar aia laica 4 20 REPLACING THE MANIFOLD ASSEMBLY ccsecececeeeeeeeeseseceeeeeeeeeeettteeessggaags 4 21 4 12 1 Removing the Manifold Assembly c cece cece eee nennen nun nn 4 21 4 12 2 Installing the Manifold Assembly ccc cece cece neces nennen nn nn 4 25 REPLACING THE OXYGEN SENSOR 1a u un ee 4 26 4 13 1 Re
52. ice Manual 4 31 Removing and Reinstalling Modules Replacing the Solenoid Board Assembly DIME MA scor FL HH I www Figure 52 Solenoid board connectors 6 Remove the silicon tubes from the fittings on the redundancy solenoid Figure 53 Removing the Silicon Tubes 7 Remove the solenoid board assembly 4 18 2 Installing the Solenoid Board Assembly To install the solenoid board assembly 1 Insert the solenoid assembly 2 Insert the purge board assembly 4 32 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Solenoid Assembly 3 Connect the silicon tube attached to the female connector to the inner fitting on the redundancy solenoid 4 Using the other silicon tube connect the Solenoid assembly to the outer fitting on the redundancy solenoid Figure 54 Connecting the Silicon Tubes 4 19 Replacing the Solenoid Assembly 4 19 1 Removing the Solenoid Assembly To remove the solenoid assembly 1 Remove the ventilator cover 2 For iO internal mixer model Remove the O leak sensor 3 Remove the 2 screws securing the O leak sensor bracket Remove the bracket Br Figure 55 Remove O leak sensor bracket Flight 60 Service Manual 4 33 Removing and Reinstalling Modules Replacing the Solenoid Assembly 4 Disconnect the solenoid cable from the solenoid board P1 If it s hard to reach you can remove the screws that secure the front panel and move the
53. ide continuous or intermittent mechanical ventilation support for the care of individuals who require mechanical ventilation Specifically the FLIGHT 60 Ventilator is applicable for adult and pediatric patients greater than or equal to 10 kg 22 lbs 1 2 Symbols Symbol Description Front Panel On Off Alarm Reset OK Enter Decrease Button Increase Button Cancel Panel Lock Manual Breath Parameters Screen MADURO Flight 60 Service Manual 1 1 Introduction Symbols Symbol O A Rear Panel aa el ila 2 4 6 2 BAR O ER 35 90 psi Vmax 15 l min 1 2 FLIGHT 60 Service Manual Description Extended Screen Technical Screen Nebulizer Port Caution consult accompanying documents Type BF applied part Temperature limitation Humidity limitation Atmospheric pressure limitation DC Direct Current AC Alternating Current USB Universal Serial Bus LAN Local Area Network High Pressure and Low Flow Oxygen Port Safety Instructions General Warnings 2 Safety Instructions At all times strictly follow this manual The safe use of the FLIGHT 60 Ventilator requires full understanding of its operation and adherence to the manual s instructions The equipment is only to be used for the purpose specified in section 1 1 Observe all of the WARNINGS and CAUTIONS posted in this manual and on buttons found on the FLIGHT 60 Ventilator and associated acc
54. ion Volume Factor Calibration Oxygen Sensor calibration O Leak Sensor calibration Circuit Test Volume verification To test the device for pressure 1 Set the ventilator to STS settings 2 Activate the ventilator and verify that the volume is between 450 and 550ml If the test fails Repeat the following m Volume factor calibration Pressure Verification PEEP Pressure Trigger Exhalation Valve Leak High Pressure Alarm Battery Charger Power Supply Inlet Leak Buzzer Test Flight 60 Service Manual 7 5 Operation Verification Procedure OVP Required Equipment 7 1 Required Equipment Required equipment includes E Adult test lung specified up to 90cm H20 with adjustable lung compliance of C 10 20 50 u Pressure meter range to 120cm H20 accuracy of 0 1 cmH 0 Note that this is not required if the adult test lung has autonomous pressure measuring capability m Screwdrivers Phillips screwdriver PH1 Flat screwdriver 0 8x4 Torx screwdriver BT10x200 Reusable patient circuit P N V60 50000 60 Vacuum gauge range to 1bar Oxygen Analyzer Parabolic resistors Rp5 Rp20 Rp50 Made by Michigan Instruments Inc Medical grade Oxygen source pressure over 50PSI Oxygen Mixer By Flight Medical P N V13 00010 60 7 2 Standard Ventilator Settings STS Refer to the following specifications whenever STS settings are called for m ACMV m VCV 500 mL m PEEP 0 um Ptrig 1 0 m Rate 15 m Ti 1 Waveform
55. ixer Neb board Inlet assembly O leak sensor Internal O mixer LULU Figure 7 Ventilator Modules Internal Mixer P N V60 60002 65 V60 21000 65 V60 13000 65 V60 21000 60 ELE 0001 V60 21400 69 G60 25000 29 SUB 0101 Flight 60 Service Manual 3 11 Functional Description Pneumatic Diagram 3 8 Pneumatic Diagram y Ye zzz Ie DUPER YA ff a TR TRRTILLIIRILILIRLTLTLLTRLTRLLIIIIIRTRTRRTLTLLTIILIILILTLR mh SEBS S55 i css 3 12 FLIGHT 60 Service Manual Functional Description Pneumatic Diagram iO2 Internal mixer model 3 9 Pneumatic Diagram iO Internal mixer model UNI JUN eg ja pino sazijnqan soyeundas 13141 TO aunssasd y3iy In PMen INGIN NNN m7 q Ts A Fi GLLLLLLLL YS SAA gt gt gt gt gt gt gt gt gt gt 5 585 N y Sp a p ur q nA Flight 60 Service Manual 3 13 Functional Description Electrical Diagram 3 10 Electrical Diagram su er rr Oxygen Sensor Power Board Main Board MES Display Adapter eee ae a sm ae ae ee i Keypad Solenoid Board Solenoid Assembly Purge Board D Type Board Main Battery sec Battery 3 14 FLIGHT 60 Service Manual Functional Description Electrical Diagram iO2 Internal Mixer model 3 11 Electrical Diagram iO Internal Mixer model Power Supply 4 2 ce ers m mm m 20 1 Power Board i 3 Main Boar
56. kk ki kk ik kk ki kin kk ik ik kik innit ink innit init nti ni ml latas Refer to Flight Medical Service Notes for a list of approved Oxygen sensors a a a il 4 13 1 Removing the Oxygen Sensor To remove the oxygen sensor 1 Remove the detachable battery see section 4 3 and the internal battery see section 4 4 2 Remove the ventilator cover see section 4 5 Remove the front panel see section 4 8 4 Disconnect the electrical cable from the oxygen sensor 4 26 FLIGHT 60 Service Manual Removing and Reinstalling Modules Figure 47 Removing the Oxygen Sensor 5 Turn the oxygen sensor counterclockwise until it comes out 4 13 2 Installing the Oxygen Sensor To install the oxygen sensor m Follow the above procedure in reverse order 4 14 Replacing the O leak sensor iO Internal mixer model only 4 14 1 Removing the O leak sensor To remove the O leak sensor 1 Remove the ventilator cover see section 4 5 2 Disconnect the electrical cable from the O leak sensor 3 Turn the O leak sensor counterclockwise until it comes out 4 14 2 Installing the O leak sensor To install the oxygen sensor m Follow the above procedure in reverse order Flight 60 Service Manual 4 27 Removing and Reinstalling Modules Replacing the Oxygen mixer i02 Internal mixer model only 4 15 Replacing the Oxygen mixer iO Internal mixer model only 4 15 1 Removing the Oxygen mixer
57. let assembly ON AH AWN Flight 60 Service Manual 4 35 Removing and Reinstalling Modules Replacing the Lower Board and D type Board Figure 59 Removing the Outlet assembly 10 Disconnect connectors P5 P6 and P7 from the lower board Figure 60 Disconnecting P7 connector 11 Unscrew the 6 Philips screws securing the lower board and 2 Philips screws securing the D type board 12 Gently lift the back side of the lower board and pull the lower board with D type board out of the ventilator base 4 36 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Lower Board and D type Board T zZ Figure 61 Removing the Lower Board and D type Board 13 Disconnect the D type board from the Lower board an y Figure 62 D type and Lower boards Flight 60 Service Manual 4 37 Removing and Reinstalling Modules Replacing the Fuse 4 20 2 Installing the Lower Board and D type Board To install the Lower and D type boards m Follow the above procedure in reverse order 4 21 Replacing the Fuse The fuse does not need regularly scheduled servicing Servicing is required only in case of a problem 4 21 1 Removing the Fuse To remove the fuse 1 Pull out the plastic fuse housing at the back of the device with the aid of a flat screwdriver MM 7 i f S i 3 R 3 2 fl AA Figure 63 Removing the Fuse 4 21 2 Installing the Fuse To install the fuse
58. lso include the ventilator s log files and a detailed description of the failure analysis and the repair efforts undertaken Items can be returned only after an RGA number was provided by FLIGHT MEDICAL Copies of the RGA form and the Service Call should be included with the returned item RGA Returns Use the following guidelines to return a FLIGHT 60 ventilator m Use the original box and packaging Remove both batteries and any accessories from the ventilator m When returning a module place it in the original box and packaging If not available place it in a box large enough to allow for it to be wrapped in a sufficient amount of packaging material m Write the RGA number on the shipping label Ship RGA items to FLIGHT MEDICAL INNOVATIONS Ltd 13 Hamelacha St Lod 71520 ISRAEL Tel 972 8 923 5111 Flight 60 Service Manual 10 1 Spare parts Electronic 11 Spare parts 11 1 Electronic Main Board A i co MA V60 60002 65 co ka Y Connecting cables not part of the board 1 MB to SB cable V60 70100 29 I I F nn 2 Oz sensor cable V60 00130 29 3 FPC MB to PB cable V60 21000 29 Power Board V60 21000 65 eu cables not part of the board Power Supply V60 13000 65 11 2 FLIGHT 60 Service Manual Spare parts Electronic Lower Board V60 22000 65 D Type Board V60 24000 65 Purge Board V60 23000 65 Solenoid Board V60 26000 65 Con
59. moving the Oxygen Sensor u2seeennennnnnnnnnnnnnnnnnnnnnnnnnnnnn nen 4 26 4 13 2 Installing the Oxygen SENSOP cccccccsscceessenneeeeeeeeeeesseeeeanaes 4 27 REPLACING THE O LEAK SENSOR IO INTERNAL MIXER MODEL OMLY 4 27 4 14 1 Removing the O leak sensor 222se sennnnnnnnnnnnnn nennen non nn n une 4 27 4 14 2 Installing the O leak sensor u222seeeenennnnnn nenn nun nn nennen nn nun nenn 4 27 REPLACING THE OXYGEN MIXER IO gt INTERNAL MIXER MODEL ONLY seeeeceeees 4 28 4 15 1 Removing the Oxygen mixer asaan 4 28 4 15 2 Installing the Oxygen mixer sssssssssssssssssnssssnssrnnessnnessenee 4 29 REPLACING THE O MIXER FILTERS TO gt INTERNAL MIXER MODEL OMLY 4 30 REPLACING THE PURGE BOARD ASSEMBLY vsuunnnnnnnennunnnnnnnennunnnnnnnen nun nnn nennen 4 30 4 17 1 Removing the Purge Board ASSEMDI cece cece eee eeeeeeeeeeeees 4 30 4 17 2 Installing the Purge Board Assembly cece cece eeeeeeeeeeeeees 4 31 REPLACING THE SOLENOID BOARD ASSEMBLY csceeceeeesseceeeeeeeeeeeeteeeessngagas 4 31 4 18 1 Removing the Solenoid Board AssemBDB ly ueeeeeeerersererseese 4 31 4 18 2 Installing the Solenoid Board Assembly z22222220nnnnnnnnnn0n 4 32 REPLACING THE SOLENOID ASSEMBLY ns ne ai ia 4 33 4 19 1 Removing the Solenoid ASSEMDIY c cece cece eee eeeeeeeeeeeees 4 33 4 19 2 Installing the Solenoid ASSEMDIY ccc cece cece ee eee eeeeeeeeeeee
60. n on the ventilator press Technical A and press Show Info 15 Verify the new software version is displayed and the System serial number Compressor serial number and Hour meter values have not changed To update System serial number Compressor serial number and Hour meter Press Technical X and then press ADVANCED Screen Enter the code 5844 and confirm by pressing Y Press SERVICE SCREEN Press SERVICE Enter the code 2009 and confirm by pressing Y Use the numerical keyboard to update the System serial number Compressor serial number and Hour meter with the values previously recorded in step 2 6 2 Calibration integrity check 1 Refer to 6 1 par 2 above Set the ventilator to the same ventilation modes 2 Connect the same patient circuit and test lung used in par 6 1 par 2 above 3 Start ventilation 4 Verify the following Vti Within the 450 550 spec PIP 1cmH gt O difference from the pre upgrade values Pbase 5 1cm HO O 5 difference from the pre upgrade values 5 If any of those values is out of spec perform the appropriate calibration and check again 6 4 FLIGHT 60 Service Manual Operation Verification Procedure OVP Calibration integrity check 7 Operation Verification Procedure OVP The following verification procedure is to insure that the ventilator is calibrated and performing as per the specifications Front Panel Self Test Pressure Sensors Calibration Pressure Relief Calibrat
61. necting cables not part of the board 1 MBtoSBcable 53 V60 70100 29 _ Flight 60 Service Manual 11 3 Spare parts Electronic O Mixer Neb board ELE 0001 Detachable main battery V60 19000 67 Integral battery V60 19100 63 Keypad English V60 74000 68 Keypad Symbols SUB 0087 11 4 FLIGHT 60 Service Manual Spare parts Mechanical Assemblies 11 2 Mechanical Assemblies Front Subassembly V60 70010 60 English Keypad SUB 0020 Symbols Keypad Connected items 2 Front Left bracket V60 76022 03 Manifold V60 21000 60 Filter Cover V11 35201 07 Flight 60 Service Manual 11 5 Spare parts Mechanical Assemblies Oxygen Sensor Leak sensor G60 25000 29 Air Oxygen Entrainment mixer V13 00030 60 Inlet Assembly V60 15000 63 mm a nn I 1 Silicon tube V60 32000 06 Internal Mixer Nebulizer SUB 0101 11 6 FLIGHT 60 Service Manual Spare parts Mechanical Assemblies Muffler MEC 0040 L connector G27 00017 27 Flex tube short V60 25010 06 Flex tube long V60 25020 06 For Dual Limb Ventilator 2 Diaphragm V64 11200 06 aren a HH 3 Exhalation Valve DL MEC 0034 _ i n L AAA On Flight 60 Service Manual 11 7 Spare parts Cables 11 3 Cables Internal AC Cable V60 40300 29 Internal DC Cable V60 40200 29 FPC MB PB cable V60 21000 29 MB SB cable
62. noid and redo calibration m If the patient pressure outlet pressure difference is more than 0 1cmH gt 0 Flight 60 Service Manual 7 9 Operation Verification Procedure OVP Pressure Relief Calibration O a KR W N EH Repeat the calibration up to 3 times If the desired results are not obtained after three attempts Examine the silicon tube connections and try to locate a leak Verify that the relief valve is not activated Replace the solenoid Perform the required calibrations see section 7 21 Replace the Main Boar Perform the required calibrations see section 7 21 Pressure Relief Calibration To calibrate the pressure relief mechanism Connect the ventilator to the test lung using a patient circuit Set the test lung to minimum compliance Press Technical X and then press ADVANCED Screen Enter the code 5844 and confirm by pressing Y Press SERVICE SCREEN Press Calibrate Relief and then Enter to start the motor and increase pressure 7 Follow the instructions which appear on the display The pressure measurements are displayed 9 Verify that there is no air leakage from the exhalation valve Air should only be coming out via the pressure relief valve 10 Verify that the displayed pressure reading is between 105 and 120 cmH 0 11 If the pressure is not within this range need to adjust the Relief valve The relief valve adjustment needs to be done when the ventilator
63. o consideration that the purchase and use of the equipment is restricted to trained professionals and that certain inherent characteristics of the ventilator are known to the operator Instructions warnings and caution statements are therefore limited to the specifics of the FLIGHT 60 Ventilator This Operator s Manual excludes references to various hazards which are obvious to medical professionals and operators of this equipment to the consequences of product misuse and to potential adverse effects in patients with abnormal conditions When the FLIGHT 60 Ventilator is used in homecare and subacute environments only properly trained personnel should operate the ventilator The FLIGHT 60 Ventilator is a restricted medical device designed for use by respiratory therapists or other properly trained and qualified personnel under the direction of a physician and in accordance with applicable state laws and regulations Transport of patients with the FLIGHT 60 Ventilator requires that medical staff have a good working knowledge of the ventilator s use and problem resolution Proper emergency backup equipment must be immediately available during transport FLIGHT 60 Ventilator operators must recognize their responsibility for implementing Safety monitoring mechanisms which supply appropriate information on equipment performance and patient condition Patient safety may be achieved through a wide variety of means such as electronic surveill
64. ower a a a a a a a a a a a a a a a a aa The batteries should be replaced when the batteries no longer meet the needs of the user This depends on a number of factors including settings and usage patterns alain Charge the batteries for a minimum of three hours before powering the ventilator from the batteries This provides fully charged batteries a a a a a a a a a a aa a a a a a aa aa aa aa aa a aa a a a aa a a a aa aa aa aa aa aa a aa aa a a aa a a a a a a aa aa aa aa aa aa a aa a a a a aa a a a a a a aa aa aa aa aa a aa a a a a a a a a a a aa aa aa aa aa aaa rr During storage charge the batteries for a minimum of three hours every 30 days This provides charged batteries latas Always ensure that the green Ext Power LED is illuminated after connecting the FLIGHT 60 Ventilator to an external AC or DC power source If the LED is not illuminated check all power connections and resolve any problems alain Always plug the FLIGHT 60 Ventilator into an AC power supply source when not in use to ensure best battery performance atan The flow resistance of the air inlet filter located on the right side of the ventilator is likely to increase with repeated use Ensure that the filter is changed regularly laten Only a FLIGHT MEDICAL approved patient circuit can be used with the FLIGHT 60 Ventilator 2 2 FLIGHT 60 Service Manual Safety Instructions Cautions latas Only a
65. reen P trig LED flashes and a mandatory breath is forced each time the edge shoulder is raised Change settings to m SIMV m PSV 20 m Rate 5 Initiate inhalation by slightly raising the edge shoulder of the test lung to create negative pressure Verify that the green P trig LED flashes and that the ventilator provides a mandatory breath followed by pressure supporting ventilations PSV for 12 seconds Set the P trig level to 0 2 cmH O and verify that no auto triggering occurs If the test fails 1 Replace the patient circuit In case of a Flight60 DL replace the exhalation valve diaphragm Repeat the following m Pressure sensors calibration m Pressure relief calibration m Volume factor calibration m Circuit test Replace the solenoid see section 4 19 and perform the required calibrations see section 7 21 Flight 60 Service Manual 7 17 Operation Verification Procedure OVP Exhalation Valve Leak 7 14 Exhalation Valve Leak gt 1 To test the exhalation valve Set the ventilator to the following settings m Rate 10 um Ti 1 4 ACMV m VCV 1 4L Set the High Pressure alarm to 99 cmH 0 Connect the ventilator to a test lung using a patient circuit Use the following settings for the lung C 20 u Rp 20 Activate ventilation and continue for 15 breaths Verify that the pressure level is over 72 cmH50 Check for air flow from the underside of the Exhalation Valve during inh
66. ress OK You can set the solenoid and motor commands for Pressure Sensors Use UP and DOWN keys for solenoid Use MANUAL and LOCK keys for motor e Use the UP O and DOWN O buttons to change me solenoid command initial value of 65 or Manual Breathi and Panel lock KE buttons to change motor command initial value of 200 and press Enter 9 e Verify that the pressure on the external pressure meter is in the 50 75 cmH 0 range If not then repeat the above steps until the pressure is the correct range e Continue to step 2 2 Use the UP Q and DOWN buttons to change the External measurement value of 60 to the actual pressure reading of the external pressure meter 3 Press Enter The ventilator stops 4 Press Calibrate Pressure again and then Enter 5 Check the Patient Pressure and Outlet Pressure values verify the following m Values match the pressure measurement of the external pressure meter m Values are between 50 and 75 cmH5 0 The difference between the Patient Pressure and Outlet Pressure values is no more than 0 1 6 Press Cancel x to exit If the test fails 1 Replace patient circuit and redo calibration 2 Do one of the following m If the external measurement lower than 50 Check internal tubing connections for air leaks Replace the solenoid and redo calibration m If the external measurement higher than 75 Check internal tubing connections for blocking Replace the sole
67. ser to confirm parameters or mode change Turns the ventilator on or off to start or stop ventilation The Alarm Reset silences the audible alarm and clears lit alarm LEDs Technical data and selection options Additional ventilation parameters screen Flight 60 Service Manual 3 3 Functional Description Front Panel 3 1 2 LED Indicators The LED indicators on the front panel inform the user of various events The following table describes the available LED indicators LED Indicator Description TRIG Green LED indicates a patient s breathing effort EXT PWR Yellow LED indicates that an external power source is being applied to the ventilator LOW BAT Red LED indicates that total batteries charge level is below 50 BAT Orange LED indicates that the ventilator is powered on batteries FAULT Red LED indicates a ventilator malfunction APNEA Red LED indicates that no breaths have been delivered for the preset APNEA interval BUV Red LED indicates that backup ventilation is active HIGH MV Red LED indicates that the high inspiratory minute volume alarm limit is being violated LOW MV Red LED indicates that the low inspiratory minute volume alarm limit is being violated HIGH P Red LED indicates that the high peak airway pressure alarm limit is being violated LOW P Red LED indicates low peak airway pressure 3 4 FLIGHT 60 Service Manual Functional Description Left Side Panel 3 2 Left Side Panel Figure 3
68. side NL immi A A O ek ES 1 4 A a Figure 44 Detaching the Manifold Base 16 Carefully lift out the manifold assembly a a a a a a a a a a aa a a a a a aa aa aa aa aaa a aa a a a aa a a a aa Don t apply any force on the piston drive mechanism Don t hold the manifold by the bearings or by the metal rods 4 24 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Manifold Assembly Al Va S a NA A k J The vibration dumping frame is an integral part of the manifold and should not be disassembled from the manifold alain ev Before sending the manifold assembly to FLIGHT MEDICAL remove the short and long flex tubing 4 12 2 Installing the Manifold Assembly To install a manifold assembly m Perform the removal procedure in the reverse order with the following additional step after inserting the muffler assembly which is helpful for getting the cable ties through their slots m Insert the detachable battery until it is almost completely in and then assemble the cable ties through the slots under the muffler m If a new manifold was installed run PCS downloader to update the manifold serial number and reset working hours See section 5 2 Flight 60 Service Manual 4 25 Removing and Reinstalling Modules Replacing the Oxygen Sensor Figure 46 Assembling Cable Ties 4 a Replacing the Oxygen Sensor alain nn i HH HH ben ben tt kk ik
69. ving and Reinstalling Modules Replacing the Power Board Figure 12 Disconnecting Manifold Cable Connector P2 from Power Board 5 Disconnect the 4 pin P6 power supply connector from the power board by pressing the release tab on the connector kondi mn PO d a Lap ha pad KN Ka y na gt 1 _ nm oF apo A Figure 13 Removing Power Supply Connector P6 from Power Board 6 Remove the Torx screw connecting the power board to its bracket Flight 60 Service Manual 4 7 Removing and Reinstalling Modules Replacing the Power Board Figure 15 Lifting Power Board from Ventilator Base 7 Holding the board by the grooves carefully pull the board out by lifting up slightly on one side and then the other continuing to alternate sides until the board is released from the socket 4 8 FLIGHT 60 Service Manual Removing and Reinstalling Modules Replacing the Power Board 4 6 2 Installing the Power Board To install the power board 1 Check that the power board sockets do not have any bent pins 2 Slide the power board through the right and left guide tracks positioning the power board connectors over the sockets Figure 17 Inserting Power Board into Ventilator Base 3 Firmly push down the power board making sure that the power board connectors fit well into the sockets pin headers in the base of the ventilator Flight 60 Service Manual 4 9 Removing
70. y contacts current should not exceed 1mA The voltage on the contacts must be lower than 12 Volts SI TDA04H0SD cr Jl 6E17C009SAJ220 ma l NC k 14 LS1 R25 0 RA RII IK Chass s aaa A The legal and regulatory responsibility for this integration of the Flight 60 device into any external system lays on the integrator and not the Flight 60 i manufacturer This include but is not limited to responsibilities for the Design Implementation Installation validation verification and safety of the connection of the Flight 60 to the remote alarm Falling to comply with the specification given here may result in damage to the Flight 60 Service Manual 3 9 Functional Description Ventilator Modules 3 6 Ventilator Modules pon res Sr bin r ya ia ze u im I mi Il ne 2 eng in Sa as Figure 6 Ventilator Modules Component P N A Main board MB V60 60002 65 B Power board PB V60 21000 65 C Power supply PS V60 13000 65 D Manifold assembly V60 21000 60 E Solenoid board assembly V60 26000 65 F Solenoid assembly V60 21400 69 G Oxygen O2 Sensor V60 25000 29 H Purge board V60 23000 65 3 10 FLIGHT 60 Service Manual Functional Description Ventilator Modules 02 Internal mixer model 3 7 Ventilator Modules IO Internal mixer model J IO D gt Component Main board MB Power board PB Power supply PS Manifold assembly Oz M

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