FLIGHT MEDICAL INNOVATIONS Ltd.
FLIGHT 60T VENTILATOR
Service Manual
Models: SL; DL; iO2
LIT-0113 Rev. A01
June 2016
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 60T 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 60T Ventilator, the Operator’s and Service Manuals, and the
labeling on the ventilator, take into 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 60T
Ventilator.
Federal law (US) restricts this device to sale by or on the order of a physician.
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 60T Ventilator is used in homecare and subacute environments,
only properly trained personnel should operate the ventilator. The FLIGHT 60T
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 60T 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 60T 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 surveillance of equipment performance and
ii | FLIGHT 60T 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 60T Ventilator warranty does not apply for/ in case of:
 Defects caused by misuse, mishandling, tampering, or by modifications not
authorized by FLIGHT MEDICAL or its representatives.
 Rubber and plastic components and materials, which are guaranteed to be free of
defects at time of delivery.
Any product which proves during the warranty period to be defective in workmanship
or material, will be replaced, credited, or repaired. FLIGHT MEDICAL retains the
discretion to select the most suitable of these options. FLIGHT MEDICAL is not
responsible for deterioration, wear, or abuse. In all cases, FLIGHT MEDICAL will not
be liable beyond the original selling price.
Application of this warranty is subject to the following conditions:
 FLIGHT MEDICAL or its authorized representatives must be promptly notified
upon detection of the defective material or equipment.
 Defective material or equipment must be returned to FLIGHT MEDICAL or its
authorized representative.
 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 60T Service Manual | iii
About this Document
About this Document
This document is a service manual for the FLIGHT 60T 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 60T and F60 Dual Limb Ventilators.
For information on how to use the FLIGHT 60T Ventilator, see the FLIGHT
60T Ventilator Operator's Manual.
Style Conventions
Convention
Used for
Verdana
Regular text.
Arial Bold
Names of labels, buttons, and other elements of the user interface.
Arial Italics
Special terms, the first time they appear.
Notes, which 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 60T Service Manual
Table of Contents
Table of Contents
1
2
3
INTRODUCTION ................................................................................. 1-1
1.1
INTENDED USE ................................................................................ 1-1
1.2
SYMBOLS ....................................................................................... 1-1
SAFETY INSTRUCTIONS ..................................................................... 2-1
2.1
GENERAL WARNINGS ......................................................................... 2-1
2.2
CAUTIONS ...................................................................................... 2-3
FUNCTIONAL DESCRIPTION ............................................................... 3-1
3.1
FRONT PANEL .................................................................................. 3-1
3.1.1 Keypad / Control Buttons ..................................................... 3-2
3.1.2 LED Indicators .................................................................... 3-3
4
3.2
LEFT SIDE PANEL.............................................................................. 3-4
3.3
RIGHT SIDE PANEL............................................................................ 3-5
3.4
BACK PANEL ................................................................................... 3-6
3.5
REMOTE ALARM CONNECTION ............................................................... 3-8
3.6
PNEUMATICS DIAGRAM ....................................................................... 3-9
3.7
ELECTRICAL DIAGRAM ....................................................................... 3-10
3.8
ELECTRICAL DIAGRAM – IO2 INTERNAL MIXER MODEL .................................. 3-11
REMOVING AND REINSTALLING MODULES ........................................ 4-1
4.1
INTRODUCTION ................................................................................ 4-1
4.2
REQUIRED EQUIPMENT ....................................................................... 4-1
4.3
REPLACING THE DETACHABLE BATTERY .................................................... 4-2
4.3.1 Removing the Detachable Battery ......................................... 4-2
4.3.2 Installing the Detachable Battery .......................................... 4-2
4.4
REPLACING THE INTERNAL BATTERY ........................................................ 4-2
4.4.1 Removing the Internal Battery .............................................. 4-2
4.4.2 Installing the Internal Battery ............................................... 4-3
4.5
REMOVING THE VENTILATOR COVER ........................................................ 4-3
4.5.1 Removing the Ventilator Cover ............................................. 4-3
4.5.2 Installing the Ventilator Cover .............................................. 4-6
4.6
REPLACING THE POWER BOARD ............................................................. 4-6
4.6.1 Removing the Power Board .................................................. 4-6
4.6.2 Installing the Power Board ................................................... 4-7
4.7
REPLACING THE POWER SUPPLY ............................................................. 4-9
4.8
REPLACING THE FRONT PANEL ASSEMBLY................................................. 4-10
4.8.1 Removing the Front Panel Assembly ..................................... 4-10
Flight 60T Service Manual | v
Table of Contents
4.8.2 Connecting the Front Panel Assembly ................................... 4-12
4.9
REPLACING THE O2 MIXER NEB BOARD * (IO2 INTERNAL MIXER MODEL ONLY) ...... 4-12
4.9.1 Removing the O2 mixer neb board ........................................ 4-12
4.9.2 Installing the O2 mixer board ............................................... 4-13
4.10 REPLACING THE MAIN BOARD .............................................................. 4-13
4.10.1 Removing the Main Board ................................................... 4-13
4.10.2 Installing the Main Board .................................................... 4-16
4.11 REPLACING THE TOUCH SCREEN ........................................................... 4-16
4.12 REPLACING THE BLOWER ASSEMBLY....................................................... 4-17
4.12.1 Removing the Blower Assembly ........................................... 4-17
4.12.2 Installing the Blower Assembly ............................................ 4-18
4.13 REPLACING THE OXYGEN SENSOR ......................................................... 4-18
4.13.1 Removing the Oxygen Sensor .............................................. 4-18
4.13.2 Installing the Oxygen Sensor ............................................... 4-19
4.14 REPLACING THE O2 LEAK SENSOR * (IO2 INTERNAL MIXER MODEL ONLY) ............ 4-19
4.14.1 Removing the O2 leak sensor ............................................... 4-19
4.14.2 Installing the O2 leak sensor ................................................ 4-19
4.15 REPLACING THE OXYGEN MIXER * (IO2 INTERNAL MIXER MODEL ONLY) .............. 4-20
4.15.1 Removing the Oxygen mixer ............................................... 4-20
4.15.2 Installing the Oxygen mixer ................................................ 4-20
4.16 REPLACING THE O2 MIXER FILTERS * (IO2 INTERNAL MIXER MODEL ONLY)........... 4-21
4.17 REPLACING THE PURGE BOARD ASSEMBLY ............................................... 4-22
4.17.1 Removing the Purge Board Assembly.................................... 4-22
4.17.2 Installing the Purge Board Assembly .................................... 4-22
4.18 REPLACING THE SOLENOID BOARD ASSEMBLY ........................................... 4-23
4.18.1 Removing the Solenoid Board Assembly ................................ 4-23
4.18.2 Installing the Solenoid Board Assembly................................. 4-24
4.19 REPLACING THE SOLENOID ASSEMBLY .................................................... 4-25
4.19.1 Removing the Solenoid Assembly ......................................... 4-25
4.19.2 Installing the Solenoid Assembly .......................................... 4-25
4.20 REPLACING THE LOWER BOARD AND D-TYPE BOARD.................................... 4-26
4.20.1 Removing the Lower Board and D-type Board ........................ 4-26
4.20.2 Installing the Lower Board and D-type Board ......................... 4-28
4.21 REPLACING THE FUSE........................................................................ 4-28
4.21.1 Removing the Fuse ............................................................ 4-28
4.21.2 Installing the Fuse ............................................................. 4-28
4.22 REPLACING THE RUBBER BUMPERS ........................................................ 4-29
4.22.1 Removing the Rubber Bumpers ............................................ 4-29
4.22.2 Installing the Rubber Bumpers............................................. 4-29
vi | FLIGHT 60T Service Manual
Table of Contents
5
6
7
SERVICE/TECHNICAL MENU............................................................... 5-1
5.1
ADVANCED SCREEN ........................................................................... 5-1
5.2
SERVICE SCREEN .............................................................................. 5-2
SOFTWARE UPGRADE ......................................................................... 6-3
6.1
INSTALLING THE SW UPGRADE .............................................................. 6-3
6.2
CALIBRATION INTEGRITY CHECK ............................................................. 6-3
CALIBRATION AND VERIFICATION TESTS ......................................... 7-5
REQUIRED EQUIPMENT ............................................................................... 7-5
7.1
CALIBRATION .................................................................................. 7-5
7.1.1 Pressure Sensors Calibration ................................................ 7-5
7.1.2 Pressure Relief Calibration .................................................... 7-8
7.1.3 Bias Flow Calibration ........................................................... 7-9
7.1.4 Oxygen Sensor Calibration .................................................. 7-10
7.1.5 O2 Leak Sensor calibration* (iO2 Internal mixer model only) .... 7-11
7.2
OPERATIONAL VERIFICATION PROCEDURE (OVP) ....................................... 7-12
7.2.1
Standard Ventilator Settings (STS) ....................................... 7-12
7.2.2 Front Panel Self Test .......................................................... 7-12
7.2.3 Circuit Test ....................................................................... 7-13
7.2.4 Volume verification ............................................................ 7-14
7.2.5 Pressure Verification ........................................................... 7-14
7.2.6 Bias Flow .......................................................................... 7-15
7.2.7 PEEP ................................................................................ 7-15
7.2.8 Pressure Trigger ................................................................ 7-16
7.2.9 Exhalation Valve Leak ......................................................... 7-17
7.2.10 High Pressure Alarm ........................................................... 7-18
7.2.11 Battery /Charger /Power Supply .......................................... 7-19
7.2.12 Buzzer Test ....................................................................... 7-20
7.2.13 Oxygen Calibration Test ...................................................... 7-20
7.2.14 Nebulizer compensation test * (iO2 Internal mixer model only) 7-21
7.2.15 OVP Test Results................................................................ 7-22
7.3
8
9
TEST TABLE ................................................................................... 7-24
MAINTENANCE ................................................................................... 8-1
8.1
SCHEDULED MAINTENANCE................................................................... 8-1
8.2
DOWNLOAD LOG FILES ....................................................................... 8-1
TROUBLESHOOTING GUIDE ............................................................... 9-3
9.1
INTRODUCTION ................................................................................ 9-3
9.2
ERROR MESSAGES ............................................................................ 9-3
10 REPACKAGING AND SHIPPING ........................................................ 10-1
RGA RETURNS ....................................................................................... 10-1
11 SPARE PARTS ................................................................................... 11-2
Flight 60T Service Manual | vii
Table of Contents
11.1 ELECTRONIC .................................................................................. 11-2
11.2 MECHANICAL / ASSEMBLIES ................................................................ 11-5
11.3 CABLES ........................................................................................ 11-8
viii | FLIGHT 60T Service Manual
Introduction
Intended Use
1 Introduction
This Service Manual (V60-00002-18 Rev. A) provides information for servicing the
FLIGHT 60T Ventilator. It is for use by authorized service personnel while installing,
servicing, and repairing the ventilator.
1.1 Intended Use
The FLIGHT 60T Ventilator is intended to provide continuous or intermittent
mechanical ventilation support for the care of individuals who require mechanical
ventilation. Specifically, the FLIGHT 60T 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
Flight 60T Service Manual | 1-1
Introduction
Symbols
Symbol
Description
Extended Screen
Technical Screen
Nebulizer Port
Rear Panel
Caution; consult accompanying documents
Type BF applied part
Temperature limitation
Humidity limitation
Atmospheric pressure limitation
DC – Direct Current
AC – Alternating Current
USB – Universal Serial Bus
LAN – Local Area Network
High Pressure and Low-Flow Oxygen Port
1-2 | FLIGHT 60T Service Manual
Safety Instructions
General Warnings
2 Safety Instructions
At all times, strictly follow this manual. The safe use of the FLIGHT 60T 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 60T Ventilator and associated accessories.
2.1 General Warnings
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.
All settings and adjustments in the different ventilation modes must be made
in accordance with a physician's prescribed therapy.
Do not use electrically conductive patient circuits.
Always use a clean, disinfected patient circuit.
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.
Failure to identify and correct alarm violations may result in patient injury.
Flight 60T Service Manual | 2-1
Safety Instructions
General Warnings
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.
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 power.
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.
Charge the batteries for a minimum of three hours before powering the
ventilator from the batteries. This provides fully charged batteries.
During storage, charge the batteries for a minimum of three hours every 30
days. This provides charged batteries.
Always ensure that the green Ext. Power LED is illuminated after connecting
the FLIGHT 60T Ventilator to an external AC or DC power source. If the LED is
not illuminated, check all power connections and resolve any problems.
Always plug the FLIGHT 60T Ventilator into an AC power supply source when
not in use, to ensure best battery performance.
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.
Only a FLIGHT MEDICAL approved patient circuit can be used with the FLIGHT
60T Ventilator.
2-2 | FLIGHT 60T Service Manual
Safety Instructions
Cautions
Only a FLIGHT MEDICAL approved exhalation valve can be used with the
FLIGHT 60T Ventilator.
Perform a Circuit Test each time a clean circuit/exhalation valve is installed.
This FLIGHT 60T 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.
2.2 Cautions
Only use medical grade oxygen with the Air/Oxygen Entrainment Mixer or
Oxygen Blending Bag Kit.
Do not place liquid containers in the immediate vicinity or on top of the FLIGHT
60T Ventilator. Liquids that get into the ventilator can cause equipment
malfunction and damage.
After the FLIGHT 60T Ventilator is serviced, it must completely pass an
Operational Verification Procedure (OVP) before being returned to patient use.
Flight 60T Service Manual | 2-3
Safety Instructions
Cautions
An authorized FLIGHT MEDICAL factory-trained technician must do all service
or repairs performed on the FLIGHT 60T Ventilator.
Do not open the ventilator or perform service on an open unit while connected
to external power.
Use standard antistatic techniques while working inside the ventilator or
handling any electronic parts.
Clean all external accessories of the ventilator prior to servicing.
Water in the oxygen supply can cause equipment malfunction and damage.
Batteries contain Li-Ion. Do not discard them in an incinerator or force them
open. Batteries should not be disposed of with normal waste.
Use the tools and equipment specified in this manual to perform specific
procedures.
2-4 | FLIGHT 60T 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.
Figure 1 – Front Panel
Label
Name
Description
1
Patient Circuit Connector
Composed of a gas outlet and quick connector.
2
+/- button
Enables the user to adjust setting parameters.
3
Panel Lock button
Enables the user to lock the ventilator’s control, preventing
accidental changes. Pressing the button of a locked panel and
then Enter, unlocks the panel.
4
On/Off button
Turns the ventilator on or off, to start or stop ventilation.
5
Manual Breath button
Delivers a user initiated manual inflation.
6
Audio Paused / Alarm Reset
Toggle button. Pressing Audio Paused temporarily silences the
button
audible alarm; pressing Alarm Reset clears lit alarm LEDs.
Flight 60T Service Manual | 3-1
Functional Description
Front Panel
Label
Name
Description
7
Pressure Gauge
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
+20 cmH2O, each notch equals 2 cmH2O; from 20 to
50 cmH2O, each notch equals 5 cmH2O; above 50 cmH2O,
each notch equals 10 cmH2O.
8
Display touch screen
Enables the user to modify the ventilation, alarm, and
technical settings, and to view real time patient data, alarms,
battery status and logs.
9
LED Indicators
Inform the user of various events.
10
Primary Alarm LED
Flashes red to indicate that there is a high priority alarm.
11*
Dual Limb Exhalation Valve
Connects the patient circuit expiratory limb.
(DL model only)
12**
Nebulizer Port (iO2 Internal
Connects to the pneumatic nebulizer.
mixer model only)
3.1.1
Keypad / Control Buttons
Figure 2 – Keypad / Control buttons
Item
Symbol
Description
1 – Parameters
The Parameters screen is the Flight 60T's default screen.
(home)
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.
2 - Manual Breath
3-2 | FLIGHT 60T Service Manual
Delivers a user initiated manual inflation.
Functional Description
Front Panel
Item
Symbol
3 – Panel Lock
Description
Enables the user to lock the ventilator’s control, preventing
accidental changes. Pressing the button of a locked panel
and then Enter, unlocks the panel.
4 – Cancel
Enable the user to cancel parameters change.
5 – Increase
Enables the user to adjust setting parameters upwards.
Button
6 – Decrease
Enables the user to adjust setting parameters downwards.
Button
7 – OK (Enter)
Enable the user to confirm parameters or mode change.
8 – On/Off
Turns the ventilator on or off, to start or stop ventilation.
9 – Alarm Reset
The Alarm Reset silences the audible alarm and clears lit
alarm LEDs.
10 – Technical
Technical data and selection options.
11 – Extended
Additional ventilation parameters screen.
3.1.2 LED Indicators
The LED indicators on the front panel inform the user of various events.
The following table describes the available LED indicators.
LED Indicator
Description
TRIG
Green LED indicates a patient’s breathing effort.
EXT PWR
Yellow LED indicates that an external power source is being applied to the ventilator.
LOW BAT
Red LED indicates 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.
Flight 60T Service Manual | 3-3
Functional Description
Left Side Panel
3.2 Left Side Panel
Figure 3 – Left Side Panel
Label
Name
Description
1
Emergency Air Intake
Enables the patient to pull ambient air into the patient circuit in the
event of a complete system failure. The Air Intake opening pressure
is approximately -3 cmH2O (-3 mbar).
3-4 | FLIGHT 60T Service Manual
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 60T Ventilator Air/Oxygen Entrainment Mixer
or Oxygen Blending Bag.
Flight 60T Service Manual | 3-5
Functional Description
Back Panel
3.4 Back Panel
Figure 5 – Back Panel
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 V DC
4
RS-232 Serial Port (COM2)
Remote alarm connector (Normally Open and Normally Closed
options).
5
RS-232 Serial Port (COM1)
Online output of events and error messages to the PC, using a
dedicated PCS2 protocol; for authorized and qualified service
technicians only.
6
USB B type
PC connector: USB port for downloading the main application
from the PC using a dedicated PCS2 protocol; for authorized
and qualified service technicians only.
3-6 | FLIGHT 60T Service Manual
Functional Description
Label
Name
Description
7
USB A type
USB port for uploading LOG files to an external memory stick;
for authorized and qualified service technicians only.
8
LAN (RJ45)
LAN for network logging (currently not available).
9
Mini RS-485 (COM3)
For connecting FLIGHT MEDICAL peripherals. For future use.
10
Low Flow Oxygen Port
Low flow oxygen enrichment source.
11*
High Pressure O2 Port (iO2
Connects to high pressure O2.
Internal mixer model only)
Flight 60T Service Manual | 3-7
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).
 Normally Open – Pin 7 – closing the contacts to transmit an alarm.
 Normally Closed – Pin 8 – opening the contacts to transmit an alarm.
The dry contacts current should not exceed 1mA.
The voltage on the contacts must be lower than 12 Volts.
Remote Alarm Electrical schematics
The legal and regulatory responsibility for this integration of the Flight
60T device into any external system lays on the integrator and not the
Flight 60T 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 device and will void its warranty.
3-8 | FLIGHT 60T Service Manual
Functional Description
Pneumatics Diagram
3.6 Pneumatics Diagram
Flight 60T Service Manual | 3-9
Functional Description
Electrical Diagram
3.7 Electrical Diagram
3-10 | FLIGHT 60T Service Manual
Functional Description
Electrical Diagram – iO2 Internal Mixer model
3.8 Electrical Diagram – iO2 Internal Mixer model
Flight 60T Service Manual | 3-11
Removing and Reinstalling Modules
Introduction
4 Removing and Reinstalling Modules
4.1 Introduction
This chapter provides detailed procedures on how to remove FLIGHT 60T 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 60T Ventilator's operation
before attempting any service or maintenance.
Ventilator log files must be downloaded prior to any service attempt.
Refer to the Maintenance chapter for instructions.
Hazardous voltages are present inside the ventilator. Disconnect
electrical power and oxygen sources before attempting any
disassembly. Remove watch and any jewelry. Failure to do so may
result in injury to service personnel or damage to the ventilator.
4.2 Required Equipment
The following equipment is required to remove and replace FLIGHT 60T ventilator
modules:
 Antistatic wrist strap
 Phillips screwdriver PH1
 Flat screwdriver 0.8x4
 Torx screwdriver BT10x200
 Cutter
 Cable ties: PLT1M-M69; PLT4S-M69
To protect external parts and the touch screen from any damage while in
contact with the working surface, place the ventilator on a cushioned surface
while it is being serviced.
After servicing the ventilator modules, refer to the Test Table in the Operational
Verification Procedure (OVP) chapter and perform the necessary Operation
Verification Tests.
Flight 60T Service Manual | 4-1
Removing and Reinstalling Modules
Replacing the Detachable Battery
4.3 Replacing the Detachable Battery
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 6 – 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 60T Service Manual
Removing and Reinstalling Modules
Removing the Ventilator Cover
Figure 7 – 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:
 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 order to access the ventilator modules.
To remove the ventilator cover:
1. Remove the two Torx screws inside the ventilator handle.
Flight 60T Service Manual | 4-3
Removing and Reinstalling Modules
Removing the Ventilator Cover
Figure 8 – Removing Screws Inside Handle
2. Remove the two Torx screws connecting the ventilator cover to the back panel.
Figure 9 – Removing Back Screws
3. Remove the two Torx screws from the bottom panel.
4-4 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Removing the Ventilator Cover
Figure 10 – Removing the Bottom Panel Screws
4. Remove the ventilator cover.
The modules of the ventilator are now exposed and accessible.
Figure 11 – Removing the Ventilator Cover
Cover screws are longer than the rest of the screws used in the ventilator
Flight 60T Service Manual | 4-5
Removing and Reinstalling Modules
Replacing the Power Board
4.5.2 Installing the Ventilator Cover
To reattach the ventilator cover:
 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).
3. Disconnect the flat flex cable (1), connectors 2, 3, 4 from the power board
Figure 12 – Disconnecting the Power Board
4. Remove the Torx screw (5) connecting the power board to its bracket.
Do not hold the power board by its components. To pull the board out,
hold the grooves. Refer to the figure below for correct positioning.
4-6 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Power Board
Figure 13 – Lifting Power Board from Ventilator Base
4. 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.
4.6.2 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 14 – Power Board Slots and Tracks
Flight 60T Service Manual | 4-7
Removing and Reinstalling Modules
Replacing the Power Board
Figure 15 – 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.
Figure 16 – Pushing Power Board into Ventilator Base
4. Perform steps 1 to 6 of the removal procedure in the reverse order.
4-8 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Power Supply
4.7 Replacing 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 Blower motor cable from the cable clamps on the power supply.
4. Disconnect the 2 cables from the Power Supply:
Figure 17 – Power Supply cables
Disconnect the output cable from the Power Board first. Use flat/needle nose
pliers to gently pull out the connector from the Power Supply
5. Remove the 4 Torx screws securing the bracket
Figure 18 – Securing screws
6. Remove the 4 Philips screws securing the bracket to the Power Supply
Flight 60T Service Manual | 4-9
Removing and Reinstalling Modules
Replacing the Front Panel Assembly
Figure 19 – Detaching the Power Supply from Its Bracket
To install the power supply:
Follow the above procedure in reverse order
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).
3. Disconnect the flat flex cable P16 from the Main Board.
Figure 20 – 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.
4-10 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Front Panel Assembly
Figure 21 – Loosening the Torx Screws Under the Front Panel
5. Remove the Torx screws from the front panel brackets (one on each side).
Carefully slide the front panel outwards to allow access to electrical cables and
silicon tubes.
Figure 22 – Torx Screws on Front Panel Bracket
For iO2 Internal Mixer model
6. Disconnect the 2 silicon tubes from the O2 mixer neb board.
7. Disconnect the nebulizer cable from the O2 mixer neb board.
8. Disconnect the mixer cable from the O2 mixer neb board.
9. Disconnect the O2 leak sensor cable from the O2 mixer neb board.
Flight 60T Service Manual | 4-11
Removing and Reinstalling Modules
Replacing the O2 mixer Neb board * (iO2 Internal mixer model only)
Figure 23 – Disconnecting from O2 mixer neb board
10. Disconnect the 3 silicon tubes coming from the main board. Note the color coding.
Disconnect them from the Y connectors and not from the board itself.
11. Disconnect the Blower cable.
12. Disconnect the solenoid board flat cable.
13. Disconnect the O2 sensor cable.
14. Remove the front panel from the ventilator.
4.8.2 Connecting the Front Panel Assembly
To connect the front panel assembly:
 Follow the above procedure in reverse order.
4.9 Replacing the O2 mixer Neb board * (iO2 Internal mixer
model only)
4.9.1 Removing the O2 mixer neb board
To remove the O2 mixer neb board:
1.
Follow the procedures for removing the front panel assembly (see section 4.8 )
2.
remove the 3 screws securing the O2 mixer Neb board to the Main Board.
4-12 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Main Board
Figure 24 – Securing screws
3.
Pull the mixer board out of the connector .
4.9.2 Installing the O2 mixer board
To connect the O2 mixer board:
 Follow the above procedure in reverse order.
4.10
Replacing the Main Board
Record system S/N, Blower S/N and motor hours prior to replacing the main
board. After replacing the board need to update the SW with those numbers,
as described in chapter 8.
4.10.1 Removing the Main Board
To remove the main board:
1. For iO2 internal mixer model - Follow the procedure for Removing the O2 mixer
neb board (see section 4.9)
2. Remove the 6 Torx screws holding the Main Board to the front panel
3. On the bottom side of the Main Board, disconnect buzzer connectors LS1 and LS2.
4. Disconnect the back light cable from connector P5.
Do not pull the wires. Press the locker and then remove.
Flight 60T Service Manual | 4-13
Removing and Reinstalling Modules
Replacing the Main Board
LS1
P5
LS2
Figure 25 – LS1; LS2; P5 connectors
Figure 26 – Disconnecting LS2 connector
5. Disconnect the P13 flat cable by pressing hard on the locker and then pulling it
out.
4-14 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Main Board
Figure 27 – Disconnecting the P13 Flat Cable
6. Remove the six Philips screws securing the Main Board to the front panel.
Figure 28 – Detaching the Main Board from the Front Panel
7. Remove the grounding screw at the top left of the board.
Flight 60T Service Manual | 4-15
Removing and Reinstalling Modules
Replacing the Touch Screen
Figure 29 – Detaching the Grounding Screw
8. Lift the Main Board. Carefully detach the flat cables from the connectors on the
main board.
10. Remove the Main Board.
Do not remove the silicon tubes from the main board when it is sent for repair.
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:
 Perform the above procedure in reverse order.
4-16 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Blower Assembly
4.12
Replacing the Blower Assembly
4.12.1 Removing the Blower Assembly
To remove the blower assembly:
1. Remove the detachable battery (see section ‎4.3) and the internal battery (see
section ‎4.4).
2. Remove the ventilator cover (see section ‎4.5).
3. Disconnect the blower cable from the front panel assembly.
4. Disconnect the blower cable from the power board.
5. Disconnect the internal mixer tubing *(for IO2 models only – see Figure 30)
6. Disconnect the Inlet and outlet silicon hoses (see Figure 30)
Figure 30 – Blower disconnection
7. Remove the 6 screws (3 on each side) securing the blower to the base – see
Figure 31.
Flight 60T Service Manual | 4-17
Removing and Reinstalling Modules
Replacing the Oxygen Sensor
Figure 31- Blower screws
8. Remove the blower
4.12.2 Installing the Blower Assembly
To install a Blower assembly:
 Perform the removal procedure in the reverse order.
4.13
Replacing the Oxygen Sensor
Refer to Flight Medical Service Notes for a list of approved Oxygen
sensors
4.13.1 Removing the Oxygen Sensor
To remove the oxygen sensor:
1. Remove the detachable battery (see section ‎4.3) and the internal battery (see
section ‎4.4).
2. Remove the ventilator cover (see section ‎4.5).
3. Remove the front panel (see section ‎4.8).
4. Disconnect the electrical cable from the oxygen sensor.
4-18 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Figure 30 – 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:
 Follow the above procedure in reverse order.
4.14 Replacing the O2 leak sensor * (iO2 Internal mixer
model only)
4.14.1 Removing the O2 leak sensor
To remove the O2 leak sensor:
1. Remove the ventilator cover (see section ‎4.5).
2. Disconnect the electrical cable from the O2 leak sensor.
3. Turn the O2 leak sensor counterclockwise until it comes out.
4.14.2 Installing the O2 leak sensor
To install the oxygen sensor:
 Follow the above procedure in reverse order.
Flight 60T Service Manual | 4-19
Removing and Reinstalling Modules
Replacing the Oxygen mixer * (iO2 Internal mixer model only)
4.15 Replacing the Oxygen mixer * (iO2 Internal mixer
model only)
4.15.1 Removing the Oxygen mixer
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).
3. Remove the Power Supply and the power supply base plate + the solenoid (see
section 4.7).
4. Remove the O2 leak sensor
5. Remove the 2 silicon tubes and disconnect the Nebulizer & O2 Mixer cables from
the O2 mixer Neb board
6. Gently pull out the O2 mixer
Figure 31 – Pulling out the mixer
4.15.2 Installing the Oxygen mixer
To install the oxygen mixer:
 Follow the above procedure in reverse order. Make sure the flat surface of the
mixer is aligned with the metal bracket.
4-20 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the O2 mixer filters * (iO2 Internal mixer model only)
Figure 32 – Mixer orientation
4.16 Replacing the O2 mixer filters * (iO2 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 O2 input and push all the way in
4. Push the O-ring in, verify it's in the groove, securing the filters in place
Figure 33 – O2 regulator filter
Flight 60T Service Manual | 4-21
Removing and Reinstalling Modules
Replacing the Purge Board Assembly
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).
2. Remove the ventilator cover (see section ‎4.5).
3. 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.
Figure 34 – Disconnecting the Check Valves
5. 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.
6. 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.
4-22 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Solenoid Board Assembly
4.18
Replacing the Solenoid Board Assembly
4.18.1 Removing the Solenoid Board Assembly
To remove the solenoid board assembly:
1. Remove the detachable battery (see section ‎4.3) and the internal battery (see
section ‎4.4).
2. Remove the ventilator cover (see section ‎4.5).
3. Remove the front panel (see section ‎4.8).
4. Remove the purge board (see section ‎0).
5.
Disconnect connector P1 and the flat cable from the solenoid board.
Figure 35 – Solenoid board connectors
6. Remove the silicon tubes from the fittings on the redundancy solenoid.
Flight 60T Service Manual | 4-23
Removing and Reinstalling Modules
Replacing the Solenoid Assembly
Figure 36 – 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.
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 37 – Connecting the Silicon Tubes
4-24 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Solenoid Assembly
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 iO2 internal mixer model - Remove the O2 leak sensor.
3. Remove the 2 screws securing the O2 leak sensor bracket. Remove the bracket.
Figure 40 – Remove O2 leak sensor bracket
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 front
panel so gain better access.
5. Disconnect the 3 silicon tubes from the solenoid assembly.
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
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.
Flight 60T Service Manual | 4-25
Removing and Reinstalling Modules
Replacing the Lower Board and D-type Board
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).
2. Remove the ventilator cover (see section ‎4.5).
3. Remove the front panel assembly (see section ‎4.8).
4. Remove the Power board (see section 4.6)
5. Remove the Power Supply and its base plate (see section 4.7)
6. Remove the internal O2 mixer (see section 4.15)
7. Remove the Blower assembly (see section 4.11)
9. Unscrew the 2 Torx screws (plastic washers) securing the Outlet assembly.
Remove the Outlet assembly.
Figure 41 – Removing the Outlet assembly
10. Disconnect connectors P5, P6 and P7 from the lower board
4-26 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Lower Board and D-type Board
Figure 38 – 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
Figure 39 – Removing the Lower Board and D-type Board
13. Disconnect the D-type board from the Lower board
Flight 60T Service Manual | 4-27
Removing and Reinstalling Modules
Replacing the Fuse
D-type Board
Lower Board
Figure 40 – D-type and Lower boards
4.20.2 Installing the Lower Board and D-type Board
To install the Lower and D-type boards:
 Follow the above procedure in reverse order.
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.
4.21.2 Installing the Fuse
To install the fuse:
Reposition the fuse housing (flat edge on the left) and press firmly to make sure that
it is inserted completely.
4-28 | FLIGHT 60T Service Manual
Removing and Reinstalling Modules
Replacing the Rubber Bumpers
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.
Figure 41 – 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.
Flight 60T Service Manual | 4-29
Service/Technical Menu
Advanced Screen
5 Service/Technical Menu
To enter the Service/Technical menu:
1. Press Technical /
2. Press ADVANCED Screen.
3. Enter the code 5844, and confirm by pressing

5.1 Advanced Screen
Button
Options
Description
Enable B-LEVEL
ON/OFF
Enable/Disable B-LEVEL ventilation mode
Enable O2 mixer
O2 Only
O2+Neb.
OFF
Nebulizer is disabled
Mixer + Nebulizer
Additional Config
Quick Start
Customized BUV
Enable/Disable quick start buttons
Enable/Disable Customized Back Up
Ventilation
Screen Intensity
Value
Increase/decrease the screen intensity
Language
Choosing 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 60T Service Manual | 5-1
Service/Technical Menu
Service Screen
5.2 Service Screen
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
Calibrate Relief
Activate Over pressure relief valve calibration
SERVICE
Change serial numbers and working hours
Enter the code 2009, confirm by pressing
Factory Defaults

Default calibration parameters, to recover
from calibration data corruption.
Enter the code 2009, confirm by pressing
Neb. Comp.
*
Calibrate O2 Leak
Bar Intensity
Value
*

Volume compensation when nebulizer is on.
Leak sensor calibration
Single/Full
Number of lit LEDs in the ventilator’s pressure
gauge
* iO2 INTERNAL MIXER MODEL ONLY
5-2 | FLIGHT 60T Service Manual
Software Upgrade
Installing the SW upgrade
6 Software Upgrade
Required equipment:

USB storage device with the SW version (.pkg file)
Software upgrade will not run if the batteries are charged below
50%.
6.1 Installing the SW upgrade
1. Turn off the ventilator, disconnect from AC.
2. Copy the new SW version (.pkg file) to a USB storage device.
3. Plug the USB storage device to the vent USB port.
4. Connect the ventilator to AC.
5. The ventilator powers up and a software update screen opens, displaying the
current version and the new version to update.
6. Press OK on the touch screen.
7. Once upgrade is done, the ventilator displays " Finished updating, please remove
DOK"
8. Remove the USB storage device and press OK on the touch screen.
9. Turn on the ventilator, press Technical /
and press Show Info.
10. Verify the new software version is displayed.
6.2 Calibration integrity check
1. Set the ventilator to the same ventilation modes:

ACMV

VCV = 500 mL

PEEP = 5

P trig = -5.0

Rate = 15

Ti = 1

O2 = 80%

Waveform = Square
2. Connect to a patient circuit. Perform circuit test.
3. Start ventilation.
Flight 60T Service Manual | 6-3
Software Upgrade
Calibration integrity check
4. Verify the following:
Vti
Within the 450-550 spec.
Pbase
5 ± 1cm H2O
O2
72% - 88% for External O2 Mixer.
76% - 84% for Internal O2 mixer (iO2) model
5. If any of those values is out of spec, perform the appropriate calibration and
check again.
6-4 | FLIGHT 60T Service Manual
Calibration and Verification tests
Required Equipment
7 Calibration and Verification tests
Required Equipment

Adult test lung specified up to 90cm H2O with adjustable lung compliance of
C=10;20;50

Pressure/flow analyzer, specified to 120cm H2O, accuracy of 0.1 cmH2O

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) – for non IO2 models.
7.1 Calibration
7.1.1 Pressure Sensors Calibration
To calibrate the pressure sensors:
1. Connect the ventilator to an external pressure meter using a reusable patient
circuit.
2. Connect the pressure meter to the test lung.
3. Use the following settings for the test lung:
 C = 10
 Rp = 5
4. Press Technical /
and then press ADVANCED Screen.
5. Enter the code 5844, and confirm by pressing

6. Press SERVICE SCREEN
7. Disconnect the patient circuit from the ventilator to verify there is no pressure
buildup in the circuit. Reconnect the circuit to the ventilator
8. Press Calibrate Pressure and then Enter /
pressure.
. The ventilator starts to build
Flight 60T Service Manual | 7-5
Calibration and Verification tests
Calibration
9. The following screen opens:
10. Check the Patient Pressure and Outlet Pressure values, verify the following:
 Values match the pressure measurement of the external pressure meter.
 Values are between 45 and 75 cmH2O.
 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 cmH2O
range, continue to step 2.
If the pressure is less than 50 cmH2O:

Press Cancel /
.

Press Calibrate Pressure again. The calibration screen will come up with the
following message " You can set the solenoid and motor commands for
pressure sensor" and displays default values of 65 200.

Use the UP /
and DOWN /
buttons to change the solenoid command (
initial value of 65) or Manual Breath /
and Panel lock /
motor command (initial value of 200) and press Enter/
buttons to change
.

Verify that the pressure on the external pressure meter is in the 50-75 cmH2O
range. If not then repeat the above steps until the pressure is the correct
range.

Continue to step 2.
2. Use the UP /
and DOWN /
buttons to change the External measurement value
of 60 to the actual pressure reading of the external pressure meter.
7-6 | FLIGHT 60T Service Manual
Calibration and Verification tests
Calibration
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:
 Values match the pressure measurement of the external pressure meter.
 Values are between 50 and 75 cmH2O.
 The difference between the Patient Pressure and Outlet Pressure values is no
more than 0.1.
6. Press Cancel /
to exit.
If the test fails:
1. Replace patient circuit and redo calibration.
2. Do one of the following:
 If the external measurement lower than 50:
Check internal tubing connections for air leaks.
Replace the solenoid and redo calibration.
 If the external measurement higher than 75:
Check internal tubing connections for blocking.
Replace the solenoid and redo calibration.
 If the patient pressure / outlet pressure difference is more than
0.1cmH2O:
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 (see ‎4.19). Perform the required
calibrations (see ‎7.3 Test table).

Replace the Main Board (see ‎4.10). Perform the required
calibrations (see ‎7.3 Test table).
Flight 60T Service Manual | 7-7
Calibration and Verification tests
Calibration
7.1.2 Pressure Relief Calibration
To calibrate the pressure-relief mechanism:
1. Connect the ventilator to the test lung using a patient circuit
2. Set the test lung to minimum compliance
3. Press Technical /
and then press ADVANCED Screen.
4. Enter the code 5844, and confirm by pressing

5. Press SERVICE SCREEN
6. Press Calibrate Relief and then Enter /
to start the motor.
7. Verify that there is no air leakage from the exhalation valve. Air should only be
coming out via the pressure-relief valve.
8. Verify that the displayed pressure reading is between 105 and 120 cmH2O.
9. If the pressure is not within this range, adjust the Relief valve:
 While the calibration is running, place the ventilator in a way that the
calibration screw is accessible from below (Refer to picture Figure 42 –
Adjusting the Pressure Relief Valve below).
 Use a Philips screwdriver to adjust the relief valve by tightening or
loosening the calibration screw located on the underside of the outlet
fitting.
Figure 42 –Adjusting the Pressure Relief Valve
10. Press Enter /
to confirm the reading and to complete the calibration.
If the calibration screw on the pressure-relief valve was adjusted, repeat the
calibration of the pressure sensors.
If the test fails:
 Check internal tubing connections.
7-8 | FLIGHT 60T Service Manual
Calibration and Verification tests
Calibration
7.1.3 Bias Flow Calibration
To calibrate the Bias Flow:
1. Connect the circuit to the ventilator.
2. Remove the flow sensor from the end of the patient circuit. Connect a test lung
to the patient circuit.

On an SL ventilator, connect the flow sensor to the exhalation valve as per
the following picture.

On a DL ventilator, connect the flow sensor to the DL exhalation valve.
3. Press Technical /
and then press ADVANCED Screen.
4. Enter the code 5844, and confirm by pressing

5. Press SERVICE SCREEN
6. Press Calibrate Bias Flow and then press the Manual Breath /
displayed value to stabilize at 15.
7. Press Enter /
. Wait for the
.
8. Repeat the Bias Flow calibration (steps 5-6) once more.
Flight 60T Service Manual | 7-9
Calibration and Verification tests
Calibration
If the test fails:
1.
Check internal tubing connections for air leaks.
2. Run the following tests:
 Pressure sensor calibration
 Circuit test
 Pressure relief calibration
7.1.4 Oxygen Sensor Calibration
To calibrate the Oxygen sensor:
For iO2 internal mixer model
1.
Connect a high pressure oxygen hose to the High Pressure O2 port
2.
Connect a calibrated Oxygen Analyzer to the ventilator's outlet.
3.
Connect a patient circuit.
4.
Press Technical /
5.
Enter the code 5844, and confirm by pressing
6.
Press SERVICE SCREEN
7.
Press Calibrate FiO2.
8.
Choose USED if calibrating the current sensor, NEW if O2 sensor is replaced.
9.
The ventilator performs 21% calibration. Verify the external Oxygen analyzer
reads 21%, wait 1 minute and press Enter /
.
and then press ADVANCED Screen.

10. The ventilator switches to 100% automatically. Verify the external Oxygen
analyzer reads 100%, wait 1 minute and press Enter /
.
For External mixer model
1. Connect the Air/Oxygen Entrainment Mixer to an Oxygen source. Install the
Air/Oxygen Entrainment Mixer on the ventilator’s air inlet.
2. Set the regulator on the oxygen source to 50 PSI.
3. Connect a calibrated Oxygen Analyzer to the ventilator's outlet.
4. connect a patient circuit
5. Press Technical /
and then press ADVANCED Screen.
6. Enter the code 5844, and confirm by pressing
7-10 | FLIGHT 60T Service Manual

Calibration and Verification tests
Calibration
7. Press SERVICE SCREEN
8. Press Calibrate FiO2.
9. Choose USED if calibrating the current sensor, NEW if O2 sensor is replaced.
10. Set the Entrainment Mixer dial to AIR.
11. Once the external Oxygen sensor displays 21%, wait 1 minute and then press
Enter /
.
12. Set the Entrainment Mixer dial to 100%.
13. Once the external Oxygen sensor displays 100%, wait 1 minute and then press
Enter /
.
7.1.5 O2 Leak Sensor calibration* (iO2 Internal mixer model only)
To calibrate the O2 leak sensor:
1. Disconnect the ventilator from any Oxygen source.
2. Connect a calibrated Oxygen Analyzer to the ventilator's outlet. Don't connect
a patient circuit!
3. Press Technical /
and then press ADVANCED Screen.
4. Enter the code 5844, and confirm by pressing

5. Press SERVICE SCREEN.
6. Press Calibrate O2 Leak. The system will be flushed with ambient air.
7. Wait 1 minute. Use the UP /
and DOWN /
buttons to match the displayed
value with the external Oxygen analyzer reading.
8. Press Enter /
Flight 60T Service Manual | 7-11
Calibration and Verification tests
Operational Verification Procedure (OVP)
7.2 Operational Verification Procedure (OVP)
7.2.1 Standard Ventilator Settings (STS)
Refer to the following specifications whenever STS settings are called for:

ACMV

VCV = 500 mL

PEEP = 0

P trig = -1.0

Rate = 15

Ti = 1

Waveform = Square
For test lung:

Rp=5

C = 50 mL / cmH2O
7.2.2 Front Panel Self Test
To run the self test:
1.
Connect the ventilator to AC power.
2. Press the On Off /
button on the front panel.
3. During the self test that begins automatically, check for the following:
 Short audible beep
 All LEDs on the LED indicator light up with the same intensity, with the
following colors:
Description
Colour
TRIG (Pressure trigger)
Green
EXT PWR (External power)
Yellow
LOW 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
7-12 | FLIGHT 60T Service Manual
Calibration and Verification tests
Operational Verification Procedure (OVP)
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
 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
7.2.3 Circuit Test
Each time the Exhalation Valve or patient circuit is replaced or serviced, it must
be tested.
To test the patient circuit / exhalation valve:
1.
Connect the patient circuit to a 0.5L test lung.
2. Press Technical /
3. Press Enter /
, and then press Circuit TEST.
.
4. The test is done automatically. Checking 3 PEEP points – 20; 10; 5
5. If the test is successful, the display shows a Test PASSED message
Flight 60T Service Manual | 7-13
Calibration and Verification tests
Operational Verification Procedure (OVP)
If the test fails:
1. Press Cancel /
.
2. Replace the patient circuit. In case of a Flight60 DL check the exhalation valve
diaphragm.
3. Perform the calibration again.
4. Check internal tubing connections for air leaks.
5. Replace the solenoid and perform the required calibrations (see ‎7.3 Test table).
7.2.4 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 Volume factor calibration
7.2.5 Pressure Verification
To test the device for pressure:
1. Set the ventilator to STS settings.
2. Connect a pressure meter between the ventilator and the test lung.
3. Use the following settings for the test lung:
 C = 50
 Rp = 5
4. Activate ventilation.
5. Set Ti = 2.
6. Verify that the external pressure meter reading and the PIP value displayed on the
ventilator differ by no more than 2 cmH2O or 10%. (The higher of the two can be
used for this determination.)
If the test fails:
Repeat the following:
 Pressure sensors calibration
7-14 | FLIGHT 60T Service Manual
Calibration and Verification tests
Operational Verification Procedure (OVP)
 Pressure relief calibration
 Volume factor calibration
 Circuit Test
7.2.6 Bias Flow
To test the Bias Flow:
1. Set the test lung to compliance of 20ml/cmH2O, resistance 20
2. Set the ventilator to STS, P trig =-3; Rate = 8; PEEP = 5; Bias Flow = OFF
3. Connect a Flow meter between the patient circuit and the exhalation valve.
4. Start ventilation. Verify that the Flow meter is not measuring more than 7 L/m
5. Set Bias Flow = ON
6. Verify that the Flow meter presents a stable value between 10-30.
7. Set PEEP = 10.
8. Verify that the Flow meter presents a stable value between 10-30.
9. Set Bias Flow = OFF.
10. Verify that the Flow meter is not measuring more than 7 L/m.
If the test fails:
1. Perform Bias Flow calibration
7.2.7 PEEP
To test the PEEP:
1. Use the following settings for the test lung:
 C = 50
 Rp = 5
 If a test lung with analysis software is used, configure the analysis
software program to the same settings
2. Connect a pressure meter between the ventilator and the test lung.
3. Set the ventilator to STS settings.
Flight 60T Service Manual | 7-15
Calibration and Verification tests
Operational Verification Procedure (OVP)
4. Set PEEP to 5, Bias Flow = OFF.
5. Activate ventilation.
6. After 5 breaths, check that the basic pressure levels in the lung and in the
ventilator display are 5 ±1 cmH2O.
7. Raise the P trig level as needed, until no auto-triggering is observed.
8. Verify that the P trig level is not more than -1.5 cmH2O, and that the ventilator is
not performing an auto-trigger.
9. Set PEEP to 10, Bias Flow = OFF.
10. After five breaths, check that the basic pressure levels in the lung and in the
ventilator display are 10 ±2 cmH2O.
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 cmH2O
13. Set PEEP to 20, Bias Flow = ON.
14. After five breaths, check that the basic pressure levels in the lung and in the
ventilator display are 20 ±2 cmH2O.
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 cmH2O.
If the test fails:
1. Replace the patient circuit. In case of a Flight60 DL replace the exhalation valve
diaphragm.
2. Repeat Circuit test.
3. Replace the solenoid and run the required calibrations (see ‎7.3 Test table).
7.2.8 Pressure Trigger
To test the pressure trigger:
1.
Set the ventilator to STS
2. Connect the ventilator to the test lung using a patient circuit. Use the following
settings for the test lung:
 C = 50
 Rp = 5
3. Activate ventilation.
4. Simulate inhalation attempt by creating a negative pressure from the test lung.
5. Verify that the green P trig LED flashes and a mandatory breath is forced each time
the edge (shoulder) is raised.
7-16 | FLIGHT 60T Service Manual
Calibration and Verification tests
Operational Verification Procedure (OVP)
6. Change settings to:
 SIMV
 PSV = 20
 Rate = 5.
7. Simulate inhalation attempt by creating a negative pressure from the test lung.
8. Verify that the green P trig LED flashes and that the ventilator provides a
mandatory breath followed by pressure-supporting ventilations (PSV) for 12
seconds.
9. Set the P trig level to -0.2 cmH2O, 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.
2. Repeat the following:
 Pressure sensors calibration
 Pressure relief calibration
 Volume factor calibration
 Circuit test
3. Replace the solenoid and perform the required calibrations (see ‎7.3 Test table).
7.2.9 Exhalation Valve Leak
To test the exhalation valve:
1. Set the ventilator to the following settings:
 Rate = 10
 Ti = 1.4
 ACMV
 VCV = 1400
2. Set the High-Pressure alarm to 99 cmH2O.
3. Connect the ventilator to a test lung using a patient circuit. Use the following
settings for the lung:
 C = 20
 Rp = 20
4. Activate ventilation and continue for 15 breaths.
Flight 60T Service Manual | 7-17
Calibration and Verification tests
Operational Verification Procedure (OVP)
5. Verify that the pressure level is over 72 cmH2O. If pressure doesn’t get to 72
cmH2O, decrease the compliance or increase the resistance of the test lung. If
pressure becomes too high after changing compliance/resistance, reduce the set
volume from 1400 until achieving the required pressure level.
6. Check for air flow from the underside of the Exhalation Valve during inhalation; If
air flow is noticed there 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.
2. Repeat the following:
 Pressure sensors calibration
 Pressure relief calibration
 Volume factor calibration
 Circuit test
3. Replace the solenoid (see ‎4.19), and perform the required calibrations (see ‎7.3
Test table)
7.2.10 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.
3. Activate ventilation.
4. Set HIGH P to 10 cmH2O.
5. Check that when the pressure reaches 10 cmH2O, the following occurs:
 the audible alarm is triggered
 the visual alarm is triggered
 inhalation is interrupted.
6. Set HIGH P to 99 cmH2O.
7. Check that the following occurs:
 the audible alarm is silenced automatically
 the visual alarm is displayed until the Alarm Reset /
7-18 | FLIGHT 60T Service Manual
button is pressed.
Calibration and Verification tests
Operational Verification Procedure (OVP)
If the test fails:
1. Replace the Main Board (see ‎4.10).
2. Perform the required calibrations (see ‎7.3 Test table).
7.2.11 Battery /Charger /Power Supply
To test the power supply:
Verify that both batteries are above 60%. If not, connect to external power
and charge for at least 3 hours.
1. Ventilate is STS mode.
2. Disconnect the ventilator from AC power
3. Verify that the following occur:
 the Power Switchover indicator is displayed
 an audible beep is heard
 the EXT PWR indicator is not lit (external power)
 the battery (BAT) LED indicator is lit
4. Verify that the ventilator functions normally with no further alarms.
5. Remove the Main battery. Verify that the vent switched to Low-PowerVentilation:
PEEP = 5, Ptrig = -20 , PCV above PEEP = 15
2. After at least 90 seconds have passed, reconnect to AC power.
3. Verify that within 30 seconds of the connection time the ventilator indicates
switching back to AC power.
4. Verify that the following occur:
 the battery (BAT) LED indicator is off
 the green EXT PWR is lit
Flight 60T Service Manual | 7-19
Calibration and Verification tests
Operational Verification Procedure (OVP)
7.2.12 Buzzer Test
To test the buzzer:
Press Parameters /
and choose Screen ALARMS.
3. Tap the Buzzer button.
4. Choose HIGH and press Enter /
. Verify that a High buzzer sound is heard.
5. Tap the Buzzer button.
6. Choose LOW and press Enter /
. Verify that a Low buzzer sound is heard.
If the test fails:
 Check the buzzers cables. Make sure they are connected to the Main
Board and are intact.
 Replace the Main Board (see ‎4.10), and perform the required calibrations
(see ‎7.3 Test table).
7.2.13 Oxygen Calibration Test
For non iO2 ventilator (no internal O2 mixer)
Connect an external Air/Oxygen Entrainment Mixer to an Oxygen source. Install the
Air/Oxygen Entrainment Mixer on the ventilator’s air inlet.
O2% settings are changed with the mixer dial.
For iO2 ventilator (with internal O2 mixer)
Connect the ventilator to an Oxygen source.
O2% settings are changed by the %O2 button on the touch screen
1.
Press Technical /
and then press O2 sensor.
2. Select ON.
3. Set the Low FiO2 and the High FiO2 alarm to OFF.
4. Connect the patient circuit via a calibrated Oxygen Analyzer to the test lung.
5. Set the ventilator to STS mode. Start ventilation.
7-20 | FLIGHT 60T Service Manual
Calibration and Verification tests
Operational Verification Procedure (OVP)
6. Change O2 settings according to the following test table:
Input pressure
50 PSI
Mixer settings
Tolerance for
Tolerance for
IO2 internal mixer
External mixer
40%
36% - 44%
32% - 48%
60%
57% - 63%
52% - 68%
80%
76% - 84%
72% - 88%
100%
95% - 100%
92% - 100%
If the test fails:
1. Check for an inlet leak (see section Error! Reference source not found.).
2. Replace the sensor cable.
3. Replace the sensor.
4. Replace the Main Board (see ‎4.10) and perform the required calibrations (see ‎7.3
Test table).
7.2.14 Nebulizer compensation test * (iO2 Internal mixer model
only)
To test the Nebulizer compensation
1.
Set the ventilator to STS mode.
2.
Connect a nebulizer circuit before the patient circuit’s flow sensor. Start
ventilation.
3.
Verify that Vti is 450-550.
4.
Set O2 mixer to 50%. Activate the Nebulizer.
5.
Verify that Vti remains in the 450-550 range.
If the test fails:
1. Press Technical /
and then press ADVANCED Screen.
2. Enter the code 5844, and confirm by pressing

3. Press SERVICE SCREEN
4. Use the UP /
and DOWN /
the value will decrease Vti.
buttons to change the Neb. Comp. value. Increasing
Flight 60T Service Manual | 7-21
Calibration and Verification tests
Operational Verification Procedure (OVP)
7.2.15 OVP Test Results
7-22 | FLIGHT 60T Service Manual
Calibration and Verification tests
Operational Verification Procedure (OVP)
Serial #:
SW Version:
Hours:
Model: Flight 60T
Tested By:
Date:
Test
Results
Pass
☐
-N/A-
Front Panel self- test
External pressure gauge …………………………….
Pressure Sensors Calibration
☐
Patient Pressure …………………………..
Outlet Pressure …………………………..
Pressure Relief Valve Calibration
Relief Pressure …………………………..
Bias Flow Calibration
-N/A-
Circuit Test
-N/A-
Volume Verification
Vti ………………………… Vte …………………………
Pressures Verification
External gauge peak Pressure …………………………..
PPeak …………………………..
Bias Flow test
Bias Flow OFF ……….
Bias Flow ON …………….
PEEP Value
PEEP
Set
5
10
20
☐
☐
☐
☐
☐
☐
Pressure level …………………………..
High Pressure Alarm
-N/A-
Power Supply and Battery Charge
-N/A-
Alarm Buzzer Test
-N/A-
O2 Sensor
Ptrig
-N/A-
Pressure Trigger test (P trig)
Exhalation Valve leak
Tolerance
5±1
10 ± 2
20 ± 2
☐
☐
☐
☐
☐
☐
Set
Tolerance
Air
20.9% - 29%
40%
32% - 48%
60%
52% - 68%
80%
72% - 88%
100%
92% - 100%
Value
☐
Flight 60T Service Manual | 7-23
Calibration and Verification tests
Test Table
7.3 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.
7-24 | FLIGHT 60T Service Manual
Maintenance
Scheduled maintenance
8 Maintenance
8.1 Scheduled maintenance
BLOWER – The Blower should be replaced every 25,000 hours of operation or 5
years, whichever comes first.
For instructions on replacing the Blower, see section ‎4.12
After replacing the Blower, update the Blower serial number and zero the working
hours:
1. Press Technical /
and then press ADVANCED Screen.
2. Enter the code 5844, and confirm by pressing

3. Press SERVICE SCREEN
4. Press SERVICE
5. Enter the code 2009, and confirm by pressing

6. Press the displayed Compressor Serial Number, use the numerical keyboard to
type in the new number.
7. Press the displayed Hour Meter, use the numerical keyboard to change it to "0"
AIR INLET FILTER – Check the filter's condition whenever servicing the ventilator.
OXYGEN (O2) SENSOR – Replace once a year.
O2 LEAK SENSOR – Replace once a year.
BATTERY – Recommended replacement – every 2 years.
8.2 Download Log Files
To save log files use a FAT formatted USB mass storage device.
1. Press Technical /
and then press ADVANCED Screen.
2. Enter the code 5844, and confirm by pressing 
3. Press SERVICE SCREEN
4. Plug the USB storage device to the ventilator.
Flight 60T Service Manual | 8-1
Maintenance
Download Log Files
5. Change Auto Logs to ON. The download icon
will display.
6. Wait for the download complete icon
to display. Note that It might take few
minutes for download to complete, depending on the size of the log files
7. Check the USB device on a computer and verify that 3 log files – errors; changes;
events were downloaded.
8-2 | FLIGHT 60T Service Manual
Troubleshooting Guide
Introduction
9 Troubleshooting Guide
9.1 Introduction
The FLIGHT 60T Ventilator is used in life-support situations. As such, it is essential
that all individuals using the FLIGHT 60T 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 60T 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.
Only properly trained personnel should operate the ventilator. The FLIGHT 60T
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.
9.2 Error Messages
Displayed error
Potential Cause
Suggested Action
CHECK FiO2 SENSOR
Oxygen sensor bad reading
Run Oxygen sensor calibration
Oxygen sensor defective
Replace Oxygen sensor
O2 pressure is very low
Check O2 source pressure is 30-90PSI
O2 SUPPLY FAILED
Replace the O2 Regulator filters
PROX LINE
FLOW SENSOR ERROR
Problem in the proximal line.
Check internal hoses connections
Pressure sensors is improperly
Pressure Sensors Calibration
calibrated or defective.
Replace Main Board
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 60T Service Manual | 9-3
Troubleshooting Guide
Error Messages
Displayed error
Potential Cause
Suggested Action
HIGH MV INS
Air leakage
Check internal hoses connections
HIGH MV EXH
Calibration problem
Check internal hoses connections
Hardware problem
Perform Volume factor calibration
Replace Main Board
Replace Blower
HIGH / LOW P BASE
Solenoid malfunction
Check solenoid
Perform Circuit Test
Replace solenoid
PCV NOT REACHED
LOW MV EXH
MOTOR FAULT
PRESS SENSOR
POWER FAULT
Calibration problem
Perform Volume Factor calibration
Hardware problem
Replace Blower
Air leak
Check internal hoses connections
Hardware problem
Replace Main Board
Motor control
Replace Power Board
Motor
Replace Blower
Patient pressure sensor higher
Perform Pressure sensors calibration
than outlet
Replace Main Board
Check log file to identify failed
power:
3.3V POWER FAULT
Replace Main Board
MAIN BOARD 10V POWER FAULT
Check cables
Replace Power Board
Replace Main Board
MEMORY FAULT
POWER BOARD 10V POWER
Check cables
FAULT
Replace Power Board
5V POWER FAULT
Replace Main Board
Parameters mismatch
Perform OVP
Replace Main Board
MAIN BAT CHARGER
Charger malfunction
Replace battery
Replace Power Board
MAIN BAT V HIGH / LOW
Out of range
Replace battery
Replace Power Board
9-4 | FLIGHT 60T Service Manual
Troubleshooting Guide
Error Messages
Displayed error
Potential Cause
Suggested Action
MAIN BAT VOLTAGE
Mismatch in Battery voltage
Replace battery
reading
Replace Main Board
Battery overheating
Replace battery
MAIN BAT TEMP HIGH
Replace Power Board
MAIN BAT GAUGE
Battery control
Replace battery
SEC BAT CHARGER
Charger malfunction
Replace battery
Replace Power Board
SEC BAT V HIGH / LOW
Out of range
Replace battery
Replace Power Board
SEC BAT VOLTAGE
SEC BAT TEMP HIGH
Mismatch in Battery voltage
Replace battery
reading
Replace Main Board
Battery overheating
Replace battery
Replace Power Board
SEC BAT GAUGE
Battery control
Replace battery
Flight 60T 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. Also 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 60T ventilator:
 Use the original box and packaging.
 Remove both batteries and any accessories from the ventilator.
 When returning a module, place it in the original box and packaging. If
not available, place it in a box large enough to allow for it to be wrapped
in a sufficient amount of packaging material.
 Write the RGA number on the shipping label.
Ship RGA items to: FLIGHT MEDICAL INNOVATIONS Ltd.
21A Hamelacha St, Afek Park
Rosh Ha’ain 4809158, ISRAEL
Tel: +972-3-6731660
Flight 60T Service Manual | 10-1
Spare parts
Electronic
11
Spare parts
11.1
Electronic
Main Board
ELA-0013
Connecting cables – not part of the board:
1
MB to SB cable
V60-70100-29
2
O2 sensor cable
V60-00130-29
3
FPC MB to PB cable
V60-21000-29
Power Board
ELA-0020
Power Supply
SUB-0174
11-2 | FLIGHT 60T 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
Connecting cables – not part of the board:
1 MB to SB cable
V60-70100-29
Flight 60T Service Manual | 11-3
Spare parts
Electronic
O2 Mixer Neb board
ELE - 0001
Detachable (main) battery
V60-19000-67
Integral battery
SUB-0222
Keypad - English
V60-74000-68
Keypad - Symbols
SUB-0087
11-4 | FLIGHT 60T Service Manual
Spare parts
Mechanical / Assemblies
11.2
Mechanical / Assemblies
Front Subassembly
V60-70010-60 - English Keypad
SUB-0020 - Symbols Keypad
Connected items:
1
Front right bracket
V60-76023-03
2
Front Left bracket
V60-76022-03
Blower
SUB-0214
Connected item:
1
Cooling Fan assy.
MEB-0038
Solenoid
V60-21400-69
1
Filter Cover
V11-35201-07
2
O-ring
V11-36000-26
Flight 60T Service Manual | 11-5
Spare parts
Mechanical / Assemblies
Oxygen Sensor / Leak sensor
G60-25000-29
Air/Oxygen Entrainment mixer
V13-00030-60
Inlet Assembly
SUB-0182
Internal Mixer Nebulizer
SUB-0101
11-6 | FLIGHT 60T Service Manual
Spare parts
Mechanical / Assemblies
Cooling Fan
MEB-0038
Inlet Blower
MEC-0140
Outlet Assembly Blower
SUB-0183
For Dual Limb Ventilator
1
Dual limb Cap
2
Diaphragm (5 pcs)
3
Exhalation Valve DL
SUB-0088
V64-00050-90
MEC-0034
Flight 60T Service Manual | 11-7
Spare parts
Cables
11.3
Cables
Internal AC Cable
CBL-0053
Internal DC Cable
V60-40200-29
FPC MB-PB cable
V60-21000-29
MB – SB cable
V60-70100-29
PS-PB cable
V60-30100-29
Detachable Battery cable
V60-00050-29
11-8 | FLIGHT 60T Service Manual
Spare parts
Cables
Internal Battery cable
V60-50100-29
Oxygen Sensor cable
V60-00130-29
O2 Leak sensor cable
SUB-0010
DC-DC cable (power supply – Power board)
CBL-0054
Flight 60T Service Manual | 11-9
Index
A
AC connector, 3-6
ACMV, 6-3, 7-12, 7-17
Air/Oxygen Entrainment Mixer, 2-2, 2-3, 3-5, 7-10, 720
Alarm connector, 3-6
Alarm Reset button, 3-1, 3-3
Antistatic wrist strap, 4-1
APNEA, 3-3
LED Indicator, 3-3
LED Indicator, 7-12
Audio Paused button, 3-1
Audio Paused/Alarm Reset
LED Indicator, 7-13
B
Back panel
AC connector, 3-6
DC connector, 3-6
Detachable battery, 3-6
Low flow oxygen port, 3-7
Network logging, 3-7
PC connector, 3-6
Peripherals connector, 3-7
Remote alarm connector, 3-6
Uploading log files, 3-7
BAT
LED Indicator, 3-3, 7-19, 9-3, 9-4, 9-5
LED Indicator (Battery power), 7-12
Battery, 4-2, 7-18, 9-5
Button
Alarm Reset, 3-1, 3-3
Audio Paused, 3-1
Cancel, 3-3
Decrease, 3-3
Extended, 3-3
Home, 3-2
Increase, 3-3
Manual breath, 3-1
Manual breath, 3-2
OK, 3-3
On/Off, 3-1, 3-3
Panel lock, 3-1
Panel lock, 3-3
Parameters, 3-2
Technical, 3-3
Up/Down, 3-1
BUV
LED Indicator, 3-3
LED Indicator (Back up ventilation), 7-12
Buzzer Test, 7-20
C
Cable ties, 4-1
Cancel button, 3-3
Charger, 7-18, 9-4, 9-5
Connector, patient circuit, 3-1
Ventilator Cover, 4-3, 4-5, 4-6
Cutter, 4-1
D
DC connector, 3-6
Decrease button, 3-3
Detachable battery, 3-6
Detachable Battery, 4-2
Display touch screen, 3-2
D-type Board, 4-36
Dual limb exhalation valve, 3-2
E
Electrical Diagram, 3-14
Emergency Air Intake, 3-4
Error Messages, 9-3
Error! Reference source not found. Calibration, 7-13
EXT PWR
LED Indicator, 3-3
LED Indicator (External power), 7-12
Extended button, 3-3
F
FAULT
LED Indicator, 3-3, 9-4
LED Indicator (Device malfunction, 7-12
FILTER, 8-1
Filter Cover, 3-5
Flat screwdriver, 4-1, 7-5
Fresh Gas Intake, 3-5
Front Panel, 3-1, 4-14, 4-15, 4-16, 4-17, 4-20, 7-12
Front Panel Assembly, 4-14, 4-17
Front Panel Self Test, 7-12
Fuse, 4-39, 4-40
H
HIGH MV
LED Indicator, 3-3, 9-4
LED Indicator (High minute ventilation), 7-12
High P
LED Indicator (High pressure), 7-13
HIGH P
LED Indicator, 3-3, 7-18
High Pressure Alarm, 7-18
Home button, 3-2
Flight 60T Service Manual | 1
Index
I
Increase button, 3-3
Inlet Leak, 7-19
Internal Battery, 4-2, 4-3
L
LED indicator, 3-2
LED Indicators, 3-3
LOW MV
LED Indicator (Low minute ventilation), 7-13
LOW BAT
LED Indicator, 3-3
LED Indicator (Low battery), 7-12
Low flow oxygen port, 3-7
LOW MV
LED Indicator, 3-3, 9-4
LOW P
LED Indicator, 3-3, 9-4
LED Indicator (Low pressure), 7-13
Lower Board, 4-36
M
Main board, 3-9, 3-10
Main Board, 4-14, 4-18, 4-20, 4-21, 7-13, 7-18, 7-20, 721, 9-3, 9-4, 9-5
Maintenance, 8-1
BLOWER, 8-1
Blower Assembly, 4-22, 4-26
Manual breath button, 3-1, 3-2
N
Network logging, 3-7
O
OK button, 3-3
On/Off, 7-12
LED Indicator, 7-13
On/Off button, 3-1, 3-3, 7-12
Oxygen (O2) Sensor, 3-9, 3-10
Oxygen Blending Bag Kit, 2-2, 2-3
Oxygen Sensor, 4-27, 4-28, 7-20
P
Panel Lock
LED Indicator, 7-13
Panel lock button, 3-1, 3-3
Parameters button, 3-2
Patient Circuit
Reusable, 7-5
Patient circuit connector, 3-1
PC connector, 3-6
PEEP, 6-3, 7-12, 7-15
Peripherals connector, 3-7
I-2 | FLIGHT 60T
Phillips screwdriver PH1, 4-1, 7-5
PLT1M-M69, 4-1
PLT4S-M69, 4-1
Power Board, 4-6, 4-7, 4-8, 4-9, 4-10, 9-3, 9-4, 9-5
Power board (PB), 3-9, 3-10
Power Supply, 4-7, 4-10, 4-12, 4-14, 7-18
Power supply (PS), 3-9, 3-10
Pressure gauge, 3-2
Pressure Relief Calibration, 7-8
Pressure Sensors Calibration, 7-5, 9-3
Pressure Trigger, 7-16
Pressure Verification, 7-14
Primary alarm LED, 3-2
Purge board, 3-9, 3-10
Purge Board Assembly, 4-31, 4-32
R
Remote alarm connector, 3-6
Removing and Reinstalling Modules, 4-1
Repackaging, 10-1
RGA number, 10-1
Rubber Bumpers, 4-40, 4-41
S
OXYGEN SENSOR
Oxygen, 8-1
Shipping, 10-1
Solenoid Assembly, 4-34, 4-36
Solenoid Board Assembly, 4-32, 4-33
Standard Ventilator Settings (STS), 7-12, 7-14, 7-15, 716, 7-18, 7-19
T
Technical button, 3-3
Test Table, 7-23
Torx screwdriver BT10x200, 4-1, 7-5
Touch Screen, 4-21
TRIG
LED Indicator, 3-3
LED Indicator (Pressure trigger), 7-12
Troubleshooting Guide, 9-3
U
Uploading log files, 3-7
V
V60-13000-65, 3-9, 3-10
V60-21000-60, 3-9, 3-10
V60-21000-65, 3-9, 3-10
V60-21400-69, 3-9, 3-10
V60-23000-65, 3-9, 3-10
V60-25000-29, 3-9, 3-10
V60-26000-65, 3-9, 3-10
V60-60002-65, 3-9, 3-10
Verification, 2-3, 7-5
Volume Factor Calibration, 7-9
Flight 60T Service Manual | 3