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What This Guide Helps With
This guide addresses situations where the Apollo anesthesia machine reports flow sensor calibration errors, such as alarms during startup or spontaneous calibration failure during operation. These errors may impact accurate delivery of tidal volume and anesthetic gases.
The guide focuses on external checks and setup verification first, before assuming internal sensor or module failure.
Step-by-Step Troubleshooting
Confirm Machine Power and Startup
- Ensure the Apollo is plugged into a verified AC power source or fully charged battery.
- Proper startup is required for calibration routines; unstable power can trigger false flow sensor errors.
Check Gas Supply and Pressures
- Verify O₂, N₂O, and Air pressures are within manufacturer-specified ranges (typically 200–600 kPa).
- Low or fluctuating pressures can prevent proper flow sensor calibration.
- Inspect gas hoses for kinks or loose connections.
Inspect Flow Sensor Pathway
- Visually inspect the pediatric and adult flow sensor connectors.
- Remove any moisture, condensation, or foreign matter in the sensor housing or breathing circuit.
- Ensure sensors are seated properly; a misaligned or partially disconnected sensor can fail calibration.
Check Breathing Circuit Configuration
- Make sure the correct circuit type is selected in the machine settings.
- Disconnect or bypass any added adapters that could interfere with sensor readings.
Run Automatic Calibration Again
- Initiate the flow sensor calibration routine per the on-screen prompts.
- Observe for any error codes or specific messages; note if calibration fails consistently for one sensor only.
Swap Sensors if Possible
- If multiple flow sensors are available, swap the suspected sensor with a known good sensor.
- If the error follows the sensor, the sensor itself may be defective.
- If the error stays on the same port, the issue may be internal to the machine.
Inspect Environmental Conditions
- Excessive humidity, condensation, or cold gas lines can impact sensor calibration.
- Allow the machine and gases to reach room temperature if recently moved.
If the Problem Persists
External checks have been completed and calibration still fails.
- Remove the machine from service and label Out of Service.
- Escalate to authorized Drager service or perform bench evaluation.
- Document all troubleshooting steps taken.
- Avoid attempting internal repairs, as flow sensors are sensitive and critical for patient safety.
Clinical Use Tip
- Do not use the machine on a patient until calibration completes successfully.
- Switch to a backup anesthesia machine to ensure uninterrupted patient care.
- Perform troubleshooting in a controlled environment to avoid impacting ongoing procedures.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
“Flow sensor calibration fails during startup; machine shows error FS-03.”
Cause
What was observed during troubleshooting.
Example:
“Observed condensation in the flow sensor and loose sensor connector. Calibration failed on both adult and pediatric sensors.”
Resolution
What action was taken.
Example:
“Cleared condensation, reseated sensor connectors, re-ran calibration successfully. Machine passed self-test and ready for use.”
Helpful Details to Include
- Sensor ports checked and cleaned
- Gas pressures verified
- Circuit type confirmed
- Sensor swapped if available
- Error code and timestamps logged
- Final machine status (Ready / Out of Service)
Final Thought
Flow sensor calibration errors often stem from external factors such as moisture, gas supply issues, or misalignment. Systematic verification avoids unnecessary downtime and maintains patient safety. Proper documentation and escalation are critical when external checks do not resolve the issue.
That is successful troubleshooting.