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What This Guide Helps With
Troubleshooting failed flow-sensor calibration caused by improper removal, moisture, contamination, incorrect installation, damaged sensors, or breathing-system connection problems.
Step-by-Step Troubleshooting
1. Ensure Patient Safety First
Do not calibrate, remove, or exchange flow sensors while the Avance is supporting an active patient.
If the failure occurs during clinical use:
- Notify the anesthesia provider immediately.
- Confirm that ventilation, airway pressure, and volume monitoring remain clinically reliable.
- Transfer the patient to another verified anesthesia machine or approved ventilation method when measurement accuracy is uncertain.
- Troubleshoot the affected machine only after it is safely removed from patient use.
Expected outcome: Patient care no longer depends on equipment with questionable flow or volume measurement.
2. Confirm the Exact Failure
Record the complete displayed message and determine whether the failure involves:
- Inspiratory flow sensor
- Expiratory flow sensor
- Both flow sensors
- Calibration that will not begin
- Calibration that starts but does not complete
- Unstable or implausible volume readings after calibration
Expected outcome: The affected sensor and failure behavior are clearly identified.
3. Verify the Machine Is in the Correct State
Place the Avance in Standby and ensure that no patient is connected.
Access the flow-sensor calibration through the applicable calibration menu for the installed software version. Follow the on-screen instructions exactly.
GE guidance specifies that the sensors are removed from the breathing system during routine flow calibration.
Expected outcome: The system accepts the calibration request and displays the required preparation steps.
4. Remove Both Flow Sensors as Directed
Remove the inspiratory and expiratory flow sensors from their installed positions before starting calibration.
Confirm that:
- Both sensors are fully removed.
- No sensor remains partially engaged.
- The sensor ports are not blocked.
- The breathing-system components are not pressing against the sensor connectors.
Expected outcome: The machine recognizes the zero-flow condition required for calibration.
If calibration completes successfully, reinstall the sensors correctly, perform the required checkout, and stop troubleshooting.
5. Inspect for Moisture or Condensation
Examine both sensors for:
- Water droplets
- Condensation
- Residual cleaning solution
- Moisture inside the sensing channels
- Wet connector areas
Allow the sensors to dry completely according to facility and manufacturer-approved handling procedures. Do not use unapproved heat, compressed air, or objects inside the sensing passages.
Expected outcome: Both sensors are clean and completely dry before another calibration attempt.
6. Inspect for Contamination or Physical Damage
Visually inspect each sensor for:
- Dust or debris
- Secretion residue
- Cracked housing
- Warped sensing surfaces
- Damaged electrical contacts
- Bent, recessed, or contaminated connection points
Do not scrape or probe the sensing elements.
Expected outcome: Only clean, undamaged sensors remain in use.
Remove any visibly damaged sensor from service.
7. Check Sensor Identification and Placement
Confirm that the inspiratory and expiratory sensors are installed in their correct locations and orientations.
Check that:
- Each sensor matches the approved type for the Avance.
- Directional markings are followed.
- The sensors are fully seated.
- Latches or retaining mechanisms engage normally.
- No tubing or breathing-system component prevents full insertion.
Expected outcome: Both sensors are correctly positioned and recognized by the system.
8. Reseat the Breathing-System Connections
Inspect and reseat the accessible breathing-system assembly around the flow sensors.
Look for:
- Loose sensor-module connections
- Misaligned seals
- Improperly installed breathing-system components
- Damaged or missing accessible seals
- Components installed after cleaning in the wrong orientation
Expected outcome: The breathing system is completely and correctly assembled without stressing the sensors.
9. Repeat the Flow-Sensor Calibration
Remove the sensors again when instructed and repeat the calibration.
Do not move the machine, disturb the sensor ports, or create airflow near the open sensor locations while calibration is running.
Expected outcome: Calibration completes without an error message.
If successful:
- Reinstall both sensors.
- Complete the required machine checkout.
- Verify stable inspiratory and expiratory volume readings using an appropriate test lung or analyzer.
- Return the machine to service only after all tests pass.
10. Test With Known-Good Sensors
When permitted by facility policy, install a compatible, known-good pair of GE-approved flow sensors and repeat calibration.
GE describes these sensors as critical to accurate airway-flow and ventilation measurement.
If calibration succeeds, the original sensor or sensor pair is defective or out of specification.
If calibration still fails, the problem may involve the sensor interface, wiring, breathing-system electronics, or internal measurement circuitry.
Expected outcome: The test distinguishes a sensor problem from a machine-side fault.
11. Perform a Complete Checkout
After any sensor replacement, reseating, or successful calibration, complete the manufacturer-required pre-use checkout.
Verify:
- Flow-sensor calibration passes
- Leak testing passes
- Inspiratory and expiratory volumes are stable
- Delivered and measured tidal volumes are reasonably consistent
- No flow-sensor alarms return
- Mechanical and manual ventilation operate correctly
Expected outcome: The machine passes all required functional and safety checks before clinical use.
If the Problem Persists
If calibration continues to fail after both sensors have been removed correctly, dried, inspected, reseated, and exchanged with known-good sensors, common external causes have been ruled out.
The failure may involve the sensor connector assembly, internal wiring, signal-processing electronics, or another internal breathing-system component.
The device should be:
- Removed from service
- Labeled Out of Service
- Sent for qualified bench evaluation or GE-authorized repair
- Kept out of clinical use until calibration and the complete checkout pass
Knowing when to stop and escalate is proper troubleshooting. GE restricts detailed life-support equipment service information to appropriately trained personnel.
Clinical Use Tip
Never troubleshoot questionable flow or volume measurements on an active patient. Transfer care first, then evaluate the machine with approved test equipment in a controlled setting.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"Anesthesia staff reported that the GE Avance displayed a flow-sensor calibration failure and would not provide reliable volume measurements."
Cause
What was observed during troubleshooting.
Example:
"The expiratory flow sensor contained visible condensation and failed calibration until it was dried and correctly reseated."
Resolution
What action was taken.
Example:
"Dried and reinstalled both flow sensors, completed flow calibration and machine checkout, verified stable volumes with a test lung, and returned the Avance to service."
Helpful Details to Include (If Known)
- Exact calibration message recorded
- Inspiratory, expiratory, or both sensors affected
- Sensors removed during calibration
- Moisture or contamination observed
- Sensor contacts inspected
- Sensors reseated in correct positions
- Known-good sensors tested
- Leak test result documented
- Test-lung or analyzer readings documented
- Final device status recorded
Final Thought
Flow-sensor calibration failures should be approached by protecting the patient, confirming correct calibration conditions, checking moisture and installation, and testing known-good sensors before suspecting an internal fault. Clear CCR documentation preserves the findings and supports safe escalation.
That is successful troubleshooting.