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Manual Reference
Aisys Anesthesia Machine Technical Reference Manual, M1046983, 04/08
Manufacturer Recommendation / AEM Status
The manual lists Section 6 as the regular maintenance section and states that it covers the regular maintenance procedures “minimum requirements” needed to make sure the Aisys anesthesia machine operates to specification.
Manufacturer-Listed PM Frequencies
Every 12 Months
Replace eVap backpressure valve, stock number 1011-3983-000.
Perform AGSS maintenance.
Perform breathing system maintenance.
Perform bellows assembly maintenance and bellows assembly tests.
Perform checkout procedures.
Perform mixer outlet check valve leak test.
Zero the mixer.
Perform mixer flow verification test.
Perform alternate O2 flowmeter tests.
Perform auxiliary O2 flowmeter tests, if equipped.
Perform integrated suction regulator tests, if equipped.
Perform display diagnostics.
Perform PC Service Application diagnostics, including vaporizer test with test cassette, MOPV pressure relief valve test, pressure limit circuit test, drive gas regulator adjustment, and eVap therapy cassette leak test.
Perform listed service calibrations.
Review and clear service log/error history as appropriate.
Perform system checkout.
Perform Low P Leak test.
Perform electrical safety tests.
Every 24 Months
In addition to 12-month requirements:
Replace free breathing flapper valve, stock number 0211-1454-100.
Replace free breathing valve O-ring, stock number 1503-3208-000.
Every 48 Months
In addition to 24-month requirements:
Replace Display Unit battery, stock number 1009-5800-000.
Replace system batteries, stock number 1011-3557-000.
The manual references a battery capacity test for system batteries.
AEM Note
If a facility performs this PM at a different interval or changes the listed activities, that should be handled under the facility’s approved AEM program, risk assessment, maintenance history, and applicable regulatory requirements.
What This PM Procedure Covers
This procedure covers scheduled Aisys planned maintenance, visual and mechanical inspection, manufacturer-listed 12-month, 24-month, and 48-month maintenance items, system checkout and leak checks, mixer, vaporizer, pressure relief, alarm, power failure, optional accessory checks, electrical safety testing documentation, and copy/paste CMMS documentation.
Required Tools and Equipment
Only use trained/authorized service personnel and proper tools/test equipment. The manual cautions against servicing without proper tools, test equipment, and the most recent revision of the service manual.
Manual-Supported / Procedure-Supported Items
Approved electrical safety analyzer/test device, such as UL, CSA, or AAMI approved test device.
Test cassette for extended Agent Delivery / Vaporizer testing.
PC Service Application.
Compact Flash Special Functions card.
Test lung.
Patient circuit / breathing circuit.
Calibrated Flow Orifice test tool, stock number 1504-3016-000, for pressure limit circuit testing.
Manometer / pressure measurement equipment where required by calibration or service test procedures.
Squeeze bulb for ACGO low-pressure leak testing, if applicable.
Replacement Parts by Interval
eVap backpressure valve: 1011-3983-000
Free breathing flapper valve: 0211-1454-100
Free breathing valve O-ring: 1503-3208-000
Display Unit battery: 1009-5800-000
System batteries: 1011-3557-000
Step-by-Step PM Procedure
1. Remove From Patient Use
Action: Do not perform testing or maintenance while the Aisys is being used on a patient. Follow infection control procedures before handling breathing system components.
Expected outcome: Device is available for service without patient connection or patient risk.
Why it matters: The manual specifically warns not to perform testing or maintenance while the machine is in patient use.
2. Verify PM Interval
Action: Determine whether this is a 12-month, 24-month, or 48-month PM.
Expected outcome: Correct manufacturer-listed replacement items and tests are included.
3. Perform Visual and Mechanical Inspection
Action: Inspect for damage, loose components, damaged breathing circuit parts, loose casters, brake function, gas supply connection, cylinder wrench presence when applicable, reserve O2 supply when applicable, and AC power connection.
Expected outcome: No physical damage, missing components, loose casters, or unsafe setup conditions are found.
4. Replace Manufacturer-Listed PM Parts
Action: Replace parts based on interval.
12-month PM: Replace eVap backpressure valve, 1011-3983-000.
24-month PM: Replace eVap backpressure valve, 1011-3983-000. Replace free breathing flapper valve, 0211-1454-100. Replace free breathing valve O-ring, 1503-3208-000.
48-month PM: Replace all 12-month and 24-month items. Replace Display Unit battery, 1009-5800-000. Replace system batteries, 1011-3557-000.
Expected outcome: Correct scheduled parts are replaced before checks, tests, and calibrations.
5. Perform AGSS Maintenance
Action: Perform manufacturer-listed AGSS maintenance. Empty condensate from reservoir. Inspect active AGSS air brake for occlusion. Inspect, clean, or replace active AGSS filter.
Expected outcome: Scavenging system is not obstructed and is ready for use.
6. Perform Breathing System and Bellows Maintenance
Action: Disassemble and inspect breathing system modules and bellows assembly. Replace physically damaged or worn parts. Perform bellows assembly tests.
Expected outcome: Breathing system and bellows components are intact, clean, correctly assembled, and pass applicable checks.
7. Perform System Checkout
Action: Perform checkout procedures listed by the manual, including system inspection, pipeline and cylinder tests, O2 supply alarm test, Flush Flow test, alarm tests, and power failure test.
Expected outcome: Aisys passes checkout without unresolved failure.
8. Perform Machine Check and Leak Checks
Action: Run the Machine Check and follow on-screen instructions. The manual states the Machine Check includes System check, Circuit check, and Circuit O2 cell check if present. The leak check passes below 250 ml at 3 kPa / 30 cmH2O when default “Leak <250 ml” is set to No. Leaks above 750 ml fail and must be corrected.
Perform Low P Leak test. The manual lists a positive pressure Low P Leak pass/fail limit of 50 ml.
Expected outcome: Machine Check passes and Low P Leak test passes.
9. Perform Mixer and Vaporizer-Related Checks
Action: Perform mixer outlet check valve leak test. Zero the mixer. Perform mixer flow verification test. Perform vaporizer test with test cassette inserted. Perform eVap therapy cassette leak test.
Expected outcome: Mixer and vaporizer-related tests pass without unresolved errors.
10. Perform Pressure and Ventilation Safety Tests
Action: Perform MOPV pressure relief valve test. Perform Pressure Limit Circuit test. Adjust/check drive gas regulator as listed. Perform required service calibrations: User Calibration, Manifold P Span, Inspiratory Flow Zero, Inspiratory Flow Valve, Bleed Resistor, Paw Span, and Zero Gas Transducers.
Expected outcome: Pressure relief, pressure limit, drive gas, and calibration checks pass.
11. Perform Optional Accessory Checks When Equipped
Action: Perform alternate O2 flowmeter test, auxiliary O2 flowmeter test if equipped, and integrated suction regulator test if equipped.
Expected outcome: Installed options operate within the manual-listed procedure expectations.
12. Review Service Log / Error History
Action: Access Service Log / Error History. If error codes are present, follow appropriate troubleshooting procedures. Clear the error log after addressing issues.
Expected outcome: No unresolved error history remains after PM.
13. Perform Final Checkout
Action: Perform final system checkout after all replacement parts, tests, calibrations, and corrections are complete.
Expected outcome: Device passes final checkout and is ready for electrical safety testing and return-to-service decision.
Electrical Safety Testing if applicable
The manual lists electrical safety testing as part of planned maintenance and provides specific electrical safety limits.
Ground Resistance
Ground resistance measured in ohms, expected ≤ 0.2 Ω per manual or facility/NFPA 99 criteria if different.
Result =
Pass / Fail =
Leakage Current
Manual-listed leakage limits:
120/100 VAC: less than 300 µA
220/240 VAC: less than 500 µA
Touch/chassis leakage measured in microamps:
Facility limit used =
Manual-listed limit used = 300 µA for 120/100 VAC or 500 µA for 220/240 VAC
Result =
Pass / Fail =
Pass / Fail Criteria
PM passes when:
Correct interval-based parts are replaced.
No physical damage or unsafe condition remains.
Breathing system, bellows, AGSS, mixer, vaporizer, pressure relief, pressure limit, alarm, power failure, and optional accessory checks pass as applicable.
Machine Check and Low P Leak pass.
Service log/error history has no unresolved service issue.
Electrical safety testing passes.
Final system checkout passes.
Remove from service if:
Any required checkout, leak, pressure, alarm, mixer, vaporizer, calibration, or electrical safety test fails.
Any part is damaged, worn, missing, contaminated, or incorrectly assembled and cannot be corrected.
Leakage current or ground resistance exceeds the manual-listed or facility-approved limit.
Service log/error history indicates an unresolved failure.
The unit cannot pass final checkout.
Copy/Paste CMMS Work Order Procedure
Use the manufacturer service manual, facility policy, and approved AEM program to determine the final PM interval and return-to-service requirements.