GE Healthcare Carestation 600 Series

Asset Type

Anesthesia Machine

Manufacturer

GE Healthcare

Model

Carestation 600 Series

Manual Reference

Carestation 620/650/650c (A1/A2) Technical Reference Manual, 2076163-001, Revision U, November 2024.

Carestation 600 Series Planned Maintenance Checklist, 2076164-PMC, Revision 3, November 2024.

The technical reference manual applies to the Carestation 620, 650, and 650c configurations and identifies them collectively as the Carestation 600 Series.

Manufacturer Recommendation / AEM Status

GE provides separate 12-, 24-, 36-, and 48-month planned-maintenance checks. The manufacturer checklist indicates that the complete planned-maintenance inspection and testing sequence is performed at these intervals, with specific parts replaced according to the applicable interval.

Before beginning planned maintenance, GE directs the technician to:

• Perform the System Checkout Full Test.
• Verify that the system date and time are correct.
• Complete applicable parts replacement before performing checks, tests, and calibrations.

Manufacturer-Listed Parts Replacement

Every 12 Months

Replace the vaporizer port O-rings kit, PN 1102-3016-000.

Every 24 Months

• Vaporizer port O-rings kit, PN 1102-3016-000
• Free-breathing flapper valve, PN 0211-1454-100
• Free-breathing valve O-ring, PN 1503-3208-000

Every 36 Months

• Vaporizer port O-rings kit, PN 1102-3016-000
• System batteries as one paired set, PN 5931866-S

Every 48 Months

• Vaporizer port O-rings kit, PN 1102-3016-000
• Free-breathing flapper valve, PN 0211-1454-100
• Free-breathing valve O-ring, PN 1503-3208-000
• Display battery, PN 5129534-3
• Two breathing-system check-valve kits, PN 2071067-001-S

The system battery is listed as one paired replacement set. The breathing-system check-valve kit quantity is two per system.

AEM Note

If a facility performs this PM at a different interval or changes the listed activities, that change should be handled under the facility’s approved AEM program, risk assessment, maintenance history, and applicable regulatory requirements.

What This PM Procedure Covers

• Interval-specific parts replacement
• Visual and mechanical inspection
• Breathing-system and ventilator inspection
• Gas-supply, flow-sensing, and flow-control tests
• Display diagnostics and calibrations
• Battery and power-failure testing
• Optional ACGO, AGSS, auxiliary O2, and suction testing
• Vaporizer and alarm testing
• System checkout
• Electrical safety testing
• Final return-to-service checks

Required Tools and Equipment

Use calibrated equipment appropriate for the installed configuration and the detailed procedures in Technical Reference Manual Section 13.

• GE-compatible service access or PC Service Application, as applicable
• Manufacturer-specified test adapters and service tools
• Anesthesia machine flow or gas-flow test device capable of the listed O2, air, and N2O flows
• Oxygen concentration analyzer or flow-measurement equipment
• Breathing-circuit test lung and required circuit components
• Pressure-measurement equipment suitable for airway-pressure testing
• Electrical safety analyzer
• Stopwatch or timer
• Vacuum source, vacuum gauge, and flowmeter for the integrated suction regulator, if equipped
• Calibration gas and airway-module calibration equipment appropriate for the installed gas module
• Applicable interval replacement parts
• Manufacturer-approved lubricant for the Bag/Vent switch procedure
• PPE required by facility infection-control policy

Do not substitute unverified test equipment or perform internal maintenance without the training, adapters, software access, and procedures required by the technical reference manual.

Step-by-Step PM Procedure

1. Remove the Machine From Clinical Use

Action

• Confirm that the anesthesia machine is not connected to or supporting a patient.
• Decontaminate the equipment according to facility policy.
• Record the model, serial number, equipment ID, software version, PM interval, and current operating hours if tracked.
• Confirm that the technician is using the current technical reference manual and checklist.

Expected outcome: The machine is safely available for maintenance and contamination risks are controlled.

GE states that testing or maintenance must not be performed while the machine is being used on a patient.

2. Determine the Applicable Maintenance Interval

Action

Identify whether this is the 12-month, 24-month, 36-month, or 48-month check. Verify the previous maintenance date and determine which interval-specific parts are due.

Expected outcome: The correct manufacturer-listed replacement parts and maintenance activities are selected.

3. Perform the Initial Full Test and Verify System Time

Action

• Power on the machine.
• Verify the audible startup chirp and completion beep.
• Verify the system date and time.
• Correct the date or time when inaccurate.
• Perform the onboard System Checkout Full Test before beginning planned maintenance.

Expected outcome: The Full Test passes or any preexisting failure is documented before maintenance begins.

Do not continue as though the unit passed if the initial Full Test identifies an unresolved failure.

4. Replace Interval-Specific Parts

Action

Turn off the system before replacing electrical components. Replace all parts due for the selected interval before completing the remaining checks, tests, and calibrations.

Document:

• Part number
• Quantity
• Lot or serial information when tracked
• Maintenance interval
• Any abnormal wear or contamination

Expected outcome: All manufacturer-listed interval parts are installed correctly.

5. Perform the External Visual and Mechanical Inspection

Action

Inspect:

• Filter in the lower rear enclosure
• Displays and display arm
• Frame and mounting hardware
• Drawers and drawer locks
• Top shelf and shelves
• Screws with alignment or witness marks
• Casters and brakes
• External tubing and silicone tubing
• Electrical cables and power cord
• Pipeline hoses and fittings
• Cylinder yokes and mounting hardware
• Panels, tray tops, rails, and accessory mounts

Expected outcome

• Rear filter is clean.
• Structural parts are secure and in good condition.
• Casters roll and lock correctly and are firmly mounted.
• Tubing, hoses, and cables show no visible deterioration and remain securely connected.

Remove the machine from service for damaged gas hoses, deteriorated tubing, compromised electrical wiring, loose structural components, defective brakes, or an unstable frame.

6. Inspect the Breathing System

Action

Complete the detailed technical-reference-manual procedures for:

• Bellows assembly
• Absorber canister and canister mounting
• Inspiratory and expiratory flow sensors
• Sensor Interface Board area
• Bag/Vent switch and required lubrication
• APL valve
• Bypass assembly
• Breathing-system check valves when applicable

Perform the bellows-drop test.

Expected outcome

• Bellows do not fall within one minute.
• Components are clean, intact, correctly assembled, and move freely.
• The Bag/Vent switch operates smoothly after manufacturer-specified maintenance.
• No damaged seals, valves, sensors, housings, or mounting components are present.

7. Inspect the Ventilator

Action

Inspect the exhalation valve and associated ventilator components using the manual procedure. Replace parts when the inspection identifies deterioration or damage.

Expected outcome: The exhalation valve and ventilator components are correctly assembled, clean, undamaged, and functional.

8. Verify Audible and Visual Annunciators

Action

• Turn the system on and verify the startup chirp.
• Verify the completion beep after self-testing.
• During display diagnostics, test the speaker, LEDs, LCD, hard keys, and battery diagnostic.

Expected outcome

• Startup chirp is heard.
• Self-test completion beep is heard.
• LEDs flash five times during the diagnostic.
• Speaker sounds for two seconds.
• Each hard key produces a speaker response.
• LCD sequences through its test screens.
• Battery diagnostic displays Pass.
• System Reference completes after at least ten minutes of warm-up with a clean screen.

9. Perform the Power-Failure and Battery-Capacity Tests

Action

• Connect the power cord to mains power.
• Confirm that the mains indicator illuminates.
• Turn the system on and start a case.
• Disconnect the power cord.
• Confirm activation of the power-failure alarm.
• Reconnect mains power and confirm that the alarm clears.
• Perform the battery-capacity test according to the manual.

Expected outcome

• Mains indicator operates.
• Power-failure alarm activates when AC is disconnected.
• Alarm clears after AC is restored.
• System operates on battery for more than 50 minutes during the manufacturer PM battery-capacity test.

A battery-runtime result of 50 minutes or less fails the manufacturer checklist.

10. Test Pipeline and Cylinder Gas Supplies

Action

• Perform the O2 supply alarm test.
• Disconnect pipeline supplies and close all cylinder valves.
• Confirm that pressure readings return to zero.
• Connect pipeline supplies individually.
• Open each cylinder individually.
• Test each installed cylinder circuit for high-pressure leakage.

Expected outcome

• Low O2 supply alarm occurs.
• O2 and N2O flow stop during the O2 supply-loss test.
• Air continues when air is selected as the balance gas.
• Pressure displays identify the correct connected pipeline or cylinder.
• Cylinder pressure decay is less than 690 kPa or 100 psig in one minute for each installed cylinder position.

11. Perform the Flow-Sensing Test

Use the manufacturer setup and test adapter. Record each applicable displayed reading.

• 100% O2 at 1.5 l/min: acceptable displayed reading 1.3–1.7 l/min
• 100% O2 at 12 l/min: acceptable displayed reading 10.8–13.2 l/min
• 100% air at 1.5 l/min: acceptable displayed reading 1.3–1.7 l/min
• 100% air at 12 l/min: acceptable displayed reading 10.8–13.2 l/min
• 100% N2O at 1.2 l/min: acceptable displayed reading 1.1–1.3 l/min
• 100% N2O at 10 l/min: acceptable displayed reading 9.0–11.0 l/min

Mark N2O tests not applicable when the machine is not configured for N2O.

Expected outcome: Each applicable flow-sensor reading is within the manufacturer-listed range.

12. Perform the Flow-Control and Proportioning Tests

N2O Flow Settings

Record oxygen concentration or measured O2 flow.

• N2O at 0.2 l/min: O2 concentration ≥21% or O2 flow >0.05 l/min
• N2O at 1.6 l/min: O2 concentration 21–34% or O2 flow 0.42–0.83 l/min
• N2O at 5.0 l/min: O2 concentration 21–34% or O2 flow 1.32–2.58 l/min
• N2O at 9.0 l/min: O2 concentration 21–34% or O2 flow 2.39–4.64 l/min

O2 Flow Settings

Record oxygen concentration or measured N2O flow.

• O2 at 2.5 l/min: O2 concentration 21–34% or N2O flow 4.85–9.40 l/min
• O2 at 1.0 l/min: O2 concentration 21–34% or N2O flow 1.94–3.76 l/min
• O2 at 0.4 l/min: O2 concentration >21% or N2O flow <1.50 l/min

Expected outcome: The proportioning system prevents delivery outside the manufacturer-listed ranges.

13. Complete Ventilator Calibrations and Safety Tests

Perform the applicable procedures:

• User calibration
• Manifold P Span
• Inspiratory Flow Valve calibration
• Bleed Resistor calibration
• Zero ACGO, Zero AGSS, or combined zero, as equipped
• Paw Span or Paw and ACGO Span
• Zero Gas Transducers
• Mixer Flow Sensor Zero
• Pressure-limit circuit test
• Mechanical Over Pressure Valve test

Expected outcome

• Each calibration displays Pass.
• Gas flow stops as airway pressure reaches approximately 109 cmH2O during the pressure-limit circuit test.
• The Mechanical Over Pressure Valve relief weight relieves and pops off during the relief-valve test.

14. Test the Auxiliary O2 Flowmeter, If Equipped

Action

• Turn flow completely off and verify that the ball rests at the bottom.
• Set the flowmeter to 3 l/min.
• Measure actual flow.

Expected outcome: Measured flow is 2.5–3.5 l/min.

15. Test the Integrated Suction Regulator, If Equipped

Record actual readings for each applicable test.

• Regulator off: gauge needle rests within the zero-range bracket.
• Set to 100 mmHg: test gauge reads 62–138 mmHg.
• Set to 300 mmHg: test gauge reads 262–338 mmHg.
• Set to 500 mmHg: test gauge reads 462–538 mmHg.
• Maximum-flow test: at least 20 l/min.
• Regulation test: returns to 100 mmHg within ±10 mmHg.
• Vacuum bleed test: returns to zero range within 10 seconds.
• Vacuum leak test: reading does not increase with regulator off.

16. Test ACGO and Passive AGSS, If Equipped

ACGO Pressure-Relief Valve

Expected outcome: The pressure-relief weight relieves and pops off.

Passive AGSS Positive-Relief Test

Expected outcome: Pressure rise does not exceed 10 cmH2O.

17. Perform the Flush-Flow Test

Action: Perform the O2 flush test using the manual setup and time the bellows filling.

Expected outcome: Bellows fill in 1.3–3 seconds.

18. Test Vaporizer Back Pressure and Interlock

Action

• Test each installed vaporizer position through the applicable control range.
• Verify operation of the vaporizer interlock.

Expected outcome

• O2 flow does not decrease by more than 1 l/min through the full vaporizer test range.
• More than one vaporizer cannot be turned on at the same time.

This procedure does not replace vaporizer-specific maintenance required by the applicable vaporizer service documentation.

19. Calibrate the Airway Module, If Installed

Use the procedure and certified calibration gas applicable to the installed module.

Manufacturer checklist calibration points:

• CO2: 5.0%
• O2: 54.5%
• N2O: 36.0%
• AA/DES: 2.0%

Expected outcome: The displayed values calibrate to the specified gas concentrations and the calibration completes without error.

20. Perform Alarm Tests

Verify activation of:

• FiO2 low
• FiO2 high
• MVexp low
• Ppeak high
• PEEP high / blockage
• Ppeak low / leak

Expected outcome: Each alarm activates under the manufacturer test condition and provides the expected visual and audible indication.

21. Perform the Final System Checkout

Run the complete onboard Full Test after all maintenance, parts replacement, inspection, and calibration work is complete.

Expected outcome: Full Test passes with no unresolved failures.

Electrical Safety Testing

The manufacturer checklist includes electrical safety testing as part of planned maintenance.

Ground Resistance

The Carestation 600 Series manufacturer limit is stricter than the generic 0.5 Ω field often used for other equipment.

Ground resistance measured in ohms, manufacturer expected < 0.20 Ω:

Result =

Pass / Fail =

Leakage Current

Record the supply-voltage category used.

Touch/chassis leakage measured in microamps:

Supply voltage = 100/120 Vac or 220/240 Vac

Manufacturer limit used:

• 100/120 Vac: <300 µA
• 220/240 Vac: <500 µA

Result =

Pass / Fail =

Do not replace these manufacturer checklist values with a generic facility limit unless the facility has formally evaluated and approved that change through its maintenance program.

Final Machine Checks

Before returning the system to clinical use, verify:

• Pipeline hoses are connected.
• Work lights operate correctly.
• Vaporizers are properly mounted, locked, and turned off.
• Auxiliary O2 is set to minimum, if installed.
• Panels and tray tops are installed.
• Cylinder valves are turned off.
• AC mains power is connected.
• No tools, adapters, test plugs, or temporary tubing remain installed.
• Full Test passes.
• Electrical safety tests pass.
• No unresolved alarms, leaks, calibration failures, or service messages remain.

Pass / Fail Criteria

Pass

The PM passes when:

• Correct interval parts were replaced.
• All visual and mechanical inspections pass.
• All applicable manufacturer tests and calibrations meet the listed limits.
• Battery runtime exceeds 50 minutes.
• Final Full Test passes.
• Ground resistance is less than 0.20 Ω.
• Leakage current is below the applicable manufacturer limit.
• Final machine configuration is complete and clinically ready.

Remove From Service

Remove the machine from service when any of the following remain unresolved:

• Full Test failure
• Gas leak or failed cylinder high-pressure leak test
• Failed flow-sensing or proportioning test
• Failed ventilator calibration or pressure-relief test
• Failed alarm or annunciator
• Battery runtime of 50 minutes or less
• Ground resistance or leakage current above the manufacturer limit
• Damaged breathing-system, gas-supply, electrical, structural, or caster component
• More than one vaporizer can be activated
• Incorrect vaporizer mounting or locking
• Required panel or safety component is missing
• Any condition that prevents confirmation of safe gas delivery, ventilation, monitoring, or alarm operation

Use the manufacturer service manual, facility policy, and approved AEM program to determine the final PM interval and return-to-service requirements.