Hamilton G5

Asset Type

Ventilator

Manufacturer

Hamilton

Model

G5

Manual Reference

HAMILTON-G5 Ventilator Service Manual including maintenance, repairs and tests, PN 624093/01, March 2008. Manual coverage is listed as software versions 1.0 and 1.1x. Confirm that this manual revision applies to the device/software in service before using it as the active PM reference.

Manufacturer Recommendation / AEM Status

Manufacturer-Listed PM Frequency

The manufacturer lists complete preventive maintenance and testing at the following interval:

• Once a year or once every 5,000 operating hours, whichever comes first.
• After replacing any component.

The complete PM/testing workflow includes hospital preventive maintenance review, engineer preventive maintenance, Test Mode procedures, required part replacement, cover installation, electrical safety testing, and completion of operator-manual tests and calibrations.

Manufacturer-Listed Maintenance Items and Intervals

• Between patients and according to hospital policy: Replace or reprocess the breathing circuit, mask, inspiratory filter, flow sensor, nebulizer jar, exhalation valve cover and membrane as applicable. Run the applicable test and flow sensor calibration.
• Between patients and according to hospital policy: Run the pre-operational check from the operator's manual.
• Every day or as required: Empty accumulated water from the gas inlet water trap.
• Every 2 days or according to hospital policy: Empty breathing circuit and water traps, inspect for damage and replace as necessary.
• Every month, or more often if required: Inspect the fan filter for dust and lint; clean or replace if needed.
• Every year or every 5,000 operating hours, whichever comes first: Confirm gas inlet microfilter elements are clean; replace if discolored.
• Every year or every 5,000 operating hours, whichever comes first: Perform the CO2 sensor accuracy check when the CAPNOSTAT 5 CO2 monitor option is installed.
• Every 2 years, every 5,000 operating hours, or as necessary: Replace the 12 V internal battery.
• Every 20,000 operating hours: Replace the LCD display backlight.

Manufacturer-Listed Parts Referenced for PM

• Fan filter: PN 391175
• Gas inlet microfilter element: PN 155714
• Gas inlet water trap bowl: PN 155713
• Pediatric/adult reusable flow sensor: PN 155362
• Infant single-patient-use flow sensor: PN 155500
• Pediatric/adult single-patient-use flow sensor: PN 279331
• Oxygen cell, Catalyst: PN 396008
• Oxygen cell, Teledyne: PN 396009
• CO2 module electrical safety test cable, when CO2 module is installed: PN 159171
• CO2 sensor: PN 281718
• CO2 adult airway adapter, single use: PN 281719
• CO2 adapters, quantity 3: PN 281803
• CO2 calibration gas: PN 159172
• CO2 gas regulator: PN 159173

Electrical Safety and Post-Repair Requirements

The complete manufacturer-listed PM workflow includes electrical safety testing.

The manual specifically states that electrical safety testing must be performed after replacement of the Power Management Supply or removal of any ground/earth contact from the ventilator.

The manual also directs completion of the full test sequence after repair or adjustment and requires electrical safety testing and the pre-operational check before returning the ventilator to normal use.

AEM Note

The manufacturer-listed PM interval is annual or every 5,000 operating hours, whichever comes first, with additional maintenance intervals for specific components. A facility performing this PM at a different interval or changing the listed activities should do so under its approved AEM program, risk assessment, maintenance history and applicable regulatory requirements.

What This PM Procedure Covers

• Manufacturer-listed annual/5,000-hour preventive maintenance workflow.
• Gas inlet microfilter inspection and replacement when indicated.
• CO2 sensor accuracy check when the CAPNOSTAT 5 CO2 option is installed.
• Required Test Mode checks and calibrations.
• Electrical safety testing using Type B or Type BF criteria, depending on configuration.
• Verification of scheduled battery or LCD backlight replacement interval.
• Final pre-operational check and service documentation.

Required Tools and Equipment

Required or Manual-Supported Tools

• Appropriate personal protective equipment when handling contaminated patient accessories or bacterial filters.
• ESD grounding cable and wrist strap when opening the ventilator or handling sensitive internal components.
• Flat and cross-head screwdrivers.
• Metric wrenches.
• Metric hex/Allen keys.
• Potentiometer adjustment tool, PN R70031, when Test Mode adjustment is required.
• Digital voltmeter capable of voltage measurements to ±10 mV and resistance measurement appropriate for the listed continuity checks.
• Electrical safety analyzer, such as the Metron Safety Analyzer or equivalent IEC 60601-1 capable tester.
• Locking paint or nail varnish for securing adjustment potentiometers after adjustment.

Test Mode Equipment Listed in the Manual

• 20 ml/s capillary tube, PN 500280.
• 500 ml/s orifice tube, PN 500290.
• Pressure connector, PN 500300.
• Microflow and pressure regulator / flow restrictor, example PN 279812.
• Hand pump, example PN 500330.
• Pressure gauge, 0 to 25 mbar, accuracy ≤ 0.5%.
• Pressure gauge, 0 to 400 mbar, accuracy ≤ 0.5%.
• Pressure gauge, 0 to 10 bar, accuracy ≤ 0.5%.
• Complete WIKA gauge set, PN 500058.
• Test tubing, adapters, T-connectors, cross-connectors, stopper and bacteria filter as required by the applicable Test Mode configuration.

Additional Equipment When CO2 Monitoring Is Installed

• CO2 sensor, PN 281718.
• CO2 adult airway adapter, PN 281719.
• CO2 adapters, quantity 3, PN 281803.
• Barometric pressure gauge in mbar.
• CO2 calibration gas, PN 159172.
• CO2 gas regulator, PN 159173.
• CO2 module electrical safety test cable, PN 159171, for Type BF electrical safety testing.

Step-by-Step PM Procedure

1. Confirm PM Due Status and Device Configuration

Action: Confirm the device identity, software level, operating hours, installed options, and whether the CO2 module or Heliox option is installed. Determine whether the PM is scheduled by interval, triggered by component replacement, or being completed after repair.

Expected outcome: The correct PM scope is identified before testing begins.

Important: If the Heliox option is installed, disconnect the Heliox gas supply and connect air supply gas before performing maintenance and testing procedures.

2. Remove the Ventilator From Clinical Use

Action: Remove the ventilator from patient care before beginning maintenance or Test Mode procedures. Follow facility cleaning and infection-control processes before handling patient-contact accessories.

Expected outcome: The ventilator is available for complete testing without interrupting patient ventilation.

3. Review Hospital Preventive Maintenance Items

Action: Confirm that hospital-maintenance activities are being performed at the manufacturer-listed intervals, including patient circuit/accessory replacement or reprocessing, pre-operational checks, gas inlet water trap inspection, breathing circuit and water trap inspection, and fan filter inspection.

Expected outcome: Routine user/hospital-maintenance items are complete and any deficiencies are corrected or documented.

4. Inspect Gas Inlet Microfilters

Action: Inspect the gas inlet microfilter elements.

Expected outcome: Microfilter elements are clean and suitable for continued service.

Pass / corrective action: Replace the gas inlet microfilter elements if discolored. Manufacturer-listed microfilter element part number: 155714.

5. Inspect Scheduled Replacement Items

Action: Review operating hours, age and service history for interval-based replacements.

Expected outcome: Replacement items due by time or operating hours are identified and addressed.

• 12 V internal battery: Replace every 2 years, every 5,000 operating hours, or as necessary. Result: Due / Not due / Replaced =
• LCD display backlight: Replace every 20,000 operating hours. Result: Due / Not due / Replaced =

6. Enter Test Mode and Perform the Complete Test Sequence

Action: Connect the ventilator to mains power, switch it on, enter Test Mode and perform the manufacturer-listed test units in order. Complete the Hamilton G5 Ventilator Test Report during testing.

Expected outcome: All required Test Mode checks pass or any failed test is corrected before proceeding.

Manufacturer-listed Test Mode sequence:

• VUP checks.
• Relay and emergency checks.
• VRC-VUP communication checks.
• A/D converter checks.
• D/A converter checks.
• Zero and full-scale calibration.
• O2 cell calibration and checks.
• Mixer calibration and checks.
• Flow sensor circuit checks.
• Patient overpressure valve checks.
• Ambient valve checks.
• Inspiratory valve checks.
• Expiratory valve calibration and checks.
• Nebulizer checks.
• Internal battery / PMS.
• Extended battery, if installed.
• IPP checks.
• LCD display checks.
• User interface and alarm tone checks.
• Touchscreen calibration.
• Event log and technical status review.

Important: If testing identifies a part that must be replaced, replace the part and then repeat the complete series of tests.

7. Record Key Test Mode Results

Action: Document required test values using the Hamilton test report or facility-equivalent documentation.

Expected outcome: Test results demonstrate that critical pneumatic, electronic, battery and alarm functions remain within manufacturer-listed criteria.

• VUP CPU temperature: < 70 °C. Result =
• VUP ESM 5 V measurement: 4750 to 5250 mV. Result =
• VUP ESM 3.3 V measurement: 3182 to 3424 mV. Result =
• VRC-VUP DPRAM test: OK. Result =
• VUP-VRC test: OK. Result =
• VRC-VUP test: OK. Result =
• Internal battery temperature: < 60 °C. Result =
• Extended battery temperature, if installed: < 60 °C. Result =
• IPP CPU temperature: < 70 °C. Result =
• IPP ESM 5 V measurement: 4750 to 5250 mV. Result =
• IPP ESM 3.3 V measurement: 3235 to 3400 mV. Result =

8. Perform O2 Cell Calibration and Checks

Action: Verify an oxygen cell is installed, connect air and oxygen supplies, perform the O2 cell calibration and complete the listed checks.

Expected outcome: Oxygen cell calibration completes and displayed oxygen measurements remain within listed limits.

• O2 cell calibration completion: Message displayed: O2 cell is calibrated; Calib status = 0 at completion. Result =
• Tank gas at 50% oxygen setting: O2 cell voltage 1.25 to 4.25; Oxygen % value 47 to 53. Result =
• Air inlet: O2 cell voltage 0.5 to 1.7; Oxygen % value 19 to 23. Result =
• O2 inlet: O2 cell value 2.5 to 8.5; Oxygen % value 98 to 100. Result =

9. Perform Mixer and Pneumatic Safety Checks

Action: Perform tank tightness, mixer valve leakage, mixer gain, tank overpressure and associated pneumatic checks.

Expected outcome: Mixer and pressure-limiting systems meet manufacturer-listed criteria.

• Tank tightness: More than 8 seconds for Ptank to decrease from 300 to 280 mbar. Result =
• Mixer valve leakage, 90 ms flow: 0 to 300. Result =
• Mixer valve leakage, 100 ms flow: 0 to 200. Result =
• Mixer gain calibration: Ptank max 330 to 350 mbar. Result =
• Mixer oxygen concentration check: Displayed oxygen = selected value ±5% at 30%, 60% and 80%. Result =
• Tank overpressure check: Ptank max < 500 mbar. Result =
• Inspiratory valve tightness: Pressure gauge < 4 mbar. Result =
• Safety valve block tightness: More than 10 seconds for pressure to decrease from 90 to 43 mbar. Result =
• Patient overpressure valve opening: Ppat max = 104 to 116 mbar. Result =

10. Perform Flow Sensor, Valve and Nebulizer Checks

Action: Complete flow sensor circuit, ambient valve, inspiratory valve, expiratory valve and nebulizer testing according to the manual.

Expected outcome: Gas delivery, pressure control, exhalation control, rinse-flow function and nebulizer output remain within manufacturer-listed criteria.

• dP flow sensor autozero, silver connector blocked: Alternates between -40 to 40 μbar and 5040 to 5200 μbar. Result =
• dP flow sensor autozero, blue connector blocked: Alternates between -40 to 40 μbar and -5040 to -5200 μbar. Result =
• Rinse-flow comparison: Bubble flow appears equal from both flow-sensor tubes. Result =
• Auxiliary rinse-flow check: No bubbles visible from Paux tubing; metal plate must be in OFF position for this check. Result =
• Expiratory valve calibration: Display message: Exp Valve Cal ok; Calib status = 0. Result =
• Nebulizer pressure: 2 bar ± 0.5 bar when nebulizer valve is open. Result =
• Nebulizer valve leakage: No bubbles; maximum permitted is 3 bubbles per 10 seconds. Result =

11. Perform CO2 Sensor Accuracy Check, If Installed

Action: When the HAMILTON MEDICAL CAPNOSTAT 5 CO2 monitoring option is installed, perform the CO2 sensor accuracy check using the manufacturer-listed setup and calibration gas.

Expected outcome: CO2 measurement meets the acceptable PetCO2 range for the measured ambient temperature and barometric pressure.

• CO2 option installed: Yes / No =
• Barometric pressure measured in mbar =
• Barometric pressure verification, within 5% of actual: Pass / Fail =
• Ambient temperature =
• Displayed PetCO2 =
• Acceptable range per manufacturer graph: Pass / Fail =

12. Secure Adjustments and Reassemble the Ventilator

Action: Lock adjustment potentiometers using proprietary locking paint or nail varnish when adjustments were made. Close and secure all ventilator covers. Verify all removed accessories, cables, tubing and hardware are correctly restored.

Expected outcome: The ventilator is fully assembled and ready for safety and operational verification.

13. Perform Electrical Safety Testing

Action: Perform the electrical safety checks listed below using appropriate test equipment.

Expected outcome: Grounding, leakage-current and insulation-resistance results meet the manufacturer-listed IEC 60601-1 criteria for the installed configuration.

14. Complete Final Operational Verification

Action: Exit Test Mode. Switch the ventilator off and back on. Complete the pre-operational check described in the Hamilton G5 Operator's Manual. Complete any additional tests and calibrations required by the operator's manual. Confirm that unresolved technical faults are not present.

Expected outcome: The ventilator successfully completes final verification and is suitable for disposition according to facility policy.

Electrical Safety Testing

Manufacturer-Listed Test Classification

• CO2 module not installed: Type B electrical safety testing.
• CO2 module installed: Type BF electrical safety testing.

Important: Type BF testing with the CO2 module installed requires the CO2 module electrical safety test cable, PN 159171.

Visual Grounding Checks

Action: Inspect the yellow/green internal ground wires near the mixer block. Pull each ground wire to verify tightness. Check that contact strips in the main housing are secure.

Result: Pass / Fail =

Internal Ground Continuity Checks

• Potential equalization terminal from mains earth pin: Manufacturer-listed maximum resistance < 1 Ω. Result =
• Communication interface connector from mains earth pin: Manufacturer-listed maximum resistance < 1 Ω. Result =
• Tank overpressure valve cover from mains earth pin: Manufacturer-listed maximum resistance < 10 Ω. Result =
• Interaction panel from mains earth pin: Manufacturer-listed maximum resistance < 10 Ω. Result =
• Column from mains earth pin: Manufacturer-listed maximum resistance < 10 Ω. Result =

Protective Earth Resistance

Protective earth resistance measured in ohms, including power cord, manufacturer-listed expected limit ≤ 0.2 Ω:

Result =

Pass / Fail =

Type B Testing — CO2 Module Not Installed

• Earth leakage current measured in microamps: Facility limit used = Manufacturer-listed limit ≤ 500 μA normal condition / ≤ 1000 μA single fault condition; Result =; Pass / Fail =
• Enclosure leakage current measured in microamps: Facility limit used = Manufacturer-listed limit ≤ 100 μA normal condition / ≤ 500 μA single fault condition; Result =; Pass / Fail =
• Patient leakage current measured in microamps: Facility limit used = Manufacturer-listed limit ≤ 100 μA normal condition / ≤ 500 μA single fault condition; Result =; Pass / Fail =
• Insulating resistance: Manufacturer-listed limit > 200 MΩ. Result =; Pass / Fail =

Type BF Testing — CO2 Module Installed

• Earth leakage current measured in microamps: Facility limit used = Manufacturer-listed limit ≤ 500 μA normal condition / ≤ 1000 μA single fault condition; Result =; Pass / Fail =
• Enclosure leakage current measured in microamps: Facility limit used = Manufacturer-listed limit ≤ 100 μA normal condition / ≤ 500 μA single fault condition; Result =; Pass / Fail =
• Patient leakage current measured in microamps: Facility limit used = Manufacturer-listed limit ≤ 100 μA normal condition / ≤ 500 μA single fault condition; Result =; Pass / Fail =
• Patient leakage current, mains on applied part, measured in microamps: Facility limit used = Manufacturer-listed single fault condition limit ≤ 5000 μA; Result =; Pass / Fail =
• Insulating resistance: Manufacturer-listed limit > 200 MΩ. Result =; Pass / Fail =

Pass / Fail Criteria

PM Pass Criteria

Pass the PM when:

• Manufacturer-listed maintenance items due at the current interval have been completed.
• Due replacement items have been replaced or documented as not due.
• Required Test Mode checks and calibrations pass.
• CO2 sensor accuracy check passes when the CO2 option is installed.
• Electrical safety testing meets the manufacturer-listed Type B or Type BF criteria.
• Final operator-manual pre-operational check passes.
• No unresolved technical fault remains.

Remove From Service Criteria

Remove the ventilator from service when:

• Any required Test Mode check fails and cannot be corrected.
• A due internal battery, filter, backlight or other required component is not replaced when indicated.
• CO2 sensor accuracy fails on a unit equipped with the CO2 monitoring option.
• Electrical safety testing fails.
• The final pre-operational check fails.
• A technical fault remains unresolved.
• The unit cannot be fully reassembled, safely secured or verified after service.

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