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Manual Reference
Puritan Bennett 800 Series Ventilator System Operator's and Technical Reference Manual, document 10067720, Revision D; Puritan Bennett 840 Ventilator System Service Manual, document 10067703, Revision D. Confirm the manuals apply to the installed GUI, BDU, backup power source, compressor, software, options, cart, and regional configuration.
Manufacturer Recommendation / AEM Status
Covidien/Medtronic lists Extended Self Test (EST) every 6 months. Every year, qualified service personnel calibrate/test the atmospheric-pressure transducer, expiratory valve, flow sensors, and ventilator-inoperative circuitry, then complete performance verification. Annual performance verification includes electrical safety and inspection for mechanical damage and illegible labels.
Calibrate the atmospheric-pressure transducer whenever the ventilator moves by 1,000 feet of altitude. Replace the backup power source internal battery pack every 2 years or as necessary. Install the appropriate preventive-maintenance kits every 10,000 operating hours. The oxygen sensor has a nominal one-year life and is replaced annually from first use or as necessary. Reusable inspiratory and expiratory bacteria filters have a maximum one-year service interval; the compressor inlet filter is cleaned every 250 hours or more often when required.
These service procedures are for qualified personnel using the applicable service manual and required test equipment. If a facility changes the listed activities or intervals, that decision should be managed through its approved AEM program, documented risk assessment, maintenance history, and applicable regulatory requirements.
What This PM Procedure Covers
- Identity, configuration, operating hours, service history, and due intervals
- Exterior, cart, controls, labels, electrical and gas connections, filters, and patient-gas-path components
- Six-month EST and annual service calibrations
- Annual performance verification, POST, SST, alarms, ventilation delivery, and monitoring
- Oxygen sensor, backup power source, compressor, and 10,000-hour PM status
- Manufacturer-specified electrical safety measurements
- Final restoration, electronic service history, and CMMS documentation
Required Tools and Equipment
- Applicable Puritan Bennett 840 operator/technical and service manuals
- Approved medical air and oxygen sources with correct supply hoses
- Configuration-appropriate patient circuit, filters, test adapters, stoppers, and test lungs
- Puritan Bennett PTS 2000 Performance Test System with applicable 840 ventilator test software, or the complete current manual performance-verification setup specified by the service manual
- Calibrated pressure/flow/volume/oxygen test capability required by the selected performance-verification method
- Calibrated electrical safety analyzer
- Correct oxygen sensor, bacteria filters, BPS battery, compressor inlet filter, and 10,000-hour PM kit when due
- Approved cleaning/reprocessing materials and facility-required personal protective equipment
Step-by-Step PM Procedure
1. Remove the Ventilator From Patient Use
Action: Transfer any patient to an appropriate backup ventilator under clinical direction. Label the PB840 unavailable and move it to a controlled service area.
Expected outcome: No patient depends on the ventilator during maintenance and backup ventilation remains available.
2. Verify Identity and Configuration
Action: Record the asset tag and serial numbers for the GUI, breath delivery unit, backup power source, compressor, and cart as applicable. Record software, installed options, patient categories, power configuration, and accessories. Confirm the controlled documents apply.
Expected outcome: The complete system is positively identified and the correct test path is selected.
3. Review Hours, History, and Due Work
Action: Open Other Screens > Operational Time Log and record ventilator and compressor hours. Review previous PM, repairs, EST/SST outcomes, diagnostic and alarm history, battery and oxygen-sensor dates, location/altitude changes, recalls/field actions, and 10,000-hour kit status.
Expected outcome: Every due calendar-, condition-, altitude-, and hour-based activity is identified.
4. Inspect the Complete System
Action: Inspect the GUI, touchscreen, BDU, enclosure, handles, covers, latches, cooling openings, labels, flex arm, mounting hardware, cart, casters, and brakes. Look for cracks, looseness, contamination, corrosion, fluid entry, blocked airflow, missing hardware, illegible labels, or unauthorized modification.
Expected outcome: The ventilator is clean, complete, stable, legible, and free of mechanical damage.
5. Inspect Electrical and Gas Connections
Action: Inspect the mains cord, plug, strain relief, retaining hardware, equipotential point, BPS connection, air and oxygen hoses, inlet fittings, regulators, and compressor connections. Confirm compatible accessories are secure and undamaged.
Expected outcome: Power and gas connections are safe, correctly installed, and free of wear, leakage, and contamination.
6. Inspect Patient-Gas-Path Components
Action: Inspect inspiratory and expiratory bacteria filters, expiratory filter assembly, collector vial, drain bag/tubing, water traps, exhalation components, patient circuit, and humidification accessories. Replace damaged, contaminated, expired, cracked, crazed, or obstructed items. Run SST after any filter or circuit change.
Expected outcome: Components are clean, dry, intact, correctly assembled, and appropriate for testing.
7. Complete Scheduled Filter Maintenance
Action: Clean the compressor inlet filter every 250 hours or sooner when needed using mild soap solution; rinse and dry it thoroughly, and replace it if damaged. Replace reusable inspiratory and expiratory filters at one year maximum and use SST to verify filter/circuit resistance. Record installation dates.
Expected outcome: All filters are within their service intervals and provide an unrestricted, leak-free gas path.
8. Check the Oxygen Sensor
Action: Review oxygen-sensor age and history. Replace it annually from first use or earlier when calibration/performance requires it, using the applicable access and safety procedure. Calibrate with the 100% O₂/CAL 2 MIN or INCREASE O₂ 2 min function and complete the manual's oxygen-sensor calibration test. Run SST after replacement.
Expected outcome: The oxygen sensor is current, calibrated, stable, and passes testing without an unresolved alarm.
9. Check Backup Power
Action: Inspect the backup power source and connections. Verify age, service history, charging indication, AC-to-battery transfer, battery alarm behavior, and supported operation. Replace the BPS internal battery pack every two years or sooner when condition or testing requires it.
Expected outcome: Backup power is current, undamaged, recognized, charging, and reliable during loss of AC power.
10. Run Power-On Self-Test
Action: Start the complete ventilator system and observe POST. Verify normal display startup, controls, indicators, and audible output, with no ventilator-inoperative or unresolved technical condition.
Expected outcome: POST passes and the ventilator reaches the setup screen normally.
11. Run Extended Self Test
Action: Enter Service Mode and run the complete EST every six months using the required test circuit, stoppers, gas sources, and test lung. Follow every on-screen prompt and investigate any failure; do not override a failed result for return to service.
Expected outcome: Every EST test and the overall EST result pass.
12. Complete Annual Service Calibrations
Action: At annual PM, use the service manual to calibrate/test the atmospheric-pressure transducer, expiratory valve, flow sensors, and ventilator-inoperative circuitry. Perform the altitude-triggered pressure-transducer calibration whenever the location changes by 1,000 feet. Allow required warm-up and confirm prerequisite leak testing before calibration.
Expected outcome: Each required calibration/test passes and its date/result is recorded.
13. Complete Performance Verification
Action: Using the PTS 2000/VTS method or the complete service-manual manual-check method, perform every required annual performance-verification test. Verify delivered and monitored pressure, flow, volume, respiratory rate/timing, PEEP, oxygen concentration, safety-valve function, breath delivery, apnea/backup behavior, and installed options at the specified test points.
Expected outcome: All measured values meet the tolerances in the applicable service manual and no required test is omitted.
14. Verify the Alarm System
Action: Exercise the required audible and visual alarms under controlled test conditions, including disconnect, occlusion/high pressure, low/high delivered or monitored values, oxygen supply/concentration, apnea, AC-power loss, low/inoperative battery, device alert, and ventilator-inoperative annunciation as applicable. Verify silence/reset behavior and remote alarm when included in the configuration.
Expected outcome: Each tested alarm activates, displays, sounds, prioritizes, and resets correctly.
15. Run Short Self Test in the Final Circuit Configuration
Action: Install the intended test circuit, humidification arrangement, and filters. Run SST and record the selected circuit/patient type, resistance, compliance, leak, filter, flow-sensor, pressure, and safety-valve results presented by the ventilator.
Expected outcome: SST passes completely with the final test configuration.
16. Complete 10,000-Hour Maintenance When Due
Action: At each 10,000-hour interval, install the appropriate configuration-specific PM kit and perform every replacement, inspection, calibration, and post-installation test specified by the current service manual. Do not reset the interval or document completion if the full kit procedure is not completed.
Expected outcome: The correct kit is installed, all associated tests pass, and parts/hours are traceable.
17. Perform Electrical Safety Testing
Action: Test the complete configured system as described below, including the supplied power cord and installed compressor/accessories. Record analyzer identity, line voltage, polarity/ground conditions, limits, and readings.
Expected outcome: Protective-ground resistance and leakage currents meet the applicable PB840 service-manual limits.
18. Restore, Record, and Return to Service
Action: Remove test equipment, restore approved accessories, ensure filters/covers/doors and gas connections are secure, exit Service Mode, repeat final POST/SST/readiness checks as required, and document the work in the ventilator service history and facility CMMS.
Expected outcome: The PB840 is clean, complete, fully tested, and either returned to clinical use with traceable records or clearly removed from service.
Electrical Safety Testing
The service manual includes electrical safety in annual performance verification and requires it whenever the ventilator is serviced, according to hospital requirements. Test the ventilator with its supplied power cord and with the compressor and accessories installed and operating as directed. Do not perform whole-system dielectric/HI-POT testing unless specifically directed by current authorized documentation.
Protective-ground resistance: Use the acceptance limit in the current applicable PB840 service manual and record the actual value in ohms.
Earth leakage current: The published PB840 electrical specification is 300 µA maximum at 100–120 V AC and 500 µA maximum at 220–240 V AC. Perform forward and reverse polarity/required analyzer conditions and record every result.
Enclosure/patient leakage current: The published maximum is 100 µA for both 100–120 V and 220–240 V configurations. Humidifier leakage is limited to 50 µA at 100–120 V or 100 µA at 220–240 V when applicable. Apply the current service-manual method and facility policy.
Pass / Fail Criteria
Pass
- Identity, hours, configuration, history, exterior, labels, cart, power/gas connections, filters, and gas-path components pass inspection
- All due 250-hour, six-month, annual, two-year, altitude-triggered, and 10,000-hour activities are complete
- POST, EST, annual calibrations, performance verification, alarms, and final SST pass
- Oxygen sensor and backup power are current and pass calibration/functional testing
- Protective-ground resistance meets the current service-manual limit and all leakage measurements meet the applicable published limits
- No unresolved technical alarm, diagnostic failure, or ventilator-inoperative condition remains
- Final restoration and both service-history and CMMS documentation are complete
Remove From Service
- POST, EST, SST, a required calibration, performance-verification test, alarm, or electrical-safety test fails
- Damage, contamination, leakage, obstruction, fluid entry, illegible safety labeling, or an unreliable power/gas connection could affect safe ventilation
- The oxygen sensor cannot be calibrated or backup power cannot reliably support operation
- A due PM kit, battery, filter, test, recall/field action, or qualified service requirement cannot be completed
- Any condition remains that could affect breath delivery, monitoring, alarms, or emergency operation
Copy/Paste CMMS Work Order Procedure
The PB840 is a life-support ventilator. Never service it while supporting a patient, never bypass a failed test, and use the current manufacturer service manual, facility policy, and approved AEM program to determine final interval and return-to-service requirements.