2008-06-07-ZY9100 English Service Manual PDF

ZY9100series multi-functional Anesthesia machine
ZY9100 Series Multi-function

Anesthesia Machine
Service handbook
GE Healthcare Clinical Systems(Wuxi) Ltd., Co.
July 2006
CONTENTS
1 Introduction ……………………………………………………………………………1
……………………………………………………………………………1-1
1.1 Components of the Anesthesia System ……………………………………………
……………………………………………1
………………………1-2
1.2 Components of the Respiration System ……………………………………………1
……………………………………………1-4
1.3 LCD Control Key……………………………………………………………………1
……………………………………………………………………1-5
…………………………………………………………………………1
1.4 LCD Display………………………………………………………………………… 1- 5
………………………………………1
1.5 Signs used in this manual or on the equipment ……………………………………… 1- 6
2 Working principle ………………………………………………………………………2-1
……………………………………………………………………2
2.1 Electrical System…………………………………………………………………… 2- 2
2.2 Power supply subsystem ……………………………………………………………2
……………………………………………………………2-2
2.2.1 Summary …………………………………………………………………………2
…………………………………………………………………………2-2
2.2.2 Charging panel ……………………………………………………………………2
……………………………………………………………………2-2
………………………………………………………………2
2.3 Alarm & signal exchange……………………………………………………………… 2- 2
2.3.1 Alarm panel ………………………………………………………………………2
………………………………………………………………………2-2
2.3.2 Data link panel ……………………………………………………………………2
……………………………………………………………………2-3
2.4 Display part…… ……………………………………………………………………2
……………………………………………………………………2-3
2.4.1 Summary ……………………………………………………………………………2
……………………………………………………………………………2-3
2.4.2 Panel key and shuttle key …………
……………………………………………………
……………………………………………………2
……………………………………………2-4
2.4.3 Display connection …………………………………………………………………2
…………………………………………………………………2-4
2.4.4 Communication connection …………………………………………………………2
…………………………………………………………2-5
2.5 Control part …………………………………………………………………………2
…………………………………………………………………………2-5
2.5.1 Summary …………………………………………………………………………2
…………………………………………………………………………2-5
2.5.2 Main board ………………………………………………………………………2
………………………………………………………………………2-5
2.6 System communication ………………………………………………………………2
………………………………………………………………2-5
2.7 Schematic airway of the Anesthesia Machine ………………………………………2
………………………………………2-6
2.7.1Summary ……………………………………………………………………………2
……………………………………………………………………………2-6
2.8 Schematic airway of the respiration system ………………………………………
………………………………………2
…………………2-6
…………………………………………………………………2
2.8.1 Manual ventilation ………………………………………………………………… 2- 6
……………………………………………………………2
2.8.2 Mechanical ventilation …………………………………………………………… 2- 6
2.8.3 Fresh gas and O2 flush ……………………………………………………………2
……………………………………………………………2-6
2.9 Mechanical ventilation subsystem ……………………………………………………2
……………………………………………………2-7
2.9.1 Pressure reducing valve ……………………………………………………………2
……………………………………………………………2-7
………………………………………………2
2.9.2 Solenoid valve and VT adjusting valve……………………………………………… 2- 7
………………………………………………………………………2
2.9.3 Exhaust valve ……………………………………………………………………… 2- 7
2.9.4 Expiration valve ……………………………………………………………………2
……………………………………………………………………2-8
…………………………………………………………………………2
2.9.5 Safety valve………………………………………………………………………… 2- 8
2.9.6 Flow sensor…………………………………………………………………………2
…………………………………………………………………………2-8
3 Testing procedure ………………………………………………………………………3
………………………………………………………………………3-1
……………………………………………………3
3.1 Vaporizer back-pressure testing …………………………………………………… 3- 2
3.2 Pipeline testing………………………………………………………………………3
………………………………………………………………………3-2
3.2.1 O2 supply failure alarm test…………………………………………………………
…………………………………………………………3
……………………………………………3-2
3.3 O2 flush test…………………………………………………………………………3
…………………………………………………………………………3-2
3.4 Alarm test ………
……………………………………………………………………………3
……………………………………………………………………3-2
0
3.5 Power supply failure test……………………………………………………………3

……………………………………………………………3-3
3.6 Electrical safety test…………………………………………………………………3
…………………………………………………………………3-3
4 Calibration ……………………………………………………………………4-1
4.1 O2 flush valve… ……………………………………………………………………4-2
4.2 Paw calibration ……………………………………………………………………4-2
4.3 VT calibration ……………………………………………………………………4-3
4.4 Calibration of the O2% of inspiration ………………………………………………4-4
5 Failure exclusion …………………… ………………………………………………5-1
………………………………………………5
5.1 Normal failure exclusion ………… ……………………………………………… 5- 1
………………………………………………6
6 Repair procedure…………………… ……………………………………………… 6- 1
6.1 How to exhaust the gas pressure inside the machine …………………………………6
…………………………………6-2
6.2 How to remove the back cover board ………… ………… …………………………………6
…………………………………6-2
6.2.1 Remove the back-up cover board parts…………… ………………………………6
………………………………6-2
………………………………6
6.2.2 Remove the frame cover board of the drawer……… ……………………………… 6- 2
6.3 How to remove the parts of the desk panel …………… ……………………………6
……………………………6-3
6.4 Replacing the incoming gas filter core of the pipeline ……………………………6
……………………………6-3
6.4.1 Replacing parts of one-way valve …………………… ……………………………6……………………………6-3
6.5 Maintenance of the vaporizer installation base ………… ……………………………6
……………………………6-4
6.5.1 Maintenance of the port valve………………………… …………………………6 …………………………6-4
6.5.2 Replacing the vaporizer installation base………………… …………………………6
…………………………6-4
6.6 Replacing the one-way valve …………………………………………………………6
…………………………………………………………6-5
6.7 Replacing the truckles ……………………………………… ………………………6 ………………………6-5
7 RS-232 communication agreement……………………………………………………7
……………………………………………………7-1
7.1 Setup of the serial port ………………………………………………………………
………………………………………………………………7
…………………………………………7-2
7.2 Data cell format ………………………………………………………………………7
………………………………………………………………………7-2
8 Schematic diagram………………………………………………………………………8
………………………………………………………………………8-1
8.1 Schematic airway diagram ……………………………………………………………8
……………………………………………………………8-2
8.2 Schematic airway diagram of the respiration system………… ………………………8
………………………8-3
8.3 Schematic circuit diagram…………………………………… ……………………… ………………………88- 4
1
1 Introduction
Contents of this chapter

1.1 Components of the Anesthesia system
1.2 Components of the respiration system
1.3 LCD control key
1.4 LCD display
1.5 Signs used in this handbook or on the equipment
1-1
1.1 Components of the Anesthesia system
1
4
7 2
1 LCD of the Anesthesia system

2 Vaporizer
3 Flow meter
4 Pressure meter
5 O2 flush button
6 common gas outlet
7 Respiration system
8 truckle
figure 1-
1 -1
1-2
6
5 7
8
9
4
1 Pipeline gas joint

2 Power switch
3 Fuse socket
4 Power socket
5 Driving gas joint
6 Flow sampling joint
7 Exhaust gas outlet
8 Communication port
9 O2% sensor socket
figure1-
figure1-2
1-3
1.2 Components of the respiration system
7
1
10
2
8
6
9
1 Expiration valve
2 Airway pressure meter 12
11
3 Inspiration valve
4 O2% sensor
5 Manual/Auto switch
6 APL valve
7 Bellows integration
8 bag joint
9Fresh gas inlet
10 Auto-control joint
11 Releasing pin of the absorber canister
12 Absorber canister
figure 1-3
1-4
1.3 Control-key and Indication light of LCD
1 Ventilation mode key 6 Menu key

2 I:E ratio key 7 VT adjusting knob
3 RESP freq key 8 mute indicator light
4 Triggering key 9 Alarm indicator light
5 silence button 10 Power indicator light
11 Shuttle key
figure1
figure1-4
1.4 LCD display
Paw[hPa] O2 50 % 8 7
30
1 I:E
1/ 2.0 6
Freq
0
-10
BPM 20
0 2 4 6 8[s] TRG
Flow[L/Min]
80
hPa --
VT
L .90
1 PEAK
-80
hPa 19
0 2 4 6 8[s]
MV
MV HIGH !! ↑
01:12:20
LPM 18
2 3 4 5
1 waveform
2 Alarm indication
1-5
3 Power indication
4 Triggering indication
5 Measured value
6 Parameter value
7 Mode display
8 O2% display
figure1
figure1-5
1.5 Signs used in this manual or on the equipment
Warnings and Cautions show the possible dangerous situations if do not follow this
manual.
Warnings show possible situations that might cause harm to the operator or patients.
Cautions show possible situations that might cause damage to the equipment. Please read
and follow all the Warnings and Cautions.

Other signs are also used to replace explanation in words in this manual or on the equipment.
But it does not mean all these signs show up at the same time in this handbook or on the
equipment, and they include:
1-6
1-7
2 work principle
2.1 Electrical system
2.2 Power supply subsystem
2.2.1 Summary
2.2.2 Charging panel
2.3 Alarm & signal exchange
2.3.1 Alarm panel
2.3.2 Data link panel
2.4 Display part
2.4.1 Summary
2.4.2 Panel key and shuttle key
2.4.3 Display connection
2.4.4 Communication connection
2.5 Control part
2.5.1 Summary
2.5.2 Main board
2.6 System communication
2.7 Schematic airway of the Anesthesia Machine
2.7.1 Summary
2.8 Schematic airway of the respiration system
2.8.1 Manual ventilation
2.8.2 Mechanical ventilation
2.8.3 Fresh gas and O2 flush
2.9 Automatic ventilation subsystem
2.9.1 Pressure reducing valve
2.9.2 Solenoid valve and VT adjusting valve
2.9.3 Exhaust valve
2.9.4 Expiration valve
2.9.5 Safety valve
2.9.6 Flow sensor
2-1
2.1 Electrical system

Electrical system is composed of two main parts: display and control part
The display part is used to complete user joint function, and the operating software for the
display part is written by assemble language.
The control function is done by the control part, adopting ATMEL 89C52 CPU,and the
control software is written by assemble language.
Communication of the those parts(where mentioned above) is done by serial port.
Electrical system complete its functions through circuit panels as follows:
· Main board
· Charging panel
· Alarm panel
· Data joint panel
· Top light panel
· Display panel
· Indicator light panel
· Driven panel
· Power inverter panel
2.2 Power supply subsystem
2.2.1 Summary
AC power supply is connected to power switch by power supply switch and fuse. Power
switch sends out 24V/5A volts d.c. through AC/DC converter. This DC voltage is provided not
only to the recharging panel but also to top light panel.
2.2.2Charging panel
to main board JP1
to Power Switch +24V
to battery
When connected to AC, two battery are recharged by the charging panel, and provide power
and information of AC power to the main board. When AC does not work properly, battery will
provide power to the main board by charging panel, and provide backup battery information to
the main board.
2.3 Alarm & Signal exchange

2.3.1 Alarm panel
2-2
Connect to main board J2
Q2
The oscillatory circuit sends out impulse signals to control the buzzer’s phonation, and Q2
controls the on/off of the voice.
2.3.2 Data link panel to main board J4
to main board J6
O2% sensor socket

RS-232 Communication Link
The data link panel is used to transfer signals, and provide a RS-232 communication line to
the user, the link agreement is in Chapter 7.
2.4 Display part
2.4.1 Summary
User joint function is achieved by display part.
Display part is composed of the following main parts:
·LCD
·Display panel
·Inverter panel
·Indicator light panel
·Driven panel
Indicator light panel
Display panel
LCD
2-3
Inverter panel
Driven panel
2.4.2 Panel key and shuttle key
to shuttle key
to panel key
The display panel adopts two CPUs produced by ATMEL company. Both of them has a main
frequency of 11.0592MHz.89C2051 is used to process singles generated by the shuttle key and
89C58 is to process sigles generated by the panel key.
2.4.3 Display connection

LCD is controlled by the driven panel, the display panel transmits content to the drive panel,
and the indication light is controlled by the display panel.
Connect to driven
panel J2
Connect to indication Connect to inverter panel

light panel JP1 CN1
2-4
2.4.4 Communication connection

JP2 of the display panel is connected to J1of the main board by 89C58 to transmit signals with
main board through RS-232 serial port.
Connect to main board J1
2.5 Control part

2.5.1 Summary
Control function is achieved by the control part.
The control part has several main parts as follows:
· Main board
2.5.2 Main board
Connect to display
panel JP2
Connect to data
Connect to charging panel
joint panel JP3
Connect to alarm
Connect to data panel J1
joint panel JP1
\
The main board adopts two CPUs produced by ATMEL company. It gathers and processes flow
signal、pressure signal and O2% signal through A/D exchange circuit.According to user’s
respiration parameters, it controls the solenoid valve through D/A exchange circuit. It transmits
singles with the display part by 89C52 through RS-232 serial port.
2.6 System communication

The display part and the control part communicate through RS-232 serial port , and the BOLT
ratio is 9600
2-5
2.7 Schematic airway of the Anesthesia Machine

2.7.1 Summary
Gas supply Gas is connected into the system by pipeline-gas joint, and all of the joints are
composed of filters element and one-way valves. They are uninterchangable. The
pressure meter indicated the pressure of the gas. The alarm signal of O2 insufficiency
is provided by pressure sensor.
Gas flow direction O2 ,as the power gas source, is directly provided to the anesthesia machine.
O2 flush valve provides a heavy O2 flow to the mixed gas outlet.
Mixed gas Mixed gas flows to the vaporizer installation seat and vaporizer (if vaporizer is
opening), pass one-way valve to the common gas outlet.
2.8 schematic airway of the respiration system
2.8.1 Manual ventilation
Manual inspiration Manual/Auto exchange switch is on manual position(reservoir bag).
Gas from reservoir bag, pass absorber canister and inspiration valve to patient
In inspiration phase, fresh gas flow out from common gas outlet and converge with
inspiration gas at upper part of the inspiration valve.
Manual expiration manual/auto exchange switch is on manual position(reservoir bag).
Gas from the patient’ port, pass expiration valve to reservoir bag
In expiration phase, fresh gas converge with expiration gas at downstream of the
absorber and expiration valve.
APL valve When on manual ventilation state, use APL valve to set pressure limit.
When you turn APL valve’s knob, the pressure of the APL film shall increase or
decrease. When the pressure is too high, film will open and gas will be discharged.
2.8.2 Mechanical ventilation
Mechanical inspiration Manual/Auto exchange switch is on Auto position (Mechanical
ventilation).
Gas pressure diverged from the outlet of the solenoid valve will shut down the
expiration valve.
Driven gas pushes down the bag, then gas flows out of the bag, pass absorber
canister、 inspiration valve to the patient.
In inspiration phase, fresh gas converge with inspiration gas at upper part of the
inspiration valve
Mechanical expiration When the driven gas stops, the expiration valve opens, expired gas from
the patient, through expiration valve to bag,and the rest of the driven
gas will be discharged from the exhaust gas outlet.
In expiration phase, fresh gas converges with expiration gas at
downstream of the expiration valve.
Exhaust valve The exhaust valve limits the inside pressure of skin cell to no more than 2.5
cm H2O above driven gas pressure.
This normally occurs when the bellows reaches the top at the end of
exhalation.
Excess gas is discharged from the exhaust gas.
2.8.3 Fresh gas and O2 flush
Fresh gas from vaporizer installation seat, passes the one-way valve to mixed gas outlet.
2-6
O2 passes the pressure reducing valve to the O2 flush valve. When press the O2 flush button,
O2 and fresh gas enter the mixed gas outlet together.
2.9 Mechanical ventilation subsystem

Automatic ventilation subsystem includes:
·Pressure reducing valve
·Solenoid valve and VT adjusting valve
·Exhaust valve
·Expiration valve
2.9.1 Pressure reducing valve

The pressure reducing valve reduces the gas pressure to 200Kpa, as the input pressure of the
solenoid valve.
2.9.2 Solenoid valve and VT adjusting valve
The solenoid valve adopt 35A-ACA-DFEA-1BA type two-position T solenoid valve, which
is produced by MAC company of America.
Connect to VT adjusting valve
Connect to expiration
valve (1)
Connect to expiration valve (2)
The VT adjusting valve adjusts the flow that enters the expiration valve, therefore controls VT.
2.9.3 Exhaust valve
2-7
Exhaust valve
In respiration system, the bellows integration is the connection between driven gas and
patient’s airway, the exhaust valve of bellows integration is used to control the pressure of the
respiration loop, and discharge excessive gas from the patient from the exhaust gas outlet.
In normal condition, the exhaust valve is closed. If there is no gas flow, the pressure value of
respiration loop is maintained at 1.5cmH2o level. It’s enough to keep the bag in inflated state.
When inspires, it will be turned off until when it expires and the bag is inflated. The exhaust gas
exhausts at not more than 4L/Min when the pressure under 4cmH2O
2.9.4 Expiration valve
2 1
Usually, the expiration valve is open. When inspires, the pressure (1), which is loaded on the
expiration valve, braves the film, then the expiration valve closes. When expires, the gas pressure
disappears, then the expiration valve will open.
2.9.5 Safety valve
There is a mechanical safety valve in the expiration valve, when the pressure of driven gas is
more than safety valve’s default value (about 110cmH2o), it will open.
2.9.6Flow sensor
Flow sensor is used to monitor the expiration VT, it is installed at the patient’s T joints. If gas
flow passes through the sensor, both sides of the sensor’s film will generate a pressure difference,
the difference single will be read by the CPU of the main board, then get the VT value through
calculation.
2-8
3 Testing

3.1 Vaporizer back-pressure testing
3.2 Pipeline testing
3.2.1 O2 supply failure alarm testing
3.3 O2 flush testing
3.4 Alarm testing
3.5 Power supply failure testing
3.6 Electrical safety testing
Warning: After maintenance or repair of the equipment, inspection is needed according to the
requests of this Chapter.
Before testing required by this Chapter:
Accomplish all of necessary calibration and parts testing, and refer to separate calibration list.
Accomplish the assembly of the system.
If it does not pass the test, please make a proper repair and correct inspection.
3-1
3.1 Vaporizer back-pressure testing
Warning: During testing, the anesthetic will overflow, please use safe and appropriate
procedure to gather and treat it.

1． Turn on power supply switch
2． O2 flow adjusts to 6L/min
3． Adjust gas concentration of the vaporizer, including each scale from 0 to 1%.
·Make sure the O2 flow constantly.
·Verify the system that it is operating continuously and it does not set off any alarm.
4． Retest another vaporizer (If applicable)
3.2 Pipeline testing
1． Connect gas source to the pipeline’s inlet, and make sure the pressure meter can correctly
display the pipeline’s pressure.
3.2.1 O2 supply failure alarm testing
1． Connect the gas source O2 and N2O
2． Set O2 %to 25%
3． Set the total flow to 3L/min
4． Turn off O2 supply(separate from O2 supply pipe)
5． Make sure
·The“O2 Supply Pressure Low”alarm is on
·The flow of N2O and O2 stops,
3.3 O2 flush testing

1． Manual/auto exchange switch is at manual position(reservoir bag).
2． Connect with the patient loop, and block the patient port with plug.
3． Make sure the gas of bag has been exhausted
4. Measure the time from pressing O2 flush button to fully inflated state of bag
5． Repeat the above testing more than twice, (remove the plug from patient’s port, and
discharge the gas from bag)
The time for the bag to reach its full state should be between 1.8s to 2.3s.
Possible reasons for failure

·Big leakage (need a long time to fill up the air cell)
·The output of the pressure reducing valve is not correct.
·The connection of the pressure reducing valve is in a reversed way.
3.4 Alarm testing

1． The patient’s port is connected with a mock lung
2． Manual/Auto exchange switch is set at mechanical ventilation position.
3．Set O2 %to 30%
4． Test O2 alarm
Set FiO2 Low alarm value to 50%，FiO2 Low alarm is on
Set FiO2 Low alarm value to 21%，FiO2 Low alarm is off
3-2
Set FiO2 Low alarm value to 50%

·press O2 flush button
·make sure the FiO2 High alarm is on
·Set FiO2 High alarm value to 100%，FiO2 High alarm is off
5． Test MVLow alarm
Switch to alarm setting menu
Set MVLow alarm valuebigger than MV measure value.
Make sure the MVLow alarm is on
Set MVLow alarm off
6．Test Ppeak High alarm
Set Pmax less than Ppeak
Make sure the Ppeak High is on
Set Pmax as desired value
7． Set all the alarm values to the approved clinical values.
3.5 Power supply failure testing

1．Plug in the power plug
2．Turn off the power switch
3． Pull out the power plug
4． Make sure the alarm of the power failure is on
5． Make sure the following messages are displayed.
·The symbol of battery
6． Re-plug in the power
7． Make sure the alarm is off
3.6 Electric safety testing
Make sure the electric system is assembled in its right postion
1． Connect to the authorized testing instrument; make sure the biggest leakage flow is less
than 0.5mA
2． Make sure the grounding impedance between the touchable metal shell and the
grounding pole of the power pin is less than 0.2Ω
3-3
4 Calibration
Warning: After testing and calibration, please test again according to Chapter 3 of this
manual.
4.1O2 flush valve
4.2 Paw calibration
4.3 VT calibration
4.4 Calibration the O2% of inspiration
4-1
4.1 O2 flush pressure reducing valve
adjusting knob deferent joint
O2 flush pressure reducing valve
deferent joint
Pressure reducing valve
1． Exhaust the inner gas pressure of the instrument

2．Remove the panel cells
3． Pull out the outlet pipe of the O2 flush reducing valve, plug in T joint and connect it with
pressure meter.
4． Connect to gas source
5． Press the O2 flush button and it will form a shot of gas flow, read the value on the pressure
meter, it should be 200±20kPa
6． If need adjustment
· Pull out the adjusting knob
·Turn the knob to the pressure mentioned above.
·Push up the adjusting knob
·Calibrate the pressure value
7． Turn off the power
8． Hold O2 flush button, exhaust the gas pressure, and disconnect T pin and pressure meter.
9． Reconnect with the outlet pipe of O2 flush pressure reducing valve
10． Put on parts of the desk panel
4.2 Paw calibration
1． Go to system parameter setting menu with the following steps:
·Make sure there is no parameter is in setting state and there is no pop-up menu,
·Press menu key
·Press menu key again
·It will show 〖PASSWORD〗on the screen.
·Enter “PASSWORD ” 188
·System parameter menu shows up on the screen
4-2
Paw
Gain : xx
Paw
Zero : xx
Flow
Gain : xx
Flow
Zero : xxx
O2
Gain : xx
O2
Zero : xxx
2． Connect a pressure meter to the patient’s T joint; connect gas to the patient’s port
3． Adjust the ＰaｗＺero value, make display value of Paw to 0.
4． Connect a mock lung to the patient’s port
5． Adjust ＰaｗＧain value, make sure the display value of Paw is same as the value of the
pressure meter.
6． Repeat step1 to 5
7． Press MENU key, exit the system parameter menu
４.3 VT calibration
1． The instrument is in IPPV（VC）mode, and the setting of the respiration parameter is as
follows:
·F 20，
·I：E １：20，
·Trig OF THEF，
2． Press MENU key and enter“PASSWORD”to get into the system parameter menu
3． Connect the VT testing instrument to the patient’s T joint, and connect the mock lung to
the patient’s port.
4． Set the VT value to 200mL, adjust the Flow Zero parameter, the display value of the VT
should be as same as the value of the testing(error should be ≤±5％or ±20 mL )
5． Set the VT value to 800mL, adjust the Flow Gain parameter value, the display value of the
VT should be as same as the value of the testing(error is ≤±5％or ±20 mL )
6． If the setting value is±20％ more than the display value, then
· Remove the panel cells
· Connect the pressure meter, check the output pressure of the pressure reducing valve, it
should be 200±20kPa
·if needs adjustment
·Pull out the adjusting knob
·Turn the knob to the pressure mentioned above.
· Push up the adjusting knob
·Calibrate the pressure reading value
4-3
·Put on the parts of the desk panel

8． Repeat step1 to 7
9． Press MENU key, exit the system parameter menu
4.4 Calibration of O2% of Inspiration
１．Press MENU key and enter “PASSWORD”to get into the system parameter menu
２．Put O2% sensor in the air
３．Adjust Ｏ2 Zero parameter, make the display value of O2% to ２１％.
４．Put O2% sensor in the respiration loop again
５．Press the O2 flush button
６．Input １００％Ｏ2 with ５Ｌ／min flow
７．Adjust the Ｏ2 Gain parameter, make the display value of O2% to 100%, if the
display value is less than 95%, please replace the O2% sensor,
8．Repeat step 1 to 7
9.Press the MENU key, exit the system parameter menu.
4-4
5 Failure exclusion
CONTENTS OF THIS CHAPTER
5.1 Normal failure exclusion
Failure phenomena Possible causes Solutions

High Pressure Leakage Pipeline Leakage By listening, identify the source of
O2 flush valve leakage, repair or replace the
components that have problems.
By listening, identify the source of
leakage, ensure the pipeline is tight
closed and replace the valve.
If it has not been installed correctly,
Low Pressure Leakage The vaporizer was not please install again.
( the vaporizer has been installed correctly. If the vaporizer is leaking, please
installed) The O-ring seal of vaporizer contact the manufacturer or the
installation seat is lost or seller.
damaged. Check o-ring seal to see if it is lost
The vaporizer injection screw or damaged, if so, please replace
is not screwed tightly. the O-ring seal.
Check the medicine adding place, if
the screw is not screwed tightly,
please screw it tight.
The port valve of the vaporizer Replace the port valve of the
Low Pressure Leakage is leaking. vaporizer
( with or without vaporizer) The O2 flush valve is leaking Replace the O2 flush valve
Bellows Leakage The exhaust valve was not Install the exhaust valve again
correctly installed Install the bellows again and make
The rock reed of bellows is not the rock reed is locked
locked Checking whether the folding cell
The bellows was not correctly is tightly hitching the tray, if the
installed or the folding cell folding cell is damaged, please
was damaged replace it.
Respiration system Leakage The absorber canister is not Correctly install the absorber
installed canister
Mechanical ventilation does No O2 supply Checking O2 supply
not work
5-1
6Repair procedure
6.1 How to exhaust the machine’s inside gas pressure
6.2 How to remove the back cover board
6.2.1 Remove the back-up cover board cells
6.2.2 Remove drawer frame cover board
6.3 How to remove the panel cells
6.4 Replacing the incoming gas filter core of the pipeline
6.4.1 Replacing the one-way valve cells
6.5 Maintenance of the vaporizer installation seat
6.5.1 Maintenance of the port valve
6.5.2 Replacing the vaporizer installation seat
6.6 Replacing the one-way valve
6.7Replacing the truckles
6-1
Warning: In order to keep it away from fire

·DO NOT use lubes which contains oil or liquid, they would burn or explode when the O2
reach a certain density. .
·The material of all the cover used in this system, must be anlistatig, because static
electricity may cause a fire
Please abide by the antisepsis control and safety rules, because used equipments may
contain blood and body fluid.
The active parts and knock-down cells may catch your hand or crush it. Be careful to move
or change the parts of the system
Some inner components have sharp side, it may cut your hand, so when maintaining the
inner parts, please be more careful.
When the maintenance has been completed, check the system again.
Caution: Static discharge from the circuit panel may damage the components. Before you
take off the panel, please put on antistatic gloves, hold the insulated wire of the panel
and place the circuit panel in an anti-static container.
6.1 How to exhaust the machine’s inner gas pressure
Before you disconnect the gas source, please exhaust the inner gas pressure of the equipment
１． Turn off all gas source valves, and disconnect the gas source
２． Make sure the reading value of all the pressure values of all pipelines are 0.
３． Open the flow meter; make the gas pressure value decrease to 0 if they are not at 0.
6.2 How to remove the back cover board
You have to remove the back cover board to maintain or change some parts of the machine.
6.2.1 Remove the back-up cover board cells
１． Exhaust all of the machine’s inner gas pressure (Refer to 6.1).
２． Make sure the reading value of all the pressure values of all pipelines are 0.
３． Pull out the power plug
４． Screw off eight M4×8 stainless steel bolts, then remove the back-up cover board cells
6.2.2 Remove the drawer frame cover board
1. Exhaust all of the machine’s inner gas pressure (Refer to 6.1)
2. Make sure the reading value of all the pressure values of all pipelines are 0.
3. Pull out the power plug
4. Screw off six M4×8 stainless steel bolts, then remove the drawer frame cover board
6-2
charging panel
Power switch
storage battery
6.3 How to remove the panel cells
The panel cells is fixed on the airway box by the foot-fasteners

which locate on both sides of the panel cells and with one M5×40 stainless steel bolt.
Remove the panel following these steps:
1. Screw off the M5×40 stainless steel bolt
2. Carefully pull out the panel cells.
6.4Peplacing the inlet gas filter element of the pipeline
１． Screw off the inlet gas tie-in seat of the pipeline
２． When pull out the filter element, the O-ring seal loop should be with it.
3． Install the filter element with O-ring seal loop again.
4． Screw up the entering gas tie-in seat of the pipeline

6.4.1 Replacing the one-way valve cells
1．Remove the back-up cover board cells(Refer to 6.2.1)
2．Screw off the enter gas tie-in seat of the pipeline
3．Pull out the trachea behind the enter gas valve.
4. Use a small screwdriver to push out the one-way valve cells from behind the enter gas
valve.
6-3
１． Put a new set of one-way valve cells into the enter gas valve, and there should be one
O-ring seal loop on it, and it is towards the enter gas direction.
Caution: Make sure the one-way valve has been completely placed into the enter gas
valve.
6． Screw up the enter gas tie-in seat of the pipeline
7． Test.
6.5 Maintenance of the vaporizer installation seat
6.5.1 Maintenance of the port valve

6-3
1．Turn off the power supply
2. Remove the vaporizer from the vaporizer installation seat
3． Carefully remove the spout
３． Remove all the components which need to be replaced, refer to the following
valve 14×2.65 O-ring seal loop
spout
spring
spring seat 15×1.80 O-ring seal loop
spring 5×1.80 O-ring seal loop
6.9×1.80 O-ring seal loop
vaporizer installation seat
picture,
5．Make sure there is no dust and dirt on the components.

6． Install the port valve again in a reversed order.
6.5.2Replacing the vaporizer installation seat
1． Remove the back-up cover board cells(Refer to 6.2.1)
2．Pull out the trachea which is on the installation seat.
3． Screw off the fixing bolt.
4． Install a new installation seat again in a reversed order.
6-4
M6×12
Fixing bolt M6×12 M6×12 Fixing bolt M6×12
A
A
M6×12 Fixing bolt M6×12
6.6 Replacing the one-way valve cells(Refer to the following picture)

1． Turn off the power supply
2． Remove the panel cells(refer to 6.3)
3．Pull out the tracheas which are located at the one-way valve.
4． Screw off two fixing bolts.
5． Install a new one-way valve again in a reversed order.
Caution: The direction of the one-way valve’s arrow must point to the common gas outlet.
M4×25
one-way valve
Fixing bolt M4×25
M4×25
Common gas outlet
6.7replacing of the truckles
Warning: At least two people are needed to replace the casters. If only one person is doing
it, it might hurt himself (herself) or damage the equipment.
1．Pull out the power plug, and disconnect the gas source
Caution: Before tilting the equipment, please remove the vaporizer. If the vaporizer tilted
over, set the density of the vaporizer to 5%, use the 5L/min airflow to wash the vaporizer for 30
minutes, the interlocker can prevent washing two vaporizers at the same time.
2． Remove the respiration system, vaporizer, drawer and all of the assistant devices.
Caution: In order to prevent damage to the equipment, don’t tilt it more than 10 degree.
3． Raise one side of the defective caster still you can replace it conveniently.
4． The casters are fixed on the base plate, use a proper hatch spanner to screw off them.
5． If needed, wipe the new caster with alcohol.
6-5
6． Install the new caster.

7． Make sure the caster spin smoothly.
8． Carefully put the equipment on the ground.
6-6
7 RS-232 communication agreement
contents of this chapter

7.1 Setup the serial port
7.2 Data cell format
7-1
7.1 Setup the serial port

9600bps 8bit 1stop
7.2 Data cell format

13 bytes of each cell
D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12
D0：The original sign of the cell, it is fixed at 0AAH.

D1：Cell types: 03H means the waveform、 alarm data and set parameters. This cell is transmitted
once every 50ms.
04H means the measured data. The cell is transmitted after 25ms of the respiration cycle
ends.
D11：Verify value. D11=(the sum of D1 to D10) XOR 0FH
D12：The end sign of the cell, it is fixed at 055H
D2 PAWi Instantaneous airway pressure value (unit: hPa )

D3 ALARM2 2 alarm bytes
D4 FLOWi Instantaneous flow value (unit: 10L/min)
D5 Vti Instantaneous tidal volume value (unit : 10mL)
D6 ALARM1 1 alarm byte
D7 O2 The value of O2 density (unit : %)
D8 STATUS Status byte
D9 PNO Setup the parameter number
D10 PVALUE Setup the parameter value
when the D1=03H

When M-904E, D4、D5、D7 are not used.
When ZY9100,D5 is not used.
BIT0 ―― standby
BIT1 ―― standby
BIT2 ―― standby
BIT3 ―― standby
BIT4 Triggering Triggering status flag, 0 is not triggering, 1 is triggering.
Flag
BIT5 PAWSign Airway pressure sign, 0 is positive, 1 is negative.
BIT6 FlowSigh Flow speed sign, 0 is positive, 1 is negative.
BIT7 IE Flag Inspiration and expiration status flag, 0 is inspiration phase,1 is
expiration phase.
STATUS definition
When M-904, BIT 4、BIT 5、BIT6 are not used.
7-2
BIT0 NOGAS Gas shortage alarm

BIT1 AC Fail AC failure alarm
BIT2 Battery Low Low Battery alarm
BIT3 PAW High High PAW alarm
BIT4 PAW Low Low PAW alarm
BIT5 VT High High tidal volume alarm
BIT6 VT Low Low tidal volume alarm
BIT7 O2 High High O2 density consistency alarm
ALARM1 definition：
When M-904, BIT 5、BIT6 、BIT 7 are not used.
BIT0 O2 Low Low O2 density alarm

BIT1 MV High High minute ventilation value alarm
BIT2 MV Low Low minute ventilation value alarm
BIT3 No O2 Sensor No O2 Sensor alarm
BIT4 Sustained PAW Sustainable high PAW alarm
BIT5 ―― Standby
BIT6 ―― Standby
BIT7 ―― Standby
ALARM2 definition
When M-904, BIT 0、BIT 1、BIT2 、BIT 3 are not used.
PNO definition
7-3
PNO PVALUE
0 （ VC
MODE: Breathing machine mode: 0 is manual, 1 is auto I PPV ） mode, 2 is auto I
（ VC
PPV ） mode.M-904 and ZY9100 does not have mode 2.
1 ： Frequency respiration default value (unit: times/min)
FREQ
2 RATIO： Respiration ratio default value X10. if it is 2.0, it means the respiration ratio is
1:2.0
3 ： Triggering sensitivity default value (unit: -hPa). M-904 is not in use.
TRG
4 ： Tidal volume default value (unit: 10ml). M-904 and ZY9100 are not in use.
VT
5 ： Compliant compensation default value (unit: %). M-904 and ZY9100 are not in
CLT
use.
6 ： Sign times default value (unit: times). M-904 and ZY9100 are not in use.
SIGH
7 ： Platform time percentage default value (unit: %). M-904 and ZY9100 are not in
TIP
use.
8 ： PEEP default value (unit: -hPa). M-904 and ZY9100 are not in use.
PEEP
9 ： High Paw alarm (unit: hPa).
PH
10 ： Low Paw alarm (unit: hPa)
PL
11 ： High Tidal volume alarm (unit: 10ml). M-904E is not in use.
VTH
12 ： Lowest Tidal volume alarm (unit: 10ml). M-904E is not in use.
VTL
13 ： Highest Minute ventilation alarm (unit: L/min). M-904E is not in use.
MVH
14 ： Lowest Minute ventilation alarm (unit: L/min). M-904E is not in use.
MVL
15 ：
O2H High O2 consistency alarm (unit: %). M-904E doesn’t use.
16 ：
O2L Lowest O2 density alarm (unit: %). M-904E is not in use.
17 ： Airway Pressure gain (unit: -). System parameter. M-904E doesn’t use.
PAWGAIN
18 ： Zero Airway Pressure (unit: -). System parameter. M-904E is not in use.
PAWZERO
19 ： Tidal volume gain (unit: -). System parameter.
VTGAIN
20 ：
VTZERO Zero Tidal volume (unit: -). System parameter.
21 ： O2 density gain (unit: -). System parameter. M-904E is not in use.
O2GAIN
22 ： O2 density zero (unit: -). System parameter. M-904E doesn’t use.
O2ZERO
23 ： PEEP zero (unit: -). System parameter. M-904E doesn’t use.
PEEPZERO
24 ： Pmax default value in PC mode (unit: -). M-904 and ZY9100 don’t use.
PMAX
25 ： Type default value (unit: -). 0 is ZY9300,1is ZY9100,2 is －
SETTING M 904E.
26 ：
MUTE Mute default value (unit: -). 0 is not mute, 1 is mute.
When D1=04H
7-4
D2 VT Tidal volume measured value (unit: 10ml)

D3 MVH
Minute ventilation volume value (unit: 10ml/min)
D4 MVL
D5 PEAK Peak airway pressure measured value (unit: hPa)
D6 PMean Average measured value (unit: hPa)
D7 PEEP PEEP measured value (unit: hPa)
D8 Pplat Platform pressure measured value (unit: hPa)
D9 CL Compliance measured value (unit:L/kPa)
D10 Freq Frequency measured value (unit: times/min)
7-5
8schematic diagram
CONTENTS OF THIS CHAPTER

8.1 Schematic airway diagram
8.2Schematic airway diagram of the respiration system
8.3Schematic circuit diagram
8-1
8.1 Schematic airway diagram
1 Filter 6Vaporizer
2 Pressure meter 7 One-way valve
3 Check valve 8 O2 flush valve
4 Pressure reducing valve 9Common gas outlet
5 Flow meter 10 Vaporizer installation seat
8-2
8.2Schematic airway diagram of the respiration system
1 Pressure reducing valve

2 Solenoid valve
3 VT adjusting valve
4 Safety valve
5 Expiration valve
6 Exhaust gas joint
7 Bellows
8 Absorber
9 Inspiration valve
10 Expiration valve
11O2% sensor
12 Flow sensor
13 Auto/Manual switch
14 APL valve
15reservoir bag
16 Respiration loop
17 Fresh gas inlet
18 Water storage container
19 Exhaust valve
20 O2 driven gas coming from airway
8-3
8.3 Schematic circuit diagram
Electromagnet Alarm
ism valve panel
Key/shuttle
key
A
C Power Main board
Recharging
switch panel display
panel
Batter
y
Data link Driven Indication

board board light board
Display Inverter
Flow sensor
screen
panel
8-4
ZY9100 Series Multi-function Anesthesia Machine

Service Handbook
2006 Edition
Edited in June, 2006
By
Technical Department
GE Healthcare Clinical Systems(Wuxi) Ltd., Co.

2008-06-07-ZY9100 English Service Manual PDF

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ZY9100series multi-functional Anesthesia machine

ZY9100 Series Multi-function

GE Healthcare Clinical Systems(Wuxi) Ltd., Co.

3.5 Power supply failure test……………………………………………………………3

Contents of this chapter

1.1 Components of the Anesthesia system

1 LCD of the Anesthesia system

1 Pipeline gas joint

1.2 Components of the respiration system

1.3 Control-key and Indication light of LCD

1 Ventilation mode key 6 Menu key

and follow all the Warnings and Cautions.

2.1 Electrical system

to main board JP1

to Power Switch +24V

2.3 Alarm & Signal exchange

Connect to main board J2

2.3.2 Data link panel to main board J4

O2% sensor socket

Indicator light panel

2.4.2 Panel key and shuttle key

2.4.3 Display connection

Connect to indication Connect to inverter panel

2.4.4 Communication connection

Connect to main board J1

2.5 Control part

2.6 System communication

2.7 Schematic airway of the Anesthesia Machine

2.9 Mechanical ventilation subsystem

2.9.1 Pressure reducing valve

Connect to VT adjusting valve

Connect to expiration valve (2)

2.9.3 Exhaust valve

Contents of this chapter

3.1 Vaporizer back-pressure testing

procedure to gather and treat it.

3.3 O2 flush testing

Possible reasons for failure

3.4 Alarm testing

Set FiO2 Low alarm value to 50%

3.5 Power supply failure testing

4.1 O2 flush pressure reducing valve

adjusting knob deferent joint

O2 flush pressure reducing valve

1． Exhaust the inner gas pressure of the instrument

·Put on the parts of the desk panel

Failure phenomena Possible causes Solutions

Warning: In order to keep it away from fire

6.3 How to remove the panel cells

The panel cells is fixed on the airway box by the foot-fasteners

4． Screw up the entering gas tie-in seat of the pipeline

6.5.1 Maintenance of the port valve

valve 14×2.65 O-ring seal loop

spring seat 15×1.80 O-ring seal loop

spring 5×1.80 O-ring seal loop

6.9×1.80 O-ring seal loop

vaporizer installation seat

5．Make sure there is no dust and dirt on the components.

M6×12 Fixing bolt M6×12

6.6 Replacing the one-way valve cells(Refer to the following picture)

Common gas outlet

6.7replacing of the truckles

6． Install the new caster.