Pre-Flight Medical Device Testing: Complete Safety Checklist 2025

A POC failing at 35,000 feet. A CPAP refusing to power on in a foreign hotel. A wheelchair battery dying at airport security. These preventable emergencies happen to unprepared travelers every day.

Pre-flight testing is the difference between confident travel and medical device disasters. This comprehensive guide provides professional testing protocols for every major medical device, ensuring your equipment works flawlessly when you need it most.

Why Pre-Flight Testing Is Non-Negotiable

The Cost of Device Failure

What Happens When Devices Fail During Travel:

POC Failure:

• Emergency oxygen needed (airline cylinders, hospital visit)
• Flight delays or denial of boarding
• Trip cancellation ($1,000s in lost reservations)
• Medical emergency (respiratory distress)

CPAP Failure:

• Sleep deprivation (safety risk driving, poor decision-making)
• Missed sleep apnea therapy (health consequences)
• Expensive emergency device rental ($200-500)
• Trip disruption

Wheelchair Failure:

• Immobility at destination
• Emergency wheelchair rental ($300-800/week)
• Medical complications from immobility
• Trip cancellation

Prevention Cost: 30-60 minutes of testing before travel Failure Cost: $500-5,000+ in emergency replacements, medical care, trip disruption

When Devices Typically Fail

High-Risk Failure Points:

1. After long storage (device unused for weeks/months)
2. With fresh batteries (defective batteries, improper charging)
3. Temperature changes (cold cargo hold, hot car)
4. TSA screening (rough handling, X-ray exposure)
5. Altitude changes (pressure affects some devices)
6. International voltage (incorrect adapters, voltage spikes)

Pre-flight testing catches 90% of potential failures before they become emergencies.

Universal Testing Protocol (All Devices)

48-Hour Pre-Flight Testing Window

Why 48 Hours?:

• Time to identify problems
• Time to repair/replace device
• Time to arrange backup equipment
• Reduces pre-travel stress (not last-minute panic)

Basic Testing Sequence (All Devices):

Step 1: Visual Inspection (5 minutes)

• Check for physical damage (cracks, dents, loose parts)
• Inspect power cord (fraying, exposed wires)
• Examine connections (ports, battery terminals)
• Look for wear indicators (filters, tubing, masks)

Step 2: Power-On Test (10 minutes)

• Turn device on
• Verify startup sequence completes
• Check for error messages
• Ensure all lights/displays function normally
• Listen for unusual sounds (grinding, clicking, buzzing)

Step 3: Operational Test (20 minutes)

• Run device at normal settings
• Verify all functions work (flow rate, pressure, speed)
• Test for 20+ minutes continuous (reveals intermittent issues)
• Monitor temperature (shouldn't overheat)

Step 4: Battery Test (30 minutes)

• Test each battery individually
• Verify runtime matches specifications
• Charge/discharge cycle test
• Check battery charge indicators

Step 5: Accessory Test (10 minutes)

• Test all accessories (cannulas, masks, tubing)
• Verify proper fit and function
• Replace any worn items

If Device Passes All Tests: Safe for travel ✅ If Device Fails Any Test: Troubleshoot, repair, or replace before travel ⚠️

Device-Specific Testing Protocols

Portable Oxygen Concentrators (POCs)

Complete POC Testing Procedure:

1. Pre-Test Preparation (Day Before Testing):

• Clean POC exterior (dust, debris)
• Check/replace filters (if due for replacement)
• Charge all batteries to 100%
• Gather: POC, all batteries, cannulas, power cord

2. Visual Inspection (5 minutes):

• Exterior: No cracks, dents, or damage
• Battery compartment: Clean, no corrosion
• Air intake vents: Clear of obstructions
• FAA label: Visible and intact
• Serial number: Matches documentation

3. Filter Inspection (3 minutes):

• Locate filters (varies by model)
• Remove and inspect (clean? discolored? damaged?)
• Replace if: Dirty, >6 months old, or device manual recommends
• Reinstall securely

Common Filter Locations:

• Inogen G5: Side panel (foam filter, clean weekly)
• Philips SimplyGo Mini: Back panel (particle filter)
• Respironics EverGo: Bottom of unit

4. Power-On Test (5 minutes):

• Insert fully charged battery
• Press power button
• Observe: Startup sequence completes (lights, sounds)
• Check display: No error codes
• Verify: Device reaches normal operating state

Error Codes: Consult user manual immediately if error appears. Common errors:

• Low oxygen purity: Filter issue or compressor problem
• Battery error: Try different battery
• Service required: Contact manufacturer

5. Flow Rate Test (15 minutes):

• Set to your prescribed flow rate (e.g., 2 LPM)
• Place cannula in nostrils or use pulse oximeter
• Breathe normally
• Verify: Pulse detection indicator activates with each breath
• Change flow rate (test all settings you use)
• Verify: Device responds correctly to setting changes

6. Battery Runtime Test (Per Battery, 30-60 minutes):

Full Runtime Test (If Time Permits):

• Start with 100% charged battery
• Run device at your normal setting
• Time until battery depletes
• Compare to manufacturer's specs

Quick Runtime Test (If Limited Time):

• Run device for 15 minutes on battery
• Check battery level indicator
• Estimate: If 100% → 90% in 15 min, battery good
• If dramatic drop (100% → 50% in 15 min), battery may be failing

Expected Battery Life Examples:

• Inogen G5 (16-cell): 6.5 hours at setting 2
• Philips SimplyGo Mini (extended): 4.5 hours at 2 LPM
• If your battery lasts <50% of spec, replace before travel

7. AC Power Test (10 minutes):

• Unplug battery, plug in AC adapter
• Turn on POC
• Verify: Device operates on AC power
• Check: Charging indicator (if battery inserted)
• Test: AC cord secure (wiggle test—shouldn't cut power)

8. Alarm Test (5 minutes):

• Block air intake (cover vents briefly)
• Verify: Alarm sounds
• Check: Alarm volume adequate (hear in noisy environment?)
• Restore airflow, alarm should stop

9. Accessory Test (5 minutes):

• Cannulas: Check for kinks, cracks, stiffness
• Connection: Secure fit to POC outlet
• Tubing: No blockages (blow through to test)
• Carry case: Zippers work, straps secure

10. Documentation Check (3 minutes):

• Prescription: Current (within 12 months)
• FAA approval letter: Printed
• Battery specs: Documented (watt-hours)
• User manual: Key pages packed

POC Testing Checklist Summary: ✅ Filters clean/replaced ✅ All batteries tested (runtime verified) ✅ Flow rate functions correctly ✅ AC power works ✅ Alarms functional ✅ Accessories in good condition ✅ Documentation complete

If POC Fails Testing: Contact manufacturer (most offer 24/7 support), consider backup oxygen supplier, or delay travel.

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CPAP/BiPAP Machines

Complete CPAP Testing Procedure:

1. Visual Inspection (5 minutes):

• Machine exterior: No damage
• Water chamber: No cracks, seals intact
• Power cord: No fraying
• Air filter: Clean (foam or disposable)
• Tubing: No holes, tears, or discoloration

2. Filter Inspection and Replacement (5 minutes):

Filter Types:

• Disposable filters: Replace monthly (or per manual)
• Foam filters: Wash weekly, replace every 6 months
• Ultra-fine filters: Replace as directed (3-6 months)

How to Check:

• Remove filter from CPAP
• Hold up to light—can you see through it clearly?
• If dark, clogged, or >6 months old: Replace

3. Water Chamber Test (3 minutes):

• Fill with water (distilled preferred)
• Check for leaks (none should appear)
• Verify: Chamber attaches securely to CPAP
• Note: Empty before travel (TSA liquid rules)

4. Power-On Test (5 minutes):

• Plug in CPAP
• Turn on
• Observe: Display lights up, no error codes
• Listen: No unusual sounds (grinding, clicking)
• Feel: Air begins flowing from outlet

5. Pressure Test (10 minutes):

• Connect mask and tubing
• Set to your prescribed pressure
• Turn on CPAP
• Put on mask (or cover with pillow to simulate)
• Verify: Pressure builds to prescribed level
• Check: No major leaks (some minor leaks normal)

How to Verify Pressure:

• Most CPAPs have pressure display
• Or use CPAP data app (if available)
• Mask should feel snug but comfortable
• No whistling sounds (indicates leak)

6. Humidifier Test (If Applicable, 15 minutes):

• Fill water chamber
• Set humidity level
• Run CPAP for 15 minutes
• Check: Water vapor in tubing (condensation forming)
• Verify: No leaks from chamber

7. Mask Fit Test (10 minutes):

• Put on mask as you normally would
• Turn on CPAP
• Breathe normally for 5 minutes
• Check for leaks: Listen and feel around edges
• Adjust straps if needed

Mask Leak Test Results:

• No leaks: Perfect ✅
• Minor leaks (occasional air escape): Acceptable ⚠️
• Major leaks (constant hissing, mask won't seal): Replace mask ❌

8. Ramp and Comfort Features Test (5 minutes):

• Test ramp function (pressure starts low, increases)
• Test EPR/pressure relief (if applicable)
• Verify: All comfort settings work
• Ensure: Settings match your preferences

9. Data Review (If Applicable, 5 minutes):

• Download data from CPAP (if smart device)
• Check: Recent usage shows proper function
• Look for: No unusual events (excessive leaks, apneas)
• Baseline: Useful if you need to compare during travel

10. Backup Supplies Check (5 minutes):

• Extra mask: In good condition
• Extra filters: Packed
• Extra tubing: No damage
• Distilled water strategy: Plan to buy at destination

CPAP Testing Checklist Summary: ✅ Filters clean/replaced ✅ Water chamber leak-free ✅ Pressure reaches prescribed level ✅ Mask seals properly ✅ Humidifier functions (if used) ✅ Backup supplies ready

If CPAP Fails Testing: Contact equipment supplier, manufacturer, or doctor for troubleshooting. Consider backup device or postpone travel.

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Wheelchairs and Mobility Devices

Complete Wheelchair Testing Procedure:

1. Visual Inspection (10 minutes):

• Frame: No cracks, bends, or damage
• Wheels/tires: Proper inflation, no wear
• Brakes: Engage fully, release completely
• Joystick/controls: No cracks, buttons responsive
• Seating: Cushion intact, no tears
• Footrests: Secure, no damage

2. Battery Inspection (10 minutes):

• Battery type documented (lithium, wet cell, gel)
• Terminals clean (no corrosion)
• Watt-hour rating visible and documented
• Battery fully charged
• Charge indicator working

Battery Terminal Protection:

• Lithium batteries: Must be protected during flight
• Use: Electrical tape, terminal caps, or disconnect
• Practice disconnecting/reconnecting (you may need to at airport)

3. Power-On Test (5 minutes):

• Turn on wheelchair
• Check: Battery indicator shows full charge
• Verify: No error codes on display
• Listen: No unusual sounds (grinding, clicking)

4. Mobility Test (15 minutes):

• Drive forward/backward
• Test turning (left, right, 360°)
• Test speed settings (all speeds)
• Test on incline (if available)
• Verify: Smooth operation, no jerking or hesitation

5. Brake Test (5 minutes):

• Engage brakes
• Attempt to move wheelchair (shouldn't budge)
• Release brakes
• Verify: Wheelchair moves freely
• Test: Emergency brake/kill switch (if applicable)

6. Joystick/Control Test (10 minutes):

• Test: All directional controls
• Verify: Speed control adjusts smoothly
• Check: All buttons function (horn, lights, etc.)
• Test: Control sensitivity (not too sensitive or too loose)

7. Seating and Comfort Test (10 minutes):

• Sit in wheelchair
• Check: Cushion provides adequate support
• Verify: Footrests at proper height
• Test: Armrests secure
• Adjust: Any necessary seating positions

8. Battery Runtime Test (30-60 minutes):

Full Test (If Possible):

• Drive wheelchair until battery depletes
• Note: How long until low battery warning
• Compare: To manufacturer's specifications

Partial Test (More Practical):

• Drive for 30 minutes at normal usage
• Check battery level
• Estimate remaining range
• If drops dramatically, battery may need replacement

9. Charging Test (30+ minutes):

• Plug in charger
• Verify: Charging indicator lights up
• Monitor: Battery level increases
• Check: Charger doesn't overheat
• Confirm: Charger cord secure (wiggle test)

10. Documentation Preparation (15 minutes):

• Take photos: Multiple angles, close-ups of damage (if any)
• Measure: Length, width, height (for airline forms)
• Document: Make, model, serial number
• Prepare: Battery specs (type, watt-hours, terminal protection method)
• Print: Assembly/disassembly instructions (for airline staff)

Wheelchair Testing Checklist Summary: ✅ Battery fully charged and tested ✅ All mobility functions working ✅ Brakes engage and release properly ✅ No unusual sounds or errors ✅ Joystick/controls responsive ✅ Battery terminals protected ✅ Documentation prepared

If Wheelchair Fails Testing: Contact manufacturer, wheelchair repair service, or medical equipment supplier. Do not travel with malfunctioning wheelchair (safety risk).

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Insulin Pumps and Diabetes Devices

Complete Insulin Pump Testing Procedure:

1. Pump Inspection (5 minutes):

• Screen: No cracks
• Buttons: All responsive
• Battery compartment: Clean, no corrosion (if replaceable battery)
• Infusion site: No redness, irritation, or leakage
• Tubing: No kinks, bubbles, or blockages

2. Battery Test (10 minutes):

Rechargeable Pump (Tandem t:slim, etc.):

• Charge to 100%
• Use normally for 24 hours
• Check battery level
• Compare: To typical daily drain
• If drains faster than usual, contact manufacturer

Replaceable Battery Pump (Medtronic, etc.):

• Insert fresh battery
• Note: Start level (should show full)
• Use normally for 24 hours
• Check: Battery level
• Pack: 3× your usual battery needs

3. Basal Delivery Test (1 hour):

• Check current basal rate
• Monitor for 1 hour
• Verify: Pump delivers basal insulin (check history)
• Confirm: No occlusion alarms

4. Bolus Delivery Test (Per Meal):

• Deliver normal meal bolus
• Verify: Pump delivers full bolus (check history)
• Monitor: Blood sugar responds normally
• Check: No errors or incomplete boluses

5. Settings Backup (10 minutes):

• Screenshot: All pump settings (basal rates, I:C ratios, ISF)
• Write down: Key settings (in case pump fails)
• Email: Screenshots to yourself (backup)
• Print: Settings page (pack with travel documents)

6. CGM Test (If Applicable, 24 hours):

• Check sensor: Age (replace if expiring during trip)
• Verify: Sensor readings match fingerstick
• Test: Alerts working (high/low alarms)
• Confirm: Transmitter battery adequate (replace if <2 weeks)

7. Supplies Calculation (15 minutes):

• Count: Current supplies (infusion sets, reservoirs, sensors)
• Calculate: Trip needs (days × daily use × 3)
• Pack: 3× your calculated needs
• Include: Backup supplies (syringes, insulin pens)

8. Backup Insulin Test (If Switching to MDI):

• Have: Long-acting insulin (Lantus, Basaglar, Tresiba)
• Have: Rapid-acting insulin (Humalog, Novolog, Apidra)
• Know: Your MDI regimen (if pump fails)
• Pack: Syringes or pen needles

Diabetes Device Testing Checklist Summary: ✅ Pump battery fully charged or fresh ✅ Basal and bolus delivery working ✅ Settings backed up (screenshots, written) ✅ CGM functioning and sensor fresh ✅ 3× supplies packed ✅ Backup insulin and injection method ready

If Pump/CGM Fails Testing: Contact manufacturer (most offer 24/7 support), have backup insulin regimen ready, consider delaying travel if unable to resolve.

Troubleshooting Common Pre-Flight Test Failures

POC Won't Turn On

Possible Causes:

1. Battery dead (charge it)
2. Battery improperly inserted (remove and reinstall)
3. Internal fault (contact manufacturer)

Solutions:

• Try different battery
• Plug into AC power (if works, battery issue)
• Reset device (see user manual)
• Call manufacturer support

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CPAP No Pressure / Low Pressure

Possible Causes:

1. Dirty filter (restricts airflow)
2. Mask leak (pressure escaping)
3. Loose tubing connection
4. Humidifier chamber not sealed

Solutions:

• Clean or replace filter
• Check all connections (mask, tubing, CPAP)
• Try different mask
• Reseat water chamber

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Wheelchair Battery Dies Quickly

Possible Causes:

1. Battery old (needs replacement)
2. Charger malfunction (not fully charging)
3. Motor issue (drawing excess power)

Solutions:

• Test with different battery (if available)
• Check charger output (should charge to 100%)
• Contact wheelchair repair service
• Replace battery before travel (if >2 years old)

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Insulin Pump Occlusion Alarms

Possible Causes:

1. Kinked tubing
2. Infusion site issue
3. Bubble in tubing
4. Bad insulin cartridge

Solutions:

• Check tubing for kinks
• Change infusion site
• Prime tubing to remove bubbles
• Replace cartridge
• If persists, call manufacturer

Emergency Backup Testing

Testing Your Backup Equipment

If You Have Backup Device:

• Test backup device using same protocol as primary
• Ensure backup is fully charged and functional
• Pack backup in separate bag (don't lose both devices together)

If You Don't Have Backup:

• Research: Rental equipment at destination
• Document: Emergency oxygen suppliers, wheelchair repair, diabetes supplies
• Pack: Extra supplies (batteries, masks, insulin) to extend primary device life

Final 24-Hour Pre-Travel Checklist

Night Before Travel:

• Charge all batteries to 100% (POC, CPAP, wheelchair, pump)
• Clean devices (POC filters, CPAP mask)
• Pack tested accessories (cannulas, tubing, masks)
• Organize documentation (prescriptions, test results, battery specs)
• Screenshot device settings (pumps, CPAPs)

Morning of Travel:

• Final power-on test (verify device turns on)
• Check battery indicators (all showing full)
• Verify documentation in quick-access pouch
• Pack chargers and power adapters
• One last check: Device, batteries, meds, documents ✅

At Airport:

• Test POC before going through security (turn on briefly)
• Verify wheelchair fully charged (if checking)
• Have documentation easily accessible for TSA

When to Delay Travel

Red Flags That Require Delaying Trip: ❌ Critical device repeatedly fails testing ❌ Battery runtime <50% of specifications ❌ Manufacturer says device needs repair/service ❌ No backup equipment and primary device unreliable ❌ Unable to obtain necessary prescriptions or documentation

It's Better to Delay Than to Face Medical Emergency Mid-Flight

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Have questions about testing specific devices or troubleshooting test failures? Connect with the MedFly Safe community for advice from experienced medical device travelers who've been through the pre-flight testing process.