REMstar Auto CPAP System Service Manual

Transcription

1 REMstar Auto CPAP System Service Manual

2 REMstar Auto CPAP System is the subject of U. S. patent #5,239,995. Other patents pending. REMstar, Whisper Swivel, and Comfort Flap are trademarks of Respironics, Inc REMstar Auto CPAP System W-1

3 Limited Warranty Respironics, Inc. warrants that the REMstar Auto CPAP device shall be free from defects of workmanship and materials and will perform in accordance with the product specifications for a period of two years from the date of sale by Respironics Inc. to the dealer. If the product fails to perform in accordance with the product specifications, Respironics Inc. will repair or replace, at its option, the defective material or part. Respironics Inc. will pay customary freight charges from Respironics Inc. to the dealer location only. This warranty does not cover damage caused by accident, misuse, abuse, alteration, and other defects not related to materials or workmanship. Respironics Inc. disclaims all liability for economic loss, loss of profits, overhead, or consequential damages which may be claimed to arise from any sale or use of this product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty is given in lieu of all other express warranties. In addition, any implied warranty, including any warranty of merchantability or fitness for the particular purpose, is limited to two years. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. The warranty for repairs is ninety days for labor and one year on the part(s) that was replaced. To exercise your rights under this warranty, contact your local authorized Respironics Inc. dealer or contact Respironics Deutschland, Gewerbestrasse 17,#82211 Herrsching Germany, REMstar Auto CPAP System W-2

4 Limited Warranty Respironics Inc. warrants that this Humidifier shall be free from defects of workmanship and materials and will perform in accordance with the product specifications for a period of one year from the date of sale by Respironics, Inc. to the dealer. If the product fails to perform in accordance with the product specifications, Respironics Inc. will repair or replace, at its option, the defective material or part. Respironics Inc. will pay customary freight charges from Respironics Inc. to the dealer location only. This warranty does not cover damage caused by accident, misuse, abuse, alteration, and other defects not related to materials or workmanship. Respironics Inc. disclaims all liability for economic loss, loss of profits, overhead, or consequential damages which may be claimed to arise from any sale or use of this product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty is given in lieu of all other express warranties. In addition, any implied warranty, including any warranty of merchantability or fitness for the particular purpose, is limited to one year. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. The warranty for repairs is ninety days for labor and one year on the part(s) that was replaced. To exercise your rights under this warranty, contact your local authorized Respironics Inc. dealer or contact Respironics Deutschland, Gewerbestrasse 17, Herrsching Germany, REMstar Auto CPAP System W-3

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6 Table of Contents Overview: REMstar Auto CPAP System Chapter 1: Introduction REMstar Auto CPAP System Overview Service Notice Technical Support Statement Chapter 2: Warnings, Cautions and Notes Warnings Safety Service Cleaning Cautions Notes Table of Contents Chapter 3: Specifications, Features, Descriptions, and Theory of Operation Overview Specifications CPAP Specifications Humidifier Specifications System Features Symbols / Meanings Functional Description Theory of Operation (Subassemblies) CPAP Main Printed Circuit Assembly (Main PCA) Control Pad & Liquid Crystal Display (LCD) Power Supply Encore Pro SmartCard REMstar Auto CPAP System T-1

7 Table of Contents Chapter 4: System Setup Procedures Chapter 6: Troubleshooting and Diagnostics Overview Programming a SmartCard Changing Settings using a SmartCard REMstar Auto CPAP System Setup Display Screens Heated Humidifier System Setup Display Screens Recommended Circuit Accessories Recommended Accessories DC Power Accessories Adding Oxygen to the System Chapter 5: Routine Maintenance Overview Cleaning the System Cleaning / Replacing the Intake Filter Removing, Cleaning, and Replacing the Filter REMstar Auto CPAP System Preventive Maintenance Schedule REMstar Auto CPAP System Preventive Maintenance Schedule Overview Trouble Shooting Flow Chart Common System Level Problems Troubleshooting Table REMstar Auto Error Codes Extracting Error Codes From the Unit Extracting Error Codes Using Utility Software Smart Card Error Code Chart Humidifier LED Error Code Chart Chapter 7: Repair & Replacement Overview REMstar Auto CPAP System Repair Kits Respironics Heated Humidifier Repair Kits Warnings and Cautions Replacement Instructions Filter Cap Replacement Top Enclosure Replacement Key Pad Replacement Main Printed Circuit Assembly (Main PCA) Replacement Main Printed Circuit Assembly (Main PCA) Real Time Clock REMstar Auto CPAP System T-2

8 Table of Contents Flex Tubing Replacement Outlet Port and Flow Element Replacement Blower Assembly Replacement Bottom Enclosure Replacement Heated Humidifier Water Chamber Heated Humidifier Top Enclosure Heated Humidifier Heater Assembly Heated Humidifier Main PCA Heated Humidifier Bottom Enclosure Chapter 8:Testing Testing Process Run-in Procedure REMstar Auto CPAP System Calibration Calibration REMstar Auto CPAP System Performance Verification REMstar Auto /manual/ Heated Humidifier Test Current Draw Test REMstar Auto CPAP System Performance Verification Data Sheet REMstar Heated Humidifier Test Data Sheet Appendix A: Tools and Equipment... A-1 A.1 Service Tools and Supplies... A-3 A.2 Acceptable Test Equipment... A-4 A.2.1 Digital Manometer... A-4 A.2.2 Digital Multimeter... A-4 A.2.3 Flow Meter... A-4 Appendix B: Schematics... B-1 B.1 Schematics Statement B-2 Micro & Digital......B-3 Micro, Flash & Debug Connector......B-4 Analog Circuitry......B-5 Motor Controller......B-6 Power Supply & Decoupling Caps B-7 Digital B-8 Main Power.....B-9 Humidifier... B REMstar Auto CPAP System T-3

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10 Overview: REMstar Auto CPAP System Overview Warranty Details the Respironics warranty. Chapter 1: Introduction Introduces the REMstar Auto CPAP System. Chapter 2: Warnings, Cautions, and Notes Lists the Warnings, Cautions, and Notes. Chapter 3: Specifications, Features, Descriptions, Describes the theory of operation for the REMstar Auto CPAP System and Theory of Operation including basic operations of the subsystems. Chapter 4: System Setup Procedures Details system setup, including instructions on the Therapy Menu Display Screens and Required, Alternate, and Optional Patient Accessories. Chapter 5: Routine Maintenance Provides cleaning and routine maintenance instructions. Chapter 6: Troubleshooting and Diagnostics Provides troubleshooting flow charts and error code definitions. Chapter 7: Repair and Replacement Describes detailed procedures of removing and installing all major components within the unit, including graphics and photographs for visual identification. Chapter 8: Testing Includes the User Interface Checkout Procedure, CPAP Calibration, Run-In, CPAP Final Test, Heated Humidifier Test, Current Draw Test and Data Sheet. Appendix A:Tools and Equipment Appendix B:Schematics Details the necessary tools and test equipment required for servicing. Provides Printed Circuit Assembly (PCA) schematics. NOTE: Schematics are proprietary and are used for reference only REMstar Auto CPAP System O-1

11 Overview (This page intentionally left blank.) REMstar Auto CPAP System O-2

12 Chapter 1: Introduction Chapter 1: Introduction 1.1 REMstar Auto CPAP System Overview Service Notice Technical Support Statement REMstar Auto CPAP System 1-1

13 Chapter 1: Introduction Notes: REMstar Auto CPAP System 1-2

14 Chapter 1: Introduction Chapter 1: Introduction 1.1 REMstar Auto CPAP System Overview The REMstar Auto CPAP System shown in Figure 1-1, is a microprocessorcontrolled device that delivers Continuous Positive Airway Pressure (CPAP) therapy and Auto CPAP therapy only for the treatment of adult Obstructive Sleep Apnea (OSA). The REMstar Auto CPAP System provides a constant level of positive pressure throughout the breathing cycle to pneumatically splint the airway open. The unit incorporates a Liquid Crystal Display (LCD), operational keys with LED backlighting, internal audible and visual alarms, a ramp feature, and a Respironics SmartCard port for use with the Encore Pro Data Management Software. The unit may be operated using either AC ( VAC) or DC ( VDC) power. Figure 1-1 REMstar Auto CPAP REMstar Auto CPAP System 1-3

15 Chapter 1: Introduction 1.2 Service Notice This service manual was prepared by Respironics primarily for use by technicians to service the REMstar Auto CPAP System with the following Model No: , , , , , The individuals using this manual to service the REMstar Auto CPAP System should have prior training or experience servicing ventilatory devices. 1.3 Technical Support Statement Respironics is committed to customer satisfaction and may be contacted with any questions or for product support. For technical assistance or replacement part ordering information contact Respironics Customer Satisfaction. U.S. and Canada International Phone: Fax: Phone: Fax: Visit Respironics Home Page on the World Wide Web at: Contact Technical Support via at: REMstar Auto CPAP System 1-4

16 Chapter 2: Warnings, Cautions, and Notes Chapter 2: Warnings, Cautions, and Notes 2.1 Warnings Cautions Notes REMstar Auto CPAP System 2-1

17 Chapter 2: Warnings, Cautions, and Notes Notes: REMstar Auto CPAP System 2-2

18 Chapter 2: Warnings, Cautions, and Notes Chapter 2: WARNING: CAUTION: NOTE: 2.1 WARNINGS Safety Warnings, Cautions, and Notes Indicates the possibility of injury to the patient, operator, or technician. Indicates the possibility of damage to the device. Places emphasis on an operating characteristic. This device is intended for adult use only. This device is not intended for life support or life sustaining applications. This warning applies to most Continuous Positive Airway Pressure (CPAP) devices. At low CPAP pressures, the air flow through the exhalation port may not be enough to clear all of the exhaled gas (CO 2 ) from the mask. You may breathe in some of the air that you have exhaled. If oxygen is used with this device, the oxygen flow must be turned off when the device is turned off. If the device s air flow is turned off and the oxygen flow is left on, oxygen may accumulate in the REMstar Auto CPAP System enclosure and may create a risk of fire. This warning applies to most types of CPAP devices. When supplemental oxygen is used at a fixed flow rate, inhaled oxygen concentrations will vary depending on pressure settings, patient breathing patterns, mask selection and leak rate. The instructions in this manual are not intended to supersede established medical protocols REMstar Auto CPAP System 2-3

19 Chapter 2: Warnings, Cautions, and Notes Oxygen supports combustion. Do not use oxygen in the presence of open flames, cigarette smoke, electrical spark, or other sources of ignition. This device is not suitable for use in the presence of a flammable anesthetic mixture in combination with oxygen or air or in the presence of nitrous oxide. In situations where risk of contamination between the user and the device is high (e.g., sleep lab devices; rental devices; users with respiratory infections), a low-resistance, main flow bacteria filter should be placed in-line between this device and the circuit. Most CPAP devices have the potential to allow rebreathing of exhaled air. To reduce this potential, use Respironics circuit accessories, do not wear the mask and headgear for more than a few minutes while the unit is not operating, and do not block or try to seal the vent holes in the exhalation port. Do not use this device if the room temperature is warmer than 95 F (35 C). If this device is used at room temperatures warmer than 95 F (35 C), the temperature of the airflow may exceed 106 F (41 C). This could cause irritation to your airway Service Cleaning Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, Electro-Static Discharge (ESD) protected environment. To assure the safety of the service technician and the specified performance of the device, Respironics recommends that only technicians having prior training or experience servicing ventilatory devices perform any repairs or adjustments to the REMstar Auto CPAP System. High voltages are present inside this device. To avoid electrical shock, disconnect the electrical supply before attempting any repairs on the device. To avoid electrical shock, disconnect the electrical supply before cleaning the REMstar Auto CPAP System. DO NOT immerse this device into any fluids REMstar Auto CPAP System 2-4

20 2.2 CAUTIONS 2.3 NOTES Chapter 2: Warnings, Cautions, and Notes CAUTION: Federal law (U.S.) restricts this device to sale by, or on the order of, a physician. Care should be taken to avoid exposure of the REMstar Auto CPAP System to temperatures at or near the extremes of those specified in Chapter 3. If exposure to such temperatures has occurred, the device should be allowed to return to room temperature before being turned on. Refer to the User s Manual for product use, additional warnings, cautions, and notes. Additional WARNINGS, CAUTIONS, and NOTES are located throughout this manual. Always use an intake filter when the REMstar Auto CPAP System is in use. Discontinue using this device if any of the parts are damaged. Replace any damaged parts before continuing use. The information in this manual is provided for service personnel reference and is not intended for system setup or use. System setup should be performed by appropriate personnel using the Home Care Provider Setup Instructions. Tobacco smoke may cause tar build-up within the REMstar Auto that may result in damage REMstar Auto CPAP System 2-5

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22 Chapter 3: Chapter 3: Specifications, Features, Descriptions and Theory of Operation Specifications Features, Descriptions, and Theory of Operation 3.1 Overview Specifications System Features Functional Description Theory of Operation REMstar Auto CPAP System 3-1

23 Chapter 3: Specifications, Features, Descriptions and Theory of Operation Notes: REMstar Auto CPAP System 3-2

24 Chapter 3: Specifications, Features, Descriptions and Theory of Operation Chapter 3: Specifications, Features, Description, and Theory of Operation 3.1 Overview This chapter describes the REMstar Auto CPAP System with Heated Humidifier specifications and system features, and provides a functional description and theory of operation REMstar Auto CPAP System 3-3

25 Chapter 3: Specifications, Features, Descriptions and Theory of Operation 3.2 Specifications FUSES: CPAP Specifications Fuses There are no replaceable fuses. ENVIRONMENTAL: PHYSICAL: Operating Temperature Transport & Storage Temperature Humidity (Operating / Storage) 41 to 95 F (5 to 35 C) -4 to 140 F (-20 to 60 C) 15 to 95% non-condensing Dimensions Weight ELECTRICAL: 9 1/2 in x 6 7/8 in x 4 1/2 in (24 cm x 17 cm x 12 cm) < 4.0 lbs. (< 1.8 kg) NOTE: The outlet temperature rise can be as much as 18 F (10 C) higher than room temperature measured at the end of a 6 foot (1.83 m) smooth bore patient tubing. AC Input Voltage VAC ± 10% 50 / 60 Hz DC Voltage 12 VDC Atmospheric Pressure 83 to 102 kpascals AC Current Consumption 1.0 A maximum Elevation Tested at 0 to 5500 ft. DC Current Consumption 3.0 A maximum Sound Pressure Level Less than or equal to 30 db(a) In accordance with EN 10 cm H 2 O at the patient circuit. This measurement applies to the CPAP device with or without the optional REMstar Heated Humidifier. Type of Protection Against Electrical Shock Degree of Protection against Electrical Shock Class II Equipment 2-prong AC power inlet Type BF Applied Part REMstar Auto CPAP System 3-4

26 Chapter 3: Specifications, Features, Descriptions and Theory of Operation Degree of Protection Against Ingress of Water IPX0-Ordinary Equipment FUNCTIONS: Modes of operation: CPAP, Auto CPAP Mode of Operation Continuous RAMP: Humidifier Operation Standard Compliance: This product is designed to conform to the following standards. IEC Medical Electrical Equipment, Part 1 General Requirements for Safety and essential performance EN ISO Sleep Apnea Breathing Therapy Devices Minimum Ramp Pressure Minimum Ramp Pressure Set Point Resolution 0.2 cm H 2 0 Ramp Time 4.0 cm H 2 O to current CPAP setting 0 to 45 minutes Ramp Time Resolution 5 minute increments ALTITUDE COMPENSATION: Altitude Pressure Range kpascals Automatic Altitude Adjustment COMPLIANCE METER: Compliance Meter (LCD) Total Operation Time Therapy Time REMstar Auto CPAP System 3-5

27 Chapter 3: Specifications, Features, Descriptions and Theory of Operation PRESSURE: AC Operation 4 to 20 cm H 2 O (in 0.2 increments) DC Operation 4 to 20 cm H 2 O (in 0.2 increments) NOTE: Pressure accuracy measurements shall be taken at the end of a six foot (1.83 m) patient circuit with a Whisper Swivel II exhalation port connected to an Oxygen enrichment adapter that is occluded. The manometer should be connected to the O2 port. Static Pressure Accuracy + or cm H 2 O with no humidifier. THERAPY MEMORY: Therapy Memory STORAGE: Data Storage Max Capacity Content Retrievable by Encore Pro Software. Data storage is on a removable contact SmartCard. 6 months of data when assuming that a session is 8 hours per day Separate memory areas for prescription information and settings. Pressure Drop with Humidifier 0.3 cm H 2 20 cm H 2 O REMstar Auto CPAP System 3-6

28 Chapter 3: Specifications, Features, Descriptions and Theory of Operation Humidifier Specifications ENVIRONMENTAL: Operating Temperature 41 to 95 F (5-35 C) Storage Temperature -4 to 140 F ( C) Humidity (Operating / Storage) 15-95% non-condensing Operating Atmospheric Pressure 76.7 to 102 kpascals Storage Atmospheric Pressure kpascals PHYSICAL: AC Input Voltage VAC ± 10% 50 / 60 Hz AC Current Consumption DC Input Voltage Heater Adjustment Heater Plate Temperature Accuracy Maximum Heater Plate Temperature 1.7 A maximum No DC capabilities Ambient to 65 C adjustable in 5 discrete steps. ± 5% after reaching thermal equilibrium 65 C ± 5 C after a steady state has been achieved. Dimensions x 6.5 x in (33.7 x 16.5 x 5.4 cm) Type of Protection Against Electrical Shock Class II Equipment 2-prong AC power inlet Weight Capacity ELECTRICAL 3.5 lbs (1.5 kg) with water chamber filled and without the CPAP. Minimum of 1 2/3 cups (400 ml) of water when filled to the maximum fill line. Degree of Protection Against Electrical Shock Degree of Protection Against Ingress of Water Mode of Operation Type BF Applied Part IPX0-Ordinary Equipment Continuous Fuses There are no replaceable fuses REMstar Auto CPAP System 3-7

29 Chapter 3: Specifications, Features, Descriptions and Theory of Operation PERFORMANCE: Maximum Pressure Drop Less than 0.3 cm H 2 O pressure drop throughout the range of pressures Air Outlet Port LCD Display Connect flexible tubing here. Displays all system settings, therapy hours, blower hours, and sessions > 4 hours. STANDARDS COMPLIANCE This product complies with the requirements found in the following standards. IEC Medical Electrical Equipment, Part 1 General Requirements for Safety and Essential Performance UL UL Deviations to IEC CAN/CSAC 22.2 No M90 CSA Deviations to IEC System Features AC Power Connector DC Power Connector Connect AC power here. Optional DC power connection for CPAP only NOTE: DC mode is not for heated humidifier operation. Filter Cap & Filter Pressure On / Off Button Ramp Button Heated Humidifier Button User Buttons The pollen filter screens out normal household dust and pollens. This must be in place at all times when operating the REMstar Auto CPAP System. This button turns the air flow on or off. DO NOT turn the air flow on until the circuit tubing is connected. This button decreases the pressure to the minimum ramp pressure setting in the CPAP mode or to the minimum Auto-CPAP pressure in the Auto CPAP mode. Use this button only when the optional Heated Humidifier is connected. Follow the instructions included with the humidifier. These buttons can be used to change some of the device settings REMstar Auto CPAP System 3-8

30 Display Screen Symbols and Descriptions Chapter 3: Specifications, Features, Descriptions and Theory of Operation Attention is needed Patient disconnect alert enabled or setting is shown SmartCard is installed Button Lights are ON or setting is shown Humidifier is ON or humidifier setting is shown Minimum Pressure Setting >4 Ramp start pressure setting is shown Ramp pressure is being delivered FOSQ test questions are shown Centimeters of water (displayed with pressure readings or settings) Number of nights with more than 4 hours usage Therapy Setup Menu Maximum Pressure Setting Settings are being erased Hours of Use REMstar Auto CPAP System 3-9

31 Chapter 3: Specifications, Features, Descriptions and Theory of Operation Control Button Symbols and Descriptions Pressure On / Off Humidifier On / Off Ramp Start ~ 0123 Device Symbols and Descriptions Attention, consult accompanying documents DC Power AC Power European CE Declaration of Conformity Notified Body Approval for Standards Compliance Type BF Applied Part Class II (Double Insulated) IPX0 Ordinary Equipment Rating Canadian/US Certification REMstar Auto CPAP System 3-10

32 Chapter 3: Specifications, Features, Descriptions and Theory of Operation 3.4 Functional Description The REMstar Auto CPAP System is a microprocessor controlled Continuous Positive Airway Pressure (CPAP) device that will produce positive pressure. The REMstar Auto CPAP System operates in CPAP mode, and in the AutoCPAP mode. CPAP pressure range in the AC and DC operation: cm H 2 O. The ramp feature lets the user reduce the pressure from the REMstar Auto CPAP System so the patient can fall asleep at a lower, more comfortable pressure at any time or as many times as needed during the night. The REMstar Auto CPAP System is intended to deliver CPAP therapy and Auto CPAP therapy only. It is not intended for life support or life sustaining applications. Section 3.5 of this manual describes the major components of the REMstar Auto CPAP System and their basic theory of operation. Integral to the generation of air flow is the blower assembly. Ambient air is drawn through the air intake filter, and pressurized by the energized blower. Ultimately, therapeutic pressure is provided to the patient via the patient circuit. The microprocessor regulates the motor speed, which in turn adjusts and controls the pressure. The REMstar Auto CPAP System may be powered from either AC ( VAC) or from DC ( VDC). AC power enters the unit via an AC inlet and appropriate power cord. A DC power cord connector enables the patient to use the CPAP when AC voltage is not accessible. The system filter ensures optimum operation for the user. An air outlet port allows for connection to the patient circuit. The patient circuit is made up of flexible tubing, exhalation port, and nasal mask. The unit applies CPAP to the patient s upper airway to keep the airway open during sleep. Air flow generated from the unit is directed to the patient via a mask and flexible tubing that connects to the air outlet port of the unit REMstar Auto CPAP System 3-11

33 3.5 Theory of Operation (Subassemblies) Main Printed Circuit Assembly (Main PCA) The Main PCA is the control center of the REMstar Auto CPAP System. The Main PCA utilizes a microcontroller chip which reads from and writes to various I/O devices (control pad, LCD, memory, pressure sensor, motor control circuitry, RS-232 interface, etc.). With all of this information, the microcontroller makes appropriate decisions so the blower is properly controlled to deliver the desired CPAP therapy in a safe and reliable manner. The microcontroller and the interface circuitry provide closed loop control of the blower motor s speed. The blower motor is a three phase brushless DC motor with a permanent magnet rotor and stationary coils that are connected in a Y configuration and serve as its stator coils. The stator coils are electrically switched or commutated by drive circuits with the power FET transistors. Proper timing and sequencing of the stator coil switching is provided by the microcontroller which senses the motor s shaft position by monitoring the back-emf voltage in one of the motor s stator coils. The microcontroller also sets the motor speed (and consequently the output pressure) by varying the voltage which is delivered to the motor. Chapter 3: Specifications, Features, Descriptions and Theory of Operation Control Pad & Liquid Crystal Display (LCD) The control pad consists of five user buttons (Ramp Button, On / Off button, Heated Humidifier Button, and Right and Left User Buttons for other functions). The On / Off button activates and deactivates the pressure. The range of pressure is 4.0 to 20.0 cm H 2 O with AC and DC operation. The Ramp Button initiates a ramp cycle which incrementally and automatically increases the pressure. The Ramp begins at the set ramp pressure, and over the specified time period, increases until the therapeutic pressure is reached. Ramp Time is adjustable from 5 to 45 minutes in five minute increments. An LCD is used to show various operating parameters while the unit is powered Power Supply The unit has a switching power supply which is built on the Main PCA and mounted within the unit s top enclosure. The switching power supply operates properly on any AC voltage between VAC; HZ and produces an output of approximately 12 VDC. The switching power supply automatically adjusts for varying input voltages. No voltage selector switch or fuse changing is required, which allows for worldwide operation Encore SmartCard The REMstar Auto CPAP System is delivered with the Encore SmartCard installed. The SmartCard is a plastic card similar in size and shape to your normal credit card. But instead of holding information on a magnetic strip, it holds it in a small silicon chip embedded into the card. When installed into the REMstar Auto CPAP System, the SmartCard records the date, time at pressure, pressure levels, and other information on the sleep session. Using the Encore Pro Software, the usage data can be automatically downloaded and viewed REMstar Auto CPAP System 3-12

34 The SmartCard can also be programmed with the patient s prescription by using the Encore Pro Software and SmartCard reader/writer. When the programmed SmartCard is inserted into the device, the prescription settings are automatically transferred into the device and erased from the SmartCard. The SmartCard will then start to collect patient data. FOSQ: The REMstar Auto is programmed to allow the users to take a Functional Outcomes of Sleep Questionnaire (FOSQ). FOSQ is a quality of life questionnaire designed specifically for people with sleep disorders. The results allow health care professionals to see how therapy has improved the quality of their patient s life. Refer to the FOSQ brochure (from Respironics) for further information. The FOSQ information is also stored on the Smart Card. Chapter 3: Specifications, Features, Descriptions and Theory of Operation REMstar Auto CPAP System 3-13

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36 Chapter 4: System Setup Procedures Chapter 4: System Setup Procedures 4.1 Overview Programming a SmartCard Changing Settings using a SmartCard REMstar Auto CPAP System Setup Heated Humidifier System Setup Recommended, Alternate, and Optional Circuit Accessories REMstar Auto CPAP System 4-1

37 Chapter 4: System Setup Procedures Notes: REMstar Auto CPAP System 4-2

38 Chapter 4: System Setup Procedures Chapter 4: 4.1 Overview System Setup Procedures This section provides an overview of the system setup including detailed instructions on the therapy menu display screens. Refer to Chapter 7, Repair and Replacement, or Chapter 5, Routine Maintenance, for filter and filter cap installation instructions. NOTE: NOTE: The REMstar Auto CPAP System is delivered with an Encore SmartCard installed. This section provides directions for accessing the Therapy menu. Prescribed therapy can be set by using the SmartCard or by the Therapy menu. (The patient s User s Manual provides directions to access only the Patient menu, which limits access to settings. To prevent patients from tampering with the settings, the directions to access the Therapy menu should not be revealed to the patient). 4.2 Programming a SmartCard Step 1 Step 2 Step 3 Connect a Respironics SmartCard reader/writer directly to a PC following the instructions included with the reader/writer. Remove the SmartCard from the REMstar Auto CPAP System and insert it into the reader/writer. Open the patient s file in the Encore Pro Software (or create a new patient file). Choose SmartCard Wizard from the Communications menu. Following the prompts, complete the patient s prescription. The patient s name and prescription will be saved on the SmartCard. Remove the SmartCard from the Reader/Writer. If desired, write the patient s name on the front of the card. NOTE: NOTE: If the SmartCard is not installed, the device usage will not be recorded. If the system is not turned off properly, data will not be recorded to the SmartCard REMstar Auto CPAP System 4-3

39 Chapter 4: System Setup Procedures 4.3 Changing Settings using a SmartCard Step 1 Inserting the SmartCard Make sure that the REMstar Auto CPAP System is plugged into an electrical outlet. Insert the programmed SmartCard into the slot on the right side of the unit (logo side facing up). When the card detected screen appears, the card is inserted correctly. Card Inserted Figure 4-1 Card Inserted Correctly Screen Figure 4-2 Card Inserted REMstar Auto CPAP System 4-4

40 Chapter 4: System Setup Procedures Step 2 Verify New Settings Turn the airflow on to verify the new prescription setting. The card can now be removed or you can leave the card in the REMstar Auto CPAP System to record device usage. Once the prescription settings have been transferred to the REMstar Auto CPAP System, they will be deleted from the SmartCard. Note: If the screen below appears, the card does not have a prescription setting Figure 4-3 Prescription Verified Screen Figure 4-4 SmartCard Removed REMstar Auto CPAP System 4-5

41 Chapter 4: System Setup Procedures 4.4 REMstar Auto CPAP System Setup Hold the two top user buttons down while plugging in the power cord. Continue holding the buttons down until the REMstar Auto beeps. User Buttons AC Power Cord NOTE: The unlock symbol will appear on all of the screens indicating that you are in the Therapy Setup Menu. If you press the pressure on / off button, you will exit the Setup Menu. IMPORTANT! Prescribed therapy settings can only be set using the Therapy Menu. To prevent patients from tampering with the settings, do not reveal the directions to Therapy Menu access to the patient. 0 Figure 4-5 Touchpad Setup Figure 4-6 Connecting and Entering the Therapy Mode REMstar Auto CPAP System 4-6

42 4.4.1 Display Screens NOTE: Set the Pressures Do not turn the air flow on when you are in the Therapy Setup menu, this will exit you from the Therapy Mode. The first screen that will appear after entering the Therapy mode will be the screen that allows you to reset the compliance total. Press the right user button to go to the minimum pressure setting. Figure 4-7 Compliance Total Auto-CPAP or Split Night with Auto-CPAP Mode Set the pressure limits indicated on the CPAP prescription. The minimum pressure symbol will appear and blink. Range: 4 cm H 2 O to max. pressure setting (0.2 cm H 2 O increments) To change the setting, press the ramp or humidifier button. Press the right user button to go to the next setting. 4.0 cm H2O Figure 4-8 Minimum Pressure NOTE:The minimum pressure cannot be set higher than the maximum pressure. Example: If the current settings are 4 cm min. and 6 cm max., and you wish to change them to 8 cm min and 12 cm max., you must set the maximum pressure first. Press the right user key to go to the maximum pressure setting and then press the left user key to go back to the minimum pressure setting. Chapter 4: System Setup Procedures NOTE: For the Split Night mode, the minimum pressure setting will be the pressure delivered during the delay time. The maximum pressure symbol will appear and blink. Range: Min. pressure setting to 20 cm H 2 O (0.2 cm H 2 O increments) To change the setting, press the ramp or humidifier button. Press the right user button to go to the next setting. NOTE: The maximum pressure cannot be set lower than the minimum pressure. CPAP Mode Pressure Settings cm H2O Figure 4-9 Maximum Pressure Set both pressures to the CPAP prescription. In order for the REMstar Auto to deliver CPAP, the minimum pressure setting and the maximum pressure setting must be set to the same pressure. The minimum pressure symbol will appear and blink. Range: 4 to 20cm H 2 O (0.2 cm H 2 O increments) Press the ramp or humidifier button until the pressure setting is at the desired CPAP pressure. Press the right user button to go to the next setting. cm H2O Figure 4-10 Minimum Pressure REMstar Auto CPAP System 4-7

43 Chapter 4: System Setup Procedures NOTE: The minimum pressure cannot be set higher than the maximum pressure. Example: If the current settings are 6 cm min. and 6 cm max., and you wish to change them to 8 cm min. and 8 cm max., you must set the maximum pressure first. Press the right user key to go to the maximum pressure setting, and then press the left user key to go back to the minimum pressure setting. The maximum pressure symbol will appear and blink. Press the ramp or humidifier button until the pressure setting is the same as the minimum pressure setting. Press the right user button to go to the next setting. cm H2O Figure 4-11 Maximum Pressure Set the Patient Disconnect Alert The patient Disconnect Alert symbol will appear and blink. This setting is a beeping sound that the REMstar Auto makes when a large continuous air leak (such as mask removal) has been detected in the circuit. This alert can be turned on or off. The patient also has access to this setting in the Patient Setup Menu. = on = off Figure 4-12 Patient Disconnect Alert To change the setting, press the ramp or humidifier button. Press the right user button to go to the next setting. Set the Button Lights The button lights symbol will appear and blink. This setting allows you to have the lights behind the buttons turned on or off while the airflow is turned on. (The lights will always be on when the airflow is off) The patient also has access to this setting in the Patient Setup Menu. 0 = on = off To change the setting, press the ramp or humidifier button. Press the right user button to go to the next setting. Set the Ramp Time The ramp time symbol will appear and blink. NOTE: The ramp time range is 0 to 45 minutes. Settings of 2, 3, or 4 hours are also available but are only for the Split Night mode. 0:05 Figure 4-14 Ramp Time Figure 4-13 Button Lights NOTE: For Auto-CPAP mode, disregard the setting. The settings are complete. Press the pressure on/off button to exit the settings menu. For CPAP mode, if prescribed, set a ramp time between 5 and 45 minutes. If you do not want ramp, set the time to 0. NOTE: If the ramp time is set to 0 the settings are complete. Press the pressure on/off button to exit the settings menu. For Split Night mode, set a time of 2:00, 3:00, or 4:00 hours. NOTE: After setting the split night time, the settings are complete. Press the pressure on/off button to exit the settings menu REMstar Auto CPAP System 4-8

44 Chapter 4: System Setup Procedures To change the ramp time, press the ramp or humidifier button until the correct time appears. Press the right user button to go to the next setting. Range: 0 to 45 minutes (5 minute increments) 2 to 4 hours (1 hour increments) for Split Night mode. 4.0 Figure 4-16 Ramp Starting Pressure Pressure Delay Pressure = Minimum Pressure Delay Time Auto-CPAP Time Figure 4-15 Split Night Mode Therapy Pressure Air Flow Turned On Ramp Button Pressed Set the Ramp Starting Pressure Minimum Ramp Pressure The ramp starting pressure symbol will appear and blink. Range: 4 cm H 2 O - Minimum Pressure Setting (0.2 cm H 2 O increments) The patient also has access to this setting in the Patient Setup Menu, if prescribed. 0 cm H 2O Minutes Ramp Time NOTE: For CPAP mode only, set a ramp starting pressure. To change the setting, press the ramp or humidifier button. The settings are complete. Press the pressure on/off button to exit the settings menu REMstar Auto CPAP System 4-9

45 4.5 Heated Humidifier System Setup Step 1 Step 2 Step 3 Place the REMstar Auto CPAP System on top of the Humidifier. Plug the male end of the AC power cord into an electric outlet and the female end into the back of the Humidifier. Plug the power cord jumper from the Humidifier into the back of the REMstar Auto CPAP System. CAUTION:DC power cannot be used when the CPAP and Heated Humidifier are electrically connected together as a system. The Heated Humidifier will not function on DC power, however, it will function as a passover humidifier Display Screens Humidifier Button Chapter 4: System Setup Procedures Step 1 Set the Humidifier Temperature. Press and hold the Heated Humidifier button on the Respironics REMstar Auto CPAP Machine until you hear two single audible tones, then release the Heated Humidifier button. The temperature settings can be changed from 1 to 5. Five is the highest temperature setting. Press the Humidifier button to increase and the Ramp button to decrease the setting. Press the Pressure On/Off button to confirm settings. Ramp Button Humidifier Icon Temperature Setting Pressure On/Off Figure 4-18 Temperature Settings Step 2 Preheat Mode. Figure 4-17 Humidifier Connections Once a setting has been selected between 1 and 5, press and hold the Heated Humidifier button on the REMstar Auto CPAP System until you hear a single audible tone from the CPAP then release the Heated Humidifier button. The Heated Humidifier icon will appear on the CPAP display screen. Check to see that the green LED on the front of the Heated Humidifier is illuminated. The preheat mode will last 20 minutes if the air flow is not turned on REMstar Auto CPAP System 4-10

46 Chapter 4: System Setup Procedures Step 3 Heating Mode. Once a setting has been selected between 1 and 5, press the On/Off button on the REMstar Auto CPAP System to start the blower. Once the blower has started, press the Heated Humidifier button and hold until you hear a single audible tone then release the Heated Humidifier button. The heater icon will appear on the display of the REMstar Auto CPAP System and a solid green LED will illuminate on the front of the Heated Humidifier REMstar Auto CPAP System 4-11

47 Chapter 4: System Setup Procedures 4.6 Recommended Circuit Accessories This section addresses the recommended circuit accessories that can be used with the REMstar Auto CPAP System. For additional information, refer to the User s Manual or the Home Care Providers Manual or the literature supplied with the accessory Recommended Accessories To use the REMstar Auto CPAP System, the following accessories are recommended in order to assemble the circuit. WARNING: The REMstar Auto CPAP System should only be used with the recommended patient circuit identified below. Recommended Patient Circuit 1. Respironics Nasal Mask with integrated Exhalation Port (or Respironics mask with separate exhalation port such as the Whisper Swivel ). 2. Respironics 6 ft. (1.83 m) Flexible Tubing. Figure 4-19 REMstar Auto CPAP System with Recommended Circuit REMstar Auto CPAP System 4-12

48 WARNING: Appropriate diagnostic pressures must be determined when alternate or optional accessories are in place. Respironics reusable circuit accessories are washable, but are for single patient use only. They are not intended to be used on multiple patients DC Power Accessories The Respironics Shielded DC Power Cord (RI P/N ) can be used to operate the REMstar Auto CPAP System in a stationary recreational vehicle, boat, or motor home. The Respironics DC Battery Adapter Cable (RI P/N ) when used with the Respironics Shielded DC Power Cord enables the Respironics CPAP System to be operated from a 12 VDC freestanding battery. CAUTION: CAUTION: CAUTION: CAUTION: Chapter 4: System Setup Procedures Only use the Respironics DC Power Accessories. Use of any other system may cause damage to the REMstar Auto CPAP System or your vehicle. DC Power is not intended to be used as battery backup. DO NOT connect the DC Power while the REMstar Auto CPAP System is operating on AC Power. System damage may occur. DC power cannot be used when the CPAP and Heated Humidifier are electrically connected together as a system. The Heated Humidifier will not function on DC power and it will cause damage to the unit, however it will function as a passover humidifier. DO NOT use the Heated Humidifier on a battery or an uninterupted power source. The Heated Humidifier will not function and it will cause damage to the unit. NOTE: Respironics recommends a 100 amp-hour deep cycle marine battery. The REMstar Auto CPAP System should not be operated while the vehicle is in motion Adding Oxygen to the System Please note the warnings listed below when using oxygen with the REMstar Auto CPAP System. WARNING: When using oxygen with the REMstar Auto CPAP System, turn the unit on before turning the oxygen on. Turn the oxygen off before turning the REMstar Auto CPAP System off. This will prevent oxygen accumulation in the unit. WARNING: Oxygen supports combustion. Do not use oxygen in the presence of open flames, cigarette smoke, electrical spark, or other sources of ignition REMstar Auto CPAP System 4-13

49 Chapter 4: System Setup Procedures (This page intentionally left blank.) REMstar Auto CPAP System 4-14

50 Chapter 5: Routine Maintenance Chapter 5: Routine Maintenance 5.1 Overview Cleaning the System Cleaning / Replacing the Intake Filter REMstar Auto CPAP System Preventive Maintenance Schedule REMstar Auto CPAP System 5-1

51 Chapter 5: Routine Maintenance Notes: REMstar Auto CPAP System 5-2

52 Chapter 5: Routine Maintenance Chapter 5: 5.1 Overview Routine Maintenance This chapter provides guidelines and illustrates the cleaning and maintenance procedures for the REMstar Auto CPAP System. Before cleaning or performing any routine maintenance, always switch the REMstar Auto CPAP Systems s Pressure On / Off button to the Off position and unplug the power cord from the rear of the unit. 5.2 Cleaning the System WARNING: To avoid electrical shock, disconnect the electrical supply before attempting to clean the REMstar Auto CPAP System. DO NOT immerse the device in water or allow any liquid to enter the cabinet or the filter intake. Wipe the outside of the unit with a cloth slightly dampened with water and a mild detergent. Let the unit dry before reconnecting the electrical supply. 5.3 Cleaning / Replacing the Intake Filter The gray pollen filter is a reusable filter that screens out pollens and some household dust. This filter should be cleaned at least once every two weeks under normal usage, or as required. The filter should be replaced with a new one every six months. One additional pollen filter is included with the system. The pollen filter must be in place at all times when the unit is operating. The disposable ultra fine filter may be used to keep finer particulates out of the device. CAUTION: Removing, Cleaning, and Replacing the Filter Step 1 Failure to replace a dirty filter may cause the device to operate at higher than normal temperatures and damage the device. With the air flow turned off, disconnect the AC or DC power cord from the back of the device REMstar Auto CPAP System 5-3

53 Chapter 5: Routine Maintenance Step 2 Remove the filter cap by gently lifting up on the bottom of the filter cap, then pulling it away from the back of the device. Step 3 Remove the pollen filter by gently pulling the edges of the filter. Rinse the filter in a steady stream of running water. Squeeze out the water, and repeat. Allow the pollen filter to air dry for 8 to 12 hours, or in a clothes dryer for 15 to 20 minutes. Figure 5-1 Removing the Filter Cap Figure 5-2 The Filter Cap and Filters REMstar Auto CPAP System 5-4

54 Chapter 5: Routine Maintenance Step 4 CAUTION: Place the pollen filter into the filter area in the back of the REMstar Auto CPAP System. The pollen filter must be completely dry before use. Never place a wet filter into the device. Respironics recommends that you clean the filter in the morning and alternate using the two pollen filters provided with the system to ensure enough drying time for the cleaned filter. 5.4 REMstar Auto CPAP System Preventive Maintenance Schedule The following Preventive Maintenance Schedule lists the items that must be inspected or tested periodically, or after service is performed. Use the Preventive Maintenance Schedule to record the dates on which the maintenance items are performed. This schedule can also be used as an out of the box check-out of new devices. The Preventive Maintenance Schedule may be copied for each device serviced. CAUTION: DO NOT place both pollen filters into the device at the same time. Step 5 Install the filter cap. The opening in the filter cap for the REMstar Auto CPAP System should face down, away from the patient REMstar Auto CPAP System 5-5

55 Chapter 5: Routine Maintenance REMstar Auto CPAP System Preventive Maintenance Schedule (Factory Recommended) Maintenance Item Verification Reference Service Interval Date Record Blower Hours Displayed On Options Screen As Desired Clean / Replace Pollen Filter Section Clean every 2 weeks, or as needed / Change every 6 months. Perform Testing Process In the following order Section 8.2, 8.5, 8.4, 8.5 (Auto CPAP) Section 8.6 (Heated Humidifier) New device check-out. After service is performed. (Except when calibration is required) When requested. Cleaning Section 5.2 As required Serial Number Name Signature Date / / (This page may be copied) REMstar Auto CPAP System 5-6

56 Chapter 6: Trouble- Shooting and Diagnostics Chapter 6: Troubleshooting and Diagnostics 6.1 Overview Troubleshooting Flow Chart Common System Level Problems Troubleshooting Table REMstar Auto Error Codes REMstar Auto SmartCard Error Codes Humidifier LED Error Code Chart REMstar Auto CPAP System 6-1

57 Chapter 6: Troubleshooting and Diagnostics Notes: REMstar Auto CPAP System with Heated Humidifier 6-2

58 Chapter 6: Troubleshooting and Diagnostics Chapter 6: Troubleshooting and Diagnostics 6.1 Overview WARNING: CAUTION: Electrical Shock Hazard: Disconnect the electrical supply before repairing the unit. Electronic components used in this unit are subject to damage by static electricity. Use proper static discharge equipment and grounding precautions when servicing the equipment. Service only at a static-free workstation. This section contains information necessary to troubleshoot and diagnose problems with the REMstar Auto CPAP System. It provides a summary of common system problems as well as a flowchart and table to simplify the troubleshooting process. The error code chart lists all error codes, the associated problem, and suggested corrective action to be taken REMstar Auto CPAP System 6-3

59 Chapter 6: Troubleshooting and Diagnostics 6.2 Troubleshooting Flow Chart Problem Reported 6 Attempt to Verify Problem by: Visual Inspection Operate Unit & Observe Behavior Do a Specific Test Use Manometer to Verify Pressure Problem Not Found 6 Follow Troubleshooting Table (Section 6.4) Problem Found Problem Not Found 6 Substitute Known Good Parts (if available) Problem Not Found Perform System Functional Test in Chapter 8 Problem Not Found Problem Found Problem Found 6 6 Repair per Procedures 4 in Chapter 7 6 Run Unit for 4 Minimum 2 Hour 6 Perform System Final or Functional Test in Chapter REMstar Auto CPAP System 6-4

60 Chapter 6: Troubleshooting and Diagnostics 6.3 Common System Level Problems Screen Message Description Results Corrective Action _ A large circuit leak, such as mask removal, has been detected. The air flow will turn off in approximately 90 seconds. Check the circuit (flexible tubing assembly, mask) for any leaks and adjust the mask and headgear. Press the Pressure On / Off button to restart the air flow REMstar Auto CPAP System 6-5

61 Chapter 6: Troubleshooting and Diagnostics 6.4 Troubleshooting Table Symptom Cause Verification Corrective Action Audible Alarm - During audible alarm condition, the alarm is not audible. Main printed circuit assembly. Perform power up sequence. Visually verify the LED s and display illuminate. Reestablish original alert conditions. Listen for audible alarm. If audible alarm does not work, replace Main PCA. If visual indicators are not present at power up, perform user interface checkout procedure (see Section 8.2). If device fails user interface checkout procedure, replace Main PCA. If alarm is audible during both tests, no corrective action is required. Device does not operate from the 12 VDC power source- Faulty DC plug, low DC voltage, fuse in DC cord is blown. Main PCA. Ensure the DC voltage supply is a minimum of 11.5 VDC. Ensure the DC voltage is stable. Monitor the voltage at the back of the DC connector mounted on the Main PCA. If DC voltage is below 11.5 VDC, replace or recharge DC source. If there is no DC measured at the Main PCA, then check the DC adapter cord for continuity. If DC source is not at 11.5 VDC or higher, replace or recharge power source as required. If 12 VDC supply and DC cords are ok, replace Main PCA REMstar Auto CPAP System 6-6

62 Chapter 6: Troubleshooting and Diagnostics Symptom Cause Verification Corrective Action Display Indicator - LED or other indicator not working. Main printed circuit assembly. Perform user interface checkout procedure (section 8.2). If device fails user interface checkout procedure, replace Main PCA. Display - Display is blank or contains erroneous information. Display assembly. Main PCA. Inspect solder joints between display and Main PCA. Replace Main PCA. Intermittent Power Supply Problem - An intermittent on / off condition exists, unit alarms randomly, or indicator lights blink sporadically. Power cord, AC inlet, Main PCA, loose connections. Inspect power cord for fraying at cable ends. Inspect all connections on the Main PCA. Replace Main PCA. Noise - Missing or damaged rubber feet on bottom of unit, blower malfunctioning. Blower impeller imbalance. Turn over and inspect the bottom for missing or damaged rubber feet. Place hand on device, if vibration is detected then replace blower S/A. If rubber feet are missing, replace rubber feet. Tighten any loose screws. Resolve any air leaks. Replace Blower REMstar Auto CPAP System 6-7

63 Chapter 6: Troubleshooting and Diagnostics Symptom Cause Verification Corrective Action Odor - Tubing smells new, device smells new, airborne residue buildup. Visually inspect patient tubing for contamination. Run device in a clean environment for a few hours to eliminate new smell. Wash tubing with soap and water. To clear residue buildup, replace all subassemblies in the patient air stream (blower filters, patient circuit). Outlet air temperature - The outlet air temperature is too warm. Filters dirty, blower, Main PCA. Ensure the filter is clean and not restricting air flow. Monitor the outlet temperature at the end of the six foot patient tubing. A rise in temperature can be expected (See Section for Operating Temperature). Replace in order until solved: Filters Blower Main PCA Pressure Related Problems - The outlet pressure does not change or properly adjust. Pressure tubing has been blocked, disconnected, or kinked. Main PCA or blower malfunction. Inspect pressure tubing for secure connections and kinks. Check blower for leaks. Secure pressure tubing connections. Replace blower, pressure tubing, or Main PCA REMstar Auto CPAP System 6-8

64 Chapter 6: Troubleshooting and Diagnostics Symptom Cause Verification Corrective Action Pressure Offset - Static pressure fluctuates from -1.0 cm to +1.0 cm H 2 O of set pressure. The delivered pressure is higher or lower than the set value by more than -1.0 cm to +1.0 cm H 2 O. Perform power up process. Check internal tubing for kinks. Replace the Main PCA. No Stored Therapy Data Device LCD or Backlight failure SmartCard was not installed in device prior to use. Not a Respironics SmartCard. (error code displayed) Card not formatted or faulty SmartCard (error code displayed). Damage to LCD or backlight. No therapy data after usage. Remove power from unit and retry. Depress the blower on / off button before disconnecting the Main AC power. Reformat SmartCard. Replace SmartCard. Replace main PCA. Device on, displays pressure setpoint, No airflow. Loose connection. Blower / motor failure. Main PCA failure. Check motor plug / PCA connection. Trouble shoot by substitution with a known good Blower S/A. Ensure connections are secure. Replace the blower assembly. Replace main PCA. Pressure check out of range Occluded or restricted pressure tube. Defective pressure sensor. Check pressure with calibrated Manometer. Replace pressure tubing. Calibrate main PCA. Blower speed regulation. Leaks in flow path. Replace Main PCA. Check or replace flow element REMstar Auto CPAP System 6-9

65 Chapter 6: Troubleshooting and Diagnostics Symptom Cause Verification Corrective Action Ramp Pressure - The pressure does not ramp correctly. No ramp time prescribed in the Auto CPAP mode. Ramp minimum pressure has to be lower than CPAP pressure. Main PCA. Ramp Button not functioning. Verify the patient s prescription specified ramp. Make sure unit was set for ramp. Perform user interface checkout procedure (see Section 8.2). Set device for ramp. Replace Main PCA. If device fails user interface checkout procedure, replace control pad or Main PCA. Pressure Variation - The pressure varies around the set value, pressure fluctuates greater than 1.0 cm H 2 O. Internal air leak. Filters dirty. Replace filter. Perform Testing Process (see Section 8.1). Replace blower. If pressure still drifts, then replace Main PCA. Main PCA, blower. Check internal tubing. Air path blocked REMstar Auto CPAP System 6-10

66 Chapter 6: Troubleshooting and Diagnostics Symptom Cause Verification Corrective Action Humidifier will not turn on. Humidifier not turned back on after CPAP was turned off. Inspect main power cord for fraying at cable ends. Replace Power Cord. Faulty power cord. Broken or damaged Light Tube. No infrared connection. Inspect power cord between CPAP and humidifier base. Inspect Light Tube inside CPAP for misalignment or kinking. Replace Main PCA in humidifier base. Realign or replace light tube. Damaged Heater Plate. Humidifier Main PCA. CPAP Main PCA. Make sure receiver on Humidifier base is not damaged. Inspect Main PCA to see if there is damage to the transmitter on the Main PCA. Replace Humidifier Main PCA. Replace Main PCA. Make sure CPAP is seated on humidifier base properly. Reseat CPAP on humidifier base. Inspect Main PCA for damage to the Humidifier On / Off button. Replace Main PCA. Inspect Heater plate to see that it is connected to the humidifier Main PCA and that it is not damaged. Replace Heater Plate in humidifier base REMstar Auto CPAP System 6-11

67 6.5 REMstar Auto Error codes Chapter 6: Troubleshooting and Diagnostics This section contains information on extracting error codes that have occurred during use of the REMstar Auto. There are two ways to extract the information Extracting error codes from the unit Step 1 Humidifier Button Ramp Button Hold the humidifier button and ramp button down while plugging in the power cord. Continue holding the buttons down until the REMstar Auto beeps. Step 3 Figure 6-2: Error Code Screen By pressing the ramp key, the REMstar Auto will show the blower hours on the unit when the error occured. Pressing the humidifier key will allow the user to view the hours that each error occurred in a circular buffer fashion. Figure 6-1: Humidifier and Ramp Buttons Step 4 Figure 6-3: Blower Hours Screen To erase the error logs, press the right user button. An X will appear in the lower left corner of the LCD. Then press the Pressure On / Off key. This will erase all errors and the blower hours at which the errors occurred, and return the unit to the system self test screen. Step 2 The most recent error code will be displayed. By pressing the humidifier key, the REMstar Auto will show the previous error code, allowing the user to view the entire error log in a circular buffer fashion. Only the five most recent errors will be shown. An E-0 indicates no error. Figure 6-4: Error Log Erase REMstar Auto CPAP System with Heated Humidifier 6-12

68 Chapter 6: Troubleshooting and Diagnostics Extracting error codes using the Utility Software Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Verify utility software (Part # ) is installed on the computer. Connect the communication cable between the SleepLink card and the serial port COM1 on your computer. Insert the SleepLink card into the device and plug the device into the proper AC voltage source. With your mouse, click on the Start Button of your computer. Select: Programs Respironics Tools Read Error Log The software will load automatically. Step 7 With your mouse, click on the Run Arrow located in the upper left corner of the computer screen. Step 8 The software will automatically read and display any error codes stored in the unit along with the date and time the errors occured. NOTE: The 5 most recent error codes will be displayed. The overwritten as each new error occurs REMstar Auto CPAP System 6-13

69 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-000 NO_ERROR Reserved E-001 ERR_SOFTWARE Defective RAM chip E-002 ERR_PROGRAM_CRC_FAILURE Defective FLASH chip E-003 ERR_EXTERNAL_RAM_FAILURE Defective RAM chip E-004 ERR_FIQ_STACK_OVERFLOW Defective RAM chip E-005 ERR_FIQ_STACK_UNDERFLOW Defective RAM chip E-006 ERR_NEST_STACK_OVERFLOW Defective RAM chip E-007 ERR_NEST_STACK_UNDERFLOW Defective RAM chip E-008 ERR_IRQ_STACK_OVERFLOW Defective RAM chip E-009 ERR_IRQ_STACK_UNDERFLOW Defective RAM chip E-010 ERR_TMR_STACK_OVERFLOW Defective RAM chip E-011 ERR_TMR_STACK_UNDERFLOW Defective RAM chip E-012 ERR_SVC_STACK_OVERFLOW Defective RAM chip E-013 ERR_SVC_STACK_UNDERFLOW Defective RAM chip REMstar Auto CPAP System 6-14

70 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-014 ERR_THREAD_STACK_OVERFLOW Defective RAM chip E-015 ERR_ARM_UNDEFINED_INSTRUCTION_EXCEPTION Defective FLASH chip E-016 ERR_ARM_SWI_EXCEPTION Defective FLASH chip E-017 ERR_ARM_PREFETCH_EXCEPTION Defective FLASH chip E-018 ERR_ARM_ABORT_EXCEPTION Defective RAM chip E-019 ERR_ARM_RESERVED_EXCEPTION Defective FLASH chip Defective microprocessor E-020 ERR_AIC_DEFAULT_HANDLER Defective FLASH chip E-021 ERR_AIC_SPURIOUS_HANDLER Defective FLASH or RAM chip E-022 ERR_CAL_DATA_CRC_FAILURE Improper calibration Defective FLASH chip Recalibrate E-023 ERR_INVALID_DRIFT_INDEX_AT_CAL Improper calibration Occluded or restricted pressure tube Defective flow sensor Recalibrate Replace pressure tube E-024 ERR_UNRECOGNIZED_CAL_VERSION_BY_SW Improper calibration Defective FLASH chip Recalibrate E-025 ERR_DRIFT_FLOW_TOO_HIGH Occluded or restricted pressure tube Defective flow sensor Replace Flow Tube REMstar Auto CPAP System 6-15

71 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-026 ERR_UI_DISPLAY_FAILURE Defective LCD driver chip E-027 ERR_DRIFT_PRESSURE_TOO_HIGH Occluded or restricted pressure tube Defective pressure sensors Replace pressure tubing E-028 ERR_OVER_PRESSURE Blower control chip Defective pressure sensor Recalibrate E-029 ERR_CAL_DATA_BLANK Improper calibration Defective FLASH chip Recalibrate E-030 ERR_DRIFT_DEFAULT_ERR1 Defective RAM chip E-031 ERR_INVALID_NVDATA_SCHEMA Normal for first time power up Defective EEPROM Remove & restore power E-032 ERR_INVALID_NVDATA_LOCK Defective EEPROM E-033 ERR_INVALID_NVDATA_CHECKSUM Normal for first time power up Defective EEPROM Remove & restore power E-034 ERR_NVDATA_WRITE_FAILURE Defective EEPROM E-035 ERR_NVDATA_QUEUE_FULL Defective EEPROM E-036 ERR_NVDATA_READBACK_FAILURE Defective EEPROM E-037 ERR_NVDATA_RANGE_FAILURE Defective EEPROM REMstar Auto CPAP System 6-16

72 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-038 ERR_CORRUPT_RTC_VALUE Defective microprocessor E-039 ERR_RTC_NOT_TICKING Defective microprocessor Defective crystal E-040 ERR_UI_QUEUE_FULL Defective PCA E-041 ERR_INVALID_BIST_TEST_CALL Invalid RASP command Reissue RASP command E-042 ERR_PRESSURE_REG_UNDER Occluded or restricted pressure tube Defective pressure sensor Replace pressure tube E-043 ERR_PRESSURE_REG_OVER Occluded or restricted pressure tube Defective pressure sensor Replace pressure sensor E-044 ERR_RAMP_DEFAULT1 Defective RAM chip E-045 ERR_BIST_THREAD_LOCKED Defective PCA E-046 ERR_12VREF_FAILURE Defective power supply E-047 ERR_VREF_FAILURE Defective power supply E-048 ERR_VBULK_FAILURE Defective power supply E-049 ERR_PV12_SENSOR_RAILED Occluded or restricted pressure tube Defective pressure sensor Replace pressure tube E-050 ERR_FL12_SENSOR_RAILED Occluded or restricted pressure tube Defective flow sensor Replace flow tube REMstar Auto CPAP System 6-17

73 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-051 ERR_FLASH_FAILURE Defective FLASH chip E-052 ERR_UI_FRONT_PANEL_START_STOP Defective Keypad Defective Pad on PCA Replace Keypad E-053 ERR_UI_FRONT_PANEL_RAMP Defective Keypad Defective pad on PCA Replace Keypad E-054 ERR_UI_FRONT_PANEL_HUMIDIFIER Defective Keypad Defective pad on PCA Replace Keypad E-055 ERR_UI_FRONT_PANEL_LEFT Defective Keypad Defective pad on PCA Replace Keypad E-056 ERR_UI_FRONT_PANEL_RIGHT Defective Keypad Defective pad on PCA Replace Keypad E-057 ERR_UI_FRONT_PANEL_NO_KEY Defective Keypad Defective pad on PCA Replace Keypad E-058 ERR_UNRECOGNIZED_BOARD_REV Needs new software Defective PCA E-059 ERR_MOTOR_FAILURE Stalled or locked blower Defective motor drive chip Replace Blower E-060 ERR_BLOWER_RPM_FAILED_HIGH Defective motor drive chip E-061 ERR_BLOWER_RPM_FAILED_LOW Stalled or locked blower Defective motor drive chip Replace Blower REMstar Auto CPAP System 6-18

74 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-062 ERR_BLOWER_RPM_FAILED_TOLERANCE Stalled or locked blower Replace Blower E-063 ERR_BLOWER_OFF_CURRENT_HIGH Stalled or locked motor Defective motor drive chip Replace Blower E-064 ERR_CURRENT_BLOWER_FAILED_LOW Defective motor drive chip Stalled or locked motor Replace Blower E-065 ERR_BLOWER_PRESSURE_FAILED_LOW Stalled or locked blower Defective motor drive chip Replace Blower E-066 ERR_BLOWER_PRESSURE_FAILED_HIGH Defective motor drive chip E-067 ERR_BLOWER_FLOW_FAILED_LOW Stalled or locked blower Defective motor drive chip Replace Blower E-068 ERR_BLOWER_FLOW_FAILED_HIGH Defective motor drive chip E-069 ERR_MACH_CTRL_DEFAULT1 Defective RAM chip E-070 ERR_MACH_CTRL_DEFAULT2 Defective RAM chip E-071 ERR_MACH_CTRL_DEFAULT3 Defective RAM chip E-072 ERR_PRINTF_BUFFER_OVERFLOW Defective PCA E-073 ERR_PRESSURE_DEFAULT1 Defective RAM chip REMstar Auto CPAP System 6-19

75 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-074 ERR_FLOW_SENSOR_FAILURE Occluded or restricted flow tube Defective flow sensor Replace Flow Tube E-075 ERR_UNUSED0 Reserved E-076 ERR_COMPUTE_BPM Defective RAM chip E-077 ERR_COMPUTE_MINVENT Defective RAM chip E-078 ERR_COMPUTE_PERCENT_TI Defective RAM chip E-079 ERR_UNUSED1 Reserved E-080 ERR_UNUSED2 Reserved E-081 ERR_UNUSED3 Reserved E-082 ERR_UNUSED20 Reserved E-083 ERR_PRESSURE_CIRCUIT_ERROR Occluded or restricted pressure tube Defective pressure sensor Replace pressure tube E-084 ERR_PATIENT_EVENT_QUEUE_FULL Defective PCA E-085 ERR_PATIENT_EVENT_NULL_PTR Defective RAM chip Replace PCA E-086 ERR_KEYPAD_STUCK_KEY Verify all keys protrude through top Defective Keypad Defective pad on PCA Align keys with top Replace Keypad REMstar Auto CPAP System 6-20

76 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-087 ERR_BRMODEL_MAX_AMPLITUDE Defective RAM chip E-088 ERR_HYPOPNEA_MAX_AMPLITUDE Defective RAM chip E-089 ERR_HYPOPNEA_MAX_DURATION Defective RAM chip E-090 ERR_APNEA_MAX_AMPLITUDE Defective RAM chip E-091 ERR_APNEA_MAX_DURATION Defective RAM chip E-092 ERR_WATCHDOG_FAILURE Defective microprocessor E-093 ERR_UNEXPECTED_WATCHDOG Defective FLASH chip Defective RAM chip E-094 ERR_UNUSED7 Reserved E-095 ERR_UNUSED8 Reserved E-096 ERR_UNUSED15 Reserved E-097 ERR_UNUSED16 Reserved E-098 ERR_APCTRL_DEFAULT3 Defective RAM chip E-099 ERR_UNUSED9 Reserved E-100 ERR_UNUSED10 Reserved REMstar Auto CPAP System 6-21

77 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-101 ERR_POINTERS_MATCH Defective RAM chip E-102 ERR_RTOS_INIT_FAILURE Defective PCA E-103 ERR_UNUSED17 Reserved E-104 ERR_UNUSED11 Reserved E-105 ERR_UNUSED12 Reserved E-106 ERR_UNUSED18 Reserved E-107 ERR_UNUSED19 Reserved E-108 ERR_SERIAL_QUEUE_FULL Defective PCA E-109 ERR_SNORE_SAMPLING_THREAD_LOCKED Defective PCA E-110 ERR_MAIN_EXECUTION_THREAD_LOCKED Defective PCA E-111 ERR_UNUSED13 Reserved E-112 ERR_INTERNAL_RAM_FAILURE Defective microprocessor E-113 ERR_EVENT_LOG_QUEUE_FULL Defective PCA E-114 ERR_UNUSED14 Reserved E-115 ERR_TREND_DIV_BY_ZERO Defective RAM chip REMstar Auto CPAP System 6-22

78 Chapter 6: Troubleshooting and Diagnostics Error Code Description Probable Cause Corrective Action E-116 ERR_ROLLOVER_CASE Defective RAM chip E-117 ERR_INVALID_ERROR_CODE Reserved REMstar Auto CPAP System 6-23

79 6.6 REMstar Auto SmartCard Error Codes Chapter 6: Troubleshooting and Diagnostics Code C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-100 C-101 Label SMARTCARD_12C_WRITE_FAIL SMARTCARD_BAD_CARD_TYPE SMARTCARD_BAD_CIB_VERSION SMARTCARD_SCRIPT_DURING_PROVIDER_MODE SMARTCARD_PRESENT_IN_CAL_MODE SMARTCARD_BAD_CIB_CHECKSUM SMARTCARD_NOT_PRESENT SMARTCARD_12C_READ_FAIL SMARTCARD_WRITE_CONFIRM_FAIL SMARTCARD_BAD_RI_BRAND SMARTCARD_BAD_CPB_CHECKSUM SMARTCARD_BAD_CPB_VERSION User Action Card inserted upside-down. Remove card and reinsert properly. Otherwise, card is corrupt and should be reprogrammed. Card is not supported by this device. Otherwise, card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Remove card. Exit Provider Mode screens. Then reinsert card. Remove card. Exit Calibration Mode. Then reinsert card. Card is corrupt and should be reprogrammed Card inserted upside down. Remove card and reinsert properly. Otherwise, card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Otherwise, replace card. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed REMstar Auto CPAP System 6-24

80 Code C-102 C-103 C-104 C-105 C-106 C-107 C-108 C-109 C-200 C-201 C-202 C-203 C-204 Label SMARTCARD_INVALID_UNIT SMARTCARD_UNKNOWN_CPB_FORMAT SMARTCARD_UNKNOWN_CPB_PRESCRIPTION SMARTCARD_SCRIPT_PARM_RANGE SMARTCARD_BAD_CPB_SCRIPT_READY SMARTCARD_BAD_CPB_START_ADDR SMARTCARD_BAD_CPB_END_ADDR SMARTCARD_BAD_CPB_ERASE_PERMISSION SMARTCARD_BAD_CDCB_VERSION SMARTCARD_BAD_CDB_VERSION SMARTCARD_BAD_CDCB_CHECKSUM SMARTCARD_BAD_CDCB_CONTROL_BLOCKS SMARTCARD_BAD_CDCB_START_ADDR Chapter 6: Troubleshooting and Diagnostics User Action Card contains a prescription format that is not supported. Perhaps card is intended for another device. Card contains a prescription type that is not supported. Perhaps card is intended for another device. Card contains prescription settings that are outside of this device s range. Perhaps card is intended for another device. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card contains a storage format that is not supported. Perhaps card is intended for another device. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed REMstar Auto CPAP System 6-25

81 Code C-205 C-206 C-207 C-300 C-301 C-302 C-303 C-400 C-401 C-402 C-403 C-404 C-500 C-501 C-502 Label SMARTCARD_BAD_CDCB_END_ADDR SMARTCARD_BAD_CDB_START_ADDR SMARTCARD_BAD_CDB_END_ADDR SMARTCARD_BAD_UIDB_VERSION SMARTCARD_BAD_UIDB_CHECKSUM SMARTCARD_BAD_UIDB_START_ADDR SMARTCARD_BAD_UIDB_END_ADDR SMARTCARD_BAD_DDCB_VERSION SMARTCARD_BAD_DDCB_CHECKSUM SMARTCARD_BAD_DDCB_PROFILE_CONTROL_BLOCKS SMARTCARD_BAD_DDCB_HISTOGRAM_CONTROL_BLOCKS SMARTCARD_BAD_DDCB_FOSQ_COMPL_CONTROL_BLOCKS SMARTCARD_FILE_OPEN_FAIL SMARTCARD_FILE_TELL_FAIL SMARTCARD_FILE_SEEK_FAIL Chapter 6: Troubleshooting and Diagnostics User Action Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed REMstar Auto CPAP System 6-26

82 Code C-503 C-504 C-505 C-506 Label SMARTCARD_FILE_READ_FAIL SMARTCARD_FILE_WRITE_FAIL SMARTCARD_FILE_GET_PTR_FAIL SMARTCARD_FILE_SET_PTR_FAIL Chapter 6: Troubleshooting and Diagnostics User Action Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed. Card is corrupt and should be reprogrammed REMstar Auto CPAP System 6-27

83 6.7 Humidifier LED Error Code Chart Chapter 6: Troubleshooting and Diagnostics LED Blinks 1 2 Problem / Cause Temperature too high. Thermistor shorted, over temperature condition. Thermistor disconnected. Temperature too low. Replace Humidifier Main PCA. Corrective Action Reconnect J2 on Humidifier Main PCA. Replace Heater Plate Assembly. Replace Humidifier Main PCA. 3 Voltage too low on pin 6 of U1. Replace Humidifier Main PCA. Conditions: When the Heated Humidifier is enabled, the LED will be on constantly. When the Heated Humidifier is disabled, the LED will be off REMstar Auto CPAP System 6-28

84 Chapter 7: Repair and Replacement Chapter 7: Repair & Replacement 7.1 Overview REMstar Auto CPAP System Repair Kits Respironics Heated Humidifier System Repair Kits Warnings and Cautions Replacement Instructions REMstar Auto CPAP System 7-1

85 Chapter 7: Repair and Replacement Notes: REMstar Auto CPAP System 7-2

86 Chapter 7: 7.1 Overview Repair & Replacement Chapter 7: Repair and Replacement For technical assistance or replacement part ordering information contact Respironics Corporate Technical Service. U.S. and Canada Figure 7-1 lists the names and identifies the locations of the replaceable components in the REMstar Auto CPAP System. This provides a quick reference and overview of the unit. Within each replacement section, more detailed support information is provided to illustrate the exact component location and replacement procedure(s). International Phone: Fax: Phone: Fax: Visit Respironics Home Page on the World Wide Web at: Contact Technical Support via at: service@respironics.com REMstar Auto CPAP System 7-3

87 Chapter 7: Repair and Replacement 7.2 REMstar Auto CPAP System Repair Kits AC Power Cord (Domestic) RP # (See Note2) DC Power Cord RP # SleepLink Interface Card w/cable RP # Respironics Utility Software CD RP # REMstar Auto CPAP System 7-4

88 Chapter 7: Repair and Replacement Pollen Filter Kit RP # Ultra-Fine Filter Kit RP # REMstar Auto Filter Cap RP # REMstar Auto Top Enclosure RP # REMstar Auto CPAP System 7-5

89 Chapter 7: Repair and Replacement REMstar Auto Keypad RP # REMstar Auto PCA RP # Outlet Port RP # REMstar Auto Tubing RP # REMstar Auto CPAP System 7-6

90 Chapter 7: Repair and Replacement REMstar Auto Flow Sensor Assembly RP # Blower Top Foam RP # REMstar Auto Blower RP # Bottom Enclosure with Lite Pipe RP # (See Note1) REMstar Auto CPAP System 7-7

91 Chapter 7: Repair and Replacement REMstar Auto Warning Label RP # Water Chamber RP # Chamber Bottom Plate RP # Water Chamber Couplings RP # REMstar Auto CPAP System 7-8

92 Chapter 7: Repair and Replacement Humidifier Warning Label RP # Humidifier Top Enclosure RP # Humidifier Heater Assembly RP # Humidifier PCA RP # REMstar Auto CPAP System 7-9

93 Chapter 7: Repair and Replacement Humidifier Bottom Enclosure RP # (See Note 1 ) Note 1: Note 2: The serial number label has to be made at Respironics Technical Service Department for the bottom enclosures. Contact Respironics International Customer Service for further AC Power Cord information REMstar Auto CPAP System 7-10

94 Chapter 7: Repair and Replacement 7.4 Warnings and Cautions 7.5 Replacement Instructions WARNING: CAUTION: To prevent electrical shock, disconnect the electrical supply before attempting to make any repairs to the REMstar Auto CPAP System or the Respironics Heated Humidifier System. Electronic components used in this unit are subject to damage from static electricity. Repairs made to this unit must be performed only in an antistatic, Electro-Static Discharge (ESD)-protected environment. See Figures 7-1,7-2,7-3 and 7-4 before removing or installing any components. These figures will detail the order in which each item must be removed or installed and should be used as a guideline for quick reference REMstar Auto CPAP System 7-11

95 Chapter 7: Repair and Replacement Top Enclosure pg Filter Cap pg Removal Flow Chart 6 6 Filters pg. 5-3 Figure 7-1 Removal Flow Chart 6 Key Pad pg Main Printed Circuit Assembly (PCA) 6 pg Outlet Port and Flow Element pg Chart Usage: Determine which item is to be replaced then follow the line of flow back to the Top Enclosure and begin the removal process. Detailed procedures begin on the referenced page numbers. 6 6 Blower Assembly pg Pressure Tubing 6 6 pg Bottom Enclosure pg REMstar Auto CPAP System 7-12

96 Chapter 7: Repair and Replacement Bottom Enclosure pg Installation Flow Chart 6 Pressure Tubing 6 pg Outlet Port & Flow Element 6 Main Printed Circuit Assembly (PCA) 6 Blower Assembly 6 Key Pad pg Figure 7-2 Installation Flow Chart Chart Usage: Determine which item is to be installed then follow the line of flow down to the Top Enclosure and begin the installation process. Detailed procedures begin on the referenced page numbers. 6 pg pg pg Filters pg Filter Cap pg Top Enclosure pg REMstar Auto CPAP System 7-13

97 Chapter 7: Repair and Replacement Heated Humidifier Removal Flow Chart Humidifier Water Chamber pg Humidifier Top Enclosure pg Humidifier Bottom Enclosure pg Figure 7-3 Removal Flow Chart 6 Humidifier Heater Assembly pg Humidifier Main Printed Circuit Assembly (PCA) pg Chart Usage: Determine which item is to be replaced then follow the line of flow back to the Top Enclosure and begin the removal process. Detailed procedures begin on the referenced page numbers REMstar Auto CPAP System 7-14

98 Chapter 7: Repair and Replacement Heated Humidifier Installation Flow Chart Figure 7-4 Installation Flow Chart Main Printed Circuit Assembly (PCA) 6 Heater Assembly pg pg Chart Usage: Determine which item is to be installed then follow the line of flow down to the Top Enclosure and begin the installation process. Detailed procedures begin on the referenced page numbers. Bottom Enclosure 6 Top Enclosure Water Chamber pg pg pg REMstar Auto CPAP System 7-15

99 7.5.1 Filter Cap Replacement Chapter 7: Repair and Replacement Replacement Part Number: Included in Kit: Filter Cap (w / foam baffle) None Tools Required Procedure Removed / Installed During Process: Filter Cap WARNING: CAUTION: Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Filter Cap Figure 7-5 REMstar Auto CPAP System Filter Cap Replacement REMstar Auto CPAP System 7-16

100 Chapter 7: Repair and Replacement Step 1 Removing the Filter Cap a. Gently squeeze the sides of the filter cap, near the middle, until the locking tabs clear the filter compartment. b. Remove the filter cap by pulling it away from the back of the unit. Step 2 Installing the Filter Cap a. Align the tabs on the bottom of the filter cap with the bottom of the filter compartment. The opening in the filter cap should be positioned down or away from you. b. Gently squeeze the sides of the filter cap, near the middle, until the tabs clear the filter compartment. c. Push the filter cap into the filter compartment until the locking tabs snap into place. Figure 7-6 Removing the REMstar Auto System Filter Cap REMstar Auto CPAP System 7-17

101 7.5.2 Top Enclosure Replacement Chapter 7: Repair and Replacement Replacement Part Number Included in kit: Tools Required: Top Enclosure Phillips screwdriver (No. 2 medium) 8 Hi - Lo x 1/ 2 (x3) Procedure Removed / Installed During Process: Top Enclosure WARNING: Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Top Enclosure CAUTION: Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Figure 7-7 Top Enclosure REMstar Auto CPAP System 7-18

102 Chapter 7: Repair and Replacement Step 1 Removing the Top Enclosure Screw Location a. Place the device on a protected work surface and carefully turn it over, exposing the bottom. b. Using a Phillips screwdriver, remove the three screws that secure the top enclosure to the bottom enclosure. (See figure 7-8) c. While securely holding the top and the bottom enclosure together, carefully return the device to its upright position. d. Separate the top enclosure from the bottom enclosure by lifting up on the top enclosure.. Figure 7-8 Location of the Top Enclosure Screws REMstar Auto CPAP System 7-19

103 Chapter 7: Repair and Replacement Note: The Main PCA does not have to be disconnected for top enclosure replacement. Photos are shown for convenience. Pressure/Flow Tubing Connections Fiber Optic Connection Blower Cable Connector Figure 7-09 Location of Blower Assembly Cable Connector REMstar Auto CPAP System Figure 7-10 Top Enclosure Removed 7-20

104 7.5.3 Key Pad Replacement Chapter 7: Repair and Replacement Replacement Part Number Included in Kit: Tools Required: Key Pad Phillips screwdriver (No.2 medium) Flat-blade screwdriver (small) Procedure Removed / Installed During Process: WARNING: CAUTION: Top Enclosure (See Section for more detailed instructions). Pressure Tubing (See Section for more detailed instructions). Main PCA (See Section for more detailed instructions). Key Pad Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Figure 7-11 Key Pad Key Pad REMstar Auto CPAP System 7-21

105 Chapter 7: Repair and Replacement Step 1 Removing the Top Enclosure Removing: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) NOTE: The Display Assembly is permanently attached to the Main PCA. Step 2 Removing the Flex Tubing (optional) Removing: Flex Tubing (See Section for more detailed instructions on removing the Pressure Tubing). Step 3 Removing the Main PCA (optional) Removing: Remove Main PCA (See Section for more detailed instructions on removing the Main PCA). Step 4 Removing the Key Pad Carefully lift the Key Pad from the Main PCA. There are three rubber locking pins that hold the Key Pad to the Main PCA. Figure 7-12 Key Pad REMstar Auto CPAP System 7-22

106 Chapter 7: Repair and Replacement Step 6 Installing the Main PCA. Step 5 Installing the Key Pad a. Place the Key Pad on the Main PCA. Align the locking pins with the three holes on the Display Assembly. Press down on the locking pins until they snap into place. Install: Main PCA (See Section for more detailed instructions on installing the Main PCA.) Step 7 Installing the Flex Tubing Install: Flex Tubing (See Section for more detailed instructions on installing the Pressure Tubing). Step 8 Installing the Top Enclosure Install: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) Align Locking Pins Here Figure 7-13 Pin Location REMstar Auto CPAP System 7-23

107 7.5.4 REMstar Auto PCA (Main PCA) Replacement Replacement Part Number Chapter 7: Repair and Replacement Included in Kit: Tools Required: Main PCA Phillips screwdriver (No.2 medium) Procedure Removed / Installed During Process: Top Enclosure (See Section for more detailed instructions). Pressure Tubing (See Section for more detailed instructions). Main PCA WARNING: Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs. CAUTION: Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. CAUTION: Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to manufacturers instructions. Figure 7-14 REMstar Auto Printed Circuit Assembly REMstar Auto CPAP System 7-24

108 Chapter 7: Repair and Replacement Step 1 Removing the Top Enclosure Removing: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 2 Removing the Flex Tubing Removing: Pressure Tubing (See Section for more detailed instructions on removing the Pressure Tubing). Step 3 Removing the Main PCA a. Disconnect the motor cable and light pipe from the PCA. b. Lift the Main PCA up and away from the top enclosure assembly. Step 4 Removing the Key Pad Remove: Key Pad (See section for more detailed instructions on removing the control pad.) Step 5 Installing the Key Pad Install: Key Pad (See Section for more detailed instructions on installing the control pad.) Step 6 Installing the Main PCA. Carefully place the Main PCA in the Top Enclosure. Make sure the AC Inlet sets in the slot provided on the Top enclosure. Assure the ferrite & optical cable are seated properly in the foam insert. Step 7 Installing the Flex Tubing Install: Pressure Tubing (See Section for more detailed instructions on installing the Pressure Tubing). Step 8 Installing the Top Enclosure NOTE: The Display Assembly is permanently attached to the Main PCA. Install: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) REMstar Auto CPAP System 7-25

109 Chapter 7: Repair and Replacement Main Printed Circuit Assembly (Main PCA) / Real Time Clock Calibration NOTE: Parts Needed: Sleep Link Card ( ) Communication Cable Software ( ) During the manufacturing process, the Serial Number is programmed into the memory of the Main Printed Circuit Assembly. This process gives the Home Care Provider the ability to link the information from the Encore SmartCard to a specific device for a more complete patient record. Although this process is important for tracking patient information, it is not necessary for the performance of the unit. When the device is calibrated with the utility software, the software automatically links the serial number to the PCA. Note: Contact Respironics to obtain software for Serial Number Linkage and Realtime clock setting. See chapter 8 section Page 8-7 for software installation. Tools Required: None Minimum System Requirements Windows 95/98/2000/NT Color Monitor with 256 colors, 800 x 600 resolution Windows-compatible pointing device (mouse) Windows-supported serial port (COM1 - COM4) 2.5 MB free hard disk space CD drive NOTE: See Chapter 8 section 8.3 step 1 for initial software installation. Step 1 Connecting the Unit to your computer. a. Connect the communication cable between the Sleep link card and the serial port COM1on your computer. b. Connect the unit to the proper AC voltage source. Note: Ensure that the computers time, date, and time zone is set correctly Step 2 Using the Realtime Clock software a. With your mouse click on the Start Button of your computer. b. Select: Programs Respironics Tools Real Time Clock Calibration c. The Real Time clock software will be set to verify. With your mouse, click on the RUN arrow to start the software program. d. The time difference between the unit and your computer will show on a window in the software program. Verify that your computer is set to the correct date, time and time zone REMstar Auto CPAP System 7-26

110 Chapter 7: Repair and Replacement e. With your mouse, click on the red slider button in the upper left corner of the Real Time Clock software. If should change the slider to green and the software is now ready to set your unit to be the same as your computer. f. With your mouse, click on the RUN arrow to start the software program. g. Ensure that todays date and time shown through the software is correct. h. In the software, the seconds sent and the seconds read back should be comparable. Step 5 Disconnecting the unit from the computer a. Disconnect the communication cable between the SleepLink and the serial port COM1on your computer. b. Disconnect the unit from the AC voltage source. Step 6Closing the software. a. With your mouse, click on File and then Close to close the software or click on the X in the upper right corner of the screen. i. The software will automatically transfer the information into the memory of the new PCA. A green PASS box will appear. Step 3 Closing the software. a. With your mouse click on File. Set Clock/Verify Clock Red Slider Button b. Select: Exit Step 4 Disconnect the REMstar Auto CPAP System a. Remove the Sleep Link from the unit REMstar Auto CPAP System 7-27

111 7.5.6 Flex Tubing Replacement Replacement Part Number Chapter 7: Repair and Replacement Included in Kit: Tools Required: Pressure tubing (5 ) Phillips screwdriver Pressure tubiing (4 ) X 2 (No. 2 Medium) Procedure Removed / Installed During Process: Top enclosure (See Section for more detailed instructions) Pressure port flex tubing Flow element flex tubing WARNING: CAUTION: Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Figure 7-15 Removing Top Enclosure REMstar Auto CPAP System 7-28

112 Step 1 Removing the Top Enclosure Remove: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 2 Removing the Pressure and Flow flex Tubing a. Lift the top enclosure and Main PCA. Hold them slightly above the unit to provide access to the blower cable connector and the flex tubing on the Main Printed Circuit Assembly (Main PCA). b. Remove the blower assembly cable connector by gently pulling the connector straight off of its receptacle. c. Remove the fiber optic cable by pulling the cable straight down out of CR5. d. Mark flex tubing and ports for reinstallation. e. Remove the flex tubing from MT2 (pressure sensor) and the flex tubing from MT1 (flow sensor) on main PCA by gently pulling the tubing straight off of the ports. Prying with a small flat blade screw driver may be helpful. Chapter 7: Repair and Replacement Step 3 Installing the flex Tubing a. Connect the flex tubing to the Outlet Ports by gently pressing the tubing onto the pressure port. b. Connect the flex tubing from the flow element to the Main PCA by gently pressing the flex tubing on to MT 1 tubing connections.. c. Connect the blower assembly cable connector and fiber optic light pipe by gently pressing them into their receptacles. Step 4 Installing the PCA Install: PCA (See Section for more detailed instructions on installing the PCA.) Step 4 Installing the Top Enclosure Install: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) f. Disconnect the other ends of the tubing from the flow element and pressure pick-off REMstar Auto CPAP System 7-29

113 Chapter 7: Repair and Replacement Flow Pick-off Tubing Figure 7-16 Pressure Pick-off Flexible Tubing Placement REMstar Auto CPAP System 7-30

114 Chapter 7: Repair and Replacement Outlet Port and Flow Element Replacement Replacement Part Number Flow Element Included in Kit: Tools Required: Outlet port Phillips screwdriver Flow Element (No. 2 medium) Procedure Removed / Installed During Process: Top enclosure (See Section for more detailed instructions.) Flex tubing (See Section for more detailed instructions.) WARNING: CAUTION: Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Figure 7-17 Outlet Port Outlet Port REMstar Auto CPAP System 7-31

115 Chapter 7: Repair and Replacement Step 1 Removing the Top Enclosure Removing: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 2 Removing the Main PCA Removing: Main PCA (See Section for more detailed instructions on removing the Main PCA.) Step 3 Removing the Pressure Tubing Removing: Pressure Tubing (See Section for more detailed instructions on removing the Pressure Tubing). Step 4 Removing the Outlet Port Remove the outlet port and flow element from the blower outlet by lifting upwards until the outlet port clears the bottom enclosure and pulling it straight out from the blower. Outlet Port Flow Element Step 5Removing the Flow Element Remove the Flow Element from the Outlet Port by pulling the Flow Element straight away from the Outlet Port. Figure 7-18 Outlet Port / Flow Element REMstar Auto CPAP System 7-32

116 Step 6 Installing the Outlet Port a. Place the blower coupler on the blower assembly outlet. b. Push the Flow Element into the blower coupler while ensuring the tubing is properly placed. c. Slowly lower the Outlet Port onto the flow element while ensuring that the outlet port is properly seated in the bottom enclosure. Chapter 7: Repair and Replacement Step 7 Installing the Pressure Tubing Install: Pressure Tubing (See Section for more detailed instructions on installing the Pressure Tubing.) Step 8 Installing the Main PCA Install: Main PCA (See Section for more detailed instructions on installing the Main PCA.) Step 9 Installing the Top Enclosure Install: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) Figure 7-19 Blower Assembly Outlet REMstar Auto CPAP System 7-33

117 7.5.8 Blower Assembly Replacement Replacement Part Number Included in Kit: Tools Required: Blower Assembly Phillips screwdriver (No. 2 medium) WARNING: CAUTION: Chapter 7: Repair and Replacement Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Procedure Removed / Installed During Process Top enclosure (See Section for more detailed instructions) Pressure Tubing (See Section for more detailed instructions). Outlet port and Flow Element (See Section for more detailed instructions). Blower Assembly Figure 7-20 Blower Assembly REMstar Auto CPAP System 7-34

118 Chapter 7: Repair and Replacement Step 1 Removing the Top Enclosure Removing: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 2 Removing the Main PCA Step 6 Removing the Blower Assembly NOTE: While holding the foam enclosure insert in place, lift and remove the blower assembly. Some upward force on the edges of the blower may be necessary. Removing: Main PCA (See Section for more detailed instructions on removing the Main PCA.) Step 3 Removing the Pressure Tubing Removing: Pressure Tubing (See Section for more detailed instructions on removing the Pressure Tubing.) Step 4 Removing the Outlet Port and Flow Element Removing: Outlet Port and Flow Element (See Section for more detailed instructions on removing the Outlet Port.) Step 5 Removing the Blower Assembly cover While holding the foam enclosure insert in place, lift and remove the blower assembly cover. Blower Assembly cover Figure 7-21 Location of the Blower Assembly REMstar Auto CPAP System 7-35

119 Chapter 7: Repair and Replacement Step 5 Installing the Blower Assembly a. Place the blower assembly into the pre-molded enclosure insert. Replace the blower assembly cover. b. Make sure the ferrite is seated properly in the hole in the foam. Step 9 Installing the Top Enclosure Install: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) Step 6 Installing the Outlet Port Install: Outlet Port (See Section for more detailed instructions on installing the Outlet Port.) Step 7 Installing the Pressure Tubing Install: Pressure Tubing (See Section for more detailed instructions on installing the Pressure Tubing.) Step 8 Installing the Main PCA Install: Main PCA (See Section for more detailed instructions on installing the Main PCA.) 5 2 Blower Assembly Figure 7-22 Installing the Blower Assembly REMstar Auto CPAP System 7-36

120 7.5.9 Bottom Enclosure /w Foam Insert Replacement Replacement Part Number (See Note 1 on page 7-10) Included in Kit: Tools Required: Bottom Enclosure (wo/sn-label) Phillips screwdriver (No. 2 medium) Cautions and Warnings label 8 Hi - Lo x 1/ 2 (x3) Light Pipe Procedure Removed / Installed During Process: Filter cap (See Section for more detailed instructions.) WARNING: CAUTION: Chapter 7: Repair and Replacement Enclosure Insert Bottom Enclosure Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Filters (See Section for more detailed instructions.) Top Enclosure (See Section for more detailed instructions.) Pressure Tubing (See Section for more detailed instructions.) Outlet Port and Flow Element (See Section for more detailed instructions.) Blower Assembly (See Section for more detailed instructions.) Bottom Enclosure Figure 7-23 Bottom Enclosure REMstar Auto CPAP System 7-37

121 Step 1 Removing the Top Enclosure Remove: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 2 Removing the Pressure Tubing Remove: Pressure Tubing (See section for more detailed instructions on removing the Pressure Tubing.) Chapter 7: Repair and Replacement Step 5 Removing the Blower Assembly Remove: Blower Assembly Cover Light Pipe Blower Assembly (See section for more detailed instructions on removing the Blower.) Step 3 Removing the Main PCA Remove: Main PCA (See section for more detailed instructions on removing the Main PCA.) Step 4 Removing the Outlet Port and Flow Element Remove: Outlet Port Flow Element (See section for more detailed instructions on removing the Outlet Port.) Figure 7-24 Bottom Enclosure REMstar Auto CPAP System 7-38

122 Step 5 Installing the Bottom Enclosure NOTE: Contact Respironics Corporate Technical Service Department for Bottom Enclosure ordering information. Step 6 Installing the Blower Assembly Install: Blower Assembly Blower Assembly Cover (See section for more detailed instructions on installing the Blower Assembly.) Chapter 7: Repair and Replacement Step 9 Installing the Main PCA Install: Main PCA (See section for more detailed instructions on installing the Pressure Tubing.) Step 10 Installing the Top Enclosure Install: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) Step 7 Installing the Outlet Port and Flow Element Install: Outlet Port Flow Element (See Section for more detailed instructions on installing the Outlet Port). Step 8 Installing the Pressure Tubing Install: Pressure Tubing (See section for more detailed instructions on installing the Pressure Tubing.) REMstar Auto CPAP System 7-39

123 Chapter 7: Repair and Replacement Heated Humidifier Water Chamber Replacement Replacement Part Number: Included in Kit: Tools Required Water Chamber None Base Plate Water Chamber Coupling Step 1 Remove the Water Chamber a. Gently slide the Water Chamber out of the guide rails on the Humidifier Base. b. Remove the air inlet connector from the Water Chamber. Water Chamber Coupling Procedure Removed / Installed During Process: Water Chamber WARNING: CAUTION: Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Figure 7-25 Water Chamber Removal REMstar Auto CPAP System 7-40

124 Chapter 7: Repair and Replacement NOTE: Refer to the Heated Humidifier Users Manual for cleaning instructions for the Water Chamber. c. Place the Water Chamber Coupling on the Outlet of the Water Chamber facing the CPAP. Step 2 Installing the Water Chamber a. Align the Water Chamber with the guide rails on the Humidifier Base. Water Chamber Coupling b. Press down on the Heater Plate and slide the Water Chamber onto the Humidifier Base. Guide Rails Figure 7-26 Humidifier Base Heater Plate Figure 7-27 CPAP to Humidifier Connection REMstar Auto CPAP System 7-41

125 Heated Humidifier Top Enclosure Replacement Replacement Part Number: Included in Kit: Tools Required Top Enclosure Phillips screwdriver (No. 2 medium) Procedure Removed / Installed During Process: WARNING: Water Chamber (See Section for more detailed instructions). Top Enclosure Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Chapter 7: Repair and Replacement Step 1 Removing the Water Chamber Removing: Water Chamber (See Section for more detailed instructions on removing the Water Chamber.) Step 2 Removing the Heated Humidifier Top Enclosure a. Place the unit on a protected work surface and carefully turn it over, exposing the bottom. b. Using a Phillips screwdriver, remove the six screws that secure the top enclosure to the bottom enclosure. c. While securely holding the top and the bottom enclosure together, carefully return the device to its upright position. d. Using a Phillips screwdriver, remove the one screw that secures the top enclosure to the bottom enclosure. e. Gently lift the top enclosure up and away from the bottom enclosure. CAUTION: Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment REMstar Auto CPAP System 7-42

126 Step 3 Installing the Heated Humidifier Top Enclosure Chapter 7: Repair and Replacement a. Gently set the Top Enclosure onto the Bottom Enclosure. b. Using a Phillips screwdriver, insert the screw in the Top Enclosure. c. While securely holding the top and bottom enclosure together, carefully turn the unit over. d. Using a Phillips screwdriver insert the six screws in the Bottom Enclosure Step 4 Installing the Water Chamber Installing: Water Chamber (See Section for more detailed instructions on installing the Water Chamber.) REMstar Auto CPAP System 7-43

127 Heated Humidifier Heater Assembly Replacement Replacement Part Number: Included in Kit: Tools Required Heater Assembly Phillips screwdriver (No. 2 medium) Springs (x4) Procedure Removed / Installed During Process: WARNING: Water Chamber (See Section for more detailed instructions). Top Enclosure (See Section for more detailed instructions). Heater Assembly Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Chapter 7: Repair and Replacement Step 1 Removing the Water Chamber Removing: Water Chamber (See Section for more detailed instructions on removing the Water Chamber.) Step 2 Removing the Heated Humidifier Top Enclosure Removing: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 3 Removing the Heater Assembly a. Disconnect the Heater Plate from the J1 and J2 locations on the Main PCA. b. Remove both wire harnesses from their slots on the bottom enclosure. c. Lift the Heater Plate up and away from the Bottom Enclosure. CAUTION: Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment REMstar Auto CPAP System 7-44

128 Step 4 Installing the Heater Assembly Chapter 7: Repair and Replacement NOTE: Carefully examine the sleeving around the heater leads for cuts or cracking. Replace if necessary. a. Gently set the Heater Plate on top of the four springs, making sure the springs are in place. b. Connect the Red Connector to J1 on the Main PCA. c. Connect the Black Connector to J2 on the Main PCA. d. Gently press the cables into the slots provided on the Bottom Enclosure (they should not be resting on the bottom enclosure). Step 5 Installing the Heated Humidifier Top Enclosure Installing: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) Step 6 Installing the Water Chamber Installing: Water Chamber (See Section for more detailed instructions on installing the Water Chamber.) Figure 7-28 Heater Assembly REMstar Auto CPAP System 7-45

129 Heated Humidifier Main PCA Replacement Replacement Part Number: Included in Kit: Tools Required Main PCA Phillips screwdriver (No. 2 medium) Light Pipe Procedure Removed / Installed During Process: Water Chamber (See Section for more detailed instructions). Top Enclosure (See Section for more detailed instructions). Heater Assembly (See Section for more detailed instructions). Main PCA WARNING: CAUTION: Chapter 7: Repair and Replacement Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment REMstar Auto CPAP System 7-46

130 Step 1 Removing the Water Chamber Removing: Water Chamber (See Section for more detailed instructions on removing the Water Chamber.) Step 2 Removing the Heated Humidifier Top Enclosure Removing: Top Enclosure (See Section for more detailed instructions on removing the Top Enclosure.) Step 3 Removing the Heater Assembly (optional) Removing: Heater Assembly (See Section for more detailed instructions on removing the Heater Assembly.) Step 4 Removing the Main PCA a. Disconnect the Heater Plate from the J1 and J2 locations on the Main PCA. b. Disconnect the Light Pipe from CR 1 on the Main PCA by gently pulling the Light Pipe out of the socket on CR 1. c. Lift the Main PCA from the bottom enclosure. NOTE: Chapter 7: Repair and Replacement The Power Cord and AC Inlet will lift out of the slots on the Bottom Enclosure J 2 Figure 7-29 Main PCA CR 1 J REMstar Auto CPAP System 7-47

131 Chapter 7: Repair and Replacement Step 5 Installing the Main PCA Step 7 Installing the Heated Humidifier Top Enclosure NOTE: NOTE: Carefully examine the Pigtail Power Cord for cuts or cracks. Replace if necessary. Align the Pigtail Power Cord and AC Inlet in the slots of the Bottom Enclosure and press in place. Installing: Top Enclosure (See Section for more detailed instructions on installing the Top Enclosure.) Step 8 Installing the Water Chamber Installing: Water Chamber a. Place the Main PCA onto the three standoffs that hold the circuit board in place. (See Section for more detailed instructions on installing the Water Chamber.) b. While holding CR 1, press the open end of the Light Pipe into CR 1. c. Connect the Red Connector to J1 on the Main PCA. d. Connect the Black Connector to J2 on the Main PCA. Step 6 Installing the Heater Assembly (if previously removed) Installing: Heater Assembly (See Section for more detailed instructions on installing the Heater Assembly.) REMstar Auto CPAP System 7-48

132 Heated Humidifier Bottom Enclosure Replacement Replacement Part Number: (See Note 1 on page 7-10) Included in Kit: Tools Required Bottom Enclosure (w / label) Phillips screwdriver (No. 2 medium) 6-19 x 3/ 8 Plastite (x7) Procedure Removed / Installed During Process: Water Chamber (See Section for more detailed instructions). Top Enclosure (See Section for more detailed instructions). Heater Assembly (See Section for more detailed instructions). Main PCA (See Section for more detailed instructions). Heated Humidifier Bottom Enclosure WARNING: CAUTION: Chapter 7: Repair and Replacement Electrical shock hazard: Disconnect the electrical supply before attempting to make any repairs to the device. Electronic components used in this device are subject to damage from static electricity. Repairs made to this device must be performed only in an antistatic, ESD-protected environment. Step 1 Removing the Water Chamber Removing: Water Chamber (See Section for more detailed instructions on removing the Water Chamber.) Step 2 Removing the Heated Humidifier Bottom Enclosure a. Place the device on a protected work surface and carefully turn it over, exposing the bottom. b. Using a Phillips screwdriver, remove the six screws that secure the top enclosure to the bottom enclosure. c. While securely holding the top and the bottom enclosure together, carefully return the device to its upright position. d. Using a Phillips screwdriver, remove the one screw that secures the top enclosure to the bottom enclosure. e. Gently lift the top enclosure up and away from the bottom enclosure REMstar Auto CPAP System 7-49

133 Chapter 7: Repair and Replacement Figure 7-30 Bottom Enclosure Screw Location Figure 7-31 Top Enclosure Screw Location REMstar Auto CPAP System 7-50

134 Chapter 7: Repair and Replacement f. Disconnect the Heater Plate from the J1 and J2 locations on the Main PCA. g. Remove both wire harnesses from their slots on the bottom enclosure. h. Lift the Heater Plate up and away from the Bottom Enclosure. i. Remove the four springs that hold the Heater Plate. j. Remove the Light Pipe from CR1 on the Main PCA by gently pulling on the Light Pipe. k. Lift the Light Pipe out of the three slots that secure the light pipe to the bottom enclosure. l. Gently push the Light Pipe through the hole on the bottom enclosure and remove. k. Lift the Main PCA from the bottom enclosure. NOTE: The Power Cord and AC Inlet will lift out of the slots on the Bottom Enclosure Heater Assembly Figure 7-32 Heater Assembly REMstar Auto CPAP System 7-51

135 Chapter 7: Repair and Replacement Step 3 Installing the Heated Humidifier Bottom Enclosure NOTE: a. Place the Main PCA onto the three standoffs that hold the circuit board in place. Align the Power Cord and AC Inlet in the slots on the Bottom Enclosure and press into place. b. Slide the open end of the Light Pipe through the hole on the front of the Bottom Enclosure. c. While holding CR 1, press the open end of the Light Pipe into CR 1. j. Gently set the Top Enclosure onto the Bottom Enclosure. k. Using a Phillips screwdriver, insert the screw in the Top Enclosure. l. While securely holding the top and bottom enclosure together, carefully turn the unit over. m. Using a Phillips screwdriver insert the six screws in the Bottom Enclosure d. Gently press the Light Pipe into the slots provided to secure it. e. Place the four springs on the four standoffs on the bottom enclosure. f. Gently set the Heater Plate on top of the four springs, making sure the springs are in place. g. Connect the Red Connector to J1 on the Main PCA. h. Connect the Black Connector to J2 on the Main PCA. i. Gently press the cables into the slots provided on the Bottom Enclosure. Figure 7-33 Main PCA and Light Pipe REMstar Auto CPAP System 7-52

136 Chapter 7: Repair and Replacement Step 4 Installing the Water Chamber Installing: Water Chamber (See Section for more detailed instructions on installing the Water Chamber.) REMstar Auto CPAP System 7-53

137 Chapter 7: Repair and Replacement (This page intentionally left blank.) REMstar Auto CPAP System 7-54

138 Chapter 8: Testing Chapter 8: Testing 8.1 Testing Process REMstar Auto CPAP System Run-in REMstar Auto CPAP System Calibration REMstar Auto Performance Verification REMstar Auto Manual Heated Humidifier Test Current Draw Test REMstar Auto CPAP System Performance Verification Data Sheet REMstar Heated Humidifier Data Sheet (if so equipped) REMstar Auto CPAP System 8-1

139 Chapter 8: Testing Notes: REMstar Auto CPAP System 8-2

140 Chapter 8: Testing 8.1 Testing Process The following process should be followed after a repair has been performed on the REMstar Auto CPAP System or on the Respironics Heated Humidifier. NOTE: Tests 8.2, 8.4, 8.5, 8.6 may be used as a Performance Verification as a way to determine that the CPAP System and Heated Humidifier are functioning properly. This verification shall be performed at periodic intervals commensurate with hospital or home care provider guidelines for preventive maintenance, between rentals, or during normal patient usage (as routine maintenance, see chapter 5 ). Perform the following in order: 1.REMstar Auto CPAP Run-in* (Section 8.2) 2.REMstar Auto CPAP Calibration Test* (Section 8.3) Chapter 8: Testing 8.2 REMstar Auto CPAP System Run-In Purpose This procedure provides instructions for Run-In for the REMstar Auto CPAP System. CAUTION: Equipment Electronic components used in this device are subject to damage from static electricity. Use and follow appropriate Electro-Static Discharge (ESD) procedures. BiPAP Test Orifice (p/n ) (See Appendix A) Pressure Tubing 3.REMstar Auto CPAP Performance Verification * (Section 8.4) 4.Respironics Heated Humidifier Test* (Section 8.5) *The same data sheet is used for all tests. Sections not used due to the testing of only the CPAP or Humidifier should be marked as N/A (Not Applicable). NOTE: The SleepLink card must be inserted into the unit under test REMstar Auto CPAP System 8-3

141 Step 2 Setup a. Place the test orifice on the outlet of the unit. b. Enter the Setup menu and set the pressure to 10 cm H 2 O. (See Section 4.4 for instructions). c. Run the device for a minimum of 2 hours. Chapter 8: Testing 8.3 REMstar Auto CPAP System Calibration Purpose This procedure provides calibration of the REMstar Auto CPAP System. NOTE: Device must run-in for a minimum of two hours to avoid possible calibration failures. CAUTION: Equipment Electronic components used in this device are subject to damage from static electricity. Use and follow appropriate Electro-Static Discharge (ESD) procedures. Utility Software CD (p/n ) Digital Manometer (see Appendix A) Windows -compatible personal computer running Windows 95, 98, 2000, NT with a CD-ROM Smart link card and cable. (P/N ) Flowmeter (range: +180 to -180 lpm, 3% accuracy, 1 lpm resolution) Flow control valve Pressure pick-off adapter (O 2 Enrichment Attachment) Pressure tubing Negative flow source (CPAP capable of 60 lpm) Smooth Bore tubing for intradevice connection NOTE: See Figure 8-5 for proper connections of tubing, manometer and test equipment. NOTE: REMstar Auto CPAP System must be run-in for a minimum of two hours before calibration REMstar Auto CPAP System 8-4

142 Equipment Setup Place REMstar Auto on humidifier base. Do not use Humidifier chamber. Place pressure pick off adapter on the patient outlet of the REMstar Auto. Connect the pressure tubing from the pressure pick off port to the manometer. Connect smooth bore patient tubing to the pressure pick off adapter. Connect the other end of the patient tubing to the flow meter. CPAP (negative flow source) Flow Meter Chapter 8: Testing SleepLink card and cable Pressure Pickoff Connect the end of the flowmeter to the flow control valve with another length of patient tubing. Connect the flow control valve to the negative flow source (CPAP capable of producing at least 60 lpm). Place the SmartLink card in the unit and connect the cable from the active PC com port to the SmartLink card. Connect the AC power cords to REMstar Auto / Humidifier and negative flow source (CPAP). Laptop Computer REMstar Auto Manometer Figure 8-5 Calibration Setup Screen Flow Control Valve REMstar Auto CPAP System 8-5

143 8.3.1 Calibration NOTE: The following calibration should be performed after any repair has been performed on the REMstar Auto CPAP. All REMstar Auto CPAP units must run-in a minimum of two hours before calibration. Step 1 Installing Calibration Software a. Place the Utility Software CD (Part Number ) into the CD drive on PC. Chapter 8: Testing Step 2 Initiating Calibration Software a. Click on the Start Button of your computer. b. Select Programs Respironics Tools REMstar Auto Calibration c. Enter your name and password then click OK. b. The Software will automatically load. If Software does not load, click Run in your start menu. Go to Browse and find the setup file on the CD. c. Click the Start Button of your computer. d. Select: Programs Respironics Tools e. The Utility Software is now loaded onto the PC. f. The following programs should be found in the tools folder: Load Serial and Model Number Read Error Log Real Time Clock Calibration REMstar Auto Calibration Figure 8-6 Name / Password screen REMstar Auto CPAP System 8-6

144 Chapter 8: Testing d. Click Open. Figure 8-8 e. Click on REMstar Auto SC Test.seq f. Click on Open. g. Click on Test Unit. Figure 8-7 Figure REMstar Auto CPAP System 8-7

145 Chapter 8: Testing h. Enter the serial number of the device and click on OK. Figure 8-10 i. Enter the model number of the device and click on OK. j. Enter your name and click on OK. Figure 8-12 k. Verify the device is a REMstar Auto and click on Pass. Figure 8-14 Figure 8-13 Figure REMstar Auto CPAP System 8-8

146 Chapter 8: Testing l. The software will now run several tests and indicate a pass or fail for each of the priliminary tests. e. When 4 cm H 2 O is achieved, click on DONE. Step 3. Pressure Calibration a. The next testing requires the manometer is turned on. b. Click OK. Figure 8-15 f. Now enter the manometer reading and press enter. g. The software will now set the device motor speed to 20 cm H 2 O. h. Click on the increase or decrease button so that the manometer reads 20 cm H 2 O (+ / cm H 2 O). c. The software is now in control of the device and will set the motor speed to achieve 4 cm H 2 O (+ / cm H 2 O). d. If the pressure is not within the given range, click on the increase or decrease blower speed button. i. Click on DONE when the pressure is achieved. j. Enter the manometer reading and press enter REMstar Auto CPAP System 8-9

147 Chapter 8: Testing Step 4. Flow Calibration Sequence a. Open the flow control valve completely and click OK. g. Enter the flowmeter reading and press enter. h. The software will ask for settings from 130 lpm to 0 lpm in 10 lpm increments from this point on. i. Follow the software instructions consisting of setting the flow control valve to the proper level, press enter, entering the flowmeter reading, and pressing enter. Follow these steps to the 0.0 lpm reading screen. Complete the 0.0 lpm test by entering 0.00 lpm when a no flow condition exists between the REMstar Auto and the negative flow source. Figure 8-16 b. Increase motor speed, if needed, to achieve greater than 150 lpm, then click on DONE. c. Adjust the flow control valve to 150 lpm on the flowmeter and click on OK. d. Enter the flowmeter reading and press enter. e. The software will now ask for 140 lpm. f. Adjust the flow control valve for 140 lpm on the flowmeter and click on OK. Figure 8-17 Flow control valve REMstar Auto CPAP System 8-10

148 Chapter 8: Testing j. Connect a flow source (CPAP that produces at least 60 lpm) to the output end of the flow control valve. k. Turn on the CPAP (negative flow source) and let the device stabilize (approximately 1 minute). l. Adjust the flow control valve for -10 lpm on the flowmeter and click OK. o. Turn off the negative flow source and click on OK. This concludes the pressure and flow calibration. The next portion of the testing is to verify the heated humidifier communication link works and a touch pad test followed by the verification process of the flow and pressure. Note: Negative symbol is required on entry, e.g.: Step 5. Humidifier Communications Test test. a. Click on OK to perform the humidifier communications link Figure 8-18 m. Enter the flow meter reading and press enter. Figure 8-19 n. Follow this process up through -60 lpm REMstar Auto CPAP System 8-11

149 Chapter 8: Testing b. Verify that the heater plate LED is on and not blinking, then click on PASS. 8.4 REMstar Auto Performance Verification Purpose This procedure provides instructions for the REMstar Auto Performance Verification. Perform this procedure after the Run-in and computer based calibration has been performed. This procedure can be used as a screening procedure for an out of the box check-out or as a between patient use test. Figure 8-20 c. Verify that the heater plate LED is now off and not blinking, then click on PASS. Figure 8-21 CAUTION: NOTE: Equipment Electronic components used in this device are subject to damage from static electricity. Use and follow appropriate Electro-Static Discharge (ESD) procedures. Performance Verification may be used as a way to determine that the REMstar Auto CPAP System is functioning properly. This verification may be performed between rentals, during normal patient usage as routine maintenance, or after repairs have been performed on the REMstar Auto CPAP System. O 2 Enrichment Attachment (p/n ) (see Appendix A) Pressure Tubing REMstar Auto CPAP System 8-12