RESPIRONICS Remstar Pro C-FLEX Pro-W SM PDF

REMstar® Pro
REMstar® C-FLEX
REMstar® Pro w/C-FLEX www.respironics.com
Service Manual
This REMstar Pro, REMstar Pro with C-Flex, and REMstar C-Flex CPAP system is the subject of U. S. patent #5239995 and #6105575.Other patents
pending. REMstar is a trademark of Respironics, Inc.
REMstar Pro CPAP System

Limited Warranty
Respironics warrants that the REMstar Pro, REMstar Pro with C-Flex, and REMstar C-FLex 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. If the product fails
to perform in accordance with the product specifications, Respironics will repair or replace - at its option - the defective material or part. Respironics will
pay customary freight charges from Respironics 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 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. 1001 Murry Ridge Lane, Murrysville, Pennsylvania 15668,
1-800-345-6443 (US and Canada only) or 1-724-387-4000.

Table of Contents
Table of Contents
Overview: REMstar Pro CPAP System .......................... 0-1 Chapter 3: Specifications, Features, Descriptions,
and Theory of Operation ............................... 3-1
Chapter 1: Introduction ................................................... 1-1 3.1 Overview ...................................................................... 3-3

3.2 Specifications................................................................ 3-4
1.1 REMstar Pro CPAP System Overview... . .....................1-3 3.2.1 CPAP Specifications .......................................... 3-4
1.2 Service Notice............................................................... 1-4 3.3 System Features ............................................................ 3-7
1.3 Technical Support Statement ........................................ 1-4 Symbols / Meanings .................................................... 3-8
3.4 Functional Description................................................3-10
3.5 Theory of Operation (Subassemblies) .........................3-11
Chapter 2: Warnings, Cautions and Notes ..................... 2-1 3.5.1 Control Pad & Liquid
Crystal Display (LCD) ......................................3-11
2.1 Warnings ....................................................................... 2-3 3.5.2 Main Printed Circuit
2.1.1 Safety ................................................................ 2-3 Assembly (PCA) .............................................. 3-12
2.1.2 Service............................................................... 2-4 3.5.3 Encore Pro SmartCard ..................................... 3-12
2.1.3 Cleaning ............................................................ 2-4
2.2 Cautions ...................................................................... 2-5
2.3 Notes ........................................................................... 2-5
1011170 REMstar Pro CPAP System T-1

Table of Contents
Chapter 4: System Setup Procedures ............................... 4-1 Chapter 6: Troubleshooting and Diagnostics .................. 6-1
4.1 Overview ..................................................................... 4-3 6.1 Overview ..................................................................... 6-3

4.2 REMstar Pro CPAP System Setup ............................... 4-4 6.2 Common System Level Problems ............................... 6-4
4.2.1 Display Screens ................................................. 4-5 6.3 Trouble Shooting Flow Chart ...................................... 6-6
4.3 Recommended Circuit Accessories ............................. 4-9 6.4 Troubleshooting Table ................................................. 6-7
4.3.1 Recommended Accessories ............................... 4-9 6.5 REMstar Pro Error Code Retrieval ........................... 6-13
4.3.2 Alternate and Optional Accessories ................. 4-10 6.5.1 Error Code Retrieval ........................................ 6-13
4.3.3 DC Power Accessories......................................4-11 6.6 Error Code Chart ....................................................... 6-13
4.3.4 Adding Oxygen to the System ......................... 4-12 6.7 SmartCard Error Code Chart ..................................... 6-17
Chapter 5: Routine Maintenance ..................................... 5-1 Chapter 7: Repair & Replacement .................................. 7-1
5.1 Overview ..................................................................... 5-3 7.1 Overview ..................................................................... 7-3

5.2 Cleaning the System .................................................... 5-3 7.2 REMstar Pro CPAP System Repair Kits ..................... 7-4
5.3 Cleaning / Replacing the Intake Filter ......................... 5-3 7.3 Warnings and Cautions ................................................ 7-8
5.3.1 Removing, Cleaning, and 7.4 Replacement Instructions ............................................ 7-8
Replacing the Filter ........................................... 5-3 7.4.1 Filter Cap Replacement ..................................7-11
5.4 REMstar Pro CPAP System 7.4.2 Main Printed Circuit Assembly
Preventive Maintenance Schedule............................... 5-5 (Main PCA) Replacement ............................. 7-14
5.4.1 REMstar Pro CPAP System Preventive 7.4.3 Key Pad Replacement.................................... 7-17
Maintenance Schedule ....................................... 5-6 7.4.4 Outlet Port Replacement ............................... 7-20
7.4.5 Flow Sensor Replacement ............................. 7-22
7.4.6 Silicone Tube Replacement ........................... 7-24
7.4.7 Blower Assembly Replacement ..................... 7-26
7.4.8 Bottom Enclosure Replacement .................... 7-30

Table of Contents
Chapter 8:Testing .............................................................. 8-1 International W/SmartCard Display and SmartCard . B-12
International W/SmartCard Power Supply ................ B-13
8.1 Testing Process ............................................................ 8-3 International W/SmartCard Motor Driver ................. B-14
8.2 Run-in Procedure ......................................................... 8-4
8.3 REMstar Pro CPAP System
Pressure and Flow Calibration .................................... 8-5
8.4 REMstar Pro CPAP System Final Test ........................ 8-9
8.5 Respironics Heated Humidifier Test ......................... 8-10
8.6 Current Draw Test ......................................................8-11
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
Domestic W/SmartCard Microprocessor .................... B-3
Domestic W/SmartCard Analog Circuit ...................... B-4
Domestic W/SmartCard to CPU ................................. B-5
Domestic W/SmartCard Display and SmartCard ........ B-6
Domestic W/SmartCard Power Supply ....................... B-7
Domestic W/SmartCard Motor Driver ........................ B-8
International W/SmartCard Microprocessor ............... B-9
International W/SmartCard Analog Circuit ............... B-10
International W/SmartCard to CPU........................... B-11

Table of Contents
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Overview
Overview: REMstar Pro CPAP System

Warranty Details the Respironics warranty.
Chapter 1: Introduction Introduces the REMstar Pro 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 Pro 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 Run-In, Pressure and Flow Calibration, CPAP Final Test,
Heated Humidifier Test, Current Draw Test and Data Sheet.
Appendix A:Tools and Equipment Details the necessary tools and test equipment required for servicing.
Appendix B:Schematics Provides Printed Circuit Assembly (PCA) schematics.
NOTE: Schematics are proprietary and are used for reference only.
1011170 REMstar Pro CPAP System O-1

Overview
1011170 REMstar Pro CPAP System O-2

Chapter 1: Introduction
1.1 REMstar Pro System Overview .............1-3
1.2 Service Notice ...........................................1-4
1.3 Technical Support Statement ..................1-4
1011170 REMstar Pro CPAP System 1-1

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1.1 REMstar Pro CPAP System Overview
The REMstar Pro, REMstar Pro with C-Flex, and REMstar C-Flex CPAP
system shown in Figure 1-1, is a microprocessor-controlled device that
delivers Continious Positive Airway Pressure (CPAP) therapy only for the
treatment of adult Obstructive Sleep Apnea (OSA). CPAP provides a
constant level of positive pressure throughout the breathing cycle to
pneumatically splint the airway open. C-Flex therapy is also available on
some models of the device. In these devices, CPAP therapy is improved by
providing pressure relief when the patient exhales. The pressure relief
lowers the device pressure slightly during the patients exhalation to
improve the comfort of the device.
The unit incorporates a user interface made up of a Liquid Crystal Display

(LCD), five tactile feedback user control keys and three Light-Emitting
Diodes (LEDs). The LEDs may be used as either system alert/alarm
indicators and as back lighting for the user interface control keys. The unit
may be operated using either AC (100 - 240 VAC) or DC (11.5 - 14.5 VDC)
power.
Warning: DC power can be used only when the REMstar Pro is used
independently of the Heated Humidifier.
Figure 1-1

1.2 Service Notice

This service manual was prepared by Respironics primarily for use by International
technicians to service the REMstar Pro CPAP System with the following
Model No. Phone 1-724-387-4000
1005961 1006169 Fax: 1-724-387-5012
1010220 1010924
1011079 1006171
1012257 JP1006171
AU1006171 LA1006171
Visit Respironics Home Page on the World Wide Web at:
The individuals using this manual to service the REMstar Pro CPAP
System should have prior training or experience servicing ventilatory
devices.
www.respironics.com
1.3 Technical Support Statement
service@respironics.com
Respironics is committed to customer satisfaction and may be contacted

with any questions or for technical support. For technical assistance or
replacement part ordering information contact Respironics Customer
Satisfaction.
U.S. and Canada
Phone:1-800-345-6443
Fax 1-800-886-0245

Chapter 2: Warnings, Cautions, and Notes
Chapter 2: Warnings,
Cautions, and
Notes
2.1 Warnings .................................................... 2-3
2.2 Cautions ..................................................... 2-5
2.3 Notes ........................................................... 2-5
1011170 REMStar Pro CPAP System 2-1

Notes
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Chapter 2: Warnings, Cautions, 2.1.2 Operational

and Notes This warning applies to most Continuous Positive
Airway Pressure (CPAP) devices. At low CPAP
WARNING: Indicates the possibility of injury to the patient, pressures, the air flow through the exhalation port
operator, or technician. may not be enough to clear all of the exhaled gas
(CO2) from the mask. You may breathe in some of
CAUTION: Indicates the possibility of damage to the device. the air that you have exhaled.
NOTE: Places emphasis on an operating characteristic.
If oxygen is used with this device, the oxygen flow
must be turned off when the device is turned off. If
the devices air flow is turned off and the oxygen
flow is left on, oxygen may accumulate in the
2.1 WARNINGS REMstar Pro CPAP System enclosure and may create
a risk of fire. This warning applies to most
types of CPAP devices.
2.1.1 Safety
When supplemental oxygen is used at a fixed flow
This device is intended for adult use only. rate, inhaled oxygen concentrations will vary depending
on pressure settings, patient breathing patterns, mask
This device is not intended for life support or life selection and leak rate.
sustaining applications.
The instructions in this manual are not intended to

supersede established medical protocols.

Warnings (Continued)
Oxygen supports combustion. Do not use oxygen in 2.1.3 Service

the presence of open flames, cigarette smoke,
electrical spark, or other sources of ignition. Electronic components used in this device are
subject to damage from static electricity. Repairs
Device is not suitable for use in the presence of a made to this device must be performed only in an
flammable anesthetic mixture with air or with antistatic, Electro-Static Discharge (ESD) protected
oxygen or nitrous oxide. environment.
In situations where risk of contamination between To assure the safety of the service technician and the
the user and the device is high (e.g.: sleep lab specified performance of the device, Respironics
devices; rental devices; users with respiratory recommends that only technicians having prior
infections), a low-resistance, main flow bacteria training or experience servicing ventilatory devices
filter should be placed in-line between this device perform any repairs or adjustments to the REMstar Pro
and the circuit. CPAP System.
Most CPAP devices have the potential to induce High voltages are present inside this device. To
rebreathing of exhaled air. To reduce this potential, avoid electrical shock, disconnect the electrical
use only Respironics circuit accessories, do not wear supply before attempting any repairs on the device.
the mask and headgear for more than a few minutes
while the unit is not operating, and do not block or 2.1.4 Cleaning
try to seal the vent holes in the exhalation port.
To avoid electrical shock, disconnect the electrical
supply before cleaning the REMstar Pro CPAP System.
DO NOT immerse this device into any fluids.

2.2 CAUTIONS 2.3 NOTES

Federal law (U.S.) restricts this device to sale by, or on Refer to the REMstar Pro CPAP System Manuals
the order of a physician. for product use additional warnings, cautions,
and notes.
Care should be taken to avoid exposure of the REMstar
Pro CPAP System to temperatures at or near the extremes
of those specified in Chapter 3. If exposure to such Additional WARNINGS, CAUTIONS, and NOTES are located
temperatures has occurred, the device should be throughout this manual.
allowed to return to room temperature before being
turned on.
Always use an intake filter when the REMstar Pro CPAP

System is in use.
Never place liquids on or near the REMstar Pro CPAP

System.
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 Home
Care Dealer Instructions.

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Chapter 3: Specifications, Features, Descriptions and Theory of Operation
Chapter 3: Specifications
Features,
Description,
and Theory of
Operation
3.1 Overview .................................................... 3-3
3.2 Specifications ............................................. 3-4
3.3 System Features ........................................ 3-8
3.4 Functional Description ...........................3-10
3.5 Theory of Operation ............................... 3-11
3.6 Auto-off and Mask Alert

Description and Testing..........................3-13

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Chapter 3: Specifications, Features,

Description, and Theory
of Operation
3.1 Overview
This chapter describes the REMstar Pro CPAP System specifications and
system features, and provides a functional description and theory of
operation.

3.2 Specifications FUSES:
3.2.1 CPAP Specifications Fuses There are no replaceable fuses.
ENVIRONMENTAL: PHYSICAL:
Operating Temperature 41 to 95°F (5 to 35°C) Dimensions 9 1/2x 6 7/8 x 4 1/2

24 cm x 17 cm x 12 cm
Storage Temperature -4 to 140°F (-20 to 60°C)
Weight < 4 lbs. (1.8 kg)
Humidity (Operating / Storage) 15 to 95% non-condensing
ELECTRICAL:
NOTE: The outlet temperature rise can be as much as 18°F AC Input Voltage 100 - 240 VAC ± 10%
(10°C) higher than room temperature measured at 47 - 63 Hz
the end of a 6 ft. tube.
DC Voltage 11.5 - 14.5 VDC
Atmospheric Pressure 76.7 to 102 kPascals
AC Current Consumption 1.0 A maximum
Elevation 0 to 5500 ft. DC Current Consumption 3.0 A maximum
Power Consumption 80 VA maximum

Noise Level No specification is given because
various instruments, test procedures Type of Protection Class II Equipment
and unit operating conditions produce Against Electrical Shock 2-prong AC power inlet
varying results.
Degree of Protection Against Type BF Applied Part
Electrical Shock

Specifications (Continued)
RAMP:
Degree of Protection Against IPX0-Ordinary Equipment
Ingress of Water Minimum Ramp Press 4.0cm H2O to current CPAP setting
Degree of Safety of Application Equipment not suitable for use in the Ramp Resolution .2 cm H20
in the Presence of a Flammable Presence of a Flammable Anaesthetic
Anaesthetic Mixture with Air, Mixture with Air, Oxygen, or Nitrous Ramp Time 5 to 45 minutes
Oxygen, or Nitrous Oxide. Oxide.
Ramp Time Resolution 5 minute increments
Mode of Operation Continuous ALTITUDE COMPENSATION:
Pressure Range 77 to 102 kPascals

STANDARDS COMPLIANCE:
Automatic Altitude Adjustment
This product complies with the requirements found in the following
standards.
COMPLIANCE METER:
IEC 60601-1 General Requirements for Safety of
Medical Electrical Equipment
Compliance Meter (LCD) Total Operation Time
EN ISO 17510-1 Sleep Apnea Breathing
Therapy Time
Therapy Devices
Percent Memory Remaining
FUNCTIONS:
Modes Provider Mode COMFORT SETTING:
User Mode Therapy Type C-Flex (Only available on REMstar

Pro with C-Flex and REMstar
Diagnostic Mode
C-Flex.)
Humidifier Operation CPAP

Specifications (Continued)
PRESSURE: THERAPY MEMORY:

AC Operation 4 - 20 cm H2O Therapy Memory Retrievable by Encore
Software (version 3.0 or later)
DC Operation 4 - 20 cm H2O
STORAGE:
CPAP Mode 4 - 20 cm H2O
Data Storage Data storage shall be on a
Resolution .2 cm H2O removable contact SmartCard.
Max Capacity 6 months of data comprised

NOTE: Pressure accuracy measurements shall be taken at the end of a of 3 sessions per 24-hour
six foot patient circuit with a Whisper Swivel II exhalation port. period, with 2.5 ramps per
session.
Static Pressure Accuracy +/- 1 cm H2O of the displayed Content Separate memory areas for
pressure setting prescription information and
data storage.
Pressure Drop with Humidifier .3 cm H2O @ 20 cm H2O

3.3 System Features Heated Humidifier Button Use this button only when the
optional Heated Humidifier is
AC Power Connector Connect AC power here. connected. Follow the instruc-
tions included with the humidifier.
DC Power Connector Optional DC Power Connec-
User Buttons These buttons can be used to
tion for CPAP
change some of the device
settings.
Air Outlet Port Connect flexible tubing here.
LCD Display Displays all system settings,

blower hours, and sessions > 4
hours. Display will show icons for
international units and english
words for domestic units.
Filter Cap & Filter The pollen filter screens out

normal household dust and
pollens. This must be in place at
all times when operating the
REMstar Pro CPAP System.
Pressure On / Off Button This button turns the air flow on

or off. DO NOT turn the air flow
on until the circuit tubing is
connected.
Ramp Button This button decreases the

pressure to the minimum ramp
pressure setting.

C-FLex Symbol
Attention is needed
Patient disconnect activated/enabled
SmartCard is installed
Button lights are ON
Ramp start pressure

Display
Meanings Ramp pressure is being delivered
Screen
FOSQ test questions are shown
Centimeters of water
Humidifier is ON
Hours of use
Number of nights with
>4 more than 4 hours usage
Therapy setup menu
Settings are being erased
Pressure Start / Stop

Control
Meanings Ramp start
Buttons
Humidifier On / Off
! Attention, consult
accompanying documents
DC Power
AC Power
Type BF Applied Part
REMstar Pro Meanings Class II (Double insulated)
Labels
IPX0 Ordinary Equipment Rating
European CE Declaration
0123 of Conformity
Notified Body Approval
for Standards Compliance
Canadian / US Certification

3.4 Functional Description

The REMstar Pro CPAP System is a microprocessor controlled Continuous The ramp feature, lets the user reduce the pressure from the REMstar Pro
Positive Airway Pressure (CPAP) device that will produce positive pres- CPAP System so the patient can fall a sleep at a lower, more comfortable
sure. pressure at any time or as many times as needed during the night.
The REMstar Pro CPAP System operates in straight CPAP mode. The The REMstar Pro CPAP System is intended to deliver CPAP therapy only. It
REMstar C-Flex and the REMstar Pro with C-Flex will operate in straight is not intended for life support or life sustaining applications. The follow-
CPAP mode, or CPAP with the comfort setting of C-Flex as determined by ing sections describe the major components of the REMstar Pro CPAP
the provider. The pressure range in AC and DC operation is: 4.0 - 20.0 cm System and their basic theory of operation.
H2O.
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 Pro CPAP System may be powered from either

AC (100 - 240 VAC) or from DC (11.5 - 14.5 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 system when AC voltage is not accessible.
The system filter, ensures optimum operation for the user. An air outlet
port and pressure 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 patients 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.

3.5 Theory of Operation
3.5.1 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
Display pressure. The range of pressure is 4.0 to 20.0 cm H2O with AC and DC
Screen 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 0 to 45 minutes in five
Heated minute increments (0 would be off). An LCD is used to show various
operating parameters while the unit is powered. LCD will show icons on
Humidifier international units and English text on domestic units.
Button
User Pressure
Ramp
Buttons Start / Stop
Button
Button
Figure 3-1
User Buttons

3.5.2 Main Printed Circuit Assembly 3.5.3 Encore SmartCard
(Main PCA)
The Main PCA is the control center of the REMstar Pro CPAP System. The REMstar Pro CPAP is delivered with the Encore SmartCard installed.
The Main PCA utilizes a microcontroller chip which reads from and writes The SmartCard is a plastic card similar in size and shape to your normal
to various I/O devices (control pad, LCD, memory, pressure sensor, flow credit card. But instead of holding information on a magnetic strip, it holds
sensor, motor control circuitry, RS-232 interface, etc..) With all of this it in a small silicon chip embedded into the card.
information, the microcontroller makes appropriate decisions so the blower
is properly controlled to deliver the desired CPAP therapy in a safe and When installed into the REMstar Pro CPAP System, the SmartCard records
reliable manner. the date, time at pressure, pressure levels, and duration of each use. Using
the Encore Software (version 3.0 or higher), the usage data can be down-
The microcontroller and the interface circuitry provide closed loop control loaded and viewed.
of the blower motors speed. The blower motor is a three phase brushless
DC motor with permanent magent rotor, stationary coils that are connected The SmartCard can also be programmed with the patients prescription by
in a Y configuration and serve as its stator coils, and a Hall-Effect sensor using the Encore Software and SmartCard reader/writer. When the pro-
to detect the motion of the rotor. Proper timing and sequencing of the grammed SmartCard is inserted into the device, the prescription settings are
stator switching is provided by the microcontroller which senses the automatically transferred into the device and erased from the SmartCard.
motors shaft position by monitoring a Hall-Effect sensor within the motor. The SmartCard will then start to collect patient data.
The microcontroller also sets the motor speed (and consequently the
output pressure) by varying the voltage which is delivered to the motor. It
does this by controlling the pulse width of commutation signals.
The unit has a switching power supply which is built on the Main PCA and
mounted within the units top enclosure. The switching power supply
operates properly on any AC voltage between 100 - 240 VAC; 47 - 63 HZ
and produces an output of approximately 16 VDC. The switching power
supply automatically adjusts for varing input voltages. No voltage selector
switch or fuse changing is required, which allows for worldwide operation.

Chapter 4: System Setup Procedures
Chapter 4: System Setup

Procedures
4.1 Overview .................................................... 4-3

System Setup.............................................. 4-4
4.3 Recommended, Alternate, and Optional

Circuit Accessories ................................... 4-9

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Chapter 4: System Setup

Procedures
4.1 Overview
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: The LCD will display icons for international units and English text
for domestic units.

4.2 CPAP System Setup

User Buttons AC Power Cord
Step 1 Plug the male end of the AC power cord into an electric outlet.
Step 2 Simultaneously, press the two User buttons (below the

display screen) then plug the female end of the AC power
cord into the AC inlet on the back of the REMstar Pro CPAP
System. Continue to hold the two buttons down until the
unit beeps twice (see Figure 4-1).
NOTE: If a System Error 8 key stuck occurs, repeat the process in

Step 2 again.
Display
Screen
Heated
Humidifier
Button
Ramp User
Button Buttons Pressure
Start / Stop Button
Figure 4-1 Figure 4-2
Touchpad Features Connecting and Entering the Therapy Mode

4.2.1 Display Screens

NOTE: You cannot turn the air flow on when you are in the Step 2 Comfort Selection
Therapy Setup menu. When you exit this menu,
the Therapy Time will be displayed.
The REMstar Pro with C-Flex and the REMstar C-Flex can be placed in the
NOTE: During system setup, press the left or right User button CPAP setting which provides a constant level of positive pressure through-
to view a setting. Press the humidifier or ramp button to out the breathing cycle or it can be placed in the C-Flex setting which
change the setting.
provides the user with an adjustable pressure relief during exhalation.
NOTE: Display screens are dependent on features of Pressing the ramp or humidifier buttons will toggle between the two
international or domestic models. settings. Choose the desired setting and press the right user button to
continue to the next setting.
SETUP
Step 1 Erase the Therapy Hours CPAP

C-FLEX
The number of nights the REMstar Pro was used for therapy for more than
4 hours will appear. Press and hold the ramp or humidifier button until the Domestic Screen
erase icon disappears to delete the therapy hours. Press the right user
button to continue to the next setting.
Flashes on and off
SETUP during this selection.
NIGHTS >4 HRS
CPAP
ERASE
Domestic Screen
Figure 4-4
Setting the Mode
Figure 4-3
Erasing the Therapy Hours
System Setup (Continued)
Step 4 Setting the Comfort Setting
Step 3 Setting the Pressure
NOTE: This setting will only appear on units with C-Flex. The
comfort setting will only be displayed if the C-Flex feature
The CPAP pressure setting will be displayed. Press the ramp button or the was enabled in Step 2.
humidifier button to select the proper pressure. Press the right user button
to continue to the next setting. The comfort setting will be displayed. Press the ramp button or the
humidifier button to select 1-3. Press the right user button to continue to
Range: 4 - 20 cm H2O the next setting.
.2 cm H2O increments
SETUP
SETUP
0 2
C-FLEX
ALERT
Domestic Screen
Domestic Screen

Setting the Pressure Setting the Comfort Setting

Step 5 Setting the Ramp Time Step 6 Setting the Minimum Ramp Pressure
The ramp time will be displayed. Press the ramp button or the humidifier The ramp pressure will be displayed. Press the ramp button or the
button to select the proper setting. Press the right user button to continue humidifier button to select the proper setting. Press the right user button
to the next setting. to continue to the next setting.
Range: 4.0 - 20.0 cm H2O

.2 cm H2O increments
SETUP
SETUP
0
ALERT 0
ALERT
Domestic Screen Domestic Screen
0:05
4.0

Setting the Ramp Time Setting the Minimum Ramp Pressure

System Setup (Continued)
Step 7 Set the Mask Alert Step 8 Set the Button Lights
The mask alert setting will be displayed. Press the ramp button or the This setting allows the lights behind the buttons to be on or off when the
humidifier button to select the proper setting. Press the right user button airflow is turned on. Press the ramp button or the humidifier button to
to continue to the next setting. select the proper setting. Pressing the right user button will bring you back
to the first set up screen. Pressing the Start / Stop button will take you out
of the set-up menu.
Selection: 0 - Off SETUP

Selection: 0 - Off
1 - On 0 1 - On SETUP
ALERT
0
LED
Domestic Screen Domestic Screen
0
0

Setting the Mask Alert Setting the Button Lights

4.3 Recommended, Alternate, and

Optional Circuit Accessories
This section addresses the recommended, alternate, and optional circuit
accessories that can be used with the REMstar Pro CPAP System.
For additional information, refer to the Users Manual or the Home Care
Providers Manual or the literature supplied with accessory.
4.3.1 Recommended Accessories

To use the REMstar Pro CPAP System, the following accessories are
recommended in order to assemble the circuit.
WARNING: If using the REMstar Pro CPAP System with other patient
circuits than the recommended patient circuit identified
below, pressures should be verified before use.
Recommended Patient Circuit
Respironics Nasal Mask with integrated Exhalation Port

(or Respironics mask with separate exhalation port such
as the Whisper Swivel*).
Respironics 6 ft. (1.83 m) Flexible Tubing. Figure 4-11

REMstar Pro CPAP System with Recommended Circuit
Respironics Headgear or Softcap (not shown).

4.3.2 Alternate and Optional Circuit Accessories

The Respironics alternate accessories listed in Table 4-1 can be used in place of the recommended accessories. The optional accessories can be added to
the patient circuit. Refer to Table 4-1 for changes in the pressure / flow characteristics when using these accessories.
Table 4-1, Patient Circuit Accessory Pressure / Flow Characteristics
Pressure Drop @ 30 lpm (cm H2O) Pressure Drop @ 60 lpm (cm H2O)
Recommended Patient Circuit
Nasal Mask (disposable, reusable) 0.03 0.09
Profile Lite Nasal Mask (reusable) 0.03 0.09
Simplicity Mask 0.20 0.77
Whisper Swivel II (reusable) 0.02 0.08
6 ft. (1.83m) Flexible Tubing 0.11 0.30
Alternate Accessories
Spectrum Full Face Mask 0.04 0.10
Plateau Exhalation Valve (reusable) 0.05 0.20
6 ft. Disposable Circuit & Exhalation Port 0.20 0.34
Optional Accessories
REMstar Passover Humidifier 0.00 0.30
REMstar Heated Humidifier 0.00 0.30
King Bacteria Filter (disposable) 0.74 1.65
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.

Recommended, Alternate, and Optional Circuit Accessories (Continued) WARNING: Appropriate diagnostic pressures must be determined
when alternate or optional accessories are in place.
The following graph provides the exhaust / flow characteristics of the Respironics reusable circuit accessories are washable,
exhalation port accessories that can be used with the REMstar Pro CPAP but are for single patient use only. They are not
System. This information may help assess the CO2 rebreathing potential of intended to be used on multiple patients.
various circuit configurations at different applied pressures.
4.3.3 DC Power Accessories
Typical Exhaust
Flow/Pressure Performance The Respironics Shielded DC Power Cord (RI P/N 1001956) can be used to
45 operate the REMstar Pro CPAP System in a stationary recreational vehicle,
boat, or motor home.
40
The Respironics DC Battery Adapter Cable (RI P/N 532209) when used with
35
the Respironics Shielded DC Power Cord enables the Respironics CPAP
System to be operated from a 12 VDC freestanding battery.
30
NOTE: Respironics recommends a 100 amp-hour deep
25
cycle marine battery.
Flow (lpm)
20 The REMstar Pro CPAP System should not be operated while the vehicle is
in motion.
15
CAUTION: Only use the Respironics DC Power Accessories.
Use of any other system may cause damage to the
Disposable Circuit
Exhalation Port
10 Whisper Swivel¨ II
Exhalation Port
REMstar Pro CPAP System or your vehicle.
Simplicity Mask
5
w / Exhalation Port
Plateau Exhalation
CAUTION: DC Power is not intended to be used as battery backup.
Valve DO NOT connect the DC Power while the REMstar Pro
0 CPAP System with is operating on AC Power.
0 5 10 15 20 System damage may occur.
Pressure (cm H2O)
CAUTION: DC power can be used when the CPAP and Heated

Humidifier are connected together as a system. However
Figure 4-12 the Heated Humidifier will not function on DC power,
Typical Exhaust Flow / Pressure Performance however it will function as a cold passover humidifier.

4.3.4 Adding Oxygen to the System

Please note the warnings listed below when using oxygen with the REM-
star Pro CPAP System.
WARNING: When using oxygen with the REMstar Pro CPAP

System, turn the unit on before turning the oxygen on.
Turn the oxygen off before turning the REMstar Pro
CPAP System off. This will prevent oxygen
accumulation in the room.
WARNING: Oxygen supports combustion. Do not use oxygen in

the presence of open flames, cigarette smoke,
electrical spark, or other sources of ignition.

Chapter 5: Routine Maintenance
Chapter 5: Routine
Maintenance
5.1 Overview .................................................... 5-3
5.2 Cleaning the System ................................. 5-3
5.3 Cleaning / Replacing the

Intake Filter ............................................... 5-3

Preventive Maintenance Schedule .......... 5-5

Notes: _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________

Chapter 5: Routine Maintenance 5.3 Cleaning / Replacing the

Intake Filter
5.1 Overview 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
This chapter provides guidelines and illustrates the cleaning and weeks under normal usage, or as required, and replaced with a new one
maintenance procedures for the REMstar Pro CPAP System. 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.
Before cleaning or performing any routine maintenance, always switch the
REMstar Pro CPAP Systemss Pressure Start / Stop button to the Stop
position and unplug the power cord from the rear of the unit.
5.2 Cleaning the System

CAUTION: Failure to replace a dirty filter may cause the device
to operate at higher than normal temperatures and
WARNING: To avoid electrical shock, disconnect the electrical damage the device.
supply before attempting to clean the REMstar Pro
CPAP System. DO NOT immerse the unit in water or
allow any liquid to enter the cabinet or the filter intake.
5.3.1 Removing, Cleaning, and Replacing the

Step 1 Wipe the outside of the unit with a cloth slightly dampened Filter
with water and a mild detergent. Let the unit dry before
reconnecting the electrical supply. Step 1 With the air flow turned off, disconnect the AC or DC power
cord from the back of the unit.

Cleaning / Replacing the Intake Filters (Continued)
Step 2 Remove the filter cap by gently lifting up on the bottom of the Step 3 Remove the pollen filter by gently pulling the edges of the filter.
filter cap, then pulling it away from the back of the unit. 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.

Removing the Filter Cap The Filter Cap and Filters

Cleaning / Replacing the Intake Filters (Continued)
Step 4 Place the pollen filter into the filter area in the back of the
REMstar Pro CPAP System. Preventive Maintenance Schedule
The following Preventive Maintenance Schedule lists the items that must
CAUTION: The pollen filter must be completely dry before use. be inspected or tested periodically, or after service is performed. Use the
Never place a wet filter into the device. Preventive Maintenance Schedule to record the dates on which the
Respironics recommends that you clean the filter in maintenance items are performed.
the morning and alternate using the two pollen filters
provided with the system to ensure enough drying The Preventive Maintenance Schedule may be copied for each unit
time for the cleaned filter. serviced.
CAUTION: DO NOT place both pollen filters into the unit

at the same time.
Step 5 Install the filter cap. The opening in the filter cap for the
REMstar Pro CPAP System should face down, away
from the patient.

REMstar Pro CPAP System Preventive Maintenance Schedule (Continued)
5.4.1 REMstar Pro 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 5.3.1 Clean every 2 weeks, or as

required;
Change every 6 months.
Perform Testing Process Section 8.1 After service is performed.
Cleaning Section 5.2 As required.

Chapter 6: Troubleshooting and Diagnostics
Chapter 6: Trouble-
shooting and
Diagnostics
6.1 Overview .................................................... 6-3
6.2 Common System Level Problems............ 6-4
6.3 Troubleshooting Flow Chart ................... 6-6
6.4 Troubleshooting Table .............................. 6-7
6.5 Error Code Chart ...................................6-13
6.6 SmartCard Error Code Chart .............. 6-17

Notes: _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________

Chapter 6: Troubleshooting and

Diagnostics
6.1 Overview
WARNING: Electrical Shock Hazard: Disconnect the electrical
supply before repairing the unit.
CAUTION: 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 Pro 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.

6.2 Common System Level Problems
Screen Message Description Result Corrective Action

Mask Alert A large circuit leak, such as mask The audible alarm will sound in Press any button on the
removal, has been detected. approximately 35 - 65 seconds REMstar Pro CPAP System to
(if the mask alert feature has silence the audible alarm and
been turned on). clear the display screen.
The air flow will turn off in Check the circuit (flexible
approximately 45 - 80 seconds tubing assembly, mask) for any
(if the auto-off feature has been leaks and adjust the mask and
turned on). headgear.
Press the Pressure On / Off

button to restart the air flow.
Note: The audible Mask alarm

setting and auto-off feature
can be enabled or disabled.
(See Section 4.2 - System
Setup for instructions.)

Common System Level Problems (Continued)
Screen Message Description Result Corrective Action
Connect Pressure Line The flexible tubing may have The air flow will turn off Press any button on the unit
become disconnected from the immediately. to silence the audible alarm
system. and clear the display screen.
The alert tone will sound.
Reconnect the tubing.
The back light will flash on and
off. Press the Pressure On / Off
button to restart the air flow.
The signal light on the
humidifier will turn off. Note: This alarm setting
cannot be turned on or off.
E - XXX The REMstar Pro CPAP System is The air flow will turn off Reset the unit by unplugging
not functioning correctly and may immediately. the power cord from the
need servicing. electrical outlet and then
plugging it in again.
The alert tone will sound.
If the message appears again,
The back light will flash on and
refer to the Error Code Chart
off.
(Section 6.5) for a description
of the error and corrective
The signal light on the action.
humidifier will turn off.
Note: This alert setting cannot
be turned off.

6.3 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 Problem Found
Table (Section 6.4)
Problem
Not Found
6
Substitute Known Problem Found
Good Parts
(if available)
Problem
Not Found Problem Found
6 6
Perform System Functional Repair per Procedures
Test in Chapter 8 4 in Chapter 7
Problem
Not Found
6
Run Unit for
4 Minimum 2 Hours
6
Perform System Final or
Functional Test in Chapter 8

6.4 Troubleshooting Table
Symptom Cause Verification Corrective Action
Audible Alarm - Main printed circuit assembly. Perform power up sequence. If audible alarm does not work,
During audible alarm condition, Visually verify the LEDs and replace Main PCA.
the alarm is not audible. display illuminate. Reestablish
original alert conditions. Listen for If visual indicators are not
audible alarm. present at power up, perform user
interface checkout procedure.
If device fails user interface

checkout procedure, replace Main
PCA.
If alarm is audible during both

tests, no corrective action is
required.
Unit does not operate from the Faulty DC plug, low DC voltage, Ensure the DC voltage supply is a If DC source is not at 11.5
12 VDC power source. fuse in DC cord is blown. minimum of 11.5 VDC. Ensure the VDC or higher, replace or
DC voltage is stable. Monitor the recharge power source as
Main PCA. voltage at the back of the DC required.
connector mounted on the Main
PCA. If DC voltage is below 11.5 If 12 VDC supply is ok, replace
VDC, replace or recharge DC Main PCA.
source. If there is no DC measured
at the Main PCA, then check the DC
adapter cord for continuity.

Troubleshooting Table (Continued)
Display Indicator - Main printed circuit assembly. Perform user interface checkout If device fails user interface
LED or other indicator not working. procedure. checkout procedure, replace
Main PCA.
Display - Display assembly. Inspect solder joints between Replace Main PCA.
Display is blank or contains display board and Main PCA.
erroneous information. Main PCA.
Intermittent Power Supply Power cord, AC inlet, Main PCA, Inspect power cord for fraying at Replace Main PCA.
Problem - loose connections. cable ends.
An intermittent on / off condition
exists, unit alarms randomly, or Inspect all connections on the
indicator lights blink sporadically. Main PCA.
Noise - Missing or damaged bottom feet Turn over and inspect the bottom If bottom feet are missing,
on bottom of unit, blower for missing or damaged bottom replace bottom enclosure.
malfunctioning. feet. Tighten any loose screws.
Replace Blower.

Odor Tubing smells new, unit smells new, Visually inspect patient tubing for Run unit in a clean environment
airborne residue buildup. contamination. 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 - Filters dirty, blower, Main PCA. Ensure the filter is clean and not Replace in order until solved.
The outlet air temperature is too restricting air flow. Monitor the
warm. outlet temperature at the end of the Filters
six foot patient tubing. A rise in
temperature can be expected (See Blower
Section 3.2.1 for Operating
Temperature). Main PCA
Pressure Related Problems - Pressure tubing has been blocked, Inspect pressure tubing for secure Secure pressure tubing
The outlet pressure does not disconnected, or kinked. Main PCA connections and kinks. Check connections.
change or properly adjust. or blower malfunction. blower for leaks.
Replace blower, pressure
tubing, or Main PCA.

Pressure Offset - The delivered pressure is higher or Perform power up process. Check tubing for kinks.
Static pressure fluctuates from lower than the set value by more
-1.0 cm to +2.0 cm H2O. than -1.0 cm to +2.0 cm H2O. Replace the Main PCA.
No Stored Therapy Data SmartCard was not installed in unit No therapy data after usage. Depress the pressure on / off
prior to use. button before disconnecting the
Main AC power.
Not a Respironics SmartCard.
Card not formatted or faulty

SmartCard.

Ramp Pressure - No ramp time prescribed. Verify the patients prescription Set unit for ramp.
The pressure does not ramp specified ramp. Make sure unit
correctly. Ramp minimum pressure has to was set for ramp. Replace Main PCA.
be lower than CPAP pressure.
Perform user interface checkout If device fails user interface
Main PCA. procedure (see Section 8.1). checkout procedure, replace
control pad or display PCA.
Ramp Button not functioning.
Pressure Variation - The Internal air leak. Replace filter. Replace blower.
pressure varies around the set
value, pressure fluctuates greater Filters dirty. Perform Testing Process (see If pressure still drifts, then
than 1.0 cm H2O. (This could be Section 8.1). replace Main PCA.
normal if the device is in C-Flex Main PCA, blower.
mode and in use by the patient.)
Air path blocked.

Humidifier will not turn on. Faulty power cord. Inspect main power cord for fraying Replace Power Cord.
at cable ends.
Broken or damaged Light Tube.
Inspect power cord between CPAP Replace Main PCA in
No infrared connection. and humidifier base. humidifier base.
Damaged Heater Plate. Inspect Light Tube inside CPAP for Realign or replace light tube.
misalignment.
Humidifier Main PCA.
Make sure receiver on Humidifier Replace Humidifier Main PCA.
CPAP Main PCA. base is not damaged.
Inspect Main PCA to see if there is Replace Main PCA.

damage to the transmitter on the
Main PCA.
Make sure CPAP is seated on Reseat CPAP on humidifier base.

humidifier base properly.
Inspect Main PCA for damage to Replace Main PCA.

the Humidifier On / Off button.
Inspect Heater plate to see that it is Replace Heater Plate in humidifier

connected to the humidifier Main base.
PCA and that it is not damaged.

6.5 REMstar Pro CPAP System Step 3 Retrieving the Error Codes
a. With your mouse click on the Start Button of your
Error Code Retrieval computer.
6.5.1 Error Code Retrieval
b. Select:
The REMstar Pro CPAP System stores error codes that may aid the Programs
technician in troubleshooting. The following instructions aid in the Respironics
retrieval of those error codes. The REMstar Pro can store up to 8 error Tools
codes at a time. Once this limt is reached the error codes will be overwritten Read Error Log
beginning with the first error code.
c. The software will load automatically
Step 1 Installing the Software d. With you mouse click on the Run Arrow located
in the upper left corner of the computer screen.
a. Follow the instructions that are included with the
Respironics Utility Software. Included with the e. The software will automatically read and display any
instructions are the following: error codes stored in the unit along with the time the
error occured.
1. System requirements
2. Intended use Step 4 Closing the Software
3. Warnings
a. With your mouse click on File.
Step 2 Connecting the REMstar Pro to your Computer b. Select:

Exit
a. Connect the Sleep Link interface card and cable
between the REMstar Pro CPAP System and the Step 5 Disconnect the REMstar Pro CPAP System
computer serial port.
a. Disconnect the Power cord and the Sleep Link
b. Connect the REMstar Pro CPAP System to the proper communication cable from the REMstar Pro CPAP
power source. System with C-Flex.

6.6 Error Code Chart
Error Code Problem Corrective Action
1 PROM Test - The code in the PROM is corrupt. Replace Main PCA.
2 RAM Test - The RAM on the Main PCA is not Replace Main PCA.
functioning properly.
3 Stack Test - The Stack memory on the Main PCA is not Replace Main PCA.
functioning properly.
4 Invalid Parameters - A failure has been detected in the Reset the parameter by simultaneously pressing the on/off, ramp,
nonvolatile memory on the Main PCA. and humidifier buttons while reconnecting the power cord. Reset
will be displayed on the screen. Then remove power from the
device. Reconfigure unit and test for proper operation. If error
repeats, replace Main PCA.
5 Parameter Copies - A failure has been detected in the non- Reset the parameter by simultaneously pressing the on/off, ramp,
volatile memory on the Main PCA or an error occured and humidifier buttons while reconnecting the power cord.
while calibrating P sensor. Reconfigure unit and test for proper operation. If error repeats,
replace Main PCA. Repeat P sensor calibration if error occured
during that operation.
6 Watchdog Test - The watchdog in the 68HC16 has failed. Replace Main PCA.
7 Watchdog Time-out - The system was reset due to a Check for stuck keys under enclosure top. Cycle power to the unit.
watchdog time-out. If error repeats, replace the Main PCA.
8 Key Stuck - One of the keys is stuck in the closed Verify that nothing is pressing a key. Replace control pad.
position. If error persists, replace Main PCA.

Error Code Chart (Continued)
9 Motor Overspeed. Replace blower assembly. If error persists, replace Main PCA.
10 Motor Underspeed - The speed of the motor was determined Replace blower assembly. If error persists, replace
to be below acceptable limits. Main PCA.
11 R20 / R21 Corrupt Replace Main PCA.
12 Motor edge lost. Check blower wire connections. Replace Blower Assembly.
Replace Main PCA.
13 Motor Brake. Check blower wire connections. Replace Blower Assembly.

Replace Main PCA.
14 Motor Current - The motor current has exceeded its limit. Check blower wire connections. Replace Blower Assembly.
Replace Main PCA.
15 Rotor Locked - The motor could not be started. Check Wiring. Replace Blower Assembly. If error persists, replace
Main PCA.
16 Program Sequence - External conditions prevented the proper Replace Main PCA.
operation of the software.
17 Software Error. Replace Main PCA. Contact Respironics Product Support.
18 A/D Converter Replace Main PCA.

Error Code Chart (Continued)
19 DC voltage to low. Check DC supply voltage. Replace Main PCA.
20 DC voltage to high. Check DC supply voltage. Replace Main PCA.
21 RTC Dead. Check Battery for clock. Replace Main PCA.
22 Invalid flow table. Replace Main PCA.
23 Pressure offset. Check for leaks or kinked internal tubing. Replace Main PCA.
24 Flow offset. Check for leaks or kinked internal tubing. Replace Main PCA.
25 Pressure line loss. Check for leaks. Replace Main PCA.
26 Unknown interrupt. Replace Main PCA.
27 Invalid hardware flags. Replace Main PCA.
28 Motor edge extra. Check blower wire connections. Replace Blower Assembly.
Replace Main PCA.
29 Motor current on high. Replace Main PCA.
30 Motor VcenterEst. Bad. Replace Main PCA.
31 Invalid error. Replace Main PCA. Contact Respironics Product Support.
1011170 REMstar Pro CPAP System 6 -16

6.6 SmartCard Error Code Chart
1 Read Fail - Card orientation is wrong. Re-enter the SmartCard. If error still persists, replace SmartCard.
2 Invalid card type - orientation is wrong or wrong Re-enter the SmartCard. If error still persists, replace SmartCard.
card.
3 Invalid Card Format - Information on SmartCard is Place the SmartCard in the Reader/ Writer and re-enter the informa-
incorrectly entered. tion back onto the SmartCard.
4 Unit in Dealer Mode. Remove power from the Respironics CPAP System. Reconnect
power to unit without pressing any keys.
5 Unit in Calibration Mode. Remove power from the Respironics CPAP System. Reconnect
power to unit without pressing any keys.
6 Invalid Card ID Block. The checksum in the Remove and / or replace SmartCard.
SmartCard ID block is invalid.
100 Prescription Block Checksum Failure. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
101 Prescription Version Error. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
102 Invalid Unit. The unit is not capable of the specified Use the SmartCard Wizard in Encore 3.0 or higher to format the
prescription. SmartCard.
103 Prescription Format Error. Software cannot under Use the SmartCard Wizard in Encore 3.0 or higher to format the
stand the format of the prescription. SmartCard.

SmartCard Error Code Chart Continued
104 Prescription Invalid - The unit has no knowledge of Use the SmartCard Wizard in Encore 3.0 or higher to format the
the prescription entered. SmartCard.
105 Prescription parameter out of range. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
200 Invalid Card Data Control Block. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
201 Invalid Card Data Control Block. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
202 Card Data Control Block Check Error. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
203 Control Blocks Invalid. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
300 Invalid UIDB Version. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.
301 UIDB Block Check Error. Use the SmartCard Wizard in Encore 3.0 or higher to format the
SmartCard.

Chapter 7: Repair and Replacement
Chapter 7: Repair &

Replacement
7.1 Overview .................................................... 7-3

System Repair Kits ................................... 7-4
7.3 Warnings and Cautions ............................ 7-8
7.4 Replacement Instructions ........................ 7-8

Notes: _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________
_____________________________________________________ _____________________________________________________

Chapter 7: Repair & Replacement
7.1 Overview For technical assistance or replacement part ordering information contact
Respironics Corporate Technical Service.
Figure 7-1 lists the names and identifies the locations of the replaceable
components in the REMstar Pro CPAP system. This provides a quick
reference and overview of the unit. Within each replacement section, more U.S. and Canada
detailed support information is provided to illustrate the exact component
location and replacement procedure(s). Phone: 1-800-345-6443
Fax: 1-888-886-0245
International
Phone: 001-724-387-4000
Fax: 001-724-387-5012
Visit Respironics Home Page on the World Wide Web at:
www.respironics.com
service@respironics.com

7.2 REMstar Pro CPAP System Repair Kits
Bottom Enclosure RP# 1011929* (see note* page 7-8) Blower Assembly RP# 1011213
Outlet Port RP# 1008477 Main PCA RP# ** (see note** page 7-8)
AC Power Cord RP# 1005894*** (see note*** page 7-8) Sleep Link Communication Cable RP# 1007492
Mini DIN Plug RP# 1011220 Flow Sensor Kit RP# 1008490
REMstar Pro Blower Top Foam RP# 1011219 REMstar Pro Top Enclosure RP# 1011931*
REMstar Pro Key Pad RP # 1011221-Domestic Respironics Utility Software RP# 1011422
1008476-International
Tubing Kit RP# 1011218 Pollen Filter RP# 1005964
Ultra-Fine Filter RP# 1005945 Filter Cap RP# 1008479

* Contact Respironics Product Support for the proper labeling when
replacing the bottom enclosure, top enclosure, or keypad.
7.3 Warnings and Cautions
WARNING: To prevent electrical shock, disconnect the

** The correct part number of the main PCA for your REMstar Pro electrical supply before attempting to make any
is linked to the model number. repairs to the REMstar Pro CPAP System.
Contact Respironics Product Support and provide the model CAUTION: Electronic components used in this unit are subject
number located on the bottom of the REMstar PRO to order the to damage from static electricity. Repairs made to
correct main pca. this unit must be performed only in an antistatic,
Electro-Static Discharge (ESD)-protected
environment.
*** Contact Respironics International Customer Service for further AC
power cord ordering information.
7.4 Replacement Instructions
See Figures 7-1and 7-2 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 Pro Replacement Instructions (Continued)
Top
Enclosure Removal Flow Chart
Filter
pg. 7-10 Filters
Cover
pg. 5-3 pg. 5-3
6
Main Printed Figure 7-1
Circuit Assembly (PCA) Removal Flow Chart
6 pg. 7-13
Key
Pad
pg. 7-16 6 Chart Usage: Determine which item is to be

Outlet Port /
Flow Element replaced then follow the line of flow back to
the Top Enclosure and begin the removal process.
pg. 7-19 Detailed procedures begin on the
referenced page numbers.
6
Blower Top Foam
pg. 7-21
6
Blower Assembly
pg. 7-21
6
Bottom
Enclosure
pg. 7-24

REMstar Pro Replacement Instructions (Continued)
Bottom
Enclosure
Installation Flow Chart
pg. 7-24
6
Blower Assembly
Figure 7-2
pg. 7-21
Installation Flow Chart
6
Blower Top Foam Chart Usage: Determine which item is to be
pg. 7-21 installed then follow the line of flow down to
the Top Enclosure and begin the installation
process. Detailed procedures begin on the
6
Outlet Port / referenced page numbers.
Flow Element
pg. 7-19
Key
Pad
6
6 pg. 7-16
Main Printed
Filter Circuit Assembly (PCA)
Filters
Cover
pg. 7-13
pg. 5-10 pg. 5-10
6
Top
Enclosure
pg. 7-10

7.4.1 Top Enclosure Replacement

Replacement Part Number 1011931
NOTE: Contact Respironics Product Support Department

for Top Enclosure ordering information.
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 Top Enclosure

supply before attempting to make any repairs to
the device.
CAUTION: Electronic components used in this device are

made to this device must be performed only in an
antistatic, ESD-protected environment. Figure 7-3
Top Enclosure

Top Enclosure Replacement (Continued)
c. While securely holding the top and the bottom
enclosure together, carefully return the device to its
Step 1 Removing the Top Enclosure upright position.
a. Place the device on a protected work surface and d. Lift the top enclosure up and away from the bottom
carefully turn it over, exposing the bottom. enclosure.
b. Using a Phillips screwdriver, remove the three screws NOTE: Nothing is connected to the top enclosure.
that secure the top enclosure to the bottom enclosure.
1 2
3
Location of the Top Enclosure Screws Top Enclosure Removal

Top Enclosure Replacement (Continued)
Step 2 Installing the Top Enclosure
a. Place the new top enclosure down over the control pad
and main PCA.
b. While securely holding the top enclosure and bottom

enclosure together, carefully turn the device upside down.
c. Insert and tighten the three Phillips screws to secure the top
and bottom enclosure together.
d. Return the device to its upright position.

7.4.2 Main Printed Circuit Assembly

(Main PCA) Replacement
Replacement Part Number *
NOTE: The correct part number of the main PCA for your
REMstar Pro is linked to the model number.
Contact Respironics Product Support and provide the

model number located on the bottom of the
REMstar PRO to order the correct main PCA.
Included in Kit: Tools Required:

Main PCA Phillips screwdriver (No. 2 medium)
Procedure
Top Enclosure
(See Section 7.4.1 for more detailed instructions).
Main PCA
WARNING: Electrical shock hazard: Disconnect the electrical

the device.
subject to damage from static electricity. Repairs Figure 7-6
Main Printed Circuit Assembly
antistatic, ESD-protected environment.
Main PCA Replacement (Continued)
Step 1 Removing the Top Enclosure

Removing: Top Enclosure
(See Section 7.4.1 for more detailed instructions on

removing the Top Enclosure.)
Step 2 Removing the Main PCA
a. Lift the main PCA and hold it slightly above the

blower assembly to provide access to the blower
cable connectors and the lite pipe.
b. Disconnect the lite pipe from the PCA.
c. Disconnect the blower connectors from the main Blower Cable Connectors Lite Pipe
PCA.
d. Discconect the pressure tubing and flow sensor
tubing from the PCA.
c. Lift the main PCA up and away from the bottom

enclosure assembly.
Step 3 Removing the Key Pad

Remove: Key Pad
(See section 7.4.3 for more detailed instructions on

removing the key pad.)
NOTE: The Display Assembly is permanently attached Figure 7-7

to the main PCA. Location of the blower cable connectors and lite pipe

b. Attach the blower connectors and the lite pipe.
c. Gently set the main PCA down on the three stands
that will hold the main PCA in place.

Install: Top Enclosure

installing the top enclosure.)
PCA Stands
Pressure Tubing Flow Sensor Tubing

Figure 7-8
Flow Sensor and Pressure Tubing
Step 3 Installing the Key Pad

Install: Key Pad

installing the key pad.)
Step 4 Installing the Main PCA

a. While holding the main PCA over the bottom enclo-
sure assembly, attach the flow sensor tubing and Figure 7-9
pressure tubing to the PCA. Placement of the Main Printed Circuit Assembly

7.4.3 Key Pad Replacement

Replacement Part Number 1008476 Key Pad
Key Pad Phillips screwdriver (No. 2 medium)
Flat-blade screwdriver (small)
Procedure
Top Enclosure (See Section 7.4.1 for more detailed

instructions).
Main PCA (See Section 7.4.2 for more detailed
instructions).
Key Pad

the device.

made to this device must be performed only in an Figure 7-10
antistatic, ESD-protected environment. Key Pad

Key Pad Replacement (Continued)
Step 1 Removing the Top Enclosure


removing the top enclosure.)
Remove: Remove Main PCA

removing the Main PCA).
Step 3 Removing the Key Pad
a. Carefully lift the key pad from the main PCA.

There are three rubber locking pins that hold the key
pad to the main PCA.
NOTE: The display assembly is permanently attached to the

main PCA.
Locking Pins
Figure 7-11
Key Pad

Key Pad Replacement (Continued)
Step 4 Installing the Key Pad Step 5 Installing the Main PCA.
a. Place the key pad on the main PCA. Align the locking Install: Main PCA
pins with the three holes on the display assembly. Press
down on the locking pins until they snap into place. (See Section 7.4.2 for more detailed instructions on
installing the Main PCA.)

Align Locking Pins Here
Figure 7-12
Pin Location

7.4.4 Outlet Port Replacement
Outlet Port

Outlet port Phillips screwdriver (No. 2 medium)
Procedure
Top enclosure (See Section 7.4.1 for more detailed

instructions).

instructions).
Pressure Tubing
Outlet Port

the device.

Figure 7-13
antistatic, ESD-protected environment. Outlet Port

Outlet Port Replacement (Continued)
Step 1 Removing the Top Enclosure Step 5 Installing the Main PCA
Removing: Top Enclosure Install: Main PCA
(See Section 7.4.1 for more detailed instructions on (See Section 7.4.2 for more detailed instructions on
removing the top enclosure.) installing the main PCA.)
Removing: Main PCA
removing the main PCA.) (See Section 7.4.1 for more detailed instructions on
Step 3 Removing the Outlet Port
a. Remove the pressure tubing from the outlet port.
b. Lift the outlet port out of the bottom enclosure and

away from the flow sensor.
Step 4 Installing the Outlet Port / Silicone Tube
a. Slide the outlet port into the flow sensor.
b. Place the outlet port in the bottom enclosure.
c. Push the pressure tubing back onto the pressure pick-

off.

7.4.5 Flow Sensor Replacement WARNING: Electrical shock hazard: Disconnect the electrical
the device.
Included in Kit: Tools Required: made to this device must be performed only in an
Flow Sensor Phillips screwdriver (No. 2 medium)
Procedure Tubing Flow Sensor


instructions.)

instructions.)
Tubing (See Section 7.4.4 for more detailed
instructions.)
Outlet Port (See Section 7.4.4 for more detailed

instructions.)
Flow Sensor
Figure 7-14
Flow Sensor and Tubing

Flow Sensor Replacement (Continued)
Step 1 Removing the Top Enclosure Step 6 Installing the Outlet Port
Removing: Top Enclosure Installing Outlet Port
removing the top enclosure.) installing the outlet Port.)
Step 2 Removing the Main PCA Step 7 Installing the Main PCA
Removing: Main PCA Installing Main PCA
removing the main PCA.) installing the main PCA.)
Step 3 Removing the Outlet Port Step 8 Installing the Top Enclosure
Removing: Tubing/Outlet Port Installing Top Enclosure
removing the tubing/outlet port.) installing the top enclosure.)
Step 4 Removing the Flow Sensor

a. Gently pull flow sensor tubing off the flow sensor.
b. Slide the flow sensor out of the silicone tubing.
Step 5 Installing the Flow Sensor

a. Slide the flow sensor into the silicone tubing.
b. Connect the pressure tubing from P2 on the PCA to the port on
the flow sensor closest to the outlet port.
c. Connect the pressure tubing from P1 on the PCA to the port on
the flow sensor closest to the blower.
7.4.5 Silicone Tube Replacement WARNING: Electrical shock hazard: Disconnect the electrical
the device.
Included in Kit: Tools Required: made to this device must be performed only in an
Flow Sensor Phillips screwdriver (No. 2 medium) antistatic, ESD-protected environment.
Flow Sensor
Procedure

instructions.)

instructions.)
Outlet Port (See Section 7.4.4 for more detailed

instructions.)
Flow Sensor (See Section 7.4.5 for more detailed
instructions.)
Silicone Tube
Figure 7-15
Silicone Tube

Silicone Tube Replacement (Continued)
Step 1 Removing the Top Enclosure Step 6 Installing the Silicone Tube
Removing: Top Enclosure a. Slide the silicone tube onto the blower assembly.
(See Section 7.4.1 for more detailed instructions on Step 7 Installing the Flow Sensor
Installing: Flow Sensor
Removing: Main PCA installing the flow sensor.)
(See Section 7.4.2 for more detailed instructions on Step 8 Installing the Outlet Port
removing the main PCA.)
Installing: Outlet Port
Removing: Tubing/Outlet Port installing the outlet port.)
(See Section 7.4.4 for more detailed instructions on Step 9 Installing the Main PCA
removing the tubing/outlet port.)
Installing Main PCA
Removing: Flow Sensor installing the main PCA.)
(See Section 7.4.5 for more detailed instructions on Step 10 Installing the Top Enclosure
removing the flow sensor.)
Installing Top Enclosure
Step 5 Removing the Silicone Tube (See Section 7.4.1 for more detailed instructions on
a. Slide the silicone tube off of the blower assembly.

7.4.7 Blower Assembly Replacement WARNING: Electrical shock hazard: Disconnect the electrical
Replacement Part Number 1011213 the device.
Included in Kit: Tools Required: CAUTION: Electronic components used in this device are
Blower Assembly Phillips screwdriver (No. 2 medium) subject to damage from static electricity. Repairs
Procedure NOTE: If the Blower Assembly is replaced, the unit must
run-in for two hours.
Removed / Installed During Process

instructions.)

instructions.)
Tubing/Outlet port (See Section 7.4.4 for more

detailed instructions.)

instructions.)
Silicone Tubing (See Section 7.4.6 for more detailed

instructions.)
Blower Assembly
Figure 7-16
Blower Assembly
Blower Assembly Replacement (Continued) Step 6 Removing the Blower Assembly
Step 1 Removing the Top Enclosure a. Lift the blower top foam up and away from the blower
assembly.
(See Section 7.4.1 for more detailed instructions on b. While holding the bottom enclosure, lift the blower
removing the top enclosure.) assembly up and away from the bottom enclosure.

Blower Assembly
Removing: Main PCA

3
Step 3 Removing the Outlet Port 7
5
1
Removing: Outlet Port
(See Section 7.4.4 for more detailed instructions on 6

removing the outlet port).
Step 4 Removing the Flow Sensor 2 4
Removing: Flow Sensor

Step 5 Removing the Silicone Tube
Removing: Silicone Tube

Figure 7-17
(See Section 7.4.6 for more detailed instructions on Blower Assembly Removal
removing the silicone tube.)

Blower Assembly Replacement (Continued) Align blower air outlet here
Step 5 Installing the Blower Assembly

a. Remove the protective backing from the adhesive ring
on the blower assembly.
b. Align the blower assembly air outlet with the opening

in the foam insert.
c. Firmly press the blower assembly into the foam insert.
d. Wrap the red/green/black wiring around the bottom of

the air outlet one time.
3
e. Place the blower top foam over the blower assembly 7
5
and press into the foam insert. 1
Step 6 Installing the Silicone Tube

6
Install: Silicone Tube
2 Figure 7-18
(See Section 7.4.6 for more detailed instructions on Foam Insert
installing the silicone tube.)
Step 8 Installing the Outlet Port
Install: Outlet Port
Install: Flow Sensor
(See Section 7.4.5 for more detailed instructions on installing the outlet port.)
installing the flow sensor.)

Blower Assembly Replacement (Continued)
Step 9 Installing the Main PCA

Installing Main PCA
installing the main PCA.)

Installing Top Enclosure

7.4.8 Bottom Enclosure Replacement WARNING: Electrical shock hazard: Disconnect the electrical
Replacement Part Number 1011929 supply before attempting to make any repairs to
the device.
Bottom Enclosure (w / label) Phillips screwdriver (No. 2 medium) CAUTION: Electronic components used in this device are
8 Hi - Lo x 1/2″ (x3) subject to damage from static electricity. Repairs
Procedure antistatic, ESD-protected environment.
Filters (See Section 5.3.1 for more detailed instructions).

instructions.)

instructions.)
Tubing/Outlet port (See Section 7.4.4 for more

detailed instructions.)

instructions.)
Silicone Tubing (See Section 7.4.6 for more detailed

instructions.)
Blower Assembly (See Section 7.4.7 for more detailed Bottom Enclosure
instructions.)
Figure 7-18
Bottom Enclosure Bottom Enclosure

Bottom Enclosure Replacement (Continued)
NOTE: Remember to remove the DC Jack Plug from the old
Step 1 Removing the Top Enclosure bottom enclosure and place it on the new bottom
enclosure.


DC Jack Plug
Removing: Main PCA

Removing: Outlet Port

removing the outlet port).

Removing: Flow Sensor

Step 5 Removing the Silicone Tube
Removing: Silicone Tube

Figure 7-19
(See Section 7.4.6 for more detailed instructions on Bottom Enclosure
removing the silicone tube.)
Bottom Enclosure Replacement (Continued)
Step 11Installing the Outlet Port
Step 6 Removing the Blower Assembly
Install: Outlet Port
Remove: Blower Assembly
installing the outlet port.)
removing the blower assembly.)
Step 7 Installing the Bottom Enclosure Step 12 Installing the Main PCA
Install: Main PCA
NOTE: Contact Respironics Product Support Department for
bottom enclosure ordering information.
installing the main PCA.)
Step 8 Installing the Blower Assembly
Install: Blower Assembly
installing the blower assembly.) (See Section 7.4.1 for more detailed instructions on
Step 9 Installing the Silicone Tube
Install: Silicone Tube

installing the silicone tube.)

Install: Flow Sensor

installing the flow sensor.)
Chapter 8: Testing
Chapter 8: Testing
8.1 Testing Process ......................................... 8-3

Run-In ......................................................... 8-4

Calibration ................................................. 8-5

Final Test.................................................... 8-9
8.5 Respironics Heated Humidifier

Test ............................................................8-10
8.6 Current Draw Test .................................. 8-11
REMstar Pro CPAP System with Heated

Humidifier Testing Data Sheet .............. 8-13

Chapter 8: Testing
Notes: _____________________________________________________
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Chapter 8: Testing
Chapter 8: Testing
8.1 Testing Process
The following process should be followed after a repair has been performed
on the REMstar Pro CPAP System or on the Respironics Heated Humidifier.
NOTE: The following tests 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).
Perform the following in order:
1. REMstar Pro CPAP Run-in* (Section 8.2)
2. REMstar Pro CPAP Calibration (Section 8.3)
3. REMstar Pro CPAP Final Test* (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
NA (Not Applicable).
NOTE: The Encore SmartCard must be inserted into the unit

under test.

Chapter 8: Testing
8.2 REMstar Pro CPAP System Run-In Step 1 Blower Hours (Pre Run-In)
a. Connect the REMstar Pro CPAP System into the proper
AC Power source.
Purpose
This procedure provides setup instructions for the REMstar Pro CPAP b. Record the Blower Hours shown on the display screen
System. in the space provided on the REMstar Pro CPAP System
Data Sheet.
CAUTION: Electronic components used in this device are subject NOTE: Blower hours are temporarily displayed beside a fan symbol
to damage from static electricity. Use and follow during the power up sequence.
appropriate Electro-Static Discharge (ESD) procedures.
Step 2 Setup
a. Place the test orifice on the outlet of the UUT.
Equipment b. Enter the Setup menu and set the pressure to 10cm H2O.
(See Section 4.2 for instructions).
Test Orifice (see Appendix A)
c. Run the unit for a minimum of 2 hours.
Step 3 Blower Hours (Post Run-In)
a. With the blower still running, press the right User button
to view the Blower Hours.
c. Record the Blower Hours in the space provided on the
REMstar Pro CPAP System Data Sheet.

Chapter 8: Testing

NOTE: The SmartCard must be removed from the UUT.
Pressure and Flow Calibration
Pressure sensor calibration
Purpose
This procedure provides calibration of the REMstar Pro CPAP System. NOTE: The following calibration should be performed after any
repair has been performed on the REMstar Pro CPAP System.
CAUTION: Electronic components used in this device are subject
to damage from static electricity. Use and follow
1. Pressure Sensor (zero)
a. While holding down the humidifier and ramp button, `

Equipment connect the REMstar Pro to the correct power source.
Digital Manometer (see Appendix A) b. Continue to hold down the humidifier and ramp button
until you hear two audible tones.
Flow Meter (see Appendix A)
c. Press the right user button 5 times to reach the
1 section of pressure tubing P CAL 2 screen on the display of the REMstar Pro.
3 sections of patient tubing d. Press the ramp button to zero the pressure sensor. The
display screen will flash 0.0 for a short time then return to
1 flow control valve the P CAL 2 display screen.
O2 adapter (see Appendix A)
End cap (to produce a dead head pressure)
Negative flow source

(capable of delivering at least 120 lpm @ 20 cm H2O.)

Chapter 8: Testing
REMstar Pro CPAP System Calibration (Continued)
Equipment Setup
NOTE: Refer to Figures 8-1 for proper connections to perform
pressure calibration.
Place the O2 adapter on the outlet of the REMstar Pro.
Connect the pressure tubing between the O2 adapter

and the digital manometer.
Place the end cap on the O2 adapter.
2. Pressure Sensor (span)

a. Press the humidifier button to adjust the span of the
pressure sensor. The blower will start and the display
screen will show the motor speed.
b. Press the humidifier or ramp button to raise or lower the

the motor speed to achieve 25 cm H2O on the manometer.
c. Once you have achieved 25 cm H2O on the manometer,

press the Start / Stop button. The display screen will
flash 25.0 for a short time, the blower will stop and the
display screen should return to 0.0.
Figure 8-1
This completes the pressure sensor calibration. Pressure sensor Calibration
NOTE: Do not disconnect the REMstar Pro from the power source.
Proceed to Flow Sensor Calibration.

Chapter 8: Testing
Flow Sensor Calibration

Step 1 Flow Offset
NOTE: The following calibration should be performed after any
repair has been performed on the REMstar Pro CPAP System. a. Press the right user button 1 time to reach the
FOFS7 (flow offset) screen.
b. Press the humidifier or ramp button to adjust the flow offset.

Equipment Setup When the numbers on the display screen stop, the process is
complete.
NOTE: Refer to Figures 8-2 and 8-3 for proper connections to
perform flow calibration.
Step 2 Flow Cal
Remove the O2 adapter and monometer from the outlet of a. Press the right user button 1 time to reach the
the REMstar Pro. FCAL (flow cal) screen.
Connect one piece of patient tubing between the b. Press the ramp button to null the flow table.
REMstar Pro and the flow meter.
c. Press the humidifier button to start the flow cal. The display
Connect one piece of patient tubing between the screen will be flashing -120.
flow meter and the flow valve.
d. Turn on the negative flow source.
Connect one piece of patient tubing between the
flow valve and the negative flow source. e. Adjust the flow valve until the flow meter reads -120 lpm.
f. Press the Start / Stop button to preceed to the next value on

the display screen.
g. Adjust the flow valve and press the Start / Stop button for
each setting that appears on the display screen. When the
display screen reaches 0.0 stop.

Chapter 8: Testing
REMstar Pro CPAP System Calibration (Continued)
k. When the calibration @ 120 lpm is complete, the display will
h. Turn off the negative flow source. Disconnect the negative
stop flashing and will show the flow as measured by the
flow source and the patient tubing from the flow valve.
calibrated flow sensor..
i. The display screen should be flashing 0.0. Press the Start /
l. Calibration is complete. Disconnect the REMstar Pro form
Stop switch.
the power source.
j. Adjust the flow valve and press the Start / Stop button for
each setting that appears on the display screen.

Flow Calibration (Negative Flow) Flow Calibration (Positive Flow)

Chapter 8: Testing
8.4 REMstar Pro CPAP System Final Test
Purpose c. Connect the O2 enrichment port to the Whisper Swivel II.
This procedure provides instructions for the REMstar Pro CPAP System
Final Test. d. Place the outlet end cap on the O2 enrichment port.
e. Connect the pressure tubing between the manometer
and the O2 enrichment port.
to damage from static electricity. Use and follow
appropriate Electro-Static Discharge (ESD) procedures. Step 2 4 cm H2O Pressure
Equipment a. Enter the Setup menu and set the pressure to 4 cm H2O.
O2 Enrichment Attachment (See Section 4.2 for instructions).
Pressure tubing b. Turn the UUT blower on and allow the unit to stabilize for
1 minute.
Outlet end cap
c. Record the pressure reading of the manometer in the
Manometer space provided on the Testing Data Sheet.
6 ft. Patient tubing Step 3 20 cm H2O Pressure

Whisper Swivel II a. Enter the Setup menu and set the pressure to 20 cm H2O.
(See Section 4.2 for instructions).
Step 1 Setup b. Turn the UUT blower on and allow the unit to stabilize for
1 minute.
a. Connect one end of the patient tubing to the outlet of the c. Record the pressure reading of the manometer in the
REMstar Pro. space provided on the Testing Data Sheet.
b. Connect the Whisper Swivel II to the other end of the
6 ft. patient tubing.

Chapter 8: Testing
8.5 Respironics Heated Humidifier Test Step 1 Humidifier Preheat Test

a. Connect the REMstar Pro CPAP System to the Heated
Purpose Humidifier (See Section 4.5 for instructions.)
This procedure provides instructions for the Heated Humidifier System b. Set the Heated Humidifier setting to 1.
Test.
c. Start the preheat mode and observe the following:
CAUTION: Electronic components used in this device are subject 1. The icon appears on the CPAP display screen.
to damage from static electricity. Use and follow 2. The green LED on the front of the Heated Hunidifier is
appropriate Electro-Static Discharge (ESD) procedures. illuminated.
d. Record the results on the Testing Data Sheet.
Equipment Step 2 Humidifier Heat Test

a. All connections remain the same as in step 1.
b. Turn the UUT blower on and observe that the green LED
Test Orifice (see Appendix A) on the front of the Heated Humidifier is a solid green
LED.
1 piece of pressure tubing c. Observe heater plate warms.
d. Record the results on the Test Data Sheet.

Chapter 8: Testing
8.6 Current Draw Test Step 1 CPAP System Setup
Purpose a. Place the test orifice on the outlet of the UUT.

This procedure provides instructions for testing the current draw on the b. Enter the Setup menu and set the pressure to 20 cm H2O.
REMstar Pro CPAP System, the Respironics Heated Humidifier or both (See Section 4.2 for instructions).
units together.
Step 2 CPAP Current Draw Test

a. Connect the REMstar Pro CPAP System and the
to damage from static electricity. Use and follow Multimeter (Set to Current) in series.
b. Connect the AC power cord to the UUT.
c. Connect the AC power cord to the proper source.
Equipment
d. Turn the UUT blower on and allow the unit to stabilize
for 1 minute.
f. Record the current reading from the multimeter in the
Test Orifice (see Appendix A) space provided on the Testing Data Sheet.
1 piece of pressure tubing Step 3 Heated Humidifier System Setup

Multimeter a. Connect the REMstar Pro CPAP System to the Heated
Humidifier.
Test leads b. Set the Preheat Mode to 5.
NOTE: The Water Chamber does not need to be in place for testing.

Chapter 8: Testing
Step 4 Heated Humidifier Current Draw Test

a. Connect the Respironics Heated Humidifier System
power cord and the test leads in series.
b. Connect the test leads to the multimeter.
c. Connect the AC power cord to the UUT.
d. Connect the AC power cord to the proper source.
e. Press the Heated Humidifier button until you hear one
audible tone then release.
f. Record the current reading from the multimeter in the
space provided on the Testing Data Sheet.
NOTE: Setup remains the same for Step 5.
Step 5 CPAP / Heated Humidifier Current Draw Test

a. Turn the UUT blower on and allow the unit to stabilize for
1 minute.
b. Record the current reading from the multimeter in the
space provided on the Testing Data Sheet.
Step 6 Test Complete

a. Sign and Date the Testing Data Sheet.

REMstar Pro CPAP System with Heated Humidifier Testing Data Sheet
CPAP Testing
Notification No. ________________________ CPAP Serial No. _____________ Model No. _________________
Notification No. ________________________ Humidifier Serial No. _____________ Model No. _________________
Blower Hours Pre Run-In ( B = ____________ )
Blowers Hours Post Run-In ( B = ____________ )
Tolerance Tolerance
CPAP Final Test 4 cm H2O ( _____ ) 3.6 - 4.4 cm H2O 20 cm H2O ( _____ ) 19.6 - 20.4 cm H2O
Heated Humidifier Testing
Preheat Mode Display Screen Icon Pass _____ Fail _____ Solid Indicator Pass _____ Fail _____
Heating Mode Solid Indicator Pass _____ Fail _____

Tolerance Tolerance Tolerance
Current Draw @ 20 cm H2O ( _____ ) < 1.0 A Current Draw @ 5 Preheat ( _____ ) < .7 A Total Current Draw ( _____ ) < 1.7 A
NOTE: If a section of this Data sheet is not being used, mark that section as NA (Not Applicable)
Date ____ / ____ / ____ Signature (In Ink) ____________________________

Chapter 8: Testing

Appendix A
Appendix A: Tools and

Equipment
A.1 Service Tools and Supplies ................. A-3
A.2 Acceptable Test Equipment ................ A-4
1011170 REMstar Pro CPAP System A-1

Appendix A
Notes: _____________________________________________________
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_____________________________________________________ _____________________________________________________

Appendix A
Appendix A: Tools and Equipment

Cleaning Cloth
Digital Manometer - see Section A.2
A.1 Service Tools and Supplies Digital Multimeter - see Section A.2
You should have the following hand tools and supplies available for Flow Meter - see Section A.2
troubleshooting, testing, and repairing the REMstar Pro CPAP System.
Test Leads
Common Hand Tools
Isopropyl Alcohol
Flat-blade screwdriver - small
Mild Detergent
Phillips screwdriver - medium
Pressure Tubing
Antistatic, Electro-Static Discharge (ESD)-protected
work station - minimum requirement is a grounded Test Orifice (RI P/N 332353)
mat and wrist strap
Whisper Swivel II (RI P/N 332113)
Windows®-compatible personal computer running
Windows 95, 98, 2000, NT with a CD-ROM drive
Flow control valve
Utility Software CD (RI P/N 1011422)
CPAP (for negative flow)
SleepLink Cable (RI P/N 1007492)
O2 Enrichment Port (RI P/N 312710)

Appendix A
A.2.2 Digital Multimeter

A.2 Acceptable Test Equipment
Specifications:
2.5 digit readout minimum
A.2.1 Digital Manometer*
0.0 - 20.0 VDC
Specifications:
0 - 25 cm H2O (or better) 0.0 - 25.0 VAC
±0.3 cm H2O accuracy Acceptable Options:
±0.1 cm H2O resolution Fluke 83 or better model

Acceptable Options:
Any commercially available multimeter
that meets the above specifications.
Respironics Digital Manometer
A.2.3 Flow Meter
Merical DP2001 Specifications:
Range: +180 to -180 LPM
Sensym PDM 200CD
± 2% accuracy
RT - 200
± 1 LPM resolution
Any commercially available digital manometer Acceptable Options:
TSI 4000 Series Flow Meter
* A water column manometer may also be used.
Time Meter RT - 200
Any commercially available flowmeter

Appendix B
Appendix B: Schematics
Schematic Statement ........................................... B-2
Domestic Microprocessor .................................. B-3
Domestic Analog Circuit .................................... B-4

Domestic CPU Board ......................................... B-5
Domestic Display ................................................. B-6

Domestic Power Supply ...................................... B-7
Domestic Motor Driver ...................................... B-8
International Microprocessor............................ B-9
International Analog Circuit ............................ B-10
International CPU Board ..................................B-11

International Display ........................................ B-12
International Power Supply ............................. B-13

International Motor Driver .............................. B-14
1011170 REMstar Pro CPAP System B-1
Appendix B
Appendix B: Schematics
B.1 Schematic Statement
Schematics are supplied with this manual in direct support of the sale and
purchase of this product.
The schematics are proprietary and confidential. Do not copy the schemat-
ics or disclose them to third parties beyond the purpose for which they are
intended. Patents are pending.
The schematics are intended to satisfy administrative requirements only.

They are not intended to be used for component level testing and repair.
Any changes of components could effect the reliability of the device,
prohibit lot tracking of electronic components, and void warranties. Repairs
and testing are supported only at the complete board level.
The schematics are of the revision level in effect at the time this manual was
last revised. New revisions may or may not be distributed in the future.

Appendix B
8 7 6 5 4 3 2 1
REV C/N DESCRIPTION DATE DRAWN BY: CHECKED BY: APPROVED BY:
--- --- SEE SHEET 1 --- --- --- ---
+ C48
.22uF
C47
100uF +3.3V_MAIN
D 16V D
1.00K
R133
GND +3.3V_MAIN
U12 +3.3V_MAIN 1
86 6 3 4
P00/NMI VDD U10:A
RTC_SCL
87
P01/INTP0 VDD
34 + C42 U9 2
U10:B
6 9
.22uF
R127
C55
88 71 10uF 5 8
2.49K
R59
RTC_SDA P02/INTP1 AVDD 35V PP18 74LV00 U10:C MOTOR_CURRENT_TRIP
89 55 100 LM385M3-2.5 (7=GND,14=+3.3V_MAIN) 10
MOTOR_CURRENT_TRIP P03/INTP2 BVDD 74LV00
90 LM339M (7=GND,14=+3.3V_MAIN)
SEEPROM_SCL P04/INTP3 74LV00
91 73 FAST_CURRENT
+3.3V_MAIN SEEPROM_SDA P05/INTP4/ADTRG AVREF 4 (7=GND,14=+3.3V_MAIN)
92 GND U1:A 2
DISP_SDA P06/INTP5/RTPTRG 18 GND
93 VPP VPP +8V
DISP_SCL P07/INTP6 5
MMSZ5237BT1
39 (3=VBULK, 12=GND)
94 P120/ WAIT DC-ON
1.00K
R172
CR14
SI0 P10/SI0/SDA
10.0K
10.0K
R135
R163
95 +3.3V_MAIN
SO0 P11/SO0
2.49K
R12
96
SCK0 P12/SCK0 /SCL 30
97 P113/A4
RXD0 P13/SI1/RXD0 29
98 P112/A3
TXD0 P14/SO1/TXD0 28
2.49K
R115
99 P111/A2 TC_DATA_IN GND GND RAW_PWM
P15/SCK1 /ASCK0 27
BZX84C4V3D
BZX84C4V3D
P110/A1 TC_DATA_OUT 12
1.30K
R58
.22uF
LM339M
C67
100 11
CR13
CR15
KYP_LTG P20/S12 26 U10:D 6

1 P107/RTP7/A12 13
SM_SDA_OUT P21/SO2 25 U1:B 1
PWM
2 P106/RTP6/A11 SM_DETECT +3.3V_MAIN +3.3V_MAIN
SM_SCL P22/SCK2 24 74LV00
3 P105/RTP5/A10 CTL_HI_C 7
SM_RXD1 P23/RXD1 23 (7=GND,14=+3.3V_MAIN)
C GND GND SM_TXD1

SM_SDA_IN
4
5
P24/TXD1
P25/ASCK1
P104/RTP4/A9
P103/RTP3/A8
22
21
CTL_LO_C
CTL_HI_B
GND GND
* R203 (3=VBULK, 12=GND)
C
2.49K
R114
8 P102/RTP2/A7 CTL_LO_B R204
BUZZER_CTL P26/T12/TO2 20
9 P101/RTP1/A6 CTL_HI_A 2.49K
IR_LINK P27/T13/TO3 19
BEMF
10
P30/TI00
P100/RTP0/A5
46
CTL_LO_A
UNUSED6/UNUSED6
* R201
R202
11 P96/HLDRQ
2.49K
R109
HALL P31/TI01 45 UNUSED5/UNUSED5
12 P95/ HLDAK 2.49K
P32/TI10 44 ENGLISH DISPLAY/UNUSED4
13 P94/ASTB R199
P33/TI11 43 RTC/BRAKE ON
14 P93// DSTB/RD 2.49K
P34/TO0/A13 42 SMART CARD/MOTOR ON
RAW_PWM
FLOW_OS
15
16
P35/TO1/A14
P36/TI4/TO4/A15
P92/R/ W/WRH
P91/ UBEN
41
40
PRESSURE/2X SPEED
FLOW/COMMUTATION EVENT
* R200
R197
GND
17 P90/LBEN /WRL
P37/T15/TO5
2.49K
85 R129 90.9K
47
48
P40/AD0
P41/AD1
P83/ANI11
P82/ANI10
84
83
R167 90.9K
PHASE_C
MTR_CTR_EST * R198
R205
+3.3V_MAIN
49 P81/ANI9 SW5
.001uF
P42/AD2 82
10.0K
10.0K
CR28
R128
R159
.1uF
C52
C51
B160
50 P80/ANI8 SW4 2.49K
P43/AD3
51
52
P44/AD4
P45/AD5
P77/ANI7
81
80
SW3 VBULK * R206
R207
CONN M 9 PIN 100
J6:A
1
53 P76/ANI6 SW2 J6:B
P46/AD6 79 LVI CONN M 9 PIN 100
2
54 P75/ANI5 SW1 GND GND GND 2.49K
P47/AD7 78 GND J6:H
*
BZX84C4V3D
P74/ANI4 FLOW R208 TXD0 8
CONN M 9 PIN 100
P73/ANI3
77
PRESS
PROGRAMMING
57 J6:I
CR16
P50/AD8 76 R160 90.9K
R209
RXD0 CONN M 9 PIN 100
9 CONNECTOR
58 P72/ANI2
P51/AD9 75 J6:C
59 P71/ANI1 I_LO_SIDE 2.49K VPP CONN M 9 PIN 100
3
P52/AD10 74 R156 90.9K
B
60
P53/AD11
P70/ANI0 PHASE_A
* R210 J6:G
7
B
10.0K
10.0K
CONN M 9 PIN 100
61
P54/AD12 70
.001uF
62 P65/A21
CR29
GND
.1uF
C54
C53
B160
P55/AD13 69 GND
63 P64/A20 GND
P56/AD14 68 J6:D
64 P63/A19 SCK0 4
R152
R117
P57/AD15 CONN M 9 PIN 100
67
P62/A18 J6:E
66 SO0 CONN M 9 PIN 100
5
31 P61/A17
LVI RESET 65 GND GND GND J6:F
P60/A16 SI0 CONN M 9 PIN 100
6
38 GND
CLKOUT
32
BZX84C4V3D
BZX84C4V3D
BZX84C4V3D
P114/XT1 7
33 VSS
XT2 37
CR23
CR24
CR25
VSS
35 72
X2 AVSS
36 56
Y1 X1 BVSS +3.3V_MAIN
+3.3V_MAIN UPD70F3015A +3.3V_MAIN
20 MHz
GND
22pF
22pF
GND GND GND

C39
C40
.22uF
C41
.22uF
.22uF
.22uF
.22uF
.22uF
C34
C45
C57
C46
C56
+3.3V_MAIN
REALTIME CLOCK +3.3V_MAIN EEPROM
Y2 GND
32.768 KHZ GND
GND U15
1 8 GND
1.00K
1 4
R116
U11 A0 VCC
2.49K
2.49K
R118
R120
2 3 1 8
X1 VCC 2 7
PP21 PP22 A1 WP
2 7
X2 RST LVI 3 6
A2 SCL SEEPROM_SCL
3 6
A VBACK SCL RTC_SCL
+3.3V_MAIN 4
VSS SDA
5
SEEPROM_SDA A
4 5 24C02M8
GND SDA RTC_SDA
2.49K
PRODUCT LINE:
R142
.22uF
Domestic W/SmartCard
C37
DS1672S-33 U19
C-FLEX
GND 2
VDD
3 GND GND PROCESS: TITLE:
+ B1 VSS
1 DOMESTIC W/SMART CARD
BR1225-1HC GND RST
Microprocessor
SCHEMATIC
MCP120T-315I/TT MICROPROCESSOR
GND
SIZE DRAWING NO. REV.
DRN BY: F.PASCARLLA 5-28-02
GND
CHK BY: EDMS EDMS D S1009695 2
APPR BY: SCALE PART NO. SHEET OF
EDMS EDMS N/A 1009695 6 6
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
D D
+5V
C35
MT1 .22uF
1
NC PP1 .01uF
2
VS TP9
GND
VOUT
3
4
C36
GND
*
MPXV5004GC6U GND R110
PRESS
24.9K
.047uF
24.9K
.01uF
R111
C38
C26
GND GND GND

PP14
MT1
PROBE POINTS PP15
FOR PINS 5-8 PP16
PP17
C C
+8V
24.9K
R184
GND LM324A
3.16K
R180
12
14 R186 R188
U16:D
MT2 13 2.00K 13.7K
1
.1uF
C63
2 (4=+8V, 11=GND)
TP12
3
4
R182
1.00K
+8V
6
LM324A
U16:B
R190 * FLOW
5 GND 7 1.00K
6 5
BZX84C4V3D
(4=+8V, 11=GND)
7
24.9K
R185
CR17
8 LM324A
10uF
C60
2 R187 R189
AIRFLOW SENSOR U16:A 1 2.00K 13.7K +8V
3
GND (4=+8V, 11=GND) GND GND
.1uF
C66
B B
1.00K
R194
+8V
R191 R193
GND
4.22K 10.0K
+ C64 + C65
4.22K
R183
2.2uF 2.2uF R196

LM324A Q32 FLOW_OS
25V 25V 2.49K
9 MMBT3904LT1
U16:C 8
2.49K
R195
10 GND GND
(4=+8V, 11=GND) GND
GND
A A
PRODUCT LINE:
C-FLEX
PROCESS: TITLE:
DOMESTIC W/SMART CARD
Analog Circuit
SCHEMATIC
ANALOG CIRCUIT
SCALE PART NO. SHEET OF
APPR BY: EDMS EDMS N/A 1009695 5 6
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
KEYPAD
+3.3V_MAIN
D D
+8V
90.9K
90.9K
90.9K
90.9K
90.9K
R95
R96
R97
R93
R94
RAMP SW4
J7:A 2 1
1 CONN M 3 PIN .078
SWITCH COND RUBBER 3MM SPSTNO
SW5
.01uF
C69
+8V 2 1
+8V SWITCH COND RUBBER 3MM SPSTNO
J7:B +3.3V_MAIN SW6
2 R84
CONN M 3 PIN .078 2 1
10.0K
R113
SW1
SWITCH COND RUBBER 3MM SPSTNO 10.0K
1.00K
R112
100pF
GND
C43
1.00K
R121
J7:C 11 ON/OFF SW7
3 CONN M 3 PIN .078
13 2 1
U18:D HALL GND
10 SWITCH COND RUBBER 3MM SPSTNO
LM339M SW8
(3=VBULK, 12=GND) 2 1 R85
SW2
10.0K
R119
100pF
.22uF
C68
C44
SW9
RIGHT
2 1
GND SWITCH COND RUBBER 3MM SPSTNO GND
C GND
SW10
C
2 1 R86
SW3
ENTER
100pF
C59
VBULK SW11
LEFT
2 1 GND
SW12
2 1 R87
SW4
10.0K
R103
1/4W
R122
1/4W
R123
1/4W

412
412
412
100pF
C61
HUMID SW1
2 1
GND
IR LINK SW2
2 1
CR10 SWITCH COND RUBBER 3MM SPSTNO
ZTN155W-03 SW3
2 1 R88
SW5
R104 SWITCH COND RUBBER 3MM SPSTNO 10.0K
Q30 IR_LINK
100pF
2.49K
C62
MMBT3904LT1
GND
B B
2.49K
R105
GND
VBULK GND
GND
1/4W
1/4W
R100
1/4W
R98
R99
1K
1K
1K
KEYPAD LIGHTING
VBULK CR7 CR8 CR9
HSMG-H730 HSMG-H730 HSMG-H730

R106
1/4W
LS1
1K
1 R101
Q29 KYP_LTG
2 2.49K
MMBT3904LT1
2.49K
R102
GND
R107
Q31 BUZZER_CTL
2.49K
MMBT3904LT1
GND
2.49K
R108
A A
PRODUCT LINE:
GND GND C-FLEX

PROCESS: TITLE:
To CPU Board
SCHEMATIC
TO CPU BOARD
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
+5V
+5v_MODEM
+5v_MODEM +3.3V_MAIN
1.00K
R137
J4:A E7 * E17
* J5:A 1
10.0K
R138
C1
D 1000 OHMS @ 100 MHZ
D
7 SHIFTED_TC_DATA_IN
* E23
* J5:B 2
.22uF
C32
+3.3V_MAIN 1
TC_DATA_IN U18:B
BZT52C5V6S
J4:B +5V 6
C2 PP19
LM339M
+1.5V
SHIFTED_SM_SCL
* E18
* J5:C
3
CR19
10.0K
R125
GND +3.3V_MAIN (3=VBULK, 12=GND)
1.00K
+5V
SHIFTED_SM_SCL
R63
LM339M
SM_SCL
SHIFTED_SM_RXD1
* E19
* J5:D 4
10.0K
R140
4
1.00K
J4:C E8
R139
GND
C3
1000 OHMS @ 100 MHZ
2
(3=VBULK, 12=GND)
U17:A
5
+1.5V
TC_DATA_OUT
LM339M * E20
* J5:E 5
GND
8 SHIFTED_TC_DATA_OUT
* E24
* J5:F
BZT52C5V6S
U18:C 14
6
+1.5V
BZT52C5V6S
CR11
9
(3=VBULK, 12=GND)
SHIFTED_SM_SDA_IN
* E21
* J5:G
7
CR20
+5V
+3.3V_MAIN
GND
SHIFTED_SM_TXD1
* E22
* J5:H 8
1.00K
R89
SHIFTED_SM_RXD1
10.0K
R126
GND
J4:D E9 7
C4
1000 OHMS @ 100 MHZ 1
U17:B SM_RXD1
BZT52C5V6S
6
+1.5V
LM339M
CR12
(3=VBULK, 12=GND)
C C
GND
+3.3V_MAIN +3.3V_MAIN
+3.3V_MAIN
J4:E E10
C5
1000 OHMS @ 100 MHZ
10.0K
2.49K
2.49K
R130
R68
R69
GND
J4:F LM339M U8
C6 PP20
SM_SDA_OUT 1 40
8 DISP_SDA SDA S23 PP8
14 U17:C 2 39
+5V DISP_SCL SCL S22 PP9
+1.5V 3 38
9 +5V PP7 SYNC S21 PP10
(3=VBULK, 12=GND) +3.3V_MAIN 4 37
CLK S20 PP11
5 36
SHIFTED_SM_SDA_IN VDD S19 PP12
1.00K
R82
6 35
OSC S18
7 34
10.0K
.22uF
.22uF
R131
C24
C33
A0 S17
LM339M 8 33
J4:G E11 A1 S16
C7 9 32
10 A2 S15
1000 OHMS @ 100 MHZ U17:D SM_SDA_IN 10 31
BZT52C5V6S
13 SA0 S14
+1.5V GND GND 11 30
11 VSS S13
CR18
12 29
(3=VBULK, 12=GND) VLCD S12
13 28
BP0 S11
14 27
BP2 S10
GND 15 26
BP1 S9
16 25
BP3 S8
B GND 17
S0 S7
24 B
+5V 18 23
S1 S6
19 22
S2 S5
+3.3V_MAIN 20 21
+5V S3 S4
PCF8566T
4.22K
+1.5V
R64
10.0K
R136
SHIFTED_SM_TXD1
1.00K
R83
DS1
1
S19 23
5 2 S10
SM_TXD1 S18 22
J4:H E12 2 3 C1
C8 U18:A S17 21
4 4 S9
1.00K
.22uF
1000 OHMS @ 100 MHZ
C58
+1.5V R65 S16 20

LM339M 5 S8
S15 19
6 S7
(3=VBULK, 12=GND) S14 18
7 S6
S13 17
+3.3V_MAIN 8 S5
S12 16
GND 9 S4
S11 15
10 S3
C4 14
11 S2
1.00K
R92
C3 13
12 S1
C2
UTS-372AV
J4:J
S2 SM_DETECT
S1 J4:I
VBULK
A A
PRODUCT LINE:
GND
C-FLEX
.1uF
.1uF
C49
C50
PROCESS: TITLE:
Display and SmartCard

SCHEMATIC
DISPLAY AND SMART CARD
GND DRN BY: F.PASCARLLA 5-28-02
D S1009695 2
CHK BY: EDMS EDMS
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
ISOLATION BARRIER
2
J2 L2 L1
D 1 1 4 1 2 CR1 D
S14K320
L1 C16
4 1
1/2 W
750K
RV1
.1uF
R51
C18
AC IN 2
L2 BR86DL .001uF
+ C17
P6SMB150AT3
SCHURTER 4300.0099 2 3 4 3
F1 ICA-0885 35 mh .6A PWRGND 3 68uF GND
CR26
1.00M
400V
R52
R54
68K
2W
2.5A
998 OHMS @ 100 MHZ

998 OHMS @ 100 MHZ
PWRGND
1.00M
R55
E3
E4
VBULK VBULK VBULK
MURS160
CR2
U4
T1 C20 + C15
SMBJ10CA
1
CONTROL 7 1 1500uF
CR27
DRAIN 25V
F2
5A
4700pF
2
4 L-SENSE
.1uF
C21
SOURCE CR3
3 10
5 X-LIMIT E2
SMBJ10CA
FREQ 2 GND
SB560
CR22
TOP249Y
998 OHMS @ 100 MHZ
PWRGND PWRGND PWRGND CR5 C22 +
C C
.1uF
C23
1000uF
5 25V
B160
6 GND
.1uF
C25
4 GND GND
GND
ICA-0638 VBULK
PWRGND
F3 CR4 1 L
5A MSP845 3 SS J3
2 SC
GND
*
U5 R60 R61 CR6
6 1
PP5 +3.3V_MAIN
301 MMSZ5240BT1
5 2
4 3 GND
PP6
+5V
4.22K
10.0K
R66
R8
CNY17F-2
VBULK
R62
6.2
+8V (3=VBULK, 12=GND)
LM339M
U7 U13 +3.3V_MAIN
8
KA78M05R LT1521CST-3.3 U1:C DC-ON
1 3 14
B IN OUT IN OUT + 9 B
47uF
GND + GND +
10V
C27
.22uF
C29 C31
C28
R76
499
4 TAB
10.0K
.1uF
R33
C71
2.2uF 2.2uF
PWRGND
GND GND GND GND
R77
232
GND GND
+5V
GND U14
KA78M05R
1 3
IN OUT
GND
.22uF
C30
GND GND
+5v_MODEM
U20
KA78M05R
1 3
IN OUT
GND
.22uF
C70
A A
GND GND PRODUCT LINE:
C-FLEX
PROCESS: TITLE:
Power Supply
SCHEMATIC
POWER SUPPLY
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
0 EDMS SCHEMATIC FOR REV 6 BOARD 5-28-02 F.PASCARELLA EDMS EDMS

R177 VBULK
1 EDMS SHEET 4 - R103, R122, R123 WAS 1K 7-1-01 F.PASCARELLA EDMS EDMS
10.0K VBULK
R1 2 EDMS REV CHANGE ONLY 7-30-02 F.PASCARELLA EDMS EDMS
GND 3 1
10.0K
1 3
4 U3:A U6:A PP3
CTL_HI_C Q2 2 2
6 R2
U6:B Q1 GND LM358A
5 2.49K MMBT3904LT1 74LV08
.22uF
PWM MMBT3904LT1
C1
(4=GND, 8=+5V) (7=GND,14=+3.3V_MAIN)
74LV08
2.49K
(7=GND,14=+3.3V_MAIN) GND
R3
90.9K
GND +3.3V_MAIN
R74
Q3 GND
D 9 D
MMBT3906LT1 8
3 Q4 U2:C PP4
10
.1uF
R4 4
C2
GND VOUT 5
232 74LV00
GND VOUT 6
(7=GND,14=+3.3V_MAIN)
VOUT 7
8 GND
GND VBULK R5 2 VOUT
R6 232
1 NDS8858H
10.0K
90.9K
R75
1 Q5
CTL_LO_C
3 R7
U2:A Q6 MMBT3904LT1
2 2.49K
PWM MMBT3904LT1
74LV00
(7=GND,14=+3.3V_MAIN)
2.49K
Q7
R9
10.0K
10.0K
GND
R10
R11
MMBT3906LT1
PHASE_C
PHASE_A
GND
GND GND GND
R178 VBULK PHASE_C E1:C CONN M 3 PIN 100

1
VBULK J1:A
10.0K 165 OHMS @ 100 MHZ
R13
C3
C
GND
CTL_HI_B
9
10.0K
Q9
* C
8 R14
U6:C Q8
.22uF
MMBT3904LT1
C4
10 2.49K GND
PWM
MMBT3904LT1 PHASE_B E1:B CONN M 3 PIN 100
74LV08 2
J1:B
(7=GND,14=+3.3V_MAIN) 165 OHMS @ 100 MHZ
2.49K
90.9K
R15
R78
GND
C5
Q10
MMBT3906LT1 3
GND
Q11
*
R16 4
GND VOUT 5 GND
232
VOUT 6
GND PHASE_A E1:A CONN M 3 PIN 100
3
VOUT 7 J1:C
165 OHMS @ 100 MHZ
R17 VOUT 8
C11
2
R18
VBULK
232
1 NDS8858H
* +3.3V_MAIN
*
TP1 TP2
90.9K
10.0K
R79
2.49K
GND
R22
*
Q12
4
CTL_LO_B
R19 R20 R21 TP3
6 MMBT3904LT1
Q13
*
U2:B 10
5 2.49K 301 1.82K
PWM MMBT3904LT1 U1:D BEMF
4700pF
13
100pF
74LV00
C6
C7
11
(7=GND,14=+3.3V_MAIN) LM339M
2.49K
R23
GND (3=VBULK, 12=GND)

10.0K
Q14
R26
MMBT3906LT1 R24 R25

GND GND
B R27 R28 90.9K 5.11M B
GND
GND 1.00K 10.0K
*
GND TP4
.22uF
C8
VBULK
R179 TP5
GND
10.0K R29
VBULK
TP6
* GND
*
10.0K
12 R30 R31
CTL_HI_A
11 R32 1.00K 10.0K
U6:D Q15 Q16
.22uF
C9
13 2.49K
.22uF
C10
PWM MMBT3904LT1
MMBT3904LT1
74LV08 MTR_CTR_EST
(7=GND,14=+3.3V_MAIN)
2.49K
90.9K
R34
R80
GND
GND
Q17 TP7 GND
GND
MMBT3906LT1 R36 4
3 Q18
VOUT 5
* R37 R38
232
VOUT 6 1.00K 10.0K
GND
.22uF
.47uF
C12
C13
VOUT 7
VOUT 8 CR21
VBULK R40 2
232 B160
R42 1 NDS8858H
FAST_CURRENT GND GND
GND
90.9K
10.0K NOTES:
R81
12 1. REFER TO SEPARATE BILL OF MATERIALS FOR ADDITIONAL PART INFORMATION.

A
CTL_LO_A
U2:D
11 R43
Q20
Q19
MMBT3904LT1 R44 5
TP8
* 2.
* - INDICATES ITEMS NOT INSTALLED. A
13 2.49K R45
PWM 1.00K 7 PRODUCT LINE:
0.12
R47
MMBT3904LT1 U3:B
2W
I_LO_SIDE
74LV00 R46 6 13.7K
(7=GND,14=+3.3V_MAIN) LM358A C-FLEX
2.49K
1.00K
R48
10.0K
.22uF
GND
R49
C14
Q21 (4=GND, 8=+5V) PROCESS: TITLE:
Motor Driver
MMBT3906LT1 DOMESTIC W/SMART CARD
R50 SCHEMATIC
GND
3.16K MOTOR DRIVER
GND
GND GND GND SIZE DRAWING NO. REV.
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
+ C48
.22uF
C47
100uF +3.3V_MAIN
D 16V D
1.00K
R133
GND +3.3V_MAIN
U12 +3.3V_MAIN 1
86 6 3 4
P00/NMI VDD U10:A
RTC_SCL
87
P01/INTP0 VDD
34 + C42 U9 2
U10:B
6 9
.22uF
R127
C55
88 71 10uF 5 8
2.49K
R59
RTC_SDA P02/INTP1 AVDD 35V PP18 74LV00 U10:C MOTOR_CURRENT_TRIP
89 55 100 LM385M3-2.5 (7=GND,14=+3.3V_MAIN) 10
MOTOR_CURRENT_TRIP P03/INTP2 BVDD 74LV00
90 LM339M (7=GND,14=+3.3V_MAIN)
SEEPROM_SCL P04/INTP3 74LV00
91 73 FAST_CURRENT
+3.3V_MAIN SEEPROM_SDA P05/INTP4/ADTRG AVREF 4 (7=GND,14=+3.3V_MAIN)
92 GND U1:A 2
DISP_SDA P06/INTP5/RTPTRG 18 GND
93 VPP VPP +8V
DISP_SCL P07/INTP6 5
MMSZ5237BT1
39 (3=VBULK, 12=GND)
94 P120/ WAIT DC-ON
1.00K
R172
CR14
SI0 P10/SI0/SDA
10.0K
10.0K
R135
R163
95 +3.3V_MAIN
SO0 P11/SO0
2.49K
R12
96
SCK0 P12/SCK0 /SCL 30
97 P113/A4
RXD0 P13/SI1/RXD0 29
98 P112/A3
TXD0 P14/SO1/TXD0 28
2.49K
R115
99 P111/A2 TC_DATA_IN GND GND RAW_PWM
P15/SCK1 /ASCK0 27
BZX84C4V3D
BZX84C4V3D
P110/A1 TC_DATA_OUT 12
1.30K
R58
.22uF
LM339M
C67
100 11
CR13
CR15
KYP_LTG P20/S12 26 U10:D 6

1 P107/RTP7/A12 13
SM_SDA_OUT P21/SO2 25 U1:B 1
PWM
2 P106/RTP6/A11 SM_DETECT +3.3V_MAIN +3.3V_MAIN
SM_SCL P22/SCK2 24 74LV00
3 P105/RTP5/A10 CTL_HI_C 7
SM_RXD1 P23/RXD1 23 GND GND (7=GND,14=+3.3V_MAIN)
C GND GND SM_TXD1

SM_SDA_IN
4
5
P24/TXD1
P25/ASCK1
P104/RTP4/A9
P103/RTP3/A8
22
21
CTL_LO_C
CTL_HI_B * R203 (3=VBULK, 12=GND)
C
2.49K
R114
8 P102/RTP2/A7 CTL_LO_B R204
BUZZER_CTL P26/T12/TO2 20
9 P101/RTP1/A6 CTL_HI_A 2.49K
IR_LINK P27/T13/TO3 19
BEMF
10
P30/TI00
P100/RTP0/A5
46
CTL_LO_A
UNUSED6/UNUSED6
* R201
R202
11 P96/HLDRQ
2.49K
R109
HALL P31/TI01 45 UNUSED5/UNUSED5
12 P95/ HLDAK 2.49K
P32/TI10 44 ENGLISH DISPLAY/UNUSED4
13
14
P33/TI11
P34/TO0/A13
P94/ASTB
P93// DSTB/RD
43
42
RTC/BRAKE ON
SMART CARD/MOTOR ON
* R199
R200
15 P92/R/ W/WRH
RAW_PWM P35/TO1/A14 41 PRESSURE/2X SPEED GND
16 P91/ UBEN 2.49K
FLOW_OS P36/TI4/TO4/A15 40 FLOW/COMMUTATION EVENT
17 P90/LBEN /WRL R197
P37/T15/TO5
2.49K
85 R129 90.9K
47
48
P40/AD0
P41/AD1
P83/ANI11
P82/ANI10
84
83
R167 90.9K
PHASE_C
MTR_CTR_EST
R205
* R198
+3.3V_MAIN
49 P81/ANI9 SW5
.001uF
P42/AD2 82
10.0K
10.0K
CR28
R128
R159
.1uF
C52
C51
B160
50 P80/ANI8 SW4 2.49K
P43/AD3
51
52
P44/AD4
P45/AD5
P77/ANI7
81
80
SW3 VBULK
R207
* R206
CONN M 9 PIN 100
J6:A
1
53 P76/ANI6 SW2 J6:B
P46/AD6 79 LVI CONN M 9 PIN 100
2
54 P75/ANI5 SW1 GND GND GND 2.49K
P47/AD7 78 GND J6:H
*
BZX84C4V3D
P74/ANI4 FLOW R208 TXD0 8
CONN M 9 PIN 100
P73/ANI3
77
PRESS
PROGRAMMING
57 J6:I
CR16
P50/AD8 76 R160 90.9K
R209
RXD0 CONN M 9 PIN 100
9 CONNECTOR
58 P72/ANI2
P51/AD9 75 J6:C
59 P71/ANI1 I_LO_SIDE 2.49K VPP CONN M 9 PIN 100
3
P52/AD10 74 R156 90.9K
B
60
P53/AD11
P70/ANI0 PHASE_A
* R210 J6:G
7
B
10.0K
10.0K
CONN M 9 PIN 100
61
P54/AD12 70
.001uF
62 P65/A21
CR29
GND
.1uF
C54
C53
B160
P55/AD13 69 GND
63 P64/A20 GND
P56/AD14 68 J6:D
64 P63/A19 SCK0 4
R152
P57/AD15 67 R117 CONN M 9 PIN 100

P62/A18 J6:E
66 SO0 CONN M 9 PIN 100
5
31 P61/A17
LVI RESET 65 GND GND GND J6:F
P60/A16 SI0 CONN M 9 PIN 100
6
38 GND
CLKOUT
32
BZX84C4V3D
BZX84C4V3D
BZX84C4V3D
P114/XT1 7
33 VSS
XT2 37
CR23
CR24
CR25
VSS
35 72
X2 AVSS
36 56
Y1 X1 BVSS +3.3V_MAIN
+3.3V_MAIN UPD70F3015A +3.3V_MAIN
20 MHz
GND
22pF
22pF
GND GND GND

C39
C40
.22uF
C41
.22uF
.22uF
.22uF
.22uF
.22uF
C34
C45
C57
C46
C56
+3.3V_MAIN
REALTIME CLOCK +3.3V_MAIN EEPROM
Y2 GND
32.768 KHZ GND
GND U15
1 8 GND
1.00K
1 4
R116
U11 A0 VCC
2.49K
2.49K
R118
R120
2 3 1 8
X1 VCC 2 7
PP21 PP22 A1 WP
2 7
X2 RST LVI 3 6
A2 SCL SEEPROM_SCL
3 6
A VBACK SCL RTC_SCL
+3.3V_MAIN 4
VSS SDA
5
SEEPROM_SDA A
International W/SmartCard
4 5 24C02M8
GND SDA RTC_SDA
2.49K
PRODUCT LINE:
R142
.22uF
C37
DS1672S-33 U19
C-FLEX
GND 2
VDD
3 GND GND PROCESS: TITLE:
Microprocessor
+ B1 VSS
1 INTERNATIONAL W/SMART CARD
BR1225-1HC GND RST
SCHEMATIC
MCP120T-315I/TT MICROPROCESSOR
GND
DRN BY: C.HALLWIRTH 11-20-01
GND
CHK BY: P.DEVINNEY 11-20-01 D S1009003 9
APPR BY: P.ALEXANDER 11-20-01 N/A 1009003 6 6
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
D D
+5V
C35
MT1 .22uF
1
NC PP1 .01uF
2
VS TP9
GND
VOUT
3
4
C36
GND
*
MPXV5004GC6U GND R110
PRESS
24.9K .047uF
24.9K
.01uF
R111
C38
C26
GND GND GND

PP14
MT1
PROBE POINTS PP15
FOR PINS 5-8 PP16
PP17
C C
+8V
24.9K
R184
GND LM324A
3.16K
R180
12
14 R186 R188
U16:D
MT2 13 2.00K 13.7K
1
.1uF
C63
2 (4=+8V, 11=GND)
TP12
3
4
R182
1.00K
+8V
6
LM324A
U16:B
R190 * FLOW
5 GND 7 1.00K
6 5
BZX84C4V3D
(4=+8V, 11=GND)
7
24.9K
R185
CR17
8 LM324A
10uF
C60
2 R187 R189
AIRFLOW SENSOR U16:A 1 2.00K 13.7K +8V
3
GND (4=+8V, 11=GND) GND GND
.1uF
C66
B B
1.00K
R194
+8V
R191 R193
GND
4.22K 10.0K
+ C64 + C65
4.22K
R183
2.2uF 2.2uF R196

LM324A Q32 FLOW_OS
25V 25V 2.49K
9 MMBT3904LT1
U16:C 8
2.49K
R195
10 GND GND
(4=+8V, 11=GND) GND
GND
A A
PRODUCT LINE:
C-FLEX
PROCESS: TITLE:
Analog Circuit
INTERNATIONAL W/SMART CARD
SCHEMATIC
ANALOG CIRCUIT
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
KEYPAD
+3.3V_MAIN
D D
+8V
90.9K
90.9K
90.9K
90.9K
90.9K
R95
R96
R97
R93
R94
RAMP SW4
J7:A 2 1
1 CONN M 3 PIN .078
SW5
.01uF
C69
+8V 2 1
+8V SWITCH COND RUBBER 3MM SPSTNO
J7:B +3.3V_MAIN SW6
2 R84
CONN M 3 PIN .078 2 1
10.0K
R113
SW1
1.00K
R112
100pF
GND
C43
1.00K
R121
J7:C 11 ON/OFF SW7
3 CONN M 3 PIN .078
13 2 1
U18:D HALL GND
10 SWITCH COND RUBBER 3MM SPSTNO
LM339M SW8
(3=VBULK, 12=GND) 2 1 R85
SW2
10.0K
R119
100pF
.22uF
C68
C44
SW9
RIGHT
2 1
GND SWITCH COND RUBBER 3MM SPSTNO GND
C GND
SW10
C
2 1 R86
SW3
ENTER
100pF
C59
LEFT SW11
VBULK
2 1 GND
SW12
2 1 R87
SW4
10.0K
R103
R122
R123
1/4W
1/4W
1/4W

412
412
412
100pF
C61
HUMID SW1
2 1
GND
SW2
IR LINK 2 1
CR10 SWITCH COND RUBBER 3MM SPSTNO
ZTN155W-03 SW3
2 1 R88
SW5
R104 SWITCH COND RUBBER 3MM SPSTNO 10.0K
Q30 IR_LINK
100pF
2.49K
C62
MMBT3904LT1
GND
B B
2.49K
R105
GND
VBULK GND
GND
1/4W
1/4W
R100
1/4W
R98
R99
1K
1K
1K
KEYPAD LIGHTING
VBULK CR7 CR8 CR9
HSMG-H730 HSMG-H730 HSMG-H730

R106
1/4W
LS1
1K
1 R101
Q29 KYP_LTG
2 2.49K
MMBT3904LT1
2.49K
R102
GND
R107
Q31 BUZZER_CTL
2.49K
MMBT3904LT1
GND
2.49K
R108
A A
PRODUCT LINE:
GND GND C-FLEX

PROCESS: TITLE:
To CPU Board
SCHEMATIC
TO CPU BOARD
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
+5V
+5v_MODEM
+5v_MODEM +3.3V_MAIN
1.00K
R137
J4:A E7 * E17
* J5:A 1
10.0K
R138
C1
D 1000 OHMS @ 100 MHZ
D
7 SHIFTED_TC_DATA_IN
* E23
* J5:B 2
.22uF
C32
+3.3V_MAIN 1
TC_DATA_IN U18:B
BZT52C5V6S
J4:B +5V 6
C2 PP19
LM339M
+1.5V
SHIFTED_SM_SCL
* E18
* J5:C
3
CR19
10.0K
R125
GND +3.3V_MAIN (3=VBULK, 12=GND)
1.00K
+5V
SHIFTED_SM_SCL
R63
LM339M
SM_SCL
SHIFTED_SM_RXD1
* E19
* J5:D 4
10.0K
R140
4
1.00K
J4:C E8
R139
GND
C3
1000 OHMS @ 100 MHZ
2
(3=VBULK, 12=GND)
U17:A
5
+1.5V
TC_DATA_OUT
LM339M * E20
* J5:E 5
GND
8 SHIFTED_TC_DATA_OUT
* E24
* J5:F
BZT52C5V6S
U18:C 14
6
+1.5V
BZT52C5V6S
CR11
9
(3=VBULK, 12=GND)
SHIFTED_SM_SDA_IN
* E21
* J5:G
7
CR20
+5V
+3.3V_MAIN
GND
SHIFTED_SM_TXD1
* E22
* J5:H 8
1.00K
R89
SHIFTED_SM_RXD1
10.0K
R126
GND
J4:D E9 7
C4
1000 OHMS @ 100 MHZ 1
U17:B SM_RXD1
BZT52C5V6S
6
+1.5V
LM339M
CR12
(3=VBULK, 12=GND)
C C
GND
+3.3V_MAIN +3.3V_MAIN
+3.3V_MAIN
J4:E E10
C5
1000 OHMS @ 100 MHZ
10.0K
2.49K
2.49K
R130
R68
R69
GND
J4:F LM339M U8
C6 PP20
SM_SDA_OUT 1 40
8 DISP_SDA SDA S23 PP8
14 U17:C 2 39
+5V DISP_SCL SCL S22 PP9
+1.5V 3 38
9 +5V PP7 SYNC S21 PP10
(3=VBULK, 12=GND) +3.3V_MAIN 4 37
CLK S20 PP11
5 36
SHIFTED_SM_SDA_IN VDD S19 PP12
1.00K
R82
6 35
OSC S18
7 34
10.0K
.22uF
.22uF
R131
C24
C33
A0 S17
LM339M 8 33
J4:G E11 A1 S16
C7 9 32
10 A2 S15
1000 OHMS @ 100 MHZ U17:D SM_SDA_IN 10 31
BZT52C5V6S
13 SA0 S14
+1.5V GND GND 11 30
11 VSS S13
CR18
12 29
(3=VBULK, 12=GND) VLCD S12
13 28
BP0 S11
14 27
BP2 S10
GND 15 26
BP1 S9
16 25
BP3 S8
B GND 17
S0 S7
24 B
+5V 18 23
S1 S6
19 22
S2 S5
+3.3V_MAIN 20 21
+5V S3 S4
PCF8566T
4.22K
+1.5V
R64
10.0K
R136
SHIFTED_SM_TXD1
1.00K
R83
DS1
1
S19 23
5 2 S10
SM_TXD1 S18 22
J4:H E12 2 3 C1
C8 U18:A S17 21
4 4 S9
1.00K
.22uF
1000 OHMS @ 100 MHZ
C58
+1.5V R65 S16 20

LM339M 5 S8
S15 19
6 S7
(3=VBULK, 12=GND) S14 18
7 S6
S13 17
+3.3V_MAIN 8 S5
S12 16
GND 9 S4
S11 15
10 S3
C4 14
11 S2
1.00K
R92
C3 13
12 S1
C2
UTS-J325AV
J4:J
S2 SM_DETECT
S1 J4:I
VBULK
A A
GND
PRODUCT LINE:
C-FLEX
.1uF
.1uF
C49
C50
Display and SmartCard

PROCESS: TITLE:
SCHEMATIC
DISPLAY AND SMART CARD
GND DRN BY: C.HALLWIRTH 11-20-01
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
--- --- SEE SHEET 1 --- --- --- ---
ISOLATION BARRIER
2
J2 L2 L1
D 1 1 4 1 2 CR1 D
S14K320
L1 C16
4 1
1/2 W
750K
RV1
.1uF
R51
C18
AC IN 2
L2 BR86DL .001uF
+ C17
P6SMB150AT3
SCHURTER 4300.0099 2 3 4 3
F1 ICA-0885 35 mh .6A PWRGND 3 68uF GND
CR26
1.00M
400V
R52
R54
68K
2W
2.5A
998 OHMS @ 100 MHZ

998 OHMS @ 100 MHZ
PWRGND
1.00M
R55
E3
E4
VBULK VBULK VBULK
MURS160
CR2
U4
T1 C20 + C15
SMBJ10CA
1
CONTROL 7 1 1500uF
CR27
DRAIN 25V
F2
5A
4700pF
2
4 L-SENSE
.1uF
C21
SOURCE CR3
3 10
5 X-LIMIT E2
SMBJ10CA
FREQ 2 GND
SB560
CR22
TOP249Y
998 OHMS @ 100 MHZ
PWRGND PWRGND PWRGND CR5 C22 +
C C
.1uF
C23
1000uF
5 25V
B160
6 GND
.1uF
C25
4 GND GND
GND
ICA-0638 VBULK
PWRGND
F3 CR4 1 L
5A MSP845 3 SS J3
2 SC
GND
*
U5 R60 R61 CR6
6 1
PP5 +3.3V_MAIN
301 MMSZ5240BT1
5 2
4 3 GND
PP6
+5V
4.22K
10.0K
R66
R8
CNY17F-2
VBULK
R62
6.2
+8V (3=VBULK, 12=GND)
LM339M
U7 U13 +3.3V_MAIN
8
KA78M05R LT1521CST-3.3 U1:C DC-ON
1 3 14
B IN OUT IN OUT + 9 B
47uF
GND + GND +
10V
C27
.22uF
C29 C31
C28
R76
499
4 TAB
10.0K
.1uF
R33
C71
2.2uF 2.2uF
PWRGND
GND GND GND GND
R77
232
GND GND
+5V
GND U14
KA78M05R
1 3
IN OUT
GND
.22uF
C30
GND GND
+5v_MODEM
U20
KA78M05R
1 3
IN OUT
GND
.22uF
C70
A A
GND GND PRODUCT LINE:
C-FLEX
PROCESS: TITLE:
Power Supply
SCHEMATIC
POWER SUPPLY
8 7 6 5 4 3 2 1

Appendix B
8 7 6 5 4 3 2 1
0 EDMS SCHEMATIC FOR REV 0 BOARD 11-20-01 C.HALLWIRTH EDMS EDMS

R177 VBULK
1 EDMS SCHEMATIC FOR REV 1 BOARD 1-2-02 C.HALLWIRTH EDMS EDMS
10.0K VBULK
R1 2 EDMS SHEET 1-CHANGE VALUE OF R21 2-22-02 C.HALLWIRTH EDMS EDMS
GND 3 1
10.0K SHEET 4-ADDED HALL CIRCUIT, SWAP
1 3
4 U3:A U6:A PP3 J4 (S1 & S2)
CTL_HI_C Q2 2 2
6 R2 SHEET 2,3,5&6-CIRCUITRY CHANGES
U6:B Q1 GND LM358A
5 2.49K MMBT3904LT1 74LV08
.22uF
PWM MMBT3904LT1
C1
(4=GND, 8=+5V) (7=GND,14=+3.3V_MAIN) 3 EDMS 4-04-02 F.PASCARELLA EDMS EDMS
SHEET 2-R60-R61 WAS VBULK, CHGD
74LV08
CR2,CR6,CR26,R60,R112,U13,C29&C31
2.49K
(7=GND,14=+3.3V_MAIN) GND SHEET 3-E20 WAS TO SM_GND
R3
90.9K
GND +3.3V_MAIN
R74
Q3 GND
SHEET 4-ADDED C69
D 9 SHEET 5-R188 & R189 WAS 392K, D
MMBT3906LT1 8 R181 WAS REMOVED
3 Q4 U2:C PP4
10 SHEET 6-ADDED U19
.1uF
R4 4
C2
GND VOUT 5
232 74LV00
GND VOUT 6 4 EDMS BOM CHANGE ONLY 4-10-02 F.PASCARELLA EDMS EDMS
(7=GND,14=+3.3V_MAIN)
VOUT 7 5 EDMS SHEET 2-ADDED F3,CR4,J3,U20,C70, 4-11-02 F.PASCARELLA EDMS EDMS
VOUT 8 GND R66,R33,C71,R8
GND VBULK R5 2 SHEET3-CHGD E7&E17 PWR
R6 232 SHEET 6-CHGD Y2
1 NDS8858H
10.0K 6 EDMS SHEET 3-J5,E17,E18,E19,E20,E21&E22 5-28-02 F.PASCARELLA EDMS EDMS
90.9K
R75
CHANGED TO NOT INSTALLED
1 Q5
CTL_LO_C
R7
SHEET 4 - ADD R122, R123
3 Q6 SHEET 5 - R186 & R187 WERE 1K
U2:A MMBT3904LT1
2 2.49K SHEET 6 - R116 WAS 10K
PWM MMBT3904LT1
74LV00
(7=GND,14=+3.3V_MAIN) 7 EDMS BOM CHANGE ONLY, U12 PRGMD 6-6-02 F.PASCARELLA EDMS EDMS
2.49K
Q7
R9
10.0K
10.0K
GND
R10
R11
8 EDMS SHEET 4 - R103, R122, R123 WAS 1K 7-1-02 F.PASCARELLA EDMS EDMS
MMBT3906LT1
9 EDMS REV CHANGE ONLY 7-30-02 F.PASCARELLA EDMS EDMS
GND PHASE_C
GND GND GND PHASE_A
R178 VBULK PHASE_C E1:C CONN M 3 PIN 100

1
VBULK J1:A
10.0K 165 OHMS @ 100 MHZ
R13
C3
C
GND
CTL_HI_B
9
10.0K
Q9
* C
8 R14
U6:C Q8
.22uF
MMBT3904LT1
C4
10 2.49K GND
PWM
MMBT3904LT1 PHASE_B E1:B CONN M 3 PIN 100
74LV08 2
J1:B
(7=GND,14=+3.3V_MAIN) 165 OHMS @ 100 MHZ
2.49K
90.9K
R15
R78
GND
C5
Q10
MMBT3906LT1 3
GND
Q11
*
R16 4
GND VOUT 5 GND
232
VOUT 6
GND PHASE_A E1:A CONN M 3 PIN 100
3
VOUT 7 J1:C
165 OHMS @ 100 MHZ
R17 VOUT 8
C11
2
R18
VBULK
232
1 NDS8858H
* +3.3V_MAIN
*
TP1 TP2
90.9K
10.0K
R79
2.49K
GND
R22
*
Q12
4
CTL_LO_B
R19 R20 R21 TP3
6 MMBT3904LT1
Q13
*
U2:B 10
5 2.49K 301 1.82K
PWM MMBT3904LT1 U1:D BEMF
4700pF
13
100pF
74LV00
C6
C7
11
(7=GND,14=+3.3V_MAIN) LM339M
2.49K
R23
GND (3=VBULK, 12=GND)

10.0K
Q14
R26
MMBT3906LT1 R24 R25

GND GND
B R27 R28 90.9K 5.11M B
GND
GND 1.00K 10.0K
*
GND TP4
.22uF
C8
VBULK
R179 TP5
GND
10.0K R29
VBULK
TP6
* GND
*
10.0K
12 R30 R31
CTL_HI_A
11 R32 1.00K 10.0K
U6:D Q15 Q16
.22uF
C9
13 2.49K
.22uF
C10
PWM MMBT3904LT1
MMBT3904LT1
74LV08 MTR_CTR_EST
(7=GND,14=+3.3V_MAIN)
2.49K
90.9K
R34
R80
GND
GND
Q17 TP7 GND
GND
MMBT3906LT1 R36 4
3 Q18
VOUT 5
* R37 R38
232
VOUT 6 1.00K 10.0K
GND
.22uF
.47uF
C12
C13
VOUT 7
VOUT 8 CR21
VBULK R40 2
232 B160
R42 1 NDS8858H
FAST_CURRENT GND GND
GND
90.9K
10.0K NOTES:
R81
12 1. REFER TO SEPARATE BILL OF MATERIALS FOR ADDITIONAL PART INFORMATION.

A
CTL_LO_A
U2:D
11 R43
Q20
Q19
MMBT3904LT1 R44 5
TP8
* 2.
* - INDICATES ITEMS NOT INSTALLED. A
13 2.49K R45
PWM 1.00K 7 PRODUCT LINE:
0.12
R47
MMBT3904LT1 U3:B
2W
I_LO_SIDE
74LV00 R46 6 13.7K
(7=GND,14=+3.3V_MAIN) LM358A C-FLEX
2.49K
1.00K
R48
10.0K
.22uF
GND
R49
C14
Q21 (4=GND, 8=+5V) PROCESS: TITLE:
Motor Driver
MMBT3906LT1 INTERNATIONAL W/SMART CARD
R50 SCHEMATIC
GND
3.16K MOTOR DRIVER
GND
GND GND GND SIZE DRAWING NO. REV.
8 7 6 5 4 3 2 1

Index
Index
A C
Accessories Cautions .............................................................................................. 2-5
Alternate ................................................................................ 4-10 Circuit Accessories
DC Power .............................................................................. 4-11 Alternate ................................................................................. 4-10
Optional ................................................................................. 4-10 Optional ................................................................................. 4-10
Recommended ......................................................................... 4-9 Recommended ......................................................................... 4-9
Altitude Connect Pressure Line ...................................................................... 6-10
Altitude Compensation ....................................................................... 3-5 Continious Positive Airway Pressure (CPAP) ............................. 1-3, 2-3
Audible Alarm .................................................................................... 6-7 CPAP Mode ................................................................................. 1-3, 4-5
Available Memory .............................................................................. 3-6 Pressure Settings ...................................................................... 4-6
Ramp Time Settings ................................................................. 4-7
B Setting Minimum Ramp Pressure ............................................ 4-7
Blower Assembly D
Replacing ............................................................................... 7-26
Bottom Enclosure DC Battery Adapter Cable ................................................................ 4-11
Replacing ............................................................................... 7-30 DC Power Cord ................................................................................ 4-11
Digital Manometer
Specifications .......................................................................... A-4
Digital Multimeter
Specifications .......................................................................... A-4
Display ................................................................................................ 6-8
Display Screens .................................................................................. 4-5
1011170 REMstar Pro CPAP System I-1

Index
E I
Encore Data Management Software ................................................... 1-3 Installation Flow Chart ..................................................................... 7-10
Equipment ..................................................................................... 8-4,8-5 Intermittent Power Supply Problem ................................................... 6-8
Equipment Setup ................................................................................. 8-6
Error Code Retreval .......................................................................... 6-13 K
Error Code Chart (CPAP) ................................................................. 6-14
Error Code Chart (Humidifier) ......................................................... 6-28 Key Pad
Error Code Chart (SmartCard) ......................................................... 6-24 Replacing ............................................................................. 7-17
F
L
Filter Cap
Removing ................................................................................. 5-3 Light-Emitting Diode (LED) .............................................................. 1-3
Liquid Crystal Display (LCD) ................................................... 1-3, 3-11
Filters
Cleaning ................................................................................... 5-3
Pollen ....................................................................................... 5-4
Removing ................................................................................. 5-4
Replacing ................................................................................. 5-4
Flow Chart
Installation ............................................................................. 7-10
Removal ................................................................................... 7-9

Index
M O
Main Printed Circuit Assembly Obstructive Sleep Apnea (OSA) ......................................................... 1-3
Replacing ............................................................................... 7-14 Odor ................................................................................................. 6-9
Manometer Outlet Air Temperature ....................................................................... 6-9
Digital ..................................................................................... A-4 Outlet Port
Mask Alert Replacing ............................................................................... 7-20
Setting ...................................................................................... 4-8 Oxygen
Mask Disconnected ............................................................................. 6-5 Adding ................................................................................... 4-12
Maximum Pressure Test ...................................................................... 8-9
Minimum Pressure Test ...................................................................... 8-9 P
Minimum Ramp Pressure
Setting ...................................................................................... 4-7 Pressure
Mode ................................................................................................. 1-3 Setting ...................................................................................... 4-6
12 VDC .................................................................................... 6-7 Pressure Offset .................................................................................. 6-10
CPAP ........................................................................................ 1-3 Pressure On / Off Button .................................................................... 4-6
Setting ...................................................................................... 4-5 Pressure Related Problems ................................................................. 6-8
Multimeter Pressure Settings
Digital ..................................................................................... A-4 CPAP Mode ............................................................................. 4-6
Pressure Variation ............................................................................. 6-11
Preventive Maintenance Schedule ...................................................... 5-5
N
Noise ................................................................................................. 6-8
Notes ................................................................................................. 2-5

Index
Functions .................................................................................. 3-5

R Fuses ........................................................................................ 3-4
Physical .................................................................................... 3-4
Ramp ................................................................................................. 3-5 Pressure .................................................................................... 3-6
Ramp Operation .................................................................................. 4-7 Ramp ........................................................................................ 3-5
Ramp Pressure .................................................................................. 6-11 Therapy Memory ..................................................................... 3-6
Setting ...................................................................................... 4-7
Ramp Time Settings ............................................................................ 4-7 System
Removal Flow Chart ......................................................................... 7-19 Cleaning ................................................................................... 5-3
Run-in ................................................................................................. 8-4 System Repair Kits ............................................................................. 7-4
System Setup Procedure ..................................................................... 4-4
S
T
Schematic Statement .......................................................................... B-3
Schematics Technical Support ............................................................................... 1-4
Domestic Analog Circuit ......................................................... B-4 Test Equipment
Domestic CPU Board ............................................................. B-5 Acceptable .............................................................................. A-4
Domestic Display .................................................................... B-6 Test Orifice ........................................................................................ A-3
Domestic Power Supply .......................................................... B-7 Therapy Menu ..................................................................................... 4-4
Domestic Motor Driver ........................................................... B-8 Tools ................................................................................................ A-3
International Microprocessor .................................................. B-9 Top Enclosure Replacing .................................................................. 7-11
International Analog Circuit .................................................. B-10 Troubleshooting Flow Chart ............................................................... 6-6
International CPU Board ...................................................... B-11 Troubleshooting Table ........................................................................ 6-7
International Display ............................................................. B-12
International Power Supply ................................................... B-13
International Motor Driver .................................................... B-14 W
Specifications Warnings
Compliance Meter .................................................................... 3-5 Cleaning ................................................................................... 2-4
Electrical .................................................................................. 3-4 Safety ....................................................................................... 2-3
Environmental .......................................................................... 3-4 Service ..................................................................................... 2-4

www.respironics.com
Reorder # 1011171 Revision # 1011170

BLT 09/13/2002

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REMstar® Pro

REMstar Pro CPAP System

REMstar Pro CPAP System

Chapter 1: Introduction ................................................... 1-1 3.1 Overview ...................................................................... 3-3

1011170 REMstar Pro CPAP System T-1

4.1 Overview ..................................................................... 4-3 6.1 Overview ..................................................................... 6-3

5.1 Overview ..................................................................... 5-3 7.1 Overview ..................................................................... 7-3

1011170 REMstar Pro CPAP System T-2

Appendix A: Tools and Equipment ................................ A-1

Appendix B: Schematics .................................................. B-1

1011170 REMstar Pro CPAP System T-3

(This page intentionally left blank.)

1011170 REMstar Pro CPAP System T-4

Overview: REMstar Pro CPAP System

Chapter 1: Introduction Introduces the REMstar Pro CPAP System.

Chapter 5: Routine Maintenance Provides cleaning and routine maintenance instructions.

Appendix B:Schematics Provides Printed Circuit Assembly (PCA) schematics.

1011170 REMstar Pro CPAP System O-1

(This page intentionally left blank.)

1011170 REMstar Pro CPAP System O-2

1.1 REMstar Pro System Overview .............1-3

1.2 Service Notice ...........................................1-4

1.3 Technical Support Statement ..................1-4

1011170 REMstar Pro CPAP System 1-1

The unit incorporates a user interface made up of a Liquid Crystal Display

1011170 REMstar Pro CPAP System 1-3

1.2 Service Notice

Respironics is committed to customer satisfaction and may be contacted

U.S. and Canada

1011170 REMstar Pro CPAP System 1-4

2.1 Warnings .................................................... 2-3

2.2 Cautions ..................................................... 2-5

2.3 Notes ........................................................... 2-5

1011170 REMStar Pro CPAP System 2-1

Chapter 2: Warnings, Cautions, 2.1.2 Operational

 The instructions in this manual are not intended to

1011170 REMStar Pro CPAP System 2-3

 Oxygen supports combustion. Do not use oxygen in 2.1.3 Service

1011170 REMstar Pro CPAP System 2-4

2.2 CAUTIONS 2.3 NOTES

 Always use an intake filter when the REMstar Pro CPAP

 Never place liquids on or near the REMstar Pro CPAP

 Discontinue using this device if any of the parts are

 The information in this manual is provided for

1011170 REMStar Pro CPAP System 2-5

(This page left intentionally blank)

1011170 REMstar Pro CPAP System 2-6

3.2 Specifications ............................................. 3-4

3.3 System Features ........................................ 3-8

3.4 Functional Description ...........................3-10

3.5 Theory of Operation ............................... 3-11

3.6 Auto-off and Mask Alert

1011170 REMstar Pro CPAP System 3-1

1011170 REMstar Pro CPAP System 3-2

Chapter 3: Specifications, Features,

1011170 REMstar Pro CPAP System 3-3

3.2 Specifications FUSES:

3.2.1 CPAP Specifications Fuses There are no replaceable fuses.

Operating Temperature 41 to 95°F (5 to 35°C) Dimensions 9 1/2x 6 7/8 x 4 1/2

Elevation 0 to 5500 ft. DC Current Consumption 3.0 A maximum

Power Consumption 80 VA maximum

1011170 REMstar Pro CPAP System 3-4

Mode of Operation Continuous ALTITUDE COMPENSATION:

The instructions in this manual are not intended to

Oxygen supports combustion. Do not use oxygen in 2.1.3 Service

Always use an intake filter when the REMstar Pro CPAP

Never place liquids on or near the REMstar Pro CPAP

Discontinue using this device if any of the parts are

The information in this manual is provided for

Operating Temperature 41 to 95°F (5 to 35°C) Dimensions 9 1/2x 6 7/8 x 4 1/2

NOTE: If a System Error 8 key stuck occurs, repeat the process in

Respironics Nasal Mask with integrated Exhalation Port

Respironics 6 ft. (1.83 m) Flexible Tubing. Figure 4-11