ResMed VPAP III, VPAP III ST, VPAP III ST-A Service Manual
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ResMed VPAP III, VPAP III ST, VPAP III ST-A Service Manual

Flow generator and humidifier
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VPAP® III, VPAP III ST, VPAP III ST-A
SERVICE MANUAL
Reorder No. 248106/3 05 04
English
www.resmed.com
Waking people up to sleep

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Summary of Contents for ResMed VPAP III, VPAP III ST, VPAP III ST-A

  • Page 1 VPAP® III, VPAP III ST, VPAP III ST-A SERVICE MANUAL Reorder No. 248106/3 05 04 English www.resmed.com Waking people up to sleep...
  • Page 2 Manufactured by: ResMed Ltd 1 Elizabeth MacArthur Drive Bella Vista NSW 2153 Australia Tel: +61 (2) 8884 1000 or 1 800 658 189 (toll free) Fax: +61 (2) 8883 3114 Email: reception@resmed.com.au ResMed Offices: ResMed Corp 14040 Danielson Street Poway CA 92064-6857 USA Tel: +1 (858) 746-2400 or 1-800-424-0737 (toll free) Fax: +1 (858) 746-2900 Email: reception@resmed.com...

  • Page 3: Table Of Contents

    Contents 1 1 1 1 How to use this manual How to use this manual ..........................4 4 4 4 How to use this manual How to use this manual .......................... 2 2 2 2 Introduction Introduction Introduction Introduction ................................
  • Page 4 Replacing the power supply (VPAP III ST-A models) Replacing the Main PCB Installing the serial number and default settings Replacing the cable harness with switch and humidifier connector Replacing the switch (for VPAP III and VPAP III ST models only) Placing decals on replacement bottom cases Replacing interface assembly components Closing the flow generator...

  • Page 5: How To Use This Manual

    Appendix A: Service Request Form - Whenever you locate a fault in a flow generator, fill out this form and return it to ResMed for logging. Appendix B: Noise reduction upgrade - Lists procedures to follow to reduce noise in problem flow generators.

  • Page 6: Introduction

    • have suitable electrical and mechanical training to satisfy the requirements of the relevant regulatory authorities • use the correct antistatic procedures described in this manual Use only approved ResMed parts and never use parts that have failed, show excessive wear, have been contaminated, or are ineffective for their intended use. Note: Schematics of all PCBs in this flow generator are available to authorised service centres.

  • Page 7: Software Changes

    Software changes ResMed continually develops and improves its products. The VPAP III, VPAP III ST and VPAP III ST-A have undergone a number of software changes as outlined below: VPAP III, VPAP III ST Software version Significant features SX365-0108 • Original issue SX365-0109 •...

  • Page 8: General Inspection And Servicing

    Enter the results in the electronic form provided in the service software. Equipment required • ResMed Spirit 2.1 Service Software (30967) or available in service software kit 30966, which includes null modem cable, oxygen sideport connector, closed Bubble Cushion ®...

  • Page 9: Software Buttons

    Software buttons Perform the audible alarm test Flow generator settings dialog Perform the pressure calibration test Service record results form Perform the flow calibration test Record Perform the blower test Function keys VPAP III and VPAP III ST keypad and LCD LCD Screen Left key Right key...

  • Page 10: Clean The Flow Generator

    1 1 1 1 Clean the flow generator Clean the flow generator Clean the flow generator Clean the flow generator Before servicing the unit it should be wiped down using a lint free cloth and a cleaning agent with a high alcohol content, for example, isopropyl alcohol.

  • Page 11: External Examination

    3 3 3 3 External examination External examination External examination External examination 1 Visually examine the flow generator for external damage such as: • deformation or cracking of the upper or lower cases • damaged components such as the mains power inlet or mains power switch •...

  • Page 12: Replace The Air Filter

    3 Check the appropriate box in the Record of Service window. Caution Only use genuine ResMed spare parts, because the filter affects the flow characteristics of the flow generator, which in turn affects the pressure supplied to the patient. 6 6 6 6...

  • Page 13: Flow Calibration Test

    8 8 8 8 Flow calibration test Flow calibration test Flow calibration test Flow calibration test 1 Select Performance Tests>Flow calibration test, or press the Perform the flow calibration test button at the top of the main window. 2 Set up the test equipment as instructed by the software. 3 Select Next and follow the steps as instructed.

  • Page 14: Dc Power Test (Vpap Iii St-A Only)

    HumidAire 2i test HumidAire 2i test The VPAP III, VPAP III ST and VPAP III ST-A is designed to integrate with the ResMed HumidAire 2i heated humidifier. The units automatically detect the HumidAire 2i docking station when it is connected to the flow generator.
  • Page 15 Note: The VPAP III ST-A will display the standard patient menu or advanced patient menu series after the welcome message. Press the right key until the warm-up feature prompt is displayed. 5 Turn the knob to 5. 6 Press the right key to start the HumidAire 2i warming up. Ensure the light on the humidifier turns on to indicate the unit is warming.

  • Page 16: 14 Reload Clinical Settings

    1 If any problems are found with the flow generator, fill out the Service request form in Appendix A of this manual, and send it to ResMed in Sydney for review and logging. (The address may be found on the first page of this manual.) 2 Check the appropriate Fill out product problem report box in the Service details window.

  • Page 17: Static Precautions

    Static Precautions Warning Prior to disassembly or assembly, make sure that the power is not connected to the flow generator. Integrated circuits (ICs) within the various PCBs can be badly damaged by electrostatic discharge or transient voltages. The following procedures are recommended to avoid component damage: 1 Work benches where handling and repairs are done must have surfaces of suitable conducting material connected via a 1 MΩ...

  • Page 18: Replacing Major Subassemblies

    Replacing major subassemblies This section contains brief instructions and points to be aware of as you replace major subassemblies and reassemble the flow generator. Caution When a Main PCB or motor is replaced, the flow generator must be recalibrated by following the procedures in Section 7 Calibration procedures.

  • Page 19: Opening The Flow Generator

    Opening the flow generator Remove the front muffler assembly 1 Press the latch underneath the front muffler assembly. 2 While pressing on the latch, pull away the front muffler assembly from the unit. VPAP® III, VPAP III ST, VPAP III ST-A Service Manual...

  • Page 20: Removing The Interface Assembly

    Removing the interface assembly 3 Using a screwdriver, release the two front lock tabs while pulling the interface assembly upwards. Front lock tabs Use a screw driver to push against locking tabs 4 Lift up the module carefully, so as not to place any strain on the flexible cable or PCB underneath.

  • Page 21: Remove The Filter

    5 Turn the module upside down and release the locking tabs that are holding the flexible cable. Locking tabs 6 Gently pull out the flexible cable. Remove the filter 7 Take hold of the lower end of the air filter cover and pull it out and away from the unit. Remove the top case 8 With the interface assembly removed, turn the unit upside down and undo the four screws holding on the top case, using a Phillips head screwdriver.

  • Page 22: Replacing The Blower Module Assembly

    9 Turn the unit right-side up and carefully lift off the top case, allowing the flexible cable to slip through the top case. VPAP III with top case removed Power Supply PCB Blower module Flexible cable Replacing the blower module assembly Caution The following procedures should be completed exactly as written to ensure sensor tubes are not kinked or compressed.
  • Page 23 3 Turn it over towards the left and rest it on the jig. 4 Using a small screw driver, carefully prize off the two silicone tubes connected to the base of the blower. 5 Disconnect the motor cable assembly from the Main PCB. 6 Place the new blower module on the jig.
  • Page 24 8 Connect silicone tube 1 to the right hand side of the module base from pressure sensor port 1 on left. This tube must pass behind the vibration mount once the blower is located. 9 Connect the motor cable assembly, which should run over the top of sensor tube 1. VPAP III and VPAP III ST models VPAP III ST-A model with Ferroxcube Toroid...
  • Page 25 11 Bend tube 3 to the front of the unit, as shown below: 12 Turn the blower assembly over and install it in the lower case, taking care with the location of the blower inlet connector and blower outlet connector. Pay special attention to the routing of the silicon tubes so that no kinking or compression occurs.

  • Page 26: Replacing The Blower Inlet And Outlet Connectors

    13 Connect tube 3 to the blower outlet connector on the blower. 14 Ensure that the flexible cable is not stuck underneath the blower. Note: If replacing the sensor tubes ensure they are cut to the following lengths: Slimline Tube 1 pressure 170 ±...
  • Page 27 2 Remove the top half of the blower casing. Blower inlet connector Volute Blower outlet connector 3 Remove the volute from the bottom half of the blower casing. 4 The blower inlet connector and blower outlet connector can then be removed from the volute.
  • Page 28 6 Fit the new blower inlet connector, ensuring it is seated correctly on the volute. Blower inlet connector flush to wall of volute 7 Before placing the volute in the casing, check that the motor cable is located under the tab, as shown below: Motor cable located under tab...

  • Page 29: Replacing The Fuse (For Vpap Iii And Vpap Iii St Models Only)

    10 Take the top half of the blower casing and place it on the lower half of the casing. Ensure the top half of the casing sits behind the blower outlet connector as shown below: Correct Incorrect 11 Press evenly around the edge of the casing the reseal the blower casing. Replacing the fuse (for VPAP III and VPAP III ST models only) 1 With the blower module removed the fuse casing is now accessible.

  • Page 30: Replacing The Power Supply (Vpap Iii And Vpap Iii St Models)

    6 Locate the wires and fuse to their original position. 7 Refit the blower module. Replacing the power supply (VPAP III and VPAP III ST models) 1 With the blower module removed, lift the power supply out of its mounting slots. 2 Disconnect the AC input cable and the DC output cable.

  • Page 31: Replacing The Power Supply (Vpap Iii St-A Models)

    Replacing the power supply (VPAP III ST-A models) 1 With the blower module removed, lift the power supply out of its mounting slots. 2 Disconnect the AC cable, DC cable, PSU cable harness and the humidifier mains cable. PSU cable AC cable harness from switch...

  • Page 32: Replacing The Main Pcb

    Replacing the Main PCB 1 Remove the blower module, disconnecting the sensor tubes from both the sensors on the PCB and from the blower module. Note: Remove the sensor tubes from the PCB by gently twisting and pulling upwards on the tubes to ensure that the pressure ports are not damaged.
  • Page 33 5 Release the other front lock tab. 6 Continue to lift the PCB while progressively releasing the remaining lock tabs. 7 Take out the PCB and remove the serial connector seal. Note: Not all units will contain the serial connector seal. Connector seal R300-7109 can be installed in those units that do not currently have a seal.
  • Page 34 12 Place the Main PCB in the bottom case, positioning it so that the two D-connectors align with the corresponding openings in the bottom case. The locating pin goes through the hole as shown below: Locating pin 13 Gently press down the edges of the PCB progressively from the back, working your way to the front of the PCB, until all the lock tabs have clicked into place.

  • Page 35: Installing The Serial Number And Default Settings

    Note: After loading the clinical settings and options ensure the time and date settings are correct for your region. Select Settings>Set tme and date to view and modify these settings as required. Installing the serial number and default settings If the Main PCB has been replaced and the original settings could not be downloaded from the flow generator, the default settings and serial number for the unit will need to be installed.
  • Page 36 2 Slide the humidifier connector out of its housing by depressing the two locks at the side of the connector while pushing it upwards. Location of locks 3 Locate the switch at the rear of the unit. • For older version VPAP III and III ST units push down the tabs on the top of the switch while also pushing it forwards out of the rear aperture.
  • Page 37 6 Push the switch into place, with the pins located under the rocker switch. Ensure the switch clicks securely into place. Switch - VPAP III, III ST Switch - VPAP III ST-A 7 Take the humidifier connector and slide it into the housing, ensuring it "clicks" into place. 8 Locate the wires in the route shown below.

  • Page 38: Replacing The Switch (For Vpap Iii And Vpap Iii St Models Only)

    Replacing the switch (for VPAP III and VPAP III ST models only) 1 With the cable harness removed from the bottom case, remove the cable tie from around the recepticals. For older version cable harnesses, remove the cable ties indicated below. Remove cable ties 2 Disconnect the cable harness wires from the switch.
  • Page 39 4 Feed the short blue wire in the gap between the brown and blue wires running to the AC connector, as shown below: Short blue wire 5 Connect the short blue wire to terminals 1a and N. Short blue wire connected to terminal 1a and N VPAP®...
  • Page 40 6 Connect the short brown wire to terminals 2a and L. Short brown wire connected to terminals 2a and N 7 Take a 100 mm cable tie and fasten it around the receptacles on terminals 1, 1a, 2 and 2a. The cable tie must be approximately half way down the recepticals.

  • Page 41: Placing Decals On Replacement Bottom Cases

    Placing decals on replacement bottom cases When replacing the bottom case for the VPAP III family of products the necessary warning decals need to be installed on the replacement cases. VPAP III, VPAP III ST 1 Take the replacement fuse label (R300-305) and stick it inside the bottom case, as shown below: Replacement fuse label 2 Place the mains voltage label (R300-303) on the outside of the bottom case, below the gaps for...

  • Page 42: Replacing Interface Assembly Components

    2 Take the AC switch label (R241-406) and place it on the outside of the bottom case, next to the AC switch, as shown below: Note: The AC switch label is not required for Teijin VPAP III ST-A units. AC switch label Replacing interface assembly components 1 Turn the interface assembly upside down and release the clips holding in the LCD module.

  • Page 43: Closing The Flow Generator

    2 Remove the LCD module keypad, taking care not to touch the pills on the keypad. (VPAP III keypad pictured) Do not touch the pills 3 Insert the keypad into the interface panel, once again taking care not to touch the pills on the keypad.
  • Page 44 3 Turn the unit right side up, and refit the filter, with the blue side of the filter material facing out from the flow generator. 4 Take the interface assembly and turn it upside down so that the LCD module is facing upwards. 5 Insert the flexible connector into the locking device.

  • Page 45: Replacing Front Muffler Components

    Note: Ensure the flexible cable is not pinched between the top case and interface panel. 8 Fit the interface panel. Ensure that all four clips in the interface panel are clipped properly. For VPAP III ST-A units, push down on the points indicated below. These points are above the retaining clips located on the underside of the interface panel.
  • Page 46 3 The locking plate can then be removed from the chassis, Locking plate while the front muffler seal can also be removed from the front cowl. Front muffler seal 4 Slide the locking plate onto the chassis and place the chassis in the front cowl. 5 Connect the chassis to the front cowl with the four screws.

  • Page 47: The Humidaire 2I

    The HumidAire 2i Opening the HumidAire 2i 1 Separate the water chamber from the docking station by pushing upwards on the latch on the bottom of the water chamber. 2 Turn the unit on its side and hold the flow generator with one hand, while releasing the bottom catch with the other hand.

  • Page 48: Removing Components From The Water Chamber

    Removing components from the water chamber 1 Lift the catches on the side of the water chamber. 2 Separate the water chamber lid and base. Water chamber lid Water chamber base The water chamber lid 1 Inside the chamber lid is the seal. To remove the seal, peel it away from the lid. 5 Replacing major subassemblies...

  • Page 49: The Water Chamber Base

    The water chamber base The heater plate 1 Remove the cross-member from the supports in the water chamber base. Cross member 2 Push down on the heater plate from inside the chamber to remove it from the chamber. 3 The O-ring can be removed from the tub heater plate. When placing in the new O-ring, make sure it is fitted snugly inside the channel of the heater plate.
  • Page 50 4 Turn the water chamber base upside down and insert the heater plate with the open side facing down. 5 Firmly press the plate into the chamber. 6 Turn the water chamber base right-side up and place the cross-member on its supports inside the chamber.
  • Page 51 The latch 1 Turn the water chamber base upside down. 2 Gently pull up and away from the chamber until separated from the base. 3 Take the new latch and insert the feet with locking tabs into the slots as shown below: Ensure the tab latch clicks securely into both slots 4 Push the tab at the top of the latch into the slot at the top of the heater plate.

  • Page 52: Replacement Parts List Replacement Parts List

    Replacement parts list Outside cases Top case (VPAP III, III ST) 19201 Top case (VPAP III ST-A) 19310 Also available Handle R300-794 Bottom case 19199 (base pad and base decal not included) Base pad and base decal kit (VPAP III, III ST) 19276 Base pad and base decal kit (VPAP III ST-A) 19307 Bottom case (Teijin)

  • Page 53: Interface Assembly

    Interface assembly VPAP III, VPAP III ST Interface panel (VPAP III Germany) R241-701 Interface panel (VPAP III ST Germany) R241-702 Interface panel (VPAP III) R241-703 Interface panel (VPAP III ST) R241-704 LCD module 19277 Keypad R300-716 VPAP III ST-A Interface panel R241-726-A Interface panel (Germany) R241-726-B...

  • Page 54: Internal Components

    Internal components Blower (VPAP III, III ST) 19272 Blower (VPAP III ST-A) 19303 (VPAP III ST-A pictured) Blower outlet connector R300-7108 Clipped upper airpath R300-7032 Blower inlet Clipped lower connector airpath R300-7033 R300-7056 Motor retaining flange R241-706 Vibration mount R300-736 Motor mounting R241-705 PCBs Main PCB (VPAP III)

  • Page 55: Main Wiring Harnesses

    Power supply assembly (VPAP II, III ST) 19275 Also available for VPAP III, III ST, III ST-A Cable harness (24V DC output) R300-744 Power supply assembly (VPAP III ST-A) 19306 Main wiring harnesses Main wiring harness (VPAP III, III ST) (includes IEC switch) R241-729 IEC socket/switch...

  • Page 56: Humidaire 2I Spare Parts

    Z331 HumidAire 2i spare parts HumidAire 2i knob assembly 19233 Note: The following HumidAire 2i spare parts are available as accessories. Contact your local ResMed office for prices. Tub assemblies and docking station Tub assembly, UDEL 30941 Tub assembly, PC...

  • Page 57: Warnings And Cautions

    Equipment required • ResMed Spirit 2.1 Service Software (30967) or available in service software kit 30966, which includes null modem cable, oxygen sideport connector, closed bubble cushion, standard mask frame and security key.

  • Page 58: Order Of Calibration Procedures

    Order of calibration procedures The calibration procedures must be performed in the following order: 1 Pressure calibration 2 Flow calibration 3 Motor noise calibration (VPAP III ST-A only) Cautions The flow generator clinical settings must be recorded before any calibration procedure is performed.

  • Page 59: Flow Calibration

    4 Follow the prompts on the screen. Once the calibration is complete the following screen will appear: 2 2 2 2 Flow calibration Flow calibration Flow calibration Flow calibration Caution The pressure calibration must be performed before the flow calibration. 1 Select Calibration>Flow calibration, or press the Flow calibration button at the top of the main window.

  • Page 60: Motor Noise Calibration (Vpap Iii St-A Only)

    If the unit fails calibration, ensure the test set-ups are correct. If the unit continues to fail, send the flow generator with product problem report (found on page 65 of this manual) to ResMed for further servicing. 7 Calibration procedures...

  • Page 61: Troubleshooting Guide

    Troubleshooting guide Symptom Possible Cause Solution Flow generator not operating at • Blown fuse in power supply • Replace and investigate cause all (no display when power switch of the blown fuse. turned on) • Faulty Main PCB • Replace Main PCB •...
  • Page 62 Symptom Possible Cause Solution Flow generator with humidifier • Humidifier not attached • Ensure humidifier is firmly attached continues to restart correctly attached to flow generator Error message: • Pressure sensor adaptor is not • Check and refit pressure Check hoses!! connected properly to flow sensor adaptor as required Key if done...

  • Page 63: System Specifications

    System specifications VPAP III, VPAP III ST Dynamic pressure characteristics IPAP: 2 cm H 2 O to 25 cm H 2 O (measured at the end of standard 2 m air tubing) EPAP: 2 cm H 2 O to 25 cm H 2 O (measured at the end of standard 2 m air tubing) Maximum single fault pressure: 40 cm H 2 O Dynamic flow characteristics 130 L/min at 2 to 20 cm H 2 O...

  • Page 64: Vpap Iii St-A

    VPAP III ST-A Dynamic pressure characteristics IPAP: 2 cm H 2 O to 30 cm H 2 O (measured at the end of standard 2 m air tubing) EPAP: 2 cm H 2 O to 25 cm H 2 O (measured at the end of standard 2 m air tubing) Maximum single fault pressure: 40 cm H 2 O Dynamic flow characteristics 130 L/min at 2 to 30 cm H 2 O...

  • Page 65: Recommended Maintenance Schedule

    Recommended maintenance schedule The ResMed VPAP III series of flow generators are designed to give years of trouble-free operation. The filter strip should be replaced at least every six months, and regular cleaning recommendations are given in the section, “Cleaning and maintenance” of the User Manual. All of these procedures can be carried out by the owner, so no regular servicing by a service agent is required.

  • Page 66: Appendix A: Service Request Form

    > 5 years When did the fault occur? Not being used During use Start up Unknown Is this device being returned to ResMed? Service details ResMed reference number Today’s date Distributor reference number (if applicable) AUF 19019-01/3 Appendix A: Service request form...

  • Page 67: Appendix B: Noise Reduction Upgrade

    Appendix B: Noise reduction upgrade To reduce the noise level of a VPAP III or VPAP III ST unit (with serials numbers earlier than 20040018972), you may prefer to perform the build standard upgrade rather than replacing the motor. To perform the build standard upgrade it is necessary to make the following changes: 1 Add 4 x R300-7017 blower top foam pads to the volute.
  • Page 68 Note: Ensure that each foam pad overlaps two ribs on both the upper and lower sections of the volute as shown: 4 Add the remaining two R300-7017 foam pads to the outside of the top airpath. Position them as shown: 5 Remove the two existing R300-733 foam pads from the airpath.

  • Page 69: Fit Cable Tie And Replace Blower Outlet Connector

    6 Add three R300-733 foam pads to the inside of the lower airpath. Position them as shown: Fit cable tie and replace blower outlet connector 1 With the blower removed, position a 100 mm cable tie under the top set of terminals on the power switch as shown below: 2 Fasten the cable tie around the wires and terminals so that they are bundled together.
  • Page 70 3 When complete, the protruding wires from the switch should be no more than 40 mm from the inside of the flow generator case. 40 mm 4 Replace the blower outlet connector following the instructions outlined in Section 5 Replacing major subassemblies. 5 Reassemble, test and calibrate the flow generator.

  • Page 71: Appendix C: Installing The Service Software

    Appendix C: Installing the service software The Spirit 2.1 Service Software is available by itself (30967), and in a kit (30966) which includes: • Null modem cable • Closed bubble cushion • Oxygen sideport connector • Standard mask frame • Security key The software should be installed on a computer running Windows NT, 2000 or XP.

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