Respironics REMstar Choice Service Manual
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Respironics REMstar Choice Service Manual

Respironics REMstar Choice Service Manual

Nasal cpap system
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REMstar
®
REMstar
Choice
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REMstar
Choice
LS
®
REMstar
Choice
Express
®
REMstar
®
Reliance
REMstar
®
Series II
Nasal CPAP System
Service Manual

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Summary of Contents for Respironics REMstar Choice

  • Page 1 REMstar ® REMstar Choice ® REMstar Choice ® REMstar Choice Express ® REMstar ® Reliance REMstar ® Series II Nasal CPAP System Service Manual...
  • Page 2 REMstar Choice® systems are the subject of U.S Patent #5239995 and other pending U.S. and foreign patents. REMstar is a registered trademark of Respironics,Inc. Copyright © 1997 Respironics Inc. All rights reserved.
  • Page 3 ® This manual provides service and maintenance information for the REMstar Product Family. While the units look similar and share many of the same parts, the repair instructions are not interchangeable.

  • Page 5: Table Of Contents

    SECTION 3 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE ....................3-2 3.2.1 ADJUSTING THE PRESSURE ......................3-4 3.2.2 ADJUSTING THE PRESSURE AND RAMP TIME (REMstar Choice, Express, Series II, and Reliance) ..............................3-7 3.2.3 ADJUSTING THE PRESSURE AND RAMP TIME (REMstar Choice LS)......3-10 ALTITUDE ADJUSTMENT ......................3-13 SECTION 4 TROUBLESHOOTING TROUBLESHOOTING ........................
  • Page 6 REPLACING THE POTENTIOMETER ..................6-24 6.7.1 REPLACING THE POWER SWITCH (REMstar) ..............6-26 6.7.2 REPLACING THE POWER SWITCH (REMstar Choice Series, Series II, and Reliance) ..6-27 6.8.1 REPLACING THE TIME METER ....................6-28 6.8.2 REPLACING THE TIME METER/RAMP ADJUSTMENT CIRCUIT BOARD .....6-31 6.8.3...
  • Page 7 Theory of Operation ......................... 1-5 1.2.1 Internal Wiring Diagram (REMstar)....................1-6 1.2.2 Internal Wiring Diagram (REMstar Choice, Express, and Series II) .......... 1-7 1.2.3 Internal Wiring Diagram (REMstar Choice LS, and Reliance) ........... 1-9 REMstar Product Family ........................1-10 REMstar Service Manual...

  • Page 8: Specifications

    Specifications and Wiring Diagram 1.1 SPECIFICATIONS CPAP Static Pressure Range: 3 – 20 cm H Physical Dimensions: Weight: <6.0 lbs. (2.72 kg) Height: 9.0 in. (22.9 cm) Width: 5.75 in. (14.6 cm) Unit Filters: A pollen filter and an optional 0.3 micron ultra-fine filter. Within ±1 cm H Pressure Stability: O at flows up to a 55 LPM leak through a six foot...
  • Page 9 Deep- Cycle Battery (see below). For pressures less than 11 cm H connect the unit to the cigarette lighter using a Respironics DC Cord. For pressures greater than 11 cm H O, connect the unit to the cigarette lighter using a DC Interface module.
  • Page 10 Specifications and Wiring Diagram Compliance to Standards The REMstar Product family ** meets the requirements of the EU EMC Directive 89/336 EEC. The normative documents within these requirements include: •IEC 601-1-2 •IEC 801-2 •IEC 801-3 •IEC 801-4 •CISPIR 11 **NOTE: The original REMstar (PN 367100) unit does not meet these requirements. The IEC requirements were not in effect at the time of unit design.

  • Page 11: Theory Of Operation

    Specifications and Wiring Diagram 1.2 Theory of Operation The REMstar Product family is constructed of four major component assemblies: the Motor Blower Assembly, the Printed Circuit Board Assembly, the Transformer Power Supply, and the Enclosure Housing. The CPAP pressure and flow is generated by the motor blower assembly. This assembly generates air flow via a back- ward vein impeller spinning in excess of 7000 RPM.

  • Page 12: Internal Wiring Diagram (Remstar)

    Specifications and Wiring Diagram 1.2.1 INTERNAL WIRING DIAGRAM - REMstar AC Inlet DC Inlet (Main Connection) gray Internal Connections orange Fuses white black Power Switch white red yellow Primary 1 2 3 4 5 6 Voltage Selector Transformer Switch 7 8 9 10 11 12 Secondary white black orange...
  • Page 13 Specifications and Wiring Diagram 1.2.2 INTERNAL WIRING DIAGRAMS - REMstar Choice, REMstar Express and Series II Internal Wiring Diagram, Rev 2 to Rev 6 Controller Board* AC Inlet DC Inlet (Main Connection) gray Internal Connections orange Fuses white black red yellow...
  • Page 14 Specifications and Wiring Diagram REMstar Choice, Express, and Series II Internal Wiring Diagram, Rev 7 Controller Board* AC Inlet DC Inlet (Main Connection) gray Internal Connections orange Fuses white black red yellow Primary 1 2 3 4 5 6 Voltage...

  • Page 15: Internal Wiring Diagram (Remstar Choice, Express, And Series Ii)

    Specifications and Wiring Diagram 1.2.3 INTERNAL WIRING DIAGRAM - REMstar Choice LS and Reliance AC Inlet DC Inlet (Main Connection) gray Internal Connections orange Fuses white black red yellow Primary 1 2 3 4 5 6 Voltage Selector Transformer Switch...

  • Page 16: Remstar Product Family

    Specifications and Wiring Diagram 1.3 REMstar Product Family 1-10 REMstar Service Manual...

  • Page 17: Section 2 Warnings, Cautions, And Notes

    Warnings, Cautions, Notes/Adjusting the Pressure Section 2 Warnings, Cautions, and Notes Warnings, Cautions, and Notes ...................... 2-2 REMstar Service Manual...
  • Page 18 Warnings, Cautions, Notes/Adjusting the Pressure 2.1 WARNINGS, CAUTIONS, AND NOTES WARNINGS • U.S. Federal law restricts the sale or the use of this device to be on the order of a licensed physician only. • If the patient presents a contamination risk to the unit, place a bacteria filter in-line between the unit and the patient.
  • Page 19 Preventive Maintenance ........................3-2 3.2.1 Adjusting the Pressure ........................3-4 3.2.2 Adjusting the Pressure and Ramp Time (REMstar Choice, Express, Series II, and Reliance) 3-7 3.2.3 Adjusting the Pressure and Ramp Time (REMstar Choice LS) ..........3-10 Altitude Adjustment ......................... 3-13...
  • Page 20 Preventive Maintenance 3.1 PREVENTIVE MAINTENANCE Inspect the REMstar unit annually. After inspection, fill out the maintenance chart in the Patient Instructions providing the patient with a record of all maintenance performed on the unit. ® REMstar Product Family Preventive Maintenance Schedule (Factory Recommended) Patient Dealer...
  • Page 21 Preventive Maintenance 3.1.1 Record hours from meter. NOTE: Not all units have an hour meter. 3.1.2 Verify voltage selector switch, (see following pages). 3.1.3 Set pressure to 3 cm H O and let run for 20 minutes. Verify that the delivery pressure is 3 /- 1 cm H Set pressure to 10 cm H O and let run for 20 minutes.

  • Page 22: Adjusting The Pressure

    The following items are necessary to perform REMstar installation and setup properly: a manometer capable of reading pressure in centimeters of water and a straight-shank, slotted screwdriver (smaller than 1/8”). An O Enrichment Attachment is available from Respironics (P/N 312710), to aid in pressure verification, but is not required. STEP 1 Setup of the REMstar System a.
  • Page 23 Preventive Maintenance c. Option 1 - Connect the manometer tubing to the outlet port on the mask, (see Figure 1). - or - Option 2 - Remove the mask from the circuit and replace it with an O Enrichment Attachment. Connect the manometer tubing to the outlet port on the attachment, (see Figure 2).
  • Page 24 STEP 2 Adjusting the Pressure to the Patient’s Prescription NOTE: All REMstar units are shipped from Respironics with the pressure set between 8 and 10 cm H Occlude the circuit outlet at either the mask or the O Enrichment Attachment. Observe the delivery pressure on the manometer.

  • Page 25: Adjusting The Pressure And Ramp Time (Remstar Choice, Express, Series Ii, And Reliance)

    Preventive Maintenance 3.2.2 ADJUSTING THE PRESSURE AND RAMP TIME (REMstar Choice, Express, Series II and Reliance) WARNING: If the REMstar unit has been exposed to extreme temperatures, allow the unit to adjust to room temperature before beginning the Setup and Adjustment procedures.
  • Page 26 The unit automatically turns ON. NOTE: The electronic circuits used in REMstar Choice are designed to turn the unit ON when power is supplied. This allows the patient to continue receiving CPAP therapy following a power outage during the night.
  • Page 27 Preventive Maintenance STEP 2 Adjusting the Pressure and Ramp Time a. The pressure control and the ramp time control 2. Lift cap off components are located under the unit cap. Behind the three slots located in the upper left corner of the rear panel is a vertical bar that secures the cap in place.

  • Page 28: Adjusting The Pressure And Ramp Time (Remstar Choice Ls)

    NOTE: manometer capable of reading pressure in centimeters of water and a straight-shank, slotted screwdriver (smaller than 1/8”). An O Enrichment Attachment is available from Respironics (P/N 312710), to aid in pressure verification, but is not required. STEP 1 Setup of the REMstar System a.
  • Page 29 Plug one end of the power cord into the back of the unit and the other end into an electrical outlet. The unit automatically turns ON. The electronic circuits used in REMstar Choice are designed to turn the unit ON when power NOTE: is supplied.
  • Page 30 Preventive Maintenance STEP 2 Adjusting the Pressure and Ramp Time a. The pressure control and the ramp time control 2. Lift cap off components are located under the unit cap. Behind the three slots located on the upper left corner of the rear panel is a vertical bar that secures the cap in place.
  • Page 31 Preventive Maintenance 3.3 PRESSURE ADJUSTMENT FOR ALTITUDE CHANGE The chart on the following page shows the pressure adjustment that must be made when the patient will be using the REMstar at a location that differs more than 1,000 feet in altitude from where the pressure is being set.
  • Page 32 Preventive Maintenance 3-14 REMstar Service Manual...
  • Page 33 Troubleshooting Section 4 Troubleshooting Troubleshooting ..........................4-2 4.1.1 REMstar and Series II Troubleshooting Guide ................4-3 4.1.2 REMstar Choice and Choice Express Troubleshooting Guide ........... 4-11 4.1.3 REMstar Choice LS and REMstar Reliance Troubleshooting Guide ......... 4-21 REMstar Service Manual...
  • Page 34 Electronic components used in this unit are subject to damage by static electricity. Use proper static discharge and grounding precautions when servicing the equipment. NOTE: For instructions on replacement, refer to Section 6. If you require technical assistance during any of these troubleshooting procedures, call: Respironics Technical Service Department 1-800-722-4271 REMstar Service Manual...

  • Page 35: Remstar And Series Ii Troubleshooting Guide

    Troubleshooting 4.1.1 REMstar and Series II Troubleshooting Guide Problem Possible Causes Corrective Action ON/OFF Switch lights but there is Voltage selector switch is set to Verify proper voltage setting. If no air flow. the wrong voltage. the unit is set to 230 V, but plugged into a 115 V line, the unit will not operate.
  • Page 36 Troubleshooting REMstar and Series II Problem Possible Causes Corrective Action Fuses are blown. Check the fuses for continuity Unit does not turn on and ON/ using an ohmmeter. If either fuse OFF switch does not light. measures an open circuit or appears darkened in any spot, replace both fuses.
  • Page 37 Troubleshooting REMstar and Series II Possible Causes Corrective Action Problem Motor wire is not securely Check the motor wire at J1 on the connected to J1 on the Main Main Control Board. Unit starts and stops erratically. Control Board. Unit delivers inadequate Filter(s) are dirty or clogged.
  • Page 38 Troubleshooting REMstar and Series II Problem Possible Causes Corrective Action Unit delivers inadequate Check that the pressure can be Blower or circuit board pressure. adjusted throughout the malfunction. operating pressure range with the potentiometer on the circuit board. Refer to Section 3 for instructions on setting the prescription pressure.
  • Page 39 Troubleshooting REMstar and Series II Possible Causes Corrective Action Problem Time meter does not operate. Blower or main circuit board Check that the pressure can be Unit delivers excessive pressure. malfunction. adjusted throughout the operating pressure range with the potentiometer on the circuit board.
  • Page 40 Troubleshooting REMstar and Series II Problem Possible Causes Corrective Action The air temperature at the patient Replace filter(s) if dirty, and end of a six-foot circuit must not be instruct patient on proper care as more than five (5) degrees F above detailed in the patient the ambient temperature.
  • Page 41 Troubleshooting REMstar and Series II Possible Causes Corrective Action Problem Replace the blower or Possible blower or transformer transformer. malfunction. Air from unit feels warm. NOTE: Power constantly flows across the transformer even when the unit is off. Therefore, there Excessive noise or vibration.
  • Page 42 Troubleshooting REMstar and Series II Problem Possible Causes Corrective Action (continued) Transformer needs to be replaced. Unplug the unit. Remove the unit Unit does not operate on 230 V, cover and the main circuit board. but does on 115 V. Check continuity of the following wiring connections: from the AC inlet to the transformer, from the...
  • Page 43 Troubleshooting 4.1.2 REMstar Choice and REMstar Choice Express Troubleshooting Guide Problem Possible Causes Corrective Action Unit is plugged in to a power Power cord is not firmly Check that the power cord is outlet but there is no air flow.
  • Page 44 Troubleshooting REMstar Choice and Express Problem Possible Causes Corrective Action (continued) When using a 12 volt DC source, See Section 1 for additional DC Unit is plugged in to a power check that the system polarity uses system specifications. outlet but there is no air flow.
  • Page 45 Troubleshooting REMstar Choice and Express Possible Causes Corrective Action Problem (continued) Transformer is faulty or wiring If there is no secondary voltage, Unit is plugged in to a power connections are not complete. the transformer is faulty. Replace outlet but there is no air flow.
  • Page 46 Troubleshooting REMstar Choice and Express Problem Possible Causes Corrective Action (continued) Measure the secondary voltage of Transformer is faulty or wiring Unit starts and stops erratically. the transformer between each set connections are not complete. of orange and grey wires. The voltage should be approximately 15.5 VAC ±...
  • Page 47 Troubleshooting REMstar Choice and Express Possible Causes Corrective Action Problem (continued) Blower or main circuit board Check that the pressure can be Unit delivers inadequate malfunction. adjusted throughout the operating pressure. pressure range with the potentiometer on the circuit board. Refer to Section 3 for instructions on setting the prescription pressure.
  • Page 48 Troubleshooting REMstar Choice and Express Problem Possible Causes Corrective Action (continued) Blower or main circuit board Step 2: Check the circuit board Unit delivers excessive pressure. malfunction. by plugging a known functioning blower to it. If the new blower functions properly, replace the blower.
  • Page 49 Troubleshooting REMstar Choice and Express Possible Causes Corrective Action Problem (continued) Step 2: Check the circuit board Blower or main circuit board Air from unit feels too warm. by plugging a known functioning malfunction. blower to it. If the new blower functions properly, replace the blower.
  • Page 50 Troubleshooting REMstar Choice and Express Problem Possible Causes Corrective Action Unit does not operate on 230 V, Fuses need to be replaced. Fuse type may be incorrect. but does on 115 V. Change fuses when changing the voltage setting: Unit voltage setting: 115 VAC...
  • Page 51 Troubleshooting REMstar Choice and Express Possible Causes Corrective Action Problem Transformer needs to be replaced. If there is no secondary voltage, (continued) the transformer is faulty. Replace Unit does not operate on 230V, the transformer. but does on 115V. Units S/N < 300000 ONLY.
  • Page 52 Troubleshooting REMstar Choice and Express Problem Possible Causes Corrective Action (continued) Remote control is damaged or the When functioning properly, a Remote control not functioning. battery need replacing. green light appears inside the end of the remote control. If the light...

  • Page 53: Remstar Choice Ls And Remstar Reliance Troubleshooting Guide

    Troubleshooting 4.1.3 REMstar Choice LS and REMstar Reliance Troubleshooting Guide Problem Possible Causes Corrective Action Unit plugged into a power outlet Power cord is not firmly Check that the power cord is but there is no air flow. connected to the unit, or it is not firmly connected to the unit.
  • Page 54 Troubleshooting REMstar Choice LS and Reliance Problem Possible Causes Corrective Action (continued) When using a 12 volt DC source, See Section 1 for additional DC Unit plugged into power outlet check that the system polarity uses system specifications. but there is no air flow.
  • Page 55 Troubleshooting REMstar Choice LS and Reliance Possible Causes Corrective Action Problem (continued) Transformer is faulty or wiring Measure the secondary voltage of Unit plugged to a power outlet connections are not complete the transformer between each set but there is no air flow.
  • Page 56 Troubleshooting REMstar Choice LS and Reliance Problem Possible Causes Corrective Action A difference between the primary (continued) Transformer is faulty or wiring voltage and the input voltage Unit starts and stops erratically. connections are not complete. determines a fault in the AC inlet, the primary wiring, or the voltage selector switch.
  • Page 57 Troubleshooting REMstar Choice LS and Reliance Possible Causes Corrective Action Problem (continued) Blower or main circuit board Check that the pressure can be Unit delivers inadequate malfunction. adjusted throughout the operating pressure. pressure range with the potentiometer on the circuit board.
  • Page 58 Troubleshooting REMstar Choice LS and Reliance Problem Possible Causes Corrective Action (continued) Blower or main circuit board Step 2: Check the circuit board by plugging a known functioning Unit delivers excessive pressure. malfunction. blower to it. If the new blower functions properly, replace the blower.
  • Page 59 Troubleshooting REMstar Choice LS and Reliance Possible Causes Corrective Action Problem Step 2: Check the circuit board (continued) Blower or main circuit board by plugging a known functioning Air from unit feels warm. malfunction. blower to it. If the new blower functions properly, replace the blower.
  • Page 60 Troubleshooting REMstar Choice LS and Reliance Problem Possible Causes Corrective Action Unit does not operate on 230 V, Fuses need to be replaced. Check the fuses for continuity but does on 115 V. with an ohmmeter. If either fuse measures an open circuit or appears darkened in any spot, replace both fuses.
  • Page 61 Troubleshooting REMstar Choice LS and Reliance Possible Causes Corrective Action Problem (continued) Ramp button on unit cap is Replace the unit cap if the ramp Pressing the ramp button does damaged. function works when the optical not initiate the ramp function.
  • Page 62 Removing and Replacing the Cover Section 5 Removing and Replacing the Cover 5.1.1 Removing the Cover (units without filter caps) ................5-2 5.1.2 Removing the Cover (units with filter caps) ................. 5-3 5.2.1 Replacing the Cover (units without filter caps) ................5-6 5.2.2 Replacing the Cover (units with filter caps) ..................

  • Page 63: Removing The Cover (Units Without Filter Caps)

    Removing and Replacing the Cover 5.1.1 REMOVING THE COVER (units without filter caps) NOTE: This procedure pertains to the original version of the basic REMstar units. Tools Required: • Phillips Screwdriver • Slotted Screwdriver, 3/16" Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. WARNING: CAUTION: Electronic components used in this unit are subject to damage by static electricity.

  • Page 64: Removing The Cover (Units With Filter Caps)

    Removing and Replacing the Cover 5.1.2 REMOVING THE COVER (units with filter caps) NOTE: This procedure applies to all models of the REMstar unit except the original basic REMstar. Tools Required: • Phillips Screwdriver • Slotted Screwdriver, 3/16" • Long Needle Nose Pliers (3/32" tip) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit.
  • Page 65 Removing and Replacing the Cover STEP 3 To remove the unit cap, locate the three slots on the rear of the unit in the upper 2. Lift cap off left corner. Behind the top two slots is a vertical bar that secures the cap in place. Using a slotted screwdriver (or other tool), press firmly on the bar while lifting up on the rear of the cap.
  • Page 66 Removing and Replacing the Cover STEP 5 Lift the cover off the unit while slightly pushing it forward. The cover may tend to get stuck where the three screws attach, or on the left side, where the printed circuit board is located. If this occurs, pull the base of the cover outward, away from the unit.

  • Page 67: Replacing The Cover (Units Without Filter Caps)

    Removing and Replacing the Cover 5.2.1 REPLACING THE COVER (units without filter caps) Tools Required: • Phillips Screwdriver WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. CAUTION: Electronic components used in this unit are subject to damage by static electricity. Use proper static discharge and grounding precautions when servicing the equipment.
  • Page 68 Removing and Replacing the Cover STEP 3 Position the cover over the unit. Starting on the left side, check that the opening on the back of the cover is lined up with the rear panel of the unit. Check that the cover slides between the Cover tabs on the unit back.

  • Page 69: Replacing The Cover (Units With Filter Caps)

    Removing and Replacing the Cover 5.2.2 REPLACING THE COVER (units with filter caps) Tools Required: • Phillips Screwdriver WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. CAUTION: Electronic components used in this unit are subject to damage by static electricity. Use proper static discharge and grounding precautions when servicing the equipment.
  • Page 70 Removing and Replacing the Cover STEP 3 Position the cover over the unit. Starting on the left side, check that the opening on the back of the cover is lined up with the rear panel of the unit. Check that the cover slides between the tabs on the unit back. Slide the cover down, while pushing it forward.
  • Page 71 6.5.1 Replacing the Main Circuit Board (REMstar) ................6-16 6.5.2 Replacing the Main Circuit Board (REMstar Choice, Series II, and Express) ......6-18 6.5.2.1 Replacing the Varistor on the PC Board ..................6-20 6.5.3 Replacing the Main Circuit Board (REMstar Choice and Reliance) .......... 6-22 Replacing the Potentiometer ......................
  • Page 72 FAX: 1-800-422-5816 (U.S. and Canada) or 412-733-0299 If you need replacement kit information, call: Respironics Customer Satisfaction Department Phone: 1-800-345-6443 (U.S. and Canada) or 412-733-2100 FAX: 1-800-886-0245 (U.S. and Canada) or 412-733-0245 Visit Respironics’ Home Page on the internet at: www.respironics.com REMstar Service Manual...

  • Page 73: Component Locations

    Repair and Replacement 6.1 COMPONENT LOCATIONS Cable Clip Main Circuit Board Filters Blower Top Sub-Assembly Blower Blower Transformer Sealing Tape Blower Assembly Fastener Shock Mount Stick-on Feet DC Inlet Voltage Selector Switch Handle Time Meter (Back Panel) (if applicable) Blower Assembly Fastener Power Switch...

  • Page 74: Replacing The Blower

    Repair and Replacement 6.2 REPLACING THE BLOWER Part #362532 Included with the Replacement Kit: • Complete Blower Assembly • 6-32 Nut w/ Lockwasher (3 each) • Foam Tape (1 each) • Capacitor Additional Supplies Required: ® ® • Threadlock (e.g. LOCTITE 222 or omniFIT 1150) •...
  • Page 75 Repair and Replacement STEP 3 Set the unit upright. Remove the circuit board from the groove in the unit base. If the existing blower has a ribbon cable: Disconnect the red 8-pin connector from J1 on the circuit board. Pry the rear blower assembly fastener from the back of the blower (see page 6-1) and remove the ribbon cable.
  • Page 76 Repair and Replacement STEP 10 Looking from the left side of the unit, check that the blower outlet is positioned fully into the foam coupling located on the inside of the rear panel. If the blower outlet is not aligned correctly, gently press the rear panel and the blower together until the blower outlet is properly positioned in the foam coupling.

  • Page 77: Replacing The Blower Top Assembly

    Repair and Replacement 6.3 REPLACING THE BLOWER TOP ASSEMBLY Part #362533 Included with the Replacement Kit: • Complete Blower Top Assembly • Blower Assembly Fasteners (3 each) • Blower Sealing Tape (1 each) • Wire Tape (1 each) • Shock Mounts (3 each) •...
  • Page 78 Repair and Replacement STEP 3 Set the unit upright. Remove the circuit board from the groove in the unit base. If the existing blower has a ribbon cable: Disconnect the red 8-pin connector from J1 on the circuit board. Pry the rear blower assembly fastener from the back of the blower (see page 6-1) and remove the ribbon cable.
  • Page 79 Repair and Replacement STEP 10 Place the new blower assembly on the three posts of the unit base. Check that the shock mount studs run into the posts. Replace the shock mounts as necessary. STEP 11 Lay the unit on the rear panel. Place one or two drops of threadlock to the shock mount studs. Start the nuts on the shock mount studs, and firmly tighten.

  • Page 80: Replacing The Transformer (Remstar)

    Repair and Replacement 6.4.1 REPLACING THE TRANSFORMER (REMstar) Part #362542 Included with the Replacement Kit: • Transformer • 8-32 Nut w/ Lockwashers (4 each) • Hex Head Screws (4 each) • Nylon Shoulder Washers (8 each) Additional Supplies Required: • 11/32" Socket Wrench ®...
  • Page 81 Repair and Replacement STEP 4 Using needle nose pliers, remove the 10 female spade terminals connected to the transformer. Move the wires out of the way. STEP 5 Using the 11/32" socket wrench, remove the four (4) nuts with lockwashers from the top of the transformer.
  • Page 82 Repair and Replacement STEP 10 Connect the female spade terminals according to the proper wiring diagram in Section 1. STEP 11 Connect the wires to the circuit board as shown below, and set the circuit board into the groove of the unit base.

  • Page 83: Replacing The Transformer (Remstar Choice Series, Series Ii, And Reliance)

    Repair and Replacement 6.4.2 REPLACING THE TRANSFORMER (REMstar Choice Series, Series II, and Reliance) Part #502031 Included with the Replacement Kit: • Transformer • 8-32 Nut w/ Lockwashers (4 each) • Hex Head Screws (4 each) • Base Label (1 each) •...
  • Page 84 Repair and Replacement STEP 4 Using needle nose pliers, remove the 10 female spade terminals attached to the transformer. Move the wires out of the way. STEP 5 Using the 11/32" socket wrench, remove the four (4) nuts with lockwashers from the top of the transformer.
  • Page 85 Repair and Replacement STEP 10 Connect the female spade terminals according to the proper wiring diagram in Section 1. STEP 11 Connect the wires to the circuit board as shown below, and set the circuit board into the groove of the unit base.
  • Page 86 Repair and Replacement 6.5.1 Replacing the Main Circuit Board (REMstar) Part #362534 Included with the Replacement Kit: • Main Circuit Board • Board Edge Bumper Additional Supplies Required: • Phillips Screwdriver • Slotted Screwdriver (smaller than 1/8") WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. CAUTION: Electronic components used in this unit are subject to damage by static electricity.
  • Page 87 Repair and Replacement STEP 4 Set the new circuit board into the groove on the unit base. Check that the board edge bumper is in place. STEP 5 Replace the cover according to the instructions in Section 5. STEP 6 Set the prescription pressure according to the set up instructions in Section 3.

  • Page 88: Replacing The Main Circuit Board (Remstar)

    NOTE: The REMstar Choice Main Circuit Board may be any revision from Rev 2 to later. All of the revisions have equivalent functions, except as related to the time meter. The LCD time meter works only with Rev 7 and later boards.
  • Page 89 Repair and Replacement STEP 4 Return the old circuit board to Respironics in the same packaging that the new circuit board was shipped in. STEP 5 Connect the wires to the new main circuit board according to the figure on the previous page, and set the new circuit board into the groove on the unit base.

  • Page 90: Replacing The Varistor On The Pc Board

    Additional Supplies Required: • Phillips Screwdriver • Slotted Screwdriver (smaller than 1/8") • Six-pin Jumper* (Used for REMstar Choice LS repair only) *Retained from old LS Board • Vacuum type desoldering tool • Solder: "44" Rosin Core (60% tin; 40% Lead) •...
  • Page 91 Repair and Replacement STEP 4 Inspect the solder joint after completion for: cold solder joints, incomplete joints, lifted pads from the board, etc. STEP 5 Install the repaired PC board into the unit. REMstar Service Manual 6-21...

  • Page 92: Replacing The Main Circuit Board (Remstar Choice Ls And Reliance)

    Repair and Replacement 6.5.3 REPLACING THE MAIN CIRCUIT BOARD (REMstar Choice LS and Reliance) Part #502029 Included with the Replacement Kit: • Main Circuit Board • Six-pin Jumper Additional Supplies Required: • Phillips Screwdriver • Slotted Screwdriver (smaller than 1/8") •...
  • Page 93 Rev 6) or a 10-pin connector (for circuit boards equal to or later than Rev 7). For the REMstar Choice LS, only the first two pins are empty. Pins 3 through 8 are jumpered, and pins 9 and 10 are used for the Power Switch.

  • Page 94: Replacing The Potentiometer

    Repair and Replacement 6.6 REPLACING THE POTENTIOMETER (REMstar and REMstar Choice) Part #362558 (or 362570 for REMstar Choice Units) Included with the Replacement: • Potentiometer Additional Supplies Required: • Phillips Screwdriver • Soldering Iron: Grounded or Isotip Heat setting: 750° ,sco,i, 30 Watts maximum Solder Tip Width: 1/8"...
  • Page 95 Repair and Replacement STEP 4 Remove any remaining solder from the solder pads. Board Using a cotton swab and isopropyl alcohol clean both Edge Bumper sides of the three solder pads. STEP 5 Install the new potentiometer with the adjusting screw facing the edge of the circuit board.

  • Page 96: Replacing The Power Switch (Remstar)

    Repair and Replacement 6.7.1 REPLACING THE POWER SWITCH (REMstar) Part #362543 Included with the Replacement Kit: • Power Switch Additional Supplies Required: • Phillips Screwdriver • Needle Nose Pliers Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. WARNING: CAUTION: Electronic components used in this unit are subject to damage by static electricity.
  • Page 97 Repair and Replacement 6.7.2 REPLACING THE POWER SWITCH (REMstar Choice Series, Series II, and Reliance) Part #502032 Included with the Replacement Kit: • Power Switch with Wire Harness Additional Supplies Required: • Phillips Screwdriver • Needle Nose Pliers WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit.

  • Page 98: Replacing The Time Meter

    Repair and Replacement 6.8.1 REPLACING THE TIME METER (Meter mounted on bottom of unit) Part #362538 Included with the Replacement Kit: • Time meter (1 each) • Capacitor • Time/Date Labels (2 each) • Wire Tape (1 each) Additional Supplies Required: •...
  • Page 99 Repair and Replacement Cable Clip Circuit STEP 3 Remove the time meter wires from the Board cable clip on the rear panel of the unit. Remove the wires from the wire tape attached to the blower or the second cable clip located on the rear panel, whichever is applicable.
  • Page 100 Repair and Replacement STEP 9 Record the old time meter reading and date of replacement on each of the time/date labels. Attach one of the labels to the side of the time meter and attach the other label to the bottom of the unit next to the time meter.

  • Page 101: Replacing The Time Meter/Ramp Adjustment Circuit Board

    Repair and Replacement 6.8.2 REPLACING THE TIME METER/ RAMP ADJUSTMENT CIRCUIT BOARD (Rear Panel Mounted Time Meter, Serial Number Less Than 300000) Part #502123 Included with the Replacement Kit: • Time Meter/Ramp Adjustment Circuit Board • Push-on Knob • Fiber Spacer Washer •...
  • Page 102 Repair and Replacement STEP 11 Connect the eight wire connectors to the main circuit board as shown below. Ramp Adjust. CB/ Time Meter Connector (8 Pin) Power Switch Connector (2 Pin) Motor Connector (8 Pin) Top two pins not used DC Inlet Wires (2 Pin)
  • Page 103 Repair and Replacement 6.8.3 REPLACING THE TIME METER (Rear Panel Mounted Time Meter, Serial Number Greater Than 300000) Part #502147 Included with the Replacement Kit: • Time Meter Circuit Board • Time/Date Labels (2 each) Additional Supplies Required: • Nut Driver, 3/8" WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit.
  • Page 104 Repair and Replacement Time Meter Connector (8 Pin) Power Switch Connector (2 Pin) Motor Connector (8 Pin) Top two pins not used DC Inlet Wires (2 Pin) Transformer Wires (4 Pin) 6-34 REMstar Service Manual...

  • Page 105: Replacing The Ramp Adjustment Pcb (Remstar Choice S/N <300000)

    Repair and Replacement 6.8.4 REPLACING THE RAMP ADJUSTMENT PCB (for Serial Numbers Less Than 300000) (REMstar Choice Only) Part #502034 Included with the Replacement Kit: • Ramp Adjustment Circuit Board • Push-on Knob • Fibre Spacer Washer Additional Supplies Required: •...
  • Page 106 Repair and Replacement STEP 8 Connect the six wire connectors to the main circuit board as shown below: Not used Ramp Ramp Adjustment Adjustment Knob Circuit Board Connector Connector (6 Pin) (6 Pin) Power Switch Power Switch Connector Connector (2 Pin) (2 Pin) Motor Motor...
  • Page 107 Repair and Replacement 6.9.1 REPLACING THE AC INLET (REMstar) Part #502057 Included with the Replacement Kit: • AC Inlet • Screws (2 each) • Fuse Holder Additional Supplies Required: • Phillips Screwdriver • 5/16" Socket Driver • Small Slotted Screwdriver (optional) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit.
  • Page 108 Repair and Replacement STEP 8 Remove the fuse holder from the new Inlet by releasing the small tabs on the sides of the holder. A small screwdriver may be used to help remove the holder. Place the fuses inside the holder, and insert into the unit and snap in place.
  • Page 109 Repair and Replacement 6.9.2 REPLACING THE AC INLET (REMstar Choice Series, Series II, and Reliance) Part #502057 Included with the Replacement Kit: • AC Inlet • Screws (2 each) • Fuse Holder Additional Supplies Required: • Phillips Screwdriver • 5/16" Socket Driver •...
  • Page 110 Repair and Replacement STEP 8 Connect the two female spade terminals to the rear of the AC Inlet (connect the white wire on the blower side, and the black wire on the transformer side). STEP 9 Set the blower assembly into position over the three posts. Check that the shock mount studs are lined up within the posts.

  • Page 111: Replacing The Handle (Remstar)

    Repair and Replacement 6.10.1 REPLACING THE HANDLE (REMstar) Part #362535 Included with the Replacement Kit: • Handle • Handle Fasteners (2 each) Additional Supplies Required: • Needle Nose Pliers • Nut Driver • Slotted Screwdriver (less that 1/8") • Phillips Screwdriver (#1 or #0) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit.
  • Page 112 Repair and Replacement STEP 7 Take one new handle fastener and place it, smooth end first, into the outside edge of the opening. When the grooved end of the fastener begins to contact the edge of the opening and can no longer be pushed by hand, use pliers to finish engaging the handle fastener until it is flush with the edge.

  • Page 113: Replacing The Handle (Remstar Choice Series, Series Ii, And Reliance)

    Repair and Replacement 6.10.2 REPLACING THE HANDLE (REMstar Choice Series, Series II, and Reliance) Part #362535 Included with the Replacement Kit: • Handle • Handle Fasteners (2 each) Additional Supplies Required: • Needle Nose Pliers • Nut Driver (3/8") • Slotted Screwdriver (less that 1/8") •...
  • Page 114 Repair and Replacement STEP 6 Take one new handle fastener and place it, smooth end first, into the outside edge of the opening. When the grooved end of the fastener begins to contact the edge of the opening and can no longer be pushed by hand, use pliers to finish engaging the handle fastener until it is flush with the edge.

  • Page 115: Replacing The Cover

    Refer to Section 5 for instructions on removing and replacing the cover. Model Part Number REMstar 362536 REMstar Choice 502030 REMstar Choice LS 502132 REMstar Series II 502180 REMstar Express 502183 REMstar Reliance* -------- *Contact Repironics, Inc.

  • Page 116: Replacing The Stick-On Feet

    Repair and Replacement 6.12 REPLACING THE STICK-ON FEET Part #362537 Included with the Replacement Kit: • Stick-on Feet (6 each) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. STEP 1 Lay the unit on the rear panel. Peal the rubber feet from the bottom panel of the unit. STEP 2 Using Isopropyl alcohol, (or soapy water), remove any adhesive residue left on the bottom panel of the unit.

  • Page 117: Replacing The Ultra-Fine Filter (Remstar)

    Repair and Replacement 6.13.1 REPLACING THE ULTRA-FINE FILTER (REMstar) Part #362522 Included with the Replacement Kit: • Ultra-Fine Filters (package of 6) Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. WARNING: STEP 1 Remove the pollen filter by gently pulling from around the edges.

  • Page 118: Replacing The Ultra-Fine Filter (Remstar Choice Series, Series Ii, Reliance)

    Repair and Replacement 6.13.2 REPLACING THE ULTRA-FINE FILTER (REMstar Choice Series, Series II, and Reliance) Part #362522 Included with the Replacement Kit: • Ultra-Fine Filters (package of 6) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit.

  • Page 119: Replacing The Pollen Filter (Remstar)

    Repair and Replacement 6.14.1 REPLACING THE POLLEN FILTER (REMstar) Part #362521 Included with the Replacement Kit: • Pollen Filter (1 each) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. STEP 1 Remove the pollen filter by gently pulling from around the edges.

  • Page 120: Replacing The Pollen Filter (Remstar Choice Series, Series Ii, And Reliance)

    For additional information, refer to the patient instructions. CAUTION: THE FILTER MUST BE COMPLETELY DRY BEFORE USE. NEVER PLACE A WET FILTER INTO THE REMstar Choice UNIT. 6-50 REMstar Service Manual...

  • Page 121: Replacing The Fuses

    Repair and Replacement 6.15 REPLACING THE FUSES Part #362523 (800 mA) or #362527 (400 mA) Included with the Replacement Kit: • Fuses (2 each) Additional Supplies Required: • Small Slotted Screwdriver (optional) WARNING: Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. STEP 1 Remove the fuse holder by releasing the small tabs on the sides of the holder.

  • Page 122: Replacing The Time Meter/Ramp Adjustment Wiring Harness

    Repair and Replacement 6.16 REPLACING THE TIME METER/ RAMP ADJUSTMENT WIRING HARNESS Part #502130 Included with the Replacement Kit: • Wiring Harness Electrical Shock Hazard: Disconnect the electrical supply before making repairs to the unit. WARNING: CAUTION: Electronic components used in this unit are subject to damage by static electricity. Use proper static discharge and grounding precautions when servicing the equipment.
  • Page 123 Orient the new wiring harness with the yellow wire towards the top of the unit. Connect the wiring harness to the Time Meter/Ramp Adjustment Board. STEP 5 Connect the other end of the wire to the Main Circuit Board according to the diagram on previous page. View from Inside of REMstar Choice Retaining Retaining Clip Clip...

  • Page 124: Replacing The Unit Cap

    Repair and Replacement 6.17 REPLACING THE UNIT CAP Part #502056 (for REMstar Choice) Part #502131 (for REMstar Choice LS) Part #502179 (for REMstar Series II) NOTE: Contact Repironics, Inc. Customer Service for parts when servicing the REMstar Reliance. Included with the Replacement Kit: •...

  • Page 125: Remstar Repair Parts

    Repair and Replacement REMstar Family Repair Parts Description Part Number AC Inlet ..............502057 Blower Assembly ..........362532 Blower Top Assembly ........362533 Cover ..............362536 Cover 502030 ........................Cover 502132 ........................Cover ........................Cover 502180 ........................Filter Cap .............. 362555 Filter, Pollen (Reusable) ........
  • Page 126 Voltage Selector Switch ........332175 Wire Harness, Ramp Adjust ......502134 Wire Harness, Time Meter LCD ......502130 REMstar Choice REMstar Choice LS REMstar Reliance REMstar Series II *Call Respironics, Inc. Customer Service for information on ordering REMstar Reliance parts. 6-56 REMstar Service Manual...
  • Page 127 Repair and Replacement ® REMstar Product Family Preventive Maintenance Schedule (Factory Recommended) Patient Dealer Address Address Phone Phone Model Serial Date Purchased Maintenance Item Service Interval Date Record hours on meter Annually Verify voltage selector Annually switch Check unit pressure Annually Inspect fuses Annually...
  • Page 128 System Test Section 7 System Test System Adjustment ........................... 7-2 Run-In Test ............................7-2 System Final ............................7-2 REMstar Service Manual...
  • Page 129 System Test Chapter 7: System Test After a repair, the unit should be adjusted, run-in, and tested as follows: 7.1 System Adjustment STEP 1 Connect the manometer to the outlet port on the mask, or the O enrichment attachment with a length of tubing.
  • Page 130 System Test Maximum Pressure (20.0 cm H O) Test STEP 8 Set the pressure control to 20.0 cm H STEP 9 Release the orifice. STEP 10 Verify that the pressure is in the range of 19 - 21 cm H STEP 11 Remove the orifice from the unit.
  • Page 131 Appendix A Appendix A REMstar System Schematics Wiring Diagram ..........................A-2 Schematic Statement ......................... A-2 REMstar Service Manual...
  • Page 132 Appendix A A.1 Wiring Diagram Section 1.2 of this manual contains wiring diagrams that show the major subassemblies of the REMstar system. This is the level to which service is performed. A.2 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.
  • Page 133 Appendix A REMstar Service Manual...
  • Page 134 Appendix A REMstar Service Manual...
  • Page 135 Appendix A REMstar Service Manual...
  • Page 136 Appendix B Appendix B REMstar Data Sheet REMstar Data Sheet .......................... 7-2 REMstar Service Manual...
  • Page 137 Appendix B REMstar ® Product Family Preventive Maintenance Schedule (Factory Recommended) Patient Dealer Address Address Phone Phone Model Serial Date Purchased Maintenance Item Date Service Interval Record hours on meter Annually Verify voltage selector Annually switch Check unit pressure Annually Inspect fuses Annually Watts...
  • Page 138 Appendix C: DC Operation Appendix C DC Operation DC Operation ............................. 7-2 Specifications ............................. 7-3 REMstar Service Manual...
  • Page 139 Appendix C: DC Operation C.1 DC Operation REMstar Family of Nasal CPAP systems may be run from a DC power source. A DC Interface Module is required for pressures of 11cm of H O or greater. If the unit will be operating at pressures less than 11cm O then only the DC Cord is required for DC operation.
  • Page 140 Appendix C: DC Operation C.2 Specifications Voltage In: 11.5 - 15 VDC Voltage Out: 115 VAC rms ± 5% When measuring the output voltage, use a true rms-indicating voltmeter to obtain an accurate reading. Continuous Power: 150 watts Output Frequency: 60 Hz ± 1% Efficiency: 90% Battery Use: Recommend a 12 VDC 100 amp-hour, deep - cycle marine type battery.
  • Page 141 ® ® ® 1001 Murry Ridge Drive Murrysville, Pennsylvania 11, Place Royale 15668-8550 USA 44000 Nantes France 366324 clp 5/14/97...

This manual is also suitable for:

Remstar choice lsRemstar choice expressRemstar relianceRemstar remstarRemstar ii series

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