ResMed VPAP III ST-A Service Manual Download

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VPAP® III, VPAP III ST, VPAP III ST-A

SERVICE MANUAL

English

Reorder No. 248106/3 05 04

www.resmed.com

Waking people up to sleep

Summary of Contents for VPAP III ST-A

Page 1: ...VPAP III VPAP III ST VPAP III ST A SERVICE MANUAL English Reorder No 248106 3 05 04 www resmed com Waking people up to sleep ...

Page 2: ... Auckland New Zealand Tel 0800 737 633 NZ toll free or 64 25 737 633 Fax 0800 737 634 NZ toll free or 64 9 239 0193 Email reception resmed co nz ResMed SA Parc de la Bandonnière 2 rue Maurice Audibert 69800 Saint Priest France Tel 33 0 4 37 251 251 Fax 33 0 4 37 251 260 Email reception resmed fr ResMed Singapore Pte Ltd 238A Thomson Road 12 03 04 Novena Square Tower A Singapore 307684 Tel 65 6284 ...

Page 3: ...nation 10 4 Internal examination if necessary 10 5 Replace the air filter 11 6 Keypad test 11 7 Pressure calibration test 11 8 Flow calibration test 12 9 Blower test 12 10 Audible alarm test 12 11 VPAP III ST A alarm test VPAP III ST A only 12 12 DC power test VPAP III ST A only 13 13 HumidAire 2i test 13 14 Reload clinical settings 15 15 Complete the Service record results form 15 16 Fill out pro...

Page 4: ...t required 56 Software calibration buttons 56 Order of calibration procedures 57 1 Pressure calibration 57 2 Flow calibration 58 3 Motor noise calibration VPAP III ST A only 59 8 8 8 8 Troubleshooting guide Troubleshooting guide Troubleshooting guide Troubleshooting guide 60 60 60 60 9 9 9 9 System specifications System specifications System specifications System specifications 62 62 62 62 VPAP II...

Page 5: ...een isolated to a PCB or blower and the part has been replaced Follow these procedures to calibrate the unit and to restore the owner s individual settings 8 Troubleshooting guide Gives you a way to quickly locate the problem and fix it if you know the symptoms of a faulty machine 9 System specifications Lists electrical and mechanical specifications of flow generator and air tubing 10 Recommended...

Page 6: ... generator maintains a positive pressure in the patient s airway which acts as a pneumatic splint preventing the airway from collapsing during sleep Features of the VPAP III VPAP III ST The VPAP III system provides continuous positive airway pressure CPAP and bi level therapy to patients with obstructive sleep apnea OSA The device delivers a treatment pressure with a maximum range of 2 to 25 cm H2...

Page 7: ... version Significant features SX365 0108 Original issue SX365 0109 Maintenance update Update to shipper states First VPAP III ST release SX365 0200 Number of used hours displayed extended to 8760 Software version Significant features SX384 0106 Original issue SX384 0107 Maintenance upgrade with language fixes SX384 0108 Maintenance upgrade SX384 0203 Number of used hours displayed extended to 8760...

Page 8: ...osed Bubble Cushion standard mask frame and security key Note Instructions for installing the Spirit 2 1 Service Software can be found in Appendix C Installing the service software Calibrated flow meter with flow regulation valve Note The flow meter must be capable of measuring air flows ranging from 0 to 150 L min with an accuracy of 3 or better over this range 2 metre air hose Manometer 0 30 cm ...

Page 9: ...ration test Perform the flow calibration test Service record results form Perform the blower test Perform the audible alarm test Record Front key LCD Screen Right key Keypad Left key Up down key LCD screen LEDs Right key Alarm mute Up down key Start Stop Left key Quickview VPAP III and VPAP III ST keypad and LCD VPAP III ST A keypad and LCD ...

Page 10: ... use thinners trichlorethylene bleach or other solvents Do not apply oil to any component of the flow generator 2 2 2 2 Record clinical settings Record clinical settings Record clinical settings Record clinical settings 1 Open AutoSet Spirit Service Software 2 1 2 Select Settings Flow generator settings from the main window or press the Open flow generator settings dialog button at the top of the ...

Page 11: ...g any irregularities The blower assembly is seated correctly The Power Supply PCB is seated correctly Inspect the unit for the following recording any irregularities all mechanical components are seated correctly all electrical components are mounted correctly and secured in position there are no loose terminals loose wires or incomplete insulation on electrical components or connections there are...

Page 12: ...response 3 Press the start button and confirm that the flow generator starts Press the button again and confirm that the flow generator stops 4 Record the results by checking the appropriate box in the Record of Service window 5 Press the Floppy disk button to save the results If the flow generator fails this test replace the keypad by following the procedures given in Section 5 Replacing major su...

Page 13: ...ls this test check the flow generator airpath is clear and ensure the test set up is correct If the unit continues to fail replace the blower then follow the procedures outlined in Section 7 Calibration procedures to do a full recalibration of the flow generator 10 10 10 10 Audible alarm test Audible alarm test Audible alarm test Audible alarm test 1 Select Performance Tests Audible alarm test or ...

Page 14: ... test HumidAire 2i test 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 Warning The HumidAire 2i heating plate may reach temperatures in excess of 60 C 1 Switch off the flow generator 2 Remo...

Page 15: ...n again to stop the warm up feature 8 Switch off the flow generator and remove the HumidAire 2i docking station Warning The HumidAire 2i heating plate will be extremely hot in excess of 60 c 9 Refit the front cover 10 Switch on the flow generator and observe the LCD screen Confirm that the warm up feature prompt is not displayed in the LCD screen If the flow generator fails this test switch off an...

Page 16: ...ss the Service details tab Check the Reload clinical settings box at the base of the window Check the Clean flow generator box to indicate if the unit was cleaned according to the procedures outlined in step 1 Clean the flow generator Check the appropriate HumidAire 2i test box Check the appropriate DC power test box Check the appropriate VPAP III ST A alarm test box 16 16 16 16 Fill out product p...

Page 17: ...connected to the bench surface Alternatively a heel grounding strap to ground the operator to the floor may be used Such a wrist or heel strap should not create an electrical hazard for the wearer 5 Handling of ICs should be kept to a minimum If handling is required avoid directly touching the leads The recommended procedure is to first touch the container in which the ICs are stored or the PCB in...

Page 18: ...lies 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 Outer components of the flow generator Handle Top case Filter Bottom case Interface panel Front muffler assembly VPAP III with HumidAire 2i attached Docking station Water chamber ...

Page 19: ...VPAP III ST A Service Manual 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 ...

Page 20: ...ly 3 Using a screwdriver release the two front lock tabs while pulling the interface assembly upwards 4 Lift up the module carefully so as not to place any strain on the flexible cable or PCB underneath Front lock tabs Use a screw driver to push against locking tabs ...

Page 21: ...able 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 Locking tabs Screws Screws ...

Page 22: ...ubes are not kinked or compressed If replacing the blower to reduce noise from the unit complete the procedures in Appendix B Noise reduction upgrade The application of foam rather than replacing the blower may help to reduce noise 1 Disconnect the sensor tube and elbow from the blower outlet connector on the blower 2 With both hands ease the blower module up and out of the lower case VPAP III wit...

Page 23: ...ff 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 7 The sensor tube that was connected to the blower outlet connector is connected to the third sensor port on the Main PCB Ensure that the elbow is facing towards the side of the case as shown below ...

Page 24: ...hich should run over the top of sensor tube 1 10 Take the second silicone tube running from sensor port 2 and connect it to the second port free in the blower base It should also run underneath the motor cable and behind the vibration mount with sensor tube 1 Note The fourth port is left open to measure atmospheric pressure 2 1 1 2 3 4 VPAP III and VPAP III ST models VPAP III ST A model with Ferro...

Page 25: ...e 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 Note Ensure the three vibration mounts are sitting firmly between the blower module and the lower case Blower inlet connector slides onto inlet seal post Blower outlet connector slides onto post Location of the vibration mounts ...

Page 26: ...nderneath the blower Note If replacing the sensor tubes ensure they are cut to the following lengths Replacing the blower inlet and outlet connectors 1 Grasp both halves of the blower module near the blower outlet connector in order to pull it apart Tube 1 170 5 mm Tube 2 225 5 mm Tube 3 120 5 mm Slimline pressure port fitting L shaped connector ...

Page 27: ... bottom half of the blower casing 4 The blower inlet connector and blower outlet connector can then be removed from the volute 5 Fit the new blower outlet connector ensuring it is seated properly on the volute as shown below Blower inlet connector Blower outlet connector Volute Lip of blower outlet connector seated on volute ...

Page 28: ...casing check that the motor cable is located under the tab as shown below 8 Place the volute in the blower casing Ensure the blower inlet and outlet connectors are seated as shown below 9 Place the motor cable grommet in the slot as shown below Blower inlet connector flush to wall of volute Motor cable located under tab Grommet in slot in blower casing ...

Page 29: ...ower 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 It is located under the folded PCB insulator 2 Pull out the wires to remove the fuse casing from behind the insulator 3 Push the casing together and twist in an anti clockwise direction The fuse casing will separate giving access to the fuse 4 Replace the blown...

Page 30: ...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 3 Install the new power supply reconnecting both cables and ensuring that the power supply is correctly located in the mounting slots Make sure the wires are located as shown below DC output cable AC input cable ...

Page 31: ...its mounting slots 2 Disconnect the AC cable DC cable PSU cable harness and the humidifier mains cable 3 Install the new power supply reconnecting all cables and ensuring that the power supply is correctly located in the mounting slots Make sure the wires are located as shown below DC cable from switch AC cable from switch Humidifier mains cable PSU cable harness ...

Page 32: ...e PCB by gently twisting and pulling upwards on the tubes to ensure that the pressure ports are not damaged 2 Disconnect the power supply and the humidifier interface cable 3 Undo the screw securing the PCB to the bottom of the case 4 Place a small screw driver under one of the front lock tabs and lift carefully while releasing the lock tab Screw holding Main PCB Humidifier interface cable Locatio...

Page 33: ...r seal Connector seal R300 7109 can be installed in those units that do not currently have a seal 8 Very carefully release the locking device on each side of the flexible cable using a small screw driver and pull out the cable 9 Take the new Main PCB and fit the serial connector seal 10 Install flexible cable in the locking device then carefully close both sides of the locking device at the same t...

Page 34: ... place 14 Fit the screw to hold the PCB in place Caution This is a thread cutting screw When replacing a thread cutting screw turn the screw anti clockwise until it fits into the previously cut thread otherwise the original thread may be stripped out 15 Loop the humidifier cable as shown below and reconnect it 16 Refit the blower assembly following the instructions outlined in Replacing the blower...

Page 35: ...ettings dialog button at the top of the main window 2 The following screen will appear 3 Enter the unit s product code and serial number which is located on the base of the unit 4 Press the Default button to enter the default settings 5 Press the Set button to load the settings into the flow generator Note Ensure the time and date settings are correct for your region Select Settings Set tme and da...

Page 36: ...nit 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 For all other units press on the four clips indicated to remove the switch from the bottom case 4 Remove the cable harness from the bottom case 5 Feed the new cable harness through the rear aperture Location of locks 1 2 3 4 4 1 2 3 VPAP III III ST VPA...

Page 37: ...licks into place 8 Locate the wires in the route shown below 9 Refit the PCB insulator 10 Replace the Main PCB and blower Switch VPAP III III ST Switch VPAP III ST A Wires must not overlap or cross over ribs Route cable under clip Route cable behind second clip Caution Blue wire must be on top Slot brown wire between posts on either side of fuse casing VPAP III VPAP III ST VPAP III ST A Slot both ...

Page 38: ...lder version cable harnesses remove the cable ties indicated below 2 Disconnect the cable harness wires from the switch 3 Take the new switch and connect the long wires from the cable harness Connect the brown wires to terminal 2 and the blue wires to terminal 1 as shown over page Remove cable ties Terminal 2 Terminal 1 Terminal 2a Terminal N Neutral Terminal1a Terminal L Active Switch front Switc...

Page 39: ...rvice Manual 4 Feed the short blue wire in the gap between the brown and blue wires running to the AC connector as shown below 5 Connect the short blue wire to terminals 1a and N Short blue wire Short blue wire connected to terminal 1a and N ...

Page 40: ... around the receptacles on terminals 1 1a 2 and 2a The cable tie must be approximately half way down the recepticals 8 The position of the cable tie knot must be located as shown below 9 Reinstall the main wiring harness with switch into the bottom case Short brown wire connected to terminals 2a and N Position of cable tie knot ...

Page 41: ...es VPAP III VPAP III ST 1 Take the replacement fuse label R300 305 and stick it inside the bottom case as shown below 2 Place the mains voltage label R300 303 on the outside of the bottom case below the gaps for the humidifier connector VPAP III ST A 1 Place the mains voltage sticker R300 303 on the outside of the bottom case below the gaps for the humidifier connector Replacement fuse label Mains...

Page 42: ...w Note The AC switch label is not required for Teijin VPAP III ST A units Replacing interface assembly components 1 Turn the interface assembly upside down and release the clips holding in the LCD module Take care not to touch the gold contacts on the back of the LCD module AC switch label Clips Clips Do not touch the gold contacts VPAP III LCD pictured ...

Page 43: ...protective backing from the LCD module window taking care not to touch the gold contacts Closing the flow generator 1 Take the flexible connector and carefully feed it through the top case 2 Turn the unit upside down and fix the top case to the bottom case with the Phillips head screws Screw in the rear screws first Caution Thread cutting screws are used in the flow generator When replacing a thre...

Page 44: ... 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 6 Carefully close both sides of the locking device at the same time 7 Fold the cable as shown below according to the make of flow generator VPAP III VPAP III ST VPAP III ST A ...

Page 45: ...y 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 9 Refit the front muffler assembly ensuring the snap lock on the base engages Replacing front muffler components 1 Take the front muffler and remove the four screws which hold the chassis to the front cowl 2 Remove the chassis from the front c...

Page 46: ...late onto the chassis and place the chassis in the front cowl 5 Connect the chassis to the front cowl with the four screws Caution Thread cuttings screws are used in the front muffler seal When replacing a thread cutting screw turn the screw anti clockwise until it fits into the previously cut thread otherwise the original thread may be stripped out Locking plate Front muffler seal ...

Page 47: ...re 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 3 Pull the humidifier away from the unit ...

Page 48: ...from the water chamber 1 Lift the catches on the side of the water chamber 2 Separate the water chamber lid and base The water chamber lid 1 Inside the chamber lid is the seal To remove the seal peel it away from the lid Water chamber lid Water chamber base ...

Page 49: ... the water chamber base 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 Caution Ensure the replacement O ring is not punctured or nicked Cross member ...

Page 50: ...he chamber 6 Turn the water chamber base right side up and place the cross member on its supports inside the chamber 7 Take the seal removed from the water chamber lid and fit it firmly onto the rim of the water chamber base 8 Fit the water chamber lid on top of the water chamber base and ensure the assembly is sealed 9 Lock the clips on the side of the water chamber ...

Page 51: ...own 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 4 Push the tab at the top of the latch into the slot at the top of the heater plate Ensure the tab latch clicks securely into both slots ...

Page 52: ...pad and base decal kit VPAP III ST A 19307 Bottom case Teijin R241 731 Front muffler assembly 19282 Note For instructions on inserting the serial number when replacing the bottom decal refer to Tech note 106318 Also available Handle R300 794 Female D9 connector cover Z9201 D9 Male D9 connector cover Z9202 D9 These parts are available as accessories Filter cover 30909 Filter 1 pk 30919 Filter 2 pk ...

Page 53: ...P 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 VPAP III VPAP III ST VPAP III ST A Interface panel R241 726 A Interface panel Germany R241 726 B Interface panel Teijin R241 726 C Keypad R241 724 LCD module 19301 LCD module Teijin 19302 ...

Page 54: ...7033 Clipped upper airpath R300 7032 Motor mounting R241 705 Motor retaining flange R241 706 Blower VPAP III III ST 19272 Blower VPAP III ST A 19303 VPAP III ST A pictured Main PCB VPAP III 19273 Main PCB VPAP III ST 19274 Flexible cable 19208 Buzzer E9026 Main PCB VPAP III ST A 19304 Main PCB VPAP III ST A US 19305 PCB insulator R300 7107 Serial connector seal R300 7109 ...

Page 55: ... VPAP III III ST III ST A Cable harness 24V DC output R300 744 Power supply assembly VPAP III ST A 19306 Main wiring harness VPAP III III ST includes IEC switch R241 729 IEC socket switch VPAP III III ST R300 7111 Main wiring harness VPAP III ST A includes switch R241 735 Available as an accessory VPAP III ST A Power cord clip 2pk 26914 ...

Page 56: ...ct your local ResMed office for prices Tub assemblies and docking station Tub assembly UDEL 30941 Tub assembly PC 30951 Docking station 30949 HumidAire 2iC tub assembly PC 30956 Americas only Other accessories Water chamber heating plate 30914 Water chamber O ring 30915 Latch UDEL 30917 Latch PC 30939 Side catches PC 30955 Tub main seal 30958 Lid side catches PC 30959 Lid side catches UDEL 30960 B...

Page 57: ... abnormal resonance noise or vibration of the unit must be investigated before the unit is returned to the owner 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 Note Instructions for installing the Spirit 2 1 Service Software ca...

Page 58: ...ator settings window in the service software The unit can also be reset to factory default settings via the clinical menu Once the default settings have been reloaded notify the patient Warm up the flow generator for at least 15 minutes before commencing the calibration procedures When performing any calibration ensure the humidifier setting in the Settings menu is set to none 1 1 1 1 Pressure cal...

Page 59: ... 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 2 Follow the prompts on the screen Once the calibration is complete the following screen will be displayed ...

Page 60: ...on Motor noise calibration or press the Motor noise calibration button at the top of the main window 2 Follow the prompts on screen Once the calibration is complete the following screen will appear Once the calibrations are complete repeat tests 6 12 from Section 3 General inspection and servicing If the unit fails calibration ensure the test set ups are correct If the unit continues to fail send ...

Page 61: ...or Welcome displayed but self test fails Software failure Reset by turning power off wait 10 seconds and turn on again Replace Main PCB if problem persists SmartStart can t be enabled Full face mask is selected or Mask Alarm is enabled Check settings and change as required SmartStart can t be enabled or disabled Faulty Main PCB Replace Main PCB Poor or insufficient air flow Air tubing not connecte...

Page 62: ...IPAP will return to its previous value VPAP III ST A only Message SENSOR ERROR displayed Device motor speed pressure and flow sensors out of range Replace Main PCB Replace blower assembly VPAP III ST A only Message HIGH LEAK displayed High mask leak greater than 40 L min for more than 20 seconds Check and refit tubing as required Check mask fit VPAP III ST A only Message LOW PRES ALARM displayed A...

Page 63: ... 60 Hz 40VA typical power consumption 100VA maximum power consumption Housing construction Flame retardant engineering thermoplastic Environmental conditions Operating temperature 5 C 41 F to 40 C 104 F Operating humidity 10 95 non condensing Storage and transport temperature 20 C 4 F to 60 C 140 F Storage and transport humidity 10 95 non condensing Electromagnetic compatibility Product complies w...

Page 64: ... Operating temperature 5 C 41 F to 40 C 104 F Operating humidity 10 95 non condensing Storage and transport temperature 20 C 4 F to 60 C 140 F Storage and transport humidity 10 95 non condensing Electromagnetic compatibility Product complies with all applicable electromagnetic compatibility requirements EMC according to IEC60601 1 2 for residential commercial and light industry environments Air fi...

Page 65: ...he 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 The HumidAire 2i should be regularly cleaned according to the recommendations in the section Cleaning and maintenance of the User Manual Some countries require all medical equipment to have a periodic service to confirm that the equip...

Page 66: ...nty Humidifier SmartStart Yes Yes Yes No No No Problem description Effect on user Date problem occurred Date of purchase Or If the purchase date is unknown please indicate below the time the product was used before the problem occurred 3 months 3 6 months 1 2 years 6 12 months 5 years 2 5 years When did the fault occur During use Not being used Unknown Start up Is this device being returned to Res...

Page 67: ...733 top foam pads to the lower airpath 4 Fit a cable tie to the main power switch and replace the blower outlet connector Equipment required 6 x blower top foam pad part R300 7017 3 x top foam pad part R300 733 Blower outlet connector part R300 7018 1 x 100 mm cable tie Adding foam pads to the blower assembly 1 Remove the blower assembly from the flow generator following the procedures outlined in...

Page 68: ...h 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 1 2 2 1 ...

Page 69: ...he 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 1 2 3 ...

Page 70: ...g wires from the switch should be no more than 40 mm from the inside of the flow generator case 4 Replace the blower outlet connector following the instructions outlined in Section 5 Replacing major subassemblies 5 Reassemble test and calibrate the flow generator 40 mm ...

Page 71: ...00 or XP The minimum requirement is a Pentium II with 64 MB RAM The install file will open automatically after the CD is inserted If the install file does not open follow the instructions below Installing the software 1 Insert the CD into the CD drive 2 In the Start menu select Run 3 Browse to locate the CD drive and click on the Setup exe file 4 Press the OK button in the Run dialog box 5 Follow ...

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