VPAP® III, VPAP III ST, VPAP III ST-A

VPAP® III, VPAP III ST, VPAP III ST-A
VPAP® III, VPAP III ST, VPAP III ST-A
Reorder No. 248106/3 05 04
SERVICE MANUAL
English
www.resmed.com
Waking people up to sleep
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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
ResMed (UK) Ltd 65 Milton Park Abingdon Oxfordshire OX14 4RX UK
Tel: +44 (1235) 862 997 Fax: +44 (1235) 831 336 Email: reception@resmed.co.uk
ResMed Asia Pacific Ltd 97 Waterloo Road North Ryde NSW 2113 Australia
Tel: +61 (2) 9886 5000 or 1 800 991 900 (toll free) Fax: +61 (2) 9889 1471 Email: reception@resmed.com.au
ResMed Finland Niittykatu 6 FIN 02200 Espoo Suomi
Tel: +358 9 8676820 Fax: +358 9 86768222 Email: reception@resmed.fi
ResMed GmbH & Co. KG Rudolfstraße 10 D-41068 Mönchengladbach Deutschland
Tel: +49 (0) 2161-3521-0 (Reception), +49 (0) 180 22 22 668 (Service-Telefon; 0.06 s/Anruf),
+49 (0) 180 22 66 888 (Wartungstelefon; 0.06 s/Anruf) Fax: +49 (0) 2161-3521-1499 Email: reception@resmed.de
ResMed Hong Kong Ltd Room 1714 Miramar Tower 132-134 Nathan Road Tsim Sha Tsui Hong Kong
Tel: +852 2366 0707 Fax: +852 2366 4546 Email: reception@resmed.com.hk
ResMed Japan Nihonbashi Hisamatsu Bldg. 4F 2-28-1 Nihonbashi-Hamacho Chuo-Ku, Tokyo 103-0007 Japan
Tel: +81 (3) 3662 5056 Fax: +81 (3) 3662 5040
ResMed Malaysia Sdn Bhd Suite E-10-20, Plaza Mon’t Kiara No. 2, Jalan 1/70C Mon’t Kiara 50480 Kuala Lumpur Malaysia
Tel: +60 3 6201 7177 Fax: +60 3 6201 2177 Email: reception@resmed.com.my
ResMed NZ Ltd PO Box 51-048 Pakuranga 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 7177 Fax: +65 6284 7787 Email: reception@resmed.com.sg
ResMed Spain SL C/ Arturo Soria, 245 28033 Madrid España
Tel: +34 (93) 590 8154 Fax: +34 (93) 590 8153 Email: angelo@resmed.es
ResMed Sweden AB Industrigatan 2 S-461 37 Trollhättan Sverige
Tel: +46 520 420 110 Fax: +46 520 397 15 Email: reception@resmed.se
Labhardt AG Thannerstrasse 57 CH-4054 Basel Schweiz
Tel: +41 (061) 307 9711 Fax: +41 (061) 307 9722 Email: info@labhardt.ch
ResMed Corp
ResMed (UK) Ltd
Internet: www.resmed.com
US DESIGNATED AGENT:
EU AUTHORISED REPRESENTATIVE:
Protected by patents: AU 697652, AU 699726, AU 713679, EP 0661071, EP 0858352, US 4944310, US 5199424, US 5522382, US
6213119, US 6240921, US 6705315. Other patents pending.
Protected by design registrations: AU 147283, AU 147335, AU 147336, CH 128.709, CH 128.710, CH 128.711, CH 128.712, DE
40201723, DE 40202007, DE 40202008, DE 40202020, ES 153514, ES 153515, ES 153516, ES 153518, ES 156135, ES 156136, FR 02
1407, GB 3001791, GB 3001819, GB 3001820, GB 3001821, JP 1164087, JP 1164265, JP 1164266, JP 1164267, JP 3638613, SE 75598, SE
75599, SE 75600, SE 75715, US D467335, US D468011, US D476077, US D477868, US D487311. Other designs pending
IPAP MAX, IPAP MIN, SmartStart, TiCONTROL, VPAP, Vsync and Vsync logo are trademarks of ResMed Ltd and IPAP MAX,
SmartStart, and VPAP are Registered in U.S. Patent and Trademark Office.
© 2005 ResMed Ltd.
248106/3 05 04
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Contents
1
How to use this manual .............................................................
.............................................................4
4
2
Introduction ................................................................................
................................................................................5
5
Intended users of this manual
Nasal CPAP
5
5
Features of the VPAP III, VPAP III ST
Features of the VPAP III ST-A
5
5
HumidAire 2i™
ResLink
Software changes
VPAP III, VPAP III ST
VPAP III ST-A
3
6
6
6
General inspection and servicing ..............................................7
..............................................7
Instructions for general inspection procedures
Equipment required
For VPAP III ST-A only
Software buttons
Function keys
VPAP III and VPAP III ST keypad and LCD
VPAP III ST-A keypad and LCD
1
Clean the flow generator
2
Record clinical settings
3
External examination
4
Internal examination (if necessary)
5
Replace the air filter
6
Keypad test
7
Pressure calibration test
8
Flow calibration test
9
Blower test
10 Audible alarm test
11 VPAP III ST-A alarm test (VPAP III ST-A only)
12 DC power test (VPAP III ST-A only)
13 HumidAire 2i test
14 Reload clinical settings
15 Complete the Service record results form
16 Fill out product problem report
7
7
7
8
8
8
8
9
9
10
10
11
11
11
12
12
12
12
13
13
15
15
15
4
Static Precautions .....................................................................16
.....................................................................16
5
Replacing major subassemblies ..............................................17
..............................................17
Outer components of the flow generator
Opening the flow generator
Remove the front muffler assembly
Removing the interface assembly
Remove the filter
Remove the top case
Replacing the blower module assembly
Replacing the blower inlet and outlet connectors
Replacing the fuse (for VPAP III and VPAP III ST models only)
Replacing the power supply (VPAP III and VPAP III ST models)
2
5
5
VPAP® III, VPAP III ST, VPAP III ST-A Service Manual
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18
18
19
20
20
21
25
28
29
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
Replacing front muffler components
The HumidAire 2i
Opening the HumidAire 2i
Removing components from the water chamber
The water chamber lid
The water chamber base
6
42
44
46
46
47
47
48
Replacement parts list ............................................................. 51
Outside cases
Air filter components
Interface assembly
Internal components
PCBs
Main wiring harnesses
HumidAire 2i spare parts
7
30
31
34
34
37
40
41
51
51
52
53
53
54
55
Calibration procedures ........................................................... 56
Warnings and cautions
Equipment required
Software calibration buttons
Order of calibration procedures
1
Pressure calibration
2
Flow calibration
3
Motor noise calibration (VPAP III ST-A only)
56
56
56
57
57
58
59
8
Troubleshooting guide ............................................................ 60
9
System specifications ............................................................... 62
VPAP III, VPAP III ST
VPAP III ST-A
62
63
10 Recommended maintenance schedule ................................. 64
Appendix A: Service request form ................................................. 65
Appendix B: Noise reduction upgrade .......................................... 66
Equipment required
Adding foam pads to the blower assembly
Fit cable tie and replace blower outlet connector
66
66
68
Appendix C: Installing the service software .................................. 70
Contents
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3
1
How to use this manual
Each of the sections in this manual has been written with a specific purpose in mind. Use this guide
to help you find the material which is relevant to your task at the moment.
2 Introduction – Gives a brief overview of the VPAP III family of flow generators.
3 General inspection and servicing – Gives a procedure to help you examine a flow
generator which has been brought into a service centre. The general inspection procedures
should be performed before any other work is done on the flow generator.
4 Static precautions – Lists procedures to be followed whenever PCBs are removed from the
flow generator unit. These procedures minimize the chance of ICs being damaged by static
electricity.
5 Replacing major subassemblies – Highlights points to note when replacing subassemblies,
reassembling the flow generator and indications of when recalibration is necessary.
6 Replacement parts – Shows labelled pictures and part numbers of all the spare parts and
subassemblies available from ResMed.
7 Calibration procedures – Lists procedures to follow after a fault has been 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 maintenance schedule – Provides a brief description of the maintenance
which the owner of the flow generator should carry out. If the owner is performing regular
cleaning and maintenance, there is no need for regular servicing by a service technician.
Some countries require all medical equipment to have a periodic service to confirm that the
equipment is in good working order. Section 3 General inspection and servicing
may be used in this situation.
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.
Appendix C: Installing the service software - Lists procedures for installing the service
software.
Note:
4
Schematics of all PCBs in this flow generator are available to authorised service
centres. To order, please contact your local ResMed office.
VPAP® III, VPAP III ST, VPAP III ST-A Service Manual
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2
Introduction
This manual is a guide to servicing and repairing the VPAP III, VPAP III ST and VPAP III ST-A flow
generator and humidifier. It is written for ResMed distributors, and gives instructions for replacing
subassemblies and for recalibration as appropriate. Work at the component level will normally be
carried out by ResMed.
Intended users of this manual
Before attempting any repair work, please ensure that you:
• are familiar with the operating manual and the clinical manual for the flow generator
• 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. To order, please contact your local ResMed office.
Nasal CPAP
Nasal Positive Airway Pressure systems are used to treat obstructive sleep apnea, a disorder that
causes a physical obstruction in a person’s airway while sleeping. The principle of treatment is that
filtered air is delivered by a flow generator through flexible tubing to a nasal mask worn by the
patient while sleeping. The flow 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 H2O depending on the unit’s configuration.
The data storage and processing capabilities of the VPAP system facilitate patient management.
The system provides summary data for a variety of time intervals, which can be viewed via the
LCD menus. The patient’s usage hours, mask leak, tidal volume, respiratory rate, minute
ventilation, apnoea + hypopnoea index (AHI), and apnoea index (AI) are displayed in the Results
section of the Clinical menu.
Features of the VPAP III ST-A
The VPAP III ST-A provides bi-level therapy. It combines the features of the VPAP III series along
with adjustable trigger and cycle thresholds, and a range of clinician and patient alarms.The device
delivers a treatment pressure with a maximum range of 2 to 30 cm H2O depending on the unit’s
configuration.
HumidAire 2i™
The HumidAire 2i is designed to integrate with the VPAP III system to form a single heated
humidification and VPAP unit.
ResLink
The ResLink clinical therapy management module is designed to integrate with the VPAP III
system. It provides greater insights into therapy and visible, objective evidence that the device is
delivering effective ventilation during sleep.
2 Introduction
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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
• Maintenance update
• Update to shipper states
• First VPAP III ST release
SX365-0200
• Number of used hours displayed extended to 8760
VPAP III ST-A
6
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
SX384-0200 (Teijin only)
• Original issue
SX384-0202 (USA only)
• Original issue
VPAP® III, VPAP III ST, VPAP III ST-A Service Manual
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General inspection and servicing
Instructions for general inspection procedures
Carry out the procedures on the following pages to confirm that the flow generator is in good
electrical and mechanical condition. These tests will highlight any major mechanical or electrical
problem with the unit.
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®, 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 H2O range)
• A computer running Windows NT 4.0, 2000 or XP.
Note:
There is only partial support for the VPAP III ST-A on a computer running Windows
NT 4.0. Some command settings will not be available.
• HumidAire 2i docking station
For VPAP III ST-A only
• DC-24/30 converter (ResMed part# 22015)
• DC power supply (12V battery or bench top power supply capable of supplying 3 amps or
more)
3 General inspection and servicing
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Software buttons
Flow generator settings dialog
Perform the audible alarm test
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
Right key
Left key
Keypad
Up/down key
Front key
VPAP III ST-A keypad and LCD
LCD screen
Quickview
LEDs
Right key
Left key
Alarm mute
Start/Stop
Up/down key
8
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1
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.
Caution
!
When using a cleaning agent with a high alcohol content refer to the appropriate Material
Safety Data Sheet to ensure safe handling of the cleaning agent.
Remove any stains from the cases. When removing any stains from the flow generator or mask
system use soap or detergent-based cleaning solutions. Remove excess and wipe dry after use. Do
not use thinners, trichlorethylene, bleach or other solvents. Do not apply oil to any component
of the flow generator.
2
Record clinical settings
1 Open AutoSet Spirit Service Software 2.1.
Main window in service software
2 Select Settings>Flow generator settings from the main window, or press the Open flow
generator settings dialog button at the top of the main window.
3 The following screen will appear with the flow generator settings:
4 Select File>Save screen settings to file, or select the floppy disk icon and save the settings
under the unit’s serial number.
Warning
!
If the clinical settings can not be recorded, press the Default button and save the file with
the default settings for the faulty unit. Notify the patient that the unit has been reset to
default settings.
3 General inspection and servicing
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3
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
• damage to the front panel decal or bottom decal
If either of the outside cases are fractured and require replacement, take particular care in
inspecting all other components within the cases for damage.
2 Press the Service record results button.
3 Open the file saved earlier, containing the unit’s clinical settings.
4 Check the appropriate box for the external examination.
4
Caution
!
Internal examination (if necessary)
The VPAP III uses an isolated power supply, however, it is recommended that isolation
transformers are also used for added safety while working with the cases opened up and
power switched on.
Remove the front cover, interface assembly and the top case of the flow generator by following the
instructions given in Section 5 Replacing major subassemblies. Inspect the flow generator
for the following, recording 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 no loose pieces of wire or other objects trapped in the PCB
Use an antistatic cloth or brush to remove dust or dirt from components and from the insides of
the flow generator case.
Repair or replace any missing or damaged external components. Rectify any problems either
identified by the user or noted during servicing. Should any major components such as the blower
assembly or the Main PCB require replacement, the recalibration procedure as given in Section 7
Calibration procedures must be performed before the unit is returned to the patient.
Reassemble the flow generator.
Record the results by checking the appropriate box in the Record of Service window.
Caution
!
10
Printed circuit boards can be damaged by static electricity. Please read the instructions in
Section 4 Static Precautions before attempting to replace any PCBs.
Thread cutting screws are used to fasten the cases of the flow generator. 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.
VPAP® III, VPAP III ST, VPAP III ST-A Service Manual
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5
Replace the air filter
1 Remove the filter cartridge from the flow generator.
2 Replace the air filter, with the blue side of the filter material facing out from the unit.
3 Check the appropriate box in the Record of Service window.
Caution
!
6
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.
Keypad test
1 Switch off the flow generator, then switch it back on. Wait for the Welcome message to
appear and check that the LCD back light and LEDs beneath the keypad are illuminated.
Note:
The LCD backlight and LEDs may not be clearly visible in bright light.
2 Press the Left key to enter the patient menu. Use the up/down button to cycle through the
menu and the Left and Right keys to set and change options. Confirm that all button presses
produce the appropriate 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 subassemblies. Once the keypad has been replaced, repeat the
keypad test procedure.
7
Caution
!
Pressure calibration test
Make sure the flow generator has been warmed up for at least 15 minutes before
proceeding with the remaining tests
1 Close the Record of Service window.
2 Press the Record button and select the file which contains the flow generator settings.
3 Select Performance Tests>Pressure calibration test from the main window, or press the
Perform the pressure calibration test button.
4 Set up the test equipment as instructed by the software.
5 Select Next and follow the steps as instructed.
If the flow generator fails this test, follow the procedures outlined in Section 7 Calibration
procedures to do a full recalibration of the flow generator.
3 General inspection and servicing
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8
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.
If the flow generator fails this test, follow the procedures outlined in Section 7 Calibration
procedures to do a full recalibration of the flow generator.
9
Blower test
The blower test is used to test the performance of the motor and to determine whether there are
any impediments in the air path.
1 Select Performance Tests>Blower test, or press the Perform the blower 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.
If the flow generator fails 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 Audible alarm test
1 Select Performance Tests>Audible alarm test, or press the Perform the audible
alarm test button at the top of the main window.
2 The following window will appear:
3 Follow the instructions on screen. Once complete press the Pass or Fail button to close the
window.
If the flow generator fails this test, the buzzer on the Main PCB will need to be replaced. After
replacing the buzzer, repeat the Pressure calibration test, Flow calibration test and Audible alarm
test from the general inspection procedures.
11 VPAP III ST-A alarm test (VPAP III ST-A only)
1 Hold down the alarm mute key for 3 seconds.
2 Once the key is released the alarm should sound and the LED should flash for 10 seconds.
12
VPAP® III, VPAP III ST, VPAP III ST-A Service Manual
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12 DC power test (VPAP III ST-A only)
1 Turn off the flow generator at the mains.
2 Take the DC-24/30 converter and adjust the voltage to 24V.
3 Place the converter on a level surface with the ResMed logo facing upwards.
4 Plug the flat connector end of the DC-24/30 converter into the DC input socket.
5 Connect the DC-24/30 converter to a DC power source (12V battery or bench top power
supply capable of supplying 3 amps or more)
6 Turn on the unit at the DC connector and confirm that the unit powers up.
7 Turn off the unit and reconnect it to mains power.
13 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 Remove the VPAP III front cover by referring to the instructions given in Section 5 Replacing
major subassemblies
3 Plug the HumidAire 2i docking station without the water chamber into the front of the flow
generator as shown in the picture below.
Note:
The docking station may not attach correctly to the flow generator if docking is
attempted with the water chamber installed.
4 Switch the flow generator on and observe the LCD screen. After a welcome message is
displayed, the LCD screen should display the warm-up feature prompt.
3 General inspection and servicing
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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.
Light indicating
humidifier warming
7 For VPAP III and VPAP III ST units press the right button 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 and remove the power cord. Remove the top cover
and blower assembly by referring to the instructions given in Section 5 Replacing major
subassemblies. Check that all cables inside the flow generator are connected correctly.
14
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14 Reload clinical settings
1 Select Settings>Flow generator settings from the main window.
2 Select File>Read settings from file, or select the folder icon.
3 Navigate to where the settings file was saved and open the file.
4 Once the settings are displayed on the screen, click the Set button to upload them to the flow
generator.
5 Close the Flow generator settings window.
15 Complete the Service record results form
1 Press the Service record results form button and open the file with the unit’s settings.
2 Press 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 Fill out product problem report
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.
3 Save the file. If a hard copy of the form is needed, press the Print button at the top of the
window.
4 Close the Record of Service window.
3 General inspection and servicing
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4
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 resistor to an electrical ground.
2 The area under and also in front of the work bench must be coated with a suitable conductive
floor paint, or alternatively covered with a conductive floor mat. The conductive paint coating
or floor mat must be connected to an electrical ground.
3 Soldering irons or solder baths must be at the same reference (ground) potential as the work
bench.
4 A wrist strap must be worn by service personnel working at the bench. The wrist strap must
have a conductive lead (1 MΩ) 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 which they are mounted, before touching the ICs. Service personnel should take
every precaution that the items will see the same reference potential when moved.
6 All ICs and PCB assemblies containing ICs should be stored in antistatic bags until use.
7 Service personnel should wear clothing which minimizes the build up of static charges. Cotton
is preferable to wool or synthetic fibres.
8 Service personnel should avoid electrostatic build up through the movement of air over plastic
material.
9 Plastic materials should wherever possible be kept away from the ICs as they develop and
maintain high levels of static charge.
10 Low humidity increases potential static problems. Maintaining humidity levels above 60% is one
of the most effective ways to guard against static handling problems.
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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.
Outer components of the flow generator
Handle
Top case
Interface panel
Filter
Front muffler
assembly
Bottom case
Water chamber
Docking station
VPAP III with HumidAire 2i attached
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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.
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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.
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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.
Screws
Screws
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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.
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.
Sensor tube and elbow
2 With both hands, ease the blower module up and out of the lower case.
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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.
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:
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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.
1
VPAP III and VPAP III ST models
2
1 2
3 4
1
2
VPAP III ST-A model with
Ferroxcube Toroid
Ferroxcube Toroid
1 2
3 4
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
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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.
Blower outlet connector
slides onto post
Blower inlet connector
slides onto inlet seal post
Note:
Ensure the three vibration mounts are sitting firmly between the blower module and
the lower case.
Location of the vibration
mounts
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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
pressure
port fitting
Tube 1
170 ± 5 mm
Tube 2
225 ± 5 mm
"L" shaped
connector
Tube 3
120 ± 5 mm
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.
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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.
5 Fit the new blower outlet connector, ensuring it is seated properly on the volute, as shown
below:
Lip of blower outlet
connector seated on volute
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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
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:
Grommet in slot in
blower casing
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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. It is located under the
folded PCB insulator.
2 Pull out the wires to remove the fuse casing from behind the insulator.
PCB insulator which
covers the fuse casing
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 fuse.
5 Reconnect the fuse casing
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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.
AC input cable
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:
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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.
AC cable
from switch
Humidifier
mains cable
PSU cable
harness
DC cable
from switch
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:
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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.
2 Disconnect the power supply and the humidifier interface cable.
Screw holding Main PCB
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.
Location of lock tabs
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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.
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.
Serial connector seal
10 Install flexible cable in the locking device, then carefully close both sides of the locking device at
the same time.
11 Fold the flexible cable as shown below:
Fold cable
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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.
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 anticlockwise 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 module
assembly” on page 21.
17 Once the Main PCB has been replaced, reinstall the flow generator’s settings by following the
instructions "Reload clinical settings" on page 15.
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