Remstar Pro 2 and Auto

REMstar®|Auto with C-Flex™
&
REMstar®|Pro 2
www.respironics.com
Service Manual
This REMstar Auto with C-Flex and REMstar Pro 2 CPAP devices are the subjects of U.S. patents #5239995 and #6105575. Other patents pending.
REMstar, Encore, Encore Pro SmartCard, and Whisper Swivel are registered trademarks of Respironics, Inc. The C-Flex mark is used under license.
REMstar Auto with C-Flex and REMstar Pro 2 Service Manual

Limited Warranty
Respironics warrants that the REMstar Auto with C-Flex and REMstar Pro 2 CPAP devices shall be free from defects of workmanship and materials and will
perform in accordance with the product specifications for a period of two years from the date of sale by Respironics. If the product fails to perform in
accordance with the product specifications, Respironics will repair or replace - at its option - the defective material or part. Respironics will pay customary
freight charges from Respironics to the dealer location only. Respironics warrants that REMstar Auto with C-Flex and REMstar Pro 2 CPAP devices
serviced by Respironics will be free from defects in materials for a period of one year and free from defects in workmanship for a period of 90 days from the
time of service. This warranty does not cover damage caused by accident, misuse, abuse, alteration, and other defects not related to materials or workman-
ship.
Respironics disclaims all liability for economic loss, loss of profits, overhead, or consequential damages which may be claimed to arise from any sale or use
of this product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not
apply to you.
This warranty is given in lieu of all other express warranties. In addition, any implied warranty, including any warranty of merchantability or fitness for the
particular purpose, is limited to two years. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not
apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
The warranty for repairs is ninety days for labor and one year on the part(s) that was replaced.
To exercise your rights under this warranty, contact your local authorized Respironics Inc. 1001 Murry Ridge Lane, Murrysville, Pennsylvania 15668,
1-800-345-6443 (USA and Canada only) or 1-724-387-4000.
REMstar Auto with C-Flex and REMstar Pro 2 Service Manual

Table of Contents
Table of Contents
Chapter 1: Introduction ...................................................... 1-1 Chapter 4: System Setup Procedures ................................. 4-1
1.1 System Overview... .................................... .....................1-2 4.1 Overview ........................................................................ 4-2
1.2 Service Notice ................................................................. 1-2 4.2 Programming a SmartCard .............................................. 4-2
1.3 Technical Support Statement ............................................ 1-2 4.3 System Setup .................................................................. 4-3
1.4 Training ............................................................................ 1-2 4.3.1 Therapy Mode Menu Navigation .......................... 4-4
4.3.2 Therapy Mode Display Screens ............................ 4-5
Chapter 2: Warnings, Cautions and Notes ........................ 2-1 4.4 Heated Humidifier Setup ................................................. 4-7
2.1 Warnings .......................................................................... 2-2 4.4.1 Humidifier Temperature Setup ............................... 4-7
2.2 Cautions........................................................................... 2-2 4.5 Changing Settings Using a SmartCard ............................. 4-8
2.3 Notes ............................................................................... 2-2 4.6 DC Power Accessories ................................................... 4-9
Chapter 3: Specifications and Theory of Operation ......... 3-1 Chapter 5: Routine Maintenance ...................................... 5-1
3.1 Overview ......................................................................... 3-2 5.1 Overview ........................................................................ 5-2
3.2 Specifications ................................................................... 3-3 5.2 Cleaning the System ........................................................ 5-2
3.3 Symbols and Meanings .................................................... 3-5 5.3 Cleaning / Replacing the Intake Filter .............................. 5-2
3.4 Functional Description ...................................................... 3-6 5.3.1 Removing, Cleaning, and
3.5 Theory of Operation (Subassemblies) ............................... 3-6 Replacing the Filter ............................................... 5-2
3.5.1 Main PCA ............................................................. 3-6 5.4 Preventive Maintenance Schedule ................................... 5-5
3.5.2 Control Pad & Liquid Crystal Display (LCD) ........ 3-7
3.5.3 Power Supply ........................................................ 3-7
3.5.4 Encore Pro SmartCard® ....................................... 3-7
1018658 REMstar Auto with C-Flex and REMstar Pro 2 Service Manual T-1
Table of Contents
Chapter 6: Troubleshooting and Diagnostics................... 6-1 8.3 Real-time Clock Calibration ............................................ 8-3
6.1 Overview ........................................................................ 6-2 8.4 Load Serial and Model Numbers .................................... 8-5
6.2 Common System Level Problems ................................... 6-3 8.5 Respironics Heated Humidifier Test ................................. 8-6
6.3 Troubleshooting Table ..................................................... 6-4 8.6 Current Draw Test ........................................................ 8-13
6.4 System Error Codes ..................................................... 6-10 8.7 Manual Heated Humidifier Test ..................................... 8-14
6.4.1 Extracting Error Codes from the Unit .................. 6-10 8.8 Performance verification ................................................ 8-15
8.9 Testing Data Sheets....................................................... 8-12
6.4.2 Extracting Error Codes from the Unit
Using the Utility Software ................................... 6-10
Appendix A: Tools and Equipment .................................... A-1
6.5 Humidifier LED Error Code Chart ................................ 6-22
A.1 Service Tools and Supplies ............................................ A-2
A.2 Acceptable Test Equipment............................................ A-3
Chapter 7: Repair & Replacement................................... 7-1 A.2.1 Digital Manometer .............................................. A-3
7.1 Overview ........................................................................ 7-2 A.2.2 Digital Multimeter ................................................ A-3
7.2 Repair Kits ..................................................................... 7-3 A.2.3 Flow Meter......................................................... A-4
7.3 Repair and Replacement ................................................. 7-8
7.3.1 Top Enclosure Replacement ................................ 7-9 Appendix B: Schematics .................................................... B-1
7.3.2 Key Pad Replacement ...................................... 7-11 B.1 Schematics Statement.............................................. . ..B-2
7.3.3 Main Printed Circuit Assembly Motor Driver ................................................................ B-3
(Main PCA) Replacement ................................ 7-13 Power Supply ............................................................... B-4
7.3.4 Outlet Port Replacement ................................... 7-15 Display ......................................................................... B-5
7.3.5 Flow Element Replacement ............................... 7-16 To CPU Board .............................................................. B-6
7.3.6 Dog Bone Coupler ........................................... 7-17 Analog Circuit.............................................................. B-7
7.3.7 Blower Assembly Replacement ......................... 7-18 Microprocessor ............................................................ B-8
7.4.8 Bottom Enclosure Replacement ........................ 7-20
Chapter 8: Testing ................................................................ 8-1

8.1 Overview ........................................................................ 8-2
8.2 Run-in ............................................................................. 8-2
1018658 REMstar Auto with C-Flex and REMstar Pro 2 Service Manual T-2
Chapter 1: Introduction
1.1 System Overview........................................ 1-2
1.2 Service Notice............................................. 1-2
1.3 Technical Support Statement ................... 1-2
1.4 Training ....................................................... 1-2
1018658 REMstar Auto with C-Flex and REMstar Pro 2 Service Manual 1-1
Chapter 1: Introduction 1.4 Service Training

Respironics offers service training for the CPAP devices. For more informa-
1.1 System Overview tion, contact Service Operations at:
The REMstar Auto with C-Flex and REMstar Pro 2 are Continuous Positive
Email: service.operations@respironics.com
Airway Pressure (CPAP), microprocessor-controlled devices used for the
treatment of adult Obstructive Sleep Apnea (OSA). Phone: (724) 755-8220
Fax: (724) 755-8230
1.2 Service Notice
This service manual is intended for technicians with prior training or
experience in servicing CPAP devices.
1.3 Customer Satisfaction

For technical assistance or replacement part ordering information, contact
Respironics Customer Service. Visit Respironics on the World Wide Web at:
www.respironics.com
U.S.A. and Canada International
Phone:1-800-345-6443 Phone: 1-724-387-4000

Fax: 1-800-886-0245 Fax: 1-724-387-5012
Chapter 2: Warnings, Cautions, and Notes
Chapter 2: Warnings,
Cautions, and
Notes
2.1 Warnings ..................................................... 2-2
2.2 Cautions....................................................... 2-2
2.3 Notes ............................................................ 2-2
Chapter 2: Warnings, Cautions, and Notes
Chapter 2: Warnings, Cautions, • To assure the safety of the service technician and the specified
performance of the device, Respironics recommends that only
and Notes technicians having prior training or experience servicing CPAP
devices perform any repairs or adjustments to this device.
WARNING: Indicates the possibility of injury to the patient,
operator, or technician.
2.2 Cautions
CAUTION: Indicates the possibility of damage to the device.
• Federal Law (U.S.) to sale by or on the order of a physician.
NOTE: Places emphasis on an operating/servicing characteristic. • Care should be taken to avoid exposure of the devices to tempera-
tures at or near the extremes of those specified in Chapter 3. If
2.1 Warnings exposure to such temperatures has occurred, the device should be
allowed to return to room temperature before being turned on.
• Do not immerse this device in any fluids.
• The information in this manual is provided for service personnel
• If oxygen is used with this device, the oxygen flow must be reference and is not intended for system setup or use. System
turned off when the device is turned off. Accumulated oxygen in setup should be performed by appropriate personnel using the
the system enclosure increases the risk of fire. “Home Care Provider Setup Instructions”.
• Oxygen supports combustion. Do not use oxygen in the pres- • Tobacco smoke may cause tar buildup within the device that may
ence of open flames, cigarette smoke, electrical spark, or other result in damage.
sources of ignition.
• Discontinue use of this device if any parts or components are
• This device is not suitable for use in the presence of a flammable damaged. Repair or replace device or components as necessary
anesthetic mixture in combination with oxygen or air or in the prior to continuing use.
presence of nitrous oxide.
• Check power cord for damage or signs of wear.
• Disconnect the electrical supply before cleaning or performing
any repairs on this device.
• Electronic components used in this device are subject to damage 2.3 Notes
from static electricity. Repairs made to this device must be • Notes are provided throughout this manual as necessary.
performed only in an antistatic, Electrostatic Discharge (ESD)
protected environment.
Chapter 3: Specifications and Theory of Operation
Chapter 3: Specifications
Features,
Descriptions,
and Theory of
Operation
3.1 Overview ..................................................... 3-2
3.2 Specifications .............................................. 3-3
3.3 Symbols ........................................................ 3-5
3.4 Functional Description ............................ 3-11
3.5 Theory of Operation ................................ 3-14
Chapter 3: Specifications, Features,

Description, and Theory
of Operation
3.1 Overview
This chapter describes the REMstar Auto with C-Flex and REMstar Pro 2
specifications and system features. A functional description and theory of
operation is also provided.
3.2 Specifications PHYSICAL:
Dimensions 9.5 x 6.875 x 4.5 in.

ENVIRONMENTAL:
(24 cm x 17 cm x 11 cm)
Operating Temperature 41 to 95°F (5 to 35°C)
Weight < 4.0 lbs. (< 1.8 kg)
Transport & Storage Temperature -4 to 140°F (-20 to 60°C)
ELECTRICAL:
Humidity (Operating / Storage) 15 to 95% non-condensing
AC Input Voltage 100 - 240 VAC ± 10%
Outlet Air Temperature Shall not exceed 106°F (41°C) when 50 / 60 Hz
operating at a maximum ambient
temperature of 95°F (35°C). DC Voltage 12 VDC
Atmospheric Pressure 83 to 102 kPascals AC Current Consumption 1.0 A maximum
Elevation Tested at 0 to 5500 ft. DC Current Consumption 3.0 A maximum
Sound Pressure Level 30 dB(A)

Type of Protection Class II Equipment
NOTE: In accordance with EN 17510 @ 10 cm H2O at the patient circuit. Against Electrical Shock 2-prong AC power inlet
This measurement applies to the CPAP device with or without
the optional REMstar Heated Humidifier. Degree of Protection against Type BF Applied Part
Electrical Shock
Degree of Protection Against

Ingress of Water IPX0-Ordinary Equipment
Specifications (continued)
Static Pressure Accuracy +/- 1.0 cm H2O
STANDARDS COMPLIANCE: with no humidifier.
This product is designed to conform to the following standards.

Pressure Drop with Humidifier 0.3 cm H2O @ 20 cm H2O
IEC 60601-1 Medical Electrical Equipment, Part 1
General Requirements for Safety and THERAPY MEMORY:
essential performance
Therapy Memory Retrievable by Encore Pro
EN ISO 17510-1 Sleep Apnea Software.
Breathing Therapy Devices
ALTITUDE COMPENSATION:
Altitude Pressure Range 83 - 102 kPascals (Automatic Altitude

Adjustment)
OPERATING CHARACTERISTICS:
Mode of Operation Continuous
Pressure 4 to 20 cm H2O (in 0.5 increments)
NOTE: Pressure accuracy measurements shall be taken at the end of a

six foot (1.83 m) patient circuit with a Whisper Swivel II exhala-
tion port connected to an Oxygen enrichment adapter that is
occluded. The manometer should be connected to the O2 port.
3.3 Symbols and Meanings
Display Screen Label Meaning
Meaning
Symbol Symbol
Indicates that the device requires user attention as Attention, consult accompanying documents
indicated on the screen
DC Power
Indicates that a SmartCard is inserted and detected
Indicates that the alphanumeric digits are AC Power
cm H 2O
displaying a pressure value
Class II (Double Insulated)
Indicates that the user may clear the Therapy Session
Counter
European CE Declaration of Conformity
Indicates that a C-Flex comfort setting is being displayed
or is active
Notified Body Approval for Standards Compliance
Indicates that the humidifier is turned on and/or its setting
is being displayed Canadian/US Certification
Indicates that the Therapy Hour Meter is being displayed.
This symbol is used in conjunction with the symbol Type BF Applied Part
to indicate that the session counter is being displayed
IPX0 Drip Proof Equipment
Indicates that the control panel LED backlight setting is
being displayed or is active
Indicates that a Patient Disconnect alert is active or its
setting is being displayed
Indicates that the ramp function is in progress, or during
provider mode, the ramp length is being displayed
Indicates that the session counter is being displayed;
This symbol is used in conjunction with the symbol.
Indicates that the ramp starting pressure is being displayed
Indicates that the device is in provider mode and not
user mode
3.4 Functional Description 3.5 Theory of Operation (Subassemblies)

The REMstar Auto with C-Flex and REMstar Pro 2 are microprocessor-
controlled CPAP devices. The units’ CPAP pressure range in either AC or
3.5.1 Main Printed Circuit Assembly
DC operation is 4.0 - 20.0 cm H2O, adjustable in increments of .5 cm H2O. (Main PCA)
The Main PCA is the control center of the devices. The Main PCA utilizes a
AC power enters the unit via an AC inlet and appropriate power cord. A DC microcontroller chip which reads from and writes to various I/O devices
power cord connector enables the patient to use the device when AC (control pad, LCD, memory, pressure sensor, motor control circuitry, data
voltage is not accessible. interface, etc.) With all of this information, the microcontroller makes
appropriate decisions to control the blower and deliver the desired CPAP
Integral to the generation of airflow is the blower assembly. Ambient air is therapy in a safe and reliable manner.
drawn through the air intake filter, and pressurized by the energized blower.
Ultimately, therapeutic pressure is provided to the patient via the patient The microcontroller and the interface circuitry provide closed loop control
circuit. The microprocessor regulates the motor speed, which in turn of the blower motor’s speed. The blower motor is a three phase brushless
adjusts and controls the pressure. DC motor with a permanent magnet rotor and stationary coils that are
connected in a “Y” configuration and serve as its stator coils.
The patient circuit is made up of flexible tubing, exhalation port, and nasal
mask. The unit delivers CPAP to the patient’s upper airway to keep the The stator coils are electrically switched or commutated by drive circuits
airway open during sleep. with the power field effect transistors (FET). Proper timing and sequencing
of the stator coil switching is provided by the microcontroller which senses
The REMstar Auto with C-Flex and REMstar Pro 2 are intended only to the motor’s shaft position by monitoring the back-EMF voltage in one of
deliver CPAP therapy (both with and without the enhancement of C-Flex). the motor’s stator coils.
The devices are not intended for life support or life sustaining applications.
The microcontroller also sets the motor speed (and consequently the
output pressure) by varying the voltage which is delivered to the motor.
3.5.2 Control Pad & Liquid Crystal Display 3.5.4 Encore SmartCard
(LCD) The REMstar Auto with C-Flex and REMstar Pro 2 are delivered with the
The control pad consists of five user buttons (Ramp Button, On / Off Encore SmartCard installed. Information is stored in a small silicon chip
button, Heated Humidifier Button, and Right and Left User Buttons for embedded into the card. When installed into the into the devices, the
other functions). The On / Off button activates and deactivates the SmartCard records the date, time at pressure, pressure levels, and other
pressure. The range of pressure is 4.0 to 20.0 cm H2O with AC and DC information on the sleep session. Using the Encore Pro Software, the
operation (adjustable in increments of 0.5 cm H2O). usage data can be automatically downloaded and viewed.
NOTE: Domestic and International versions of both the REMstar Auto The SmartCard can also be programmed with the patient’s prescription by
with C-Flex and REMstar Pro 2 are available. The LCD display using the Encore Pro Software and SmartCard reader/writer. When the
screens and control buttons are represented by English text on programmed SmartCard is inserted into the device, the prescription settings
the domestic variation and international symbols are used on are automatically transferred into the device and erased from the SmartCard.
the second variation of the unit. The SmartCard will then start to collect patient data.
FOSQ: The REMstar Auto with C-Flex and REMstar Pro 2 are programmed
to allow the users to take a “Functional Outcomes of Sleep Questionnaire”
3.5.3 Power Supply (FOSQ). FOSQ is a quality of life questionnaire designed specifically for
The unit has a switching power supply which is built on the Main PCA and people with sleep disorders. The results allow health care professionals to
mounted within the unit’s top enclosure. The switching power supply see how therapy has improved the quality of their patient’s life. Refer to
operates properly on any AC voltage between 100 - 240 VAC; 47 - 63 HZ the “FOSQ” brochure (from Respironics) for further information. The FOSQ
and produces an output of approximately 12 VDC. The switching power information is also stored on the SmartCard.
supply automatically adjusts for varying input voltages. No voltage
selector switch or fuse changing is required, which allows for worldwide
operation.
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Chapter 4: System Setup Procedures
Chapter 4: System Setup

Procedures
4.1 Overview ..................................................... 4-2
4.2 Programming a SmartCard ..................... 4-2
4.3 System Setup............................................... 4-3
4.4 Heated Humidifier System Setup ............ 4-7
4.5 Changing Settings

using a SmartCard .................................... 4-8
4.6 Recommended Circuit Accessories ...... 4-12
Chapter 4: System Setup 4.2 Programming a SmartCard

Procedures
Step 1 Connect a Respironics SmartCard reader/writer directly to a
4.1 Overview PC following the instructions included with the reader/writer.
Remove the SmartCard from the unit and insert it into the
This section provides an overview of the system setup including detailed reader/writer.
instructions on the therapy menu display screens. Refer to Chapter 7,
Repair and Replacement, or Chapter 5, Routine Maintenance, for filter and Step 2 Open the patient’s file in the Encore Pro software (or create a
filter cap installation instructions. new patient file). Choose “SmartCard Wizard” from the
“Communications” menu. Following the prompts, complete
NOTE: The REMstar Auto with C-Flex and REMstar Pro 2 are delivered the patient’s prescription. The patient’s name and prescrip-
with an Encore Pro SmartCard installed. tion will be saved on the SmartCard.
NOTE: This section provides directions for accessing the therapy Step 3 Remove the SmartCard from the Reader/Writer. If desired,
menu. Prescribed therapy can be set by using the SmartCard or write the patient’s name on the front of the card.
the Therapy menu. (The patient’s User’s Manual provides
directions to access only the Patient menu, which limits access
to settings. To prevent patients from tampering with the
settings, the directions to access the Therapy menu should not
be revealed to the patient).
NOTE: If the SmartCard is not installed, the device usage will not be
recorded.
NOTE: If the system is not turned off properly, data will not be recorded
to the SmartCard.
4.3 System Setup

AC Power Cord Connector
Hold the two user buttons down while plugging in the power cord. Con- User Buttons (located on the back of the
tinue holding the buttons down until the unit beeps.
unit)
NOTE: Prior to entering Therapy Mode, the firmware version of the
REMstar Auto with C-Flex or REMstar Pro 2 will be briefly
displayed. Always be sure that the most current version of
firmware is installed in the unit.
4.3.1 Therapy Mode Menu Navigation
When in Therapy Mode, press the left and right user Note: The menu screens shown below are displayed
buttons to scroll through the display screens. Use the on Domestic units. Please note that Interna-
Humidifier and Ramp buttons to change the settings on tional units’ push-buttons and menu screens
each screen. To exit Therapy Mode, push the Start/Stop are represented with graphics, symbols, and
button. icons. Refer to Chapter 3 for additional
To/from the LED Backlight
Setting screen information.
Right User Left User
Button Button
Number of nights the unit was

NIGHTS>4 HRS SETUP
used for more than four hours
Previous Next (push the Heat or
Right User
Button
Left User
Button
Ramp button to erase)
Right User SETUP
RAMP
Ramp Length Setting screen
Left User
HEAT
Exit Button Button Ranges:
5 to 45 minutes (CPAP and CFLE)
RAMP
Settings SETUP 2, 3, or 4 hours (REMstar Auto with C-Flex
START Mode Setting screen Right User Left User when APAP or AFLE is the operating mode)
STOP Button Button
RAMP
SETUP START
Ramp Start Pressure Setting screen
Button Button
NOTE: This screen appears only
Minimum Pressure Setting Screen if the Ramp Length is set to a
NOTE: This screen appears only MIN
SETUP
value between five and 45 minutes.
cm Right User
on the REMstar Auto with C-Flex H2O Button
Left User
Button
when either APAP or AFLE
Mode is Selected. SETUP
Right User Left User Patient Disconnect
Button Button
Alert Setting screen
Maximum Pressure Setting Screen ALERT
MAX
NOTE: This screen appears only SETUP
cm
on the REMstar Auto with C-Flex H2O Button Button
when either APAP or AFLE

mode is selected. SETUP
Right User Left User LED Backlight

Button Button
Setting screen
LED
C-FLEX Setting Screen SETUP

NOTE: This screen appears only when Button Button
CFLE or AFLE Mode is selected. C-FLEX
To/from the Number of Nights the Unit Was
Button Button
Used for More than Four Hours screen
4.3.2 Therapy Mode Display Screens
AFLE Indicates that the Unit is
Reset the Number of Nights the Unit Was Used for More
Than Four Hours in Auto-CPAP Mode with C-
Flex Comfort Setting
Push the Humidifier or Ramp button to erase the number of nights the unit
was used for more than four hours. Press the right user button to continue
to the Mode Setting screen.
Once you have selected the operating mode, press the right user button to
Select the Operating Mode continue to the next screen.
Select from one of two (REMstar Pro 2) or four (REMstar Auto with C-Flex) Set the Minimum Pressure (REMstar Auto with C-Flex
operating modes as follows: only)
• CPAP-Maintains a constant level of pressure throughout the
If you have selected APAP or AFLE mode, you must set minimum and
breathing cycle.
maximum pressure settings. To change the minimum pressure setting, press
• CFLE-CPAP with pressure relief upon exhalation the ramp or humidifier button. The range for the minimum pressure setting
• APAP-Automatically adjusted CPAP therapy (REMstar Auto with C- is 4 to 20 cm H2O, adjustable in increments of 0.5 cm H2O.
Flex only)
• AFLE-Automatically adjusted CPAP therapy with pressure relief NOTE: The minimum pressure cannot be set higher than the maximum
upon exhalation (REMstar Auto with C-Flex only) pressure. Example: If the current settings are 4 cm min. and 6 cm
max., and you wish to change them to 8 cm min. and 12 cm max.,
you must set the maximum pressure first. Press the right user
APAP Indicates that the Unit is button to go to the maximum pressure setting, and then press
in Auto-CPAP Mode without the left user button to go back to the minimum pressure setting.
C-Flex comfort setting
Once you have set the minimum pressure setting, press the right user
button to continue to the next screen.
Set the Maximum Pressure Set the Ramp Length
If you have selected APAP or AFLE mode, you must set minimum and If the operating mode is set to CPAP or CFLE, the range for the Ramp
maximum pressure settings. To change the maximum pressure setting, press Length is 5 to 45 minutes. If the operating mode is set to APAP or AFLE
the ramp or humidifier button. The range for the maximum pressure setting (REMstar Auto with C-FLEX only), the range for Ramp Length is 0, 2, 3, or 4
is 4 (or the value of the minimum pressure setting) to 20 cm H2O, adjustable hours.
in increments of 0.5 cm H2O.
Once you have set the patient disconnect alert to on or off, press the right
NOTE: The maximum pressure cannot be set lower than the minimum user button to go to the next setting.
pressure setting. Example: If the current settings are 8 cm min.
and 12 cm max., and you wish to change them to 6 cm min. and 9 Set the Patient Disconnect Alert to On or Off
cm max., you must set the minimum pressure first. Press the left
user button to return to the Minimum Pressure setting screen,
This patient disconnect alert is an audible tone that sounds when the unit
and then press the right user button to go back to the Maximum
detects a large continuous air leak (such as mask removal) in the patient
Pressure setting screen.
circuit. This alert can be turned on (1) or off (0) using the ramp or humidi-
fier button.
Once you have set the maximum pressure, press the right user button to
continue to the next setup display screen. If you selected APAP as the
Once you have set the patient disconnect alert to on or off, press the right
operating mode, the patient disconnect alert setup screen will be displayed
user button to go to the next setting.
next. If you selected AFLE as the operating mode, the C-Flex level setting
screen will be displayed next.
Set the Button Lights On or Off
Set the C-Flex Level
The button lights setting allows you to have the lights behind the buttons
If you have selected the AFLE (REMstar Auto with C-Flex) or CFLE turned on or off while the airflow is turned on. (The lights will always be on
operating mode, you must select a C-Flex setting. Use the ramp or humidi- when the airflow is off).
fier button to set the C-Flex to either 1, 2, or 3. Once you have selected the
C-Flex setting, press the right user button to continue to the next setup
display screen.
4.4 Heated Humidifier System Setup 4.4.1 Humidifier Temperature Setup

Set the Humidifier Temperature
Step 1 Place the REMstar Auto with C-Flex or REMstar Pro 2 on top Press and hold the Heated Humidifier button on the Respironics REMstar
of the Humidifier. Auto with C-Flex or REMstar Pro 2 until you see the temperature setting on
the display screen flashing, then release the Heated Humidifier button. Use
Step 2 Plug the male end of the AC power cord into an electric outlet the humidifier and ramp buttons to change the temperature setting. The
temperature range is 1 to 5 (adjustable in increments of 1). Five is the
and the female end into the back of the Humidifier.
highest temperature setting. Press the Pressure On/Off button to confirm
settings.
Step 3 Plug the power cord jumper from the Humidifier into the back
of the REMstar Auto with C-Flex or REMstar Pro 2.
HEAT
Humidifier Icon (As Dis-
played on Domestic Units)
Temperature Setting
Preheat Mode
To enter preheat mode, press and hold the humidifier button on the
REMstar Auto with C-Flex or REMstar Pro 2 until the humidifier icon
appears on the display screen. The green LED on the front of the Heated
Humidifier will illuminate. Preheat mode will last 20 minutes if the airflow is
not turned on.
Heating Mode
To enter heating mode, press the On/Off button on the unit to start the
blower. Once the blower has started, press and hold the humidifier button
until the humidifier icon appears on the display screen. The green LED will
illuminate on the front of the Heated Humidifier.
4.5 Changing Settings Using a SmartCard Step 2 Verify New Settings
Turn the airflow on to verify the new prescription setting. You may now
Step 1 Inserting the SmartCard
either remove the SmartCard or leave it in the unit to record device usage.
Once the prescription settings have been transferred to the unit, they will
Make sure that the unit is plugged into an electrical outlet. Insert the
be deleted from the SmartCard.
programmed SmartCard into the slot on the right side of the unit (logo side
facing up). When the “card detected” screen appears on the unit’s LCD,
the card is inserted correctly.
Insert SmartCard here
Indicates a SmartCard
MIN is Inserted
cm
H2O
CARD
4.6 DC Power Accessories CAUTION: Only use the Respironics DC Power Accessories.
Use of any other DC Power accessories may result in
The Respironics Shielded DC Power Cord (RI P/N 1001956) can be used damage.
to operate the REMstar Auto with C-Flex or REMstar Pro 2 in a stationary CAUTION: DC Power is not intended to be used as battery backup.
recreational vehicle, boat, or motor home. DO NOT connect the DC Power while the REMstar Auto
with C-Flex or REMstar Pro 2 is operating on AC Power.
The Respironics DC Battery Adapter Cable (RI P/N 532209), when used System damage may occur.
with the Respironics Shielded DC Power Cord, enables the Respironics
CPAP system to be operated from a 12 VDC freestanding battery.
NOTE: Respironics recommends a 100 amp-hour deep cycle marine

battery.
The unit should not be operated while the vehicle is in motion.
Chapter 5: Routine Maintenance
Chapter 5: Routine
Maintenance
5.1 Overview ..................................................... 5-2
5.2 Cleaning the System .................................. 5-2
5.3 Cleaning / Replacing the

Intake Filter ................................................ 5-2
5.4 Preventive Maintenance Schedule .......... 5-4
Chapter 5: Routine Maintenance 5.3 Cleaning / Replacing the

Intake Filter
5.1 Overview The gray pollen filter is a reusable filter that screens out pollen and
household dust. This filter should be cleaned at least once every two weeks
This chapter provides guidelines and illustrates the cleaning and mainte- under normal usage, or as required. The filter should be replaced every six
nance procedures for the REMstar Auto with C-Flex and REMstar Pro 2. months. One additional pollen filter is included with the system. The pollen
filter must be in place at all times when the unit is operating. The disposable
5.2 Cleaning the System ultra fine filter may be used to keep finer particulates out of the device.
CAUTION: Failure to replace a dirty filter may cause the device

WARNING: To avoid electrical shock, disconnect the electrical
to operate at higher than normal temperatures and
supply before attempting to clean the device. DO NOT
damage the device.
immerse the device in water or allow any liquid to enter
the cabinet or the filter intake.
Wipe the outside of the unit with a cloth slightly dampened with water and
5.3.1 Removing, Cleaning, and Replacing the
a mild detergent. Let the unit dry before reconnecting the electrical supply. Filter
Step 1 With the airflow turned off, disconnect the AC or DC power
cord from the back of the device.
Step 2 Remove the filter cap by gently lifting up on the bottom of the Step 3 Remove the pollen filter by gently pulling the edges of the filter.
filter cap, then pulling it away from the back of the device. Rinse the filter in a steady stream of running water. Squeeze out
the water, and repeat. Allow the pollen filter to air dry for eight to
12 hours, or in a clothes dryer for 15 to 20 minutes.
Figure 5-1 Figure 5-2

Removing the Filter Cap The Filter Cap and Filter
5.4 Preventive Maintenance Schedule

Step 4 Place the pollen filter into the filter area in the back of the
unit. The following Preventive Maintenance Schedule lists the items that must
be inspected or tested periodically, or after service is performed. Use the
Preventive Maintenance Schedule to record the dates on which the mainte-
CAUTION: The pollen filter must be completely dry before use. nance items are performed. This schedule can also be used as an out of the
Never place a wet filter into the device. box checkout of new devices.
Respironics recommends that you clean the filter in
the morning and alternate using the two pollen filters The Preventive Maintenance Schedule may be copied for each device
provided with the system to ensure enough drying serviced.
time for the cleaned filter.
CAUTION: DO NOT place both pollen filters into the device

at the same time.
Step 5 Install the filter cap. The opening in the unit’s filter cap should
face down and away from the patient.
5.4.1 Preventive Maintenance Schedule (Factory Recommended)
Maintenance Item Verification Reference Service Interval Date

Record Blower Hours Displayed On Options Screen As Desired
Clean every 2 weeks, or as

Clean / Replace Pollen Filter Section 5.3.1 needed / Change every 6 months.
Perform Testing Process Refer to Chapter 8 New device checkout.

After service is performed.
(Except when calibration is required)
When requested.
Cleaning Section 5.2 As required
Serial Number ______________Name____________________ Signature ______________________Date___/___/___
(This page may be copied)
Chapter 6: Troubleshooting and Diagnostics
Chapter 6: Trouble-
Shooting and
Diagnostics
6.1 Overview ..................................................... 6-2
6.2 Common System Level Problems ........... 6-3
6.3 Troubleshooting Table .............................. 6-4
6.5 System Error Codes ................................ 6-10
6.6 SmartCard Error Codes ........................ 6-18
6.7 Humidifier LED Error Code Chart ...... 6-22
Chapter 6: Troubleshooting and

Diagnostics
6.1 Overview
WARNING: Electrical Shock Hazard: Disconnect the electrical
supply before repairing the unit.
CAUTION: Electronic components used in this unit are subject to

damage by static electricity. Use proper static
discharge equipment and grounding precautions when
servicing the equipment. Service only at a static-free
workstation.
This section contains information necessary to troubleshoot and diagnose

problems with the REMstar Auto with C-Flex and REMstar Pro 2. It
provides a summary of common system problems as well as a flowchart and
table to simplify the troubleshooting process. The error code chart lists all
error codes, the associated problem, and suggested corrective action to be
taken.
6.2 Common System Level Problems
Screen Message Description Results Corrective Action
__ _ A large circuit leak, such as mask • No airflow in approximately 90 • Check the patient circuit for
removal, has been detected. seconds. any leaks and adjust the mask
and headgear.
• Push the Start / Stop button to

restart the airflow.
6.3 Troubleshooting Table
Symptom Cause Verification Corrective Action
Audible Alarm not Sounding - Main PCA Perform power up sequence. If audible alarm does not work,
During audible alarm condition, Visually verify the illumination replace Main PCA.
the alarm is not audible. of the LED’s and display. Reestab-
lish original alert conditions. Listen If visual indicators are not
for audible alarm. present at power up, perform
user interface checkout proce-
dure.
If device fails user interface

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

tests, no corrective action is
required.
Device does not operate from the Faulty DC plug, low DC voltage, Ensure the DC voltage supply is a If DC source is not at 11.5
12 VDC power source- fuse in DC cord is blown minimum of 11.5 VDC. Ensure the VDC or higher, replace or
DC voltage is stable. Monitor the recharge power source as
Main PCA voltage at the back of the DC required.
connector mounted on the Main
PCA. If DC voltage is below 11.5 If 12 VDC supply and DC cords
VDC, replace or recharge DC are ok, replace Main PCA.
source. If there is no DC measured
at the Main PCA, then check the
DC adapter cord for continuity.
Display Indicator - Main printed circuit assembly Perform user interface checkout If device fails user interface
LED or other indicator not working. procedure. checkout procedure, replace
Main PCA.
Display - Display assembly Inspect solder joints between Replace Main PCA.
Display is blank or contains display and Main PCA.
erroneous information. Main PCA
Intermittent Power Supply Power cord, AC inlet, Main PCA, Inspect power cord for fraying at Replace Main PCA.
Problem - loose connections cable ends.
An intermittent on / off condition
exists, unit alarms randomly, or Inspect all connections on the
indicator lights blink sporadically. Main PCA.
Noise - Missing or damaged rubber feet Inspect the bottom of the unit If rubber feet are missing,
on bottom of unit, blower for missing or damaged rubber feet. replace rubber feet. Tighten any
malfunctioning loose screws.
Blower impeller imbalance Place hand on device, if vibration is Resolve any air leaks.
detected, replace blower S/A.
Replace Blower.
Odor - Tubing smells new, device smells Visually inspect patient tubing for Run device in a clean environ-
new, airborne residue buildup contamination. ment for a few hours to eliminate
new smell. Wash tubing with
soap and water. To clear residue
buildup, replace all subassem-
blies in the patient air stream
(blower filters, patient circuit).
Outlet Air Temperature - Dirty filters, defective Blower, Main Ensure the filter is clean and not Replace in order until solved:
The outlet air temperature is too PCA restricting air flow. Monitor the
warm. outlet temperature at the end of the Filters
six foot patient tubing. A rise in
temperature can be expected. Blower
Main PCA
Pressure Related Problems - Inspect pressure tubing for secure Secure pressure tubing connections.
The outlet pressure does not Pressure tubing has been blocked, connections and kinks. Check
change or properly adjust. disconnected, or kinked. Blower for leaks. Replace blower, pressure tubing, or
Main PCA.
Main PCA or blower malfunction
Pressure Offset - The delivered pressure is higher or Perform power up process. Check internal tubing for kinks.
Static pressure fluctuates from lower than the set value by more
-1.0 cm to +1.0 cm H2O of set than -1.0 cm to +1.0 cm H2O. Replace the Main PCA.
pressure.
No Stored Therapy Data SmartCard was not installed in No therapy data after usage Depress the blower on / off
device prior to use button before disconnecting the
Main AC power.
Not a Respironics SmartCard
(error code displayed) Reformat SmartCard.
Card not formatted or faulty Replace SmartCard.

SmartCard (error code displayed)
Device LCD or Backlight failure Damage to LCD or backlight Power the unit off, then on. Replace main PCA.
Device on, displays pres- Loose connection Check motor plug / PCA Ensure connections are secure.
sure setpoint, No airflow connection.
Blower / motor failure Replace the Blower Assembly.
Troubleshoot by substitution
Main PCA failure with a known good Blower S/A. Replace Main PCA.
Occluded or restricted pressure tube Check pressure with calibrated Replace pressure tubing.
Pressure check out of range
manometer.
Defective pressure sensor Calibrate Main PCA.
Blower speed regulation Replace Main PCA.

Leaks in flow path Check or replace flow element.
Pressure Variation - The Internal air leak Replace filter. Replace Blower.
pressure varies around the set
value, pressure fluctuates greater Filters dirty Perform Testing Process (Refer to If pressure still drifts, then
than 1.0 cm H2O. Chapter 8). replace Main PCA.
Main PCA
Check internal tubing.
Blower
Air path blocked
Humidifier will not turn on Humidifier not turned back on Inspect main power cord for fraying Replace power cord.
after CPAP was turned off at cable ends.
Faulty power cord Inspect power cord between CPAP Replace Main PCA in
and humidifier base. humidifier base.
Broken or damaged light pipe
Inspect light pipe inside CPAP for Realign or replace light tube.
No infrared connection misalignment or kinking.
Damaged heater plate Make sure receiver on Humidifier Replace Humidifier Main PCA.
base is not damaged.
Humidifier Main PCA
Inspect Main PCA to see if there is Replace Main PCA.
CPAP Main PCA damage to the transmitter on the
Main PCA.
Make sure CPAP is seated on Reseat CPAP on humidifier base.

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

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

connected to the humidifier Main base.
PCA and that it is not damaged.
6.4 System Error codes 6.4.2 Extracting Error Codes Using the Utility Software
This section contains information on extracting error codes that have Step 1 Verify utility software is installed on the computer.
occurred during use of the REMstar Auto with C-Flex or REMstar Pro 2.
There are two ways to extract the information. Step 2 Connect the communication cable between the SleepLink
card and the serial port COM1 on your computer.
6.4.1 Extracting Error Codes from the Unit
Step 3 Insert the SleepLink card into the device and plug the device into
Step 1 Hold the humidifier button and ramp button down while the proper AC voltage source.
plugging in the power cord. Continue holding the buttons
down until the unit beeps. Step 4 With your mouse, click on the Start Button of your
computer.
Step 2 The most recent error code will be displayed. By pressing
the humidifier key, the unit will show the previous error code, Step 5 Select:
allowing the user to view the entire error log in a circular buffer Programs
fashion. Only the ten most recent errors will be shown. An E-0 Respironics
indicates no error. Tools
Read Error Log
Step 3 By pressing the ramp key, the unit will display the blower hours
when the error occurred. Pressing the humidifier key will allow the Step 6 The software will load automatically.
user to view the hours that each error occurred in a circular buffer
fashion.
Step 7 With your mouse, click on the Run Arrow located
Step 4 To erase the error logs, press the right user button. An X will in the upper left corner of the computer screen.
appear in the lower left corner of the LCD. Then press the
Pressure On / Off key. This will erase all errors and the blower Step 8 The software will automatically read and display any error
hours at which the errors occurred, and return the unit to the codes stored in the unit along with the date and time the errors
system self test screen. occurred.
NOTE: The ten most recent error codes will be displayed. The oldest
error code will be overwritten when a new error occurs.
Error Code Description Probable Cause Corrective Action
E-0 NO_ERROR •Reserved •N/A
E-1 ERR_SOFTWARE •Reserved •Replace Main PCA
E-2 ERR_PROGRAM_CRC_FAILURE •Defective FLASH chip •Replace Main PCA
E-3 ERR_EXTERNAL_RAM_FAILURE •Defective RAM chip •Replace Main PCA
E-4 ERR_FIQ_STACK_OVERFLOW •Defective RAM chip •Replace Main PCA
E-5 ERR_FIQ_STACK_UNDERFLOW •Defective RAM chip •Replace Main PCA
E-6 ERR_NEST_STACK_OVERFLOW •Defective RAM chip •Replace Main PCA
E-7 ERR_NEST_STACK_UNDERFLOW •Defective RAM chip •Replace Main PCA
E-8 ERR_IRQ_STACK_OVERFLOW •Defective RAM chip •Replace Main PCA
E-9 ERR_IRQ_STACK_UNDERFLOW •Defective RAM chip •Replace Main PCA
E-10 ERR_TMR_STACK_OVERFLOW •Defective RAM chip •Replace Main PCA
E-11 ERR_TMR_STACK_UNDERFLOW •Defective RAM chip •Replace Main PCA
E-12 ERR_SVC_STACK_OVERFLOW •Defective RAM chip •Replace Main PCA
E-13 ERR_SVC_STACK_UNDERFLOW •Defective RAM chip •Replace Main PCA
E-14 ERR_THREAD_STACK_OVERFLOW •Defective RAM chip •Replace Main PCA
E-15 ERR_ARM_UNDEFINED_INSTRUCTION_EXCEPTION •Defective FLASH chip •Replace Main PCA
E-16 ERR_ARM_SWI_EXCEPTION •Defective FLASH chip •Replace Main PCA
E-17 ERR_ARM_PREFETCH_EXCEPTION •Defective FLASH chip •Replace Main PCA
E-18 ERR_ARM_ABORT_EXCEPTION •Defective RAM chip •Replace Main PCA
E-19 ERR_ARM_RESERVED_EXCEPTION •Defective FLASH chip •Replace Main PCA

•Defective microprocessor •Replace Main PCA
E-20 ERR_AIC_DEFAULT_HANDLER •Defective FLASH chip •Replace Main PCA
E-21 ERR_AIC_SPURIOUS_HANDLER •Defective FLASH or RAM chip •Replace Main PCA
E-22 ERR_CAL_DATA_CRC_FAILURE •Improper calibration •Recalibrate

•Defective FLASH chip •Replace Main PCA
E-23 ERR_INVALID_DRIFT_INDEX_AT_CAL •Improper calibration •Recalibrate

•Occluded or restricted pressure tube •Replace pressure tube
•Defective flow sensor •Replace Main PCA
E-24 ERR_UNRECOGNIZED_CAL_VERSION_BY_SW •Improper calibration •Recalibrate

E-25 ERR_DRIFT_FLOW_TOO_HIGH •Occluded or restricted pressure tube •Replace Flow Tube

E-26 ERR_UI_DISPLAY_FAILURE •Defective LCD driver chip •Replace Main PCA
E-27 ERR_DRIFT_PRESSURE_TOO_HIGH •Occluded or restricted pressure tube •Replace pressure tubing

•Defective pressure sensors •Replace Main PCA
E-28 ERR_CAL_DATA_BLANK •Improper calibration •Recalibrate

E-29 ERR_DRIFT_SECONDARY_PRESSURE_TOO_HIGH •Occluded or restricted pressure tube •Replace pressure tubing

•Defective pressure sensors •Replace Main PCA
E-30 ERR_INVALID_NVDATA_SCHEMA •Normal for first time power up •Remove & restore power
•Defective EEPROM •Replace Main PCA
E-31 ERR_INVALID_NVDATA_LOCK •Defective EEPROM •Replace Main PCA
E-32 ERR_INVALID_NVDATA_CHECKSUM •Normal for first time power up •Remove & restore power
•Defective EEPROM •Replace Main PCA
E-33 ERR_NVDATA_STORAGE_ERROR •Defective EEPROM •Replace Main PCA
E-34 ERR_NVDATA_QUEUE_FULL •Defective EEPROM •Replace Main PCA
E-35 ERR_NVDATA_READBACK_FAILURE •Defective EEPROM •Replace Main PCA
E-36 ERR_NVDATA_RANGE_FAILURE •Defective EEPROM •Replace Main PCA
E-37 ERR_CORRUPT_RTC_VALUE •Defective microprocessor •Replace Main PCA
E-38 ERR_RTC_NOT_TICKING •Defective microprocessor •Replace Main PCA

•Defective crystal •Replace Main PCA
E-39 ERR_UI_QUEUE_FULL •Defective PCA •Replace Main PCA
E-40 ERR_INVALID_BIST_TEST_CALL •Invalid RASP command •Reissue RASP command
E-41 ERR_BIST_THREAD_LOCKED •Defective PCA •Replace Main PCA
E-42 ERR_ALARM_VOLTAGE_FAILURE •Defective power supply •Replace Main PCA
E-43 ERR_12VREF_FAILURE •Defective power supply •Replace Main PCA
E-44 ERR_5VREF_FAILURE •Defective power supply •Replace Main PCA
E-45 ERR_VBULK_FAILURE •Defective power supply •Replace Main PCA
E-46 ERR_NEG15VREF_FAILURE •Defective power supply •Replace Main PCA
E-47 ERR_FL12_SENSOR_RAILED •Occluded or restricted pressure tube •Replace flow tube

E-48 ERR_PV2_SENSOR_RAILED •Occluded or restricted pressure tube •Replace pressure tube

•Defective pressure sensor •Replace Main PCA
E-49 ERR_FLASH_FAILURE •Defective FLASH chip •Replace Main PCA
E-50 ERR_UNRECOGNIZED_BOARD_REV •Needs new software •Replace Main PCA

•Defective PCA •Replace Main PCA
E-51 ERR_MOTOR_FAILURE •Defective motor drive chip •Replace Main PCA
E-52 ERR_BLOWER_RPM_FAILED_TOLERANCE •Stalled or locked blower •Replace Blower

•Replace Main PCA
E-53 ERR_BLOWER_OFF_CURRENT_HIGH •Stalled or locked motor •Replace Blower

•Defective motor drive chip •Replace Main PCA
E-54 ERR_BLOWER_ON_CURRENT_HIGH •Stalled or locked motor •Replace Blower

•Defective motor drive chip •Replace Main PCA
E-55 ERR_PRINTF_BUFFER_OVERFLOW •Defective PCA •Replace Main PCA
E-56 ERR_THERAPY_EVENT_QUEUE_FULL •Defective PCA •Replace Main PCA
E-57 ERR_KEYPAD_STUCK_KEY •Verify all keys protrude through top •Align keys with top
•Defective Keypad •Replace Keypad
•Defective pad on PCA •Replace Main PCA
E-58 ERR_UNUSED_58 •Reserved ----------
E-63 ERR_WATCHDOG_FAILURE •Defective microprocessor •Replace Main PCA
E-64 ERR_UNEXPECTED_WATCHDOG •Defective FLASH chip •Replace Main PCA

•Defective RAM chip •Replace Main PCA
E-66 ERR_RTOS_INIT_FAILURE •Defective PCA •Replace Main PCA
E-67 ERR_SERIAL_QUEUE_FULL •Defective PCA •Replace Main PCA
E-68 ERR_SNORE_SAMPLING_THREAD_LOCKED •Defective PCA •Replace Main PCA
E-69 ERR_MAIN_EXECUTION_THREAD_LOCKED •Defective PCA •Replace Main PCA
E-70 ERR_INTERNAL_RAM_FAILURE •Defective microprocessor •Replace Main PCA
E-71 ERR_EVENT_LOG_QUEUE_FULL •Defective PCA •Replace Main PCA
E-72 ERR_TREND_DIV_BY_ZERO •Defective RAM chip •Replace Main PCA
E-73 ERR_ROLLOVER_CASE •Defective RAM chip •Replace Main PCA
E-74 ERR_WRONG_DISPLAY_TYPE •Defective PCA •Replace Main PCA
E-75 ERR_ALARM_CAPACITOR_FAILURE •Defective PCA •Replace Main PCA
1018658 REMstar Auto with C-Flex and REM star Pro 2 Service Manual 6-16
E-76 ERR_OVER_PRESSURE •Occluded or restricted tube •Replace Pressure tubing

E-77 ERR_UNDER_PRESSURE •Occluded or restricted tube •Replace Pressure tubing

E-78 ERR_OVER_PRESSURE_REG •Occluded or restricted tube •Replace Pressure tubing

E-79 ERR_UNDER_PRESSURE_REG •Occluded or restricted tube •Replace Pressure tubing

E-80 ERR_ROTOR_LOCKED •Locked Motor •Replace Motor

•Defective PCA •Replace PCA
E-81 ERR_MOTOR_EDGE_MISSED •Defective Motor •Replace Motor

E-82 ERR_MOTOR_EDGE_EXTRA •Defective Motor •Replace Motor

E-83 ERR_MOTOR_OVERSPEED •Defective Motor •Replace Motor

E-84 ERR_MOTOR_BRAKE •Defective Motor •Replace Motor

E-85 ERR_MOTOR_CURRENT •Defective Motor •Replace Motor

E-86 ERR_INVALID_ERROR_CODE •Reserved ----------
6.5 SmartCard Error Codes
Code Label User Action
C-1 SMARTCARD_12C_WRITE_FAIL Card inserted upside-down. Remove card and reinsert properly.
Otherwise, card is corrupt and should be reprogrammed.
C-2 SMARTCARD_BAD_CARD_TYPE Card is not supported by this device. Otherwise, card is corrupt and
should be reprogrammed.
C-3 SMARTCARD_BAD_CIB_VERSION Card is corrupt and should be reprogrammed.
C-4 SMARTCARD_SCRIPT_DURING_PROVIDER_MODE Remove card. Exit Provider Mode screens. Then reinsert card.
C-5 SMARTCARD_PRESENT_IN_CAL_MODE Remove card. Exit Calibration Mode. Then reinsert card.
C-6 SMARTCARD_BAD_CIB_CHECKSUM Card is corrupt and should be reprogrammed.
C-7 SMARTCARD_NOT_PRESENT ----------
C-8 SMARTCARD_12C_READ_FAIL Card inserted upside down. Remove card and reinsert properly.
Otherwise, card is corrupt and should be reprogrammed.
C-9 SMARTCARD_WRITE_CONFIRM_FAIL Card is corrupt and should be reprogrammed. Otherwise, replace

card.
C-10 SMARTCARD_BAD_RI_BRAND Card is corrupt and should be reprogrammed.
C-100 SMARTCARD_BAD_CPB_CHECKSUM Card is corrupt and should be reprogrammed.
C-101 SMARTCARD_BAD_CPB_VERSION Card is corrupt and should be reprogrammed.
C-102 SMARTCARD_INVALID_UNIT -----------
C-103 SMARTCARD_UNKNOWN_CPB_FORMAT Card contains a prescription format that is not supported. Perhaps
card is intended for another device.
C-104 SMARTCARD_UNKNOWN_CPB_PRESCRIPTION Card contains a prescription type that is not supported. Perhaps
card is intended for another device.
C-105 SMARTCARD_SCRIPT_PARM_RANGE Card contains prescription settings that are outside of this device’s
range. Perhaps card is intended for another device.
C-106 SMARTCARD_BAD_CPB_SCRIPT_READY Card is corrupt and should be reprogrammed.
C-107 SMARTCARD_BAD_CPB_START_ADDR Card is corrupt and should be reprogrammed.
C-108 SMARTCARD_BAD_CPB_END_ADDR Card is corrupt and should be reprogrammed.
C-109 SMARTCARD_BAD_CPB_ERASE_PERMISSION Card is corrupt and should be reprogrammed.
C-200 SMARTCARD_BAD_CDCB_VERSION Card is corrupt and should be reprogrammed.
C-201 SMARTCARD_BAD_CDB_VERSION Card contains a storage format that is not supported. Perhaps card
is intended for another device.
C-202 SMARTCARD_BAD_CDCB_CHECKSUM Card is corrupt and should be reprogrammed.
C-203 SMARTCARD_BAD_CDCB_CONTROL_BLOCKS Card is corrupt and should be reprogrammed.
C-204 SMARTCARD_BAD_CDCB_START_ADDR Card is corrupt and should be reprogrammed.
C-205 SMARTCARD_BAD_CDCB_END_ADDR Card is corrupt and should be reprogrammed.
C-206 SMARTCARD_BAD_CDB_START_ADDR Card is corrupt and should be reprogrammed.
C-207 SMARTCARD_BAD_CDB_END_ADDR Card is corrupt and should be reprogrammed.
C-300 SMARTCARD_BAD_UIDB_VERSION Card is corrupt and should be reprogrammed.
C-301 SMARTCARD_BAD_UIDB_CHECKSUM Card is corrupt and should be reprogrammed.
C-302 SMARTCARD_BAD_UIDB_START_ADDR Card is corrupt and should be reprogrammed.
C-303 SMARTCARD_BAD_UIDB_END_ADDR Card is corrupt and should be reprogrammed.
C-400 SMARTCARD_BAD_DDCB_VERSION Card is corrupt and should be reprogrammed.
C-401 SMARTCARD_BAD_DDCB_CHECKSUM Card is corrupt and should be reprogrammed.
C-402 SMARTCARD_BAD_DDCB_PROFILE_CONTROL_BLOCKS Card is corrupt and should be reprogrammed.
C-403 SMARTCARD_BAD_DDCB_HISTOGRAM_CONTROL_BLOCKS Card is corrupt and should be reprogrammed.
C-404 SMARTCARD_BAD_DDCB_FOSQ_COMPL_CONTROL_BLOCKS Card is corrupt and should be reprogrammed.
C-500 SMARTCARD_FILE_OPEN_FAIL Card is corrupt and should be reprogrammed.
C-501 SMARTCARD_FILE_TELL_FAIL Card is corrupt and should be reprogrammed.
C-502 SMARTCARD_FILE_SEEK_FAIL Card is corrupt and should be reprogrammed.
C-503 SMARTCARD_FILE_READ_FAIL Card is corrupt and should be reprogrammed.
C-504 SMARTCARD_FILE_WRITE_FAIL Card is corrupt and should be reprogrammed.
C-505 SMARTCARD_FILE_GET_PTR_FAIL Card is corrupt and should be reprogrammed.
C-506 SMARTCARD_FILE_SET_PTR_FAIL Card is corrupt and should be reprogrammed.
6.6 Humidifier LED Error Code Chart
LED Blinks Problem / Cause Corrective Action
1 Temperature too high. Replace Humidifier Main PCA.

Thermistor shorted, over temperature condition.
2 Thermistor disconnected. Reconnect J2 on Humidifier Main PCA.

Temperature too low. Replace Heater Plate Assembly.
Replace Humidifier Main PCA.
3 Voltage too low on pin 6 of U1. Replace Humidifier Main PCA.
Conditions: When the Heated Humidifier is enabled, the LED will be on constantly.
When the Heated Humidifier is disabled, the LED will be off.
1018658 REMstar Auto with C-Flex Service Manual 6-22

Chapter 7: Repair and Replacement
Chapter 7: Repair &

Replacement
7.1 Overview ..................................................... 7-2
7.2 Repair Kits .................................................. 7-3
7.3 Replacement Instructions ......................... 7-8
Chapter 7: Repair & Replacement
7.1 Overview For technical assistance or replacement part ordering information contact
Respironics Corporate Technical Service.
This chapter illustrates the replaceable components in the REMstar Auto
with C-Flex and REMstar Pro 2. Procedures for replacing the components
are also provided in this chapter. U.S. and Canada
Phone: 1-800-345-6443
Fax: 1-888-886-0245
WARNING: Disconnect the electrical supply before attempting to
make any repairs to the device.
International
CAUTION: Electronic components used in this device are
subject to damage from static electricity. Repairs Phone: 724-387-4000
made to this device must be performed only in an
Fax: 724-387-5012
antistatic, ESD-protected environment.
Email: service@respironics.com
Visit Respironics Home Page on the World Wide Web at:
www.respironics.com
7.2 Repair Kits
Bottom Enclosure RP# 1011929* (Refer to note* page 7-7) Blower Assembly RP# 1022381
Outlet Port RP# 1008477 Main PCA RP# ** (Refer to note** page 7-7)
AC Power Cord RP# 1005894*** (Refer to note*** page 7-7) Sleep Link Communication Cable RP# 1007492
Mini DIN Plug RP# 1011220 Flow Element Kit RP# 1008490
Blower Top Foam RP# 1011219 Top Enclosure RP# 1022379 (REMstar Auto w/ C-Flex)
1022378 (REMstar Pro 2)
Respironics Utility Software

(Free download from http://servicesoftware.respironics.com)
Keypad RP # 1011221-Domestic (shown)

1008476-International
Pollen Filter RP# 1005964

Tubing Kit RP# 1022380 (Includes Tubing and
Dog Bone Coupler)
Ultra-Fine Filter RP# 1005945 Filter Cap RP# 1008479

* Contact Respironics Product Support for the proper labeling when

replacing the Bottom Enclosure
** The correct part number of the main PCA for your REMstar Auto
with C-Flex or REMstar Pro 2 is linked to the model number. Main
PCA RP#s are as follows:
• 1021760 REMstar Auto with C-Flex (International)

• 1021761 REMstar Auto with C-Flex (Domestic)
• 1021764 REMstar Pro 2 (International)
• 1021765 REMstar Pro 2 (Domestic)
*** Contact Respironics International Customer Service for further AC

power cord ordering information.
7.3 Repair and Replacement
Bottom
Top Filter Enclosure
Cover Filters
Enclosure
pg. 5-2 pg. 5-2 pg. 7-20
pg. 7-9
6
Blower Assembly
pg. 7-18
6
Main Printed 6
Circuit Assembly (PCA) Blower Top Foam
6 pg. 7-13 pg. 7-18

Key Installation Flow Chart
6 Removal Flow Chart 6
Pad
Outlet Port / Dog Bone
Flow Element Coupler
pg. 7-11
pg. 7-15
6 6
Dog Bone Outlet Port /
Coupler Flow Element
Key
pg. 7-17 pg. 7-15 Pad
6 pg. 7-11
Blower Top Foam 6
Main Printed
pg. 7-18
Circuit Assembly (PCA)
6
pg. 7-13
Blower Assembly
6
pg. 7-18 Top
Filter
Filters Enclosure
6 Cover
Bottom pg. 5-2 pg. 5-2 pg. 7-9
Enclosure
pg. 7-20
Procedure
7.3.1 Top Enclosure Replacement
Step 1 Remove the Top Enclosure:
Replacement Part Number 1022379 (REMstar Auto with C-Flex) a. Place the device on a protected work surface and
1022378 (REMstar Pro 2) carefully turn it over, exposing the bottom.
b. Using a Phillips screwdriver, remove the three screws

that secure the top enclosure to the bottom enclosure.
Included in kit: Tools Required: 1 2

Top Enclosure Phillips screwdriver (No. 2 medium)
8 Hi - Lo x 1/2″ (x3)
3
c. While securely holding the top and the bottom
enclosure together, carefully return the device to its
upright position.
Top Enclosure (REMstar d. Lift the top enclosure up and away from the bottom
Auto with C-Flex Shown) enclosure.
Top Enclosure Replacement (Continued)
Step 2 Install the Top Enclosure:
a. Align the Top Enclosure with the Bottom Enclosure, Keypad

Outlet Port, etc.
b. While securely holding the Top Enclosure and Bottom

Enclosure together, carefully turn the device upside down.
c. Insert and tighten the three Phillips screws to secure the Top
Enclosure to the Bottom Enclosure.
d. Return the device to its upright position.
Procedure
7.3.2 Keypad Replacement
Replacement Part Number 1020294 (International) Step 1 Remove the Top Enclosure (Refer to section 7.3.1)
1020325 (Domestic)
Step 2 Remove the Keypad:
Included in Kit: Tools Required:
Keypad Phillips screwdriver (No. 2 medium) a. Carefully lift the Keypad from the Main PCA.
Flat-blade screwdriver (small) There are three rubber locking pins that hold the keypad to
the Main PCA.
Keypad
Locking Pins
(International
Keypad Shown)
Keypad Replacement (Continued)
Step 3 Install the Keypad:

a. Place the Keypad on the Main PCA. Align the locking
pins with the three holes on the display assembly. Press
down on the locking pins until they snap into place.
Align Locking Pins Here
Step 4 Install the Top Enclosure (Refer to section 7.3.1)
Procedure
7.3.3 Main Printed Circuit Assembly
Step 1 Remove the Top Enclosure (Refer to section 7.3.1)
(Main PCA) Replacement
Step 2 Remove the Keypad (Refer to section 7.3.2)
Replacement Part Numbers:
Step 3 Remove the Main PCA:
• 1021760 REMstar Auto with C-Flex (International)
• 1021761 REMstar Auto with C-Flex (Domestic) a. Lift the Main PCA and hold it slightly above the
Blower Assembly to provide access to the Blower
• 1021764 REMstar Pro 2 (International) Wiring Harnesses and tubing connected to the Main
• 1021765 REMstar Pro 2 (Domestic) PCA.
NOTE: The correct part number of the main PCA for your unit is linked
to the model number.

Main PCA No. 2 Phillips screwdriver
Main PCA Tubing

Wiring Harnesses Connect Here
b. Disconnect the Wiring Harnesses and tubing from the

Main PCA.
c. Lift the main PCA up and away from the bottom
enclosure assembly.
Main PCA Replacement (Continued)
Step 3 Install the Main PCA

NOTE: It is necessary to perform testing, calibration, and run-in
a. While holding the main PCA over the bottom enclo- procedures prescribed in chapter 8 of this manual anytime the
sure assembly, attach the flow element tubing and
pressure tubing to the Main PCA. Main PCA is removed and/or replaced.
b. Attach the blower connectors and the light pipe.

c. Gently set the Main PCA down on the three stands
that hold the Main PCA in place.
PCA Stands
Step 4 Install the Keypad (Refer to section 7.3.2)

Procedure
7.3.4 Outlet Port Replacement
Step 2 Remove the Main PCA (Refer to section 7.3.3)
Replacement Part Number 1008477
Step 3 Remove the Outlet Port:
Outlet port Phillips screwdriver (No. 2 medium) a. Remove the pressure tubing from the Outlet Port.
b. Separate the Outlet Port from the Flow Element.
c. Lift the Outlet Port out of the Bottom Enclosure.
Outlet Port
Step 4 Install the Outlet Port:
a. Connect the tubing to the Outlet Port.
b. Slide the Outlet Port into the Flow Element.
c. Place the Outlet Port in the Bottom Enclosure.
Step 5 Install the Main PCA (Refer to section 7.3.3)
7.3.5 Flow Element Replacement Procedure
Replacement Part Number 1008490 Step 1 Remove the Top Enclosure (Refer to section 7.3.1)
Flow Element Phillips screwdriver (No. 2 medium) Step 3 Remove the Outlet Port (Refer to section 7.3.4)
Step 4 Remove the Flow Element:

a. Gently pull flow element tubing off the flow element.
Flow Element
b. Slide the flow element out of the Dog Bone Coupler.
Step 5 Install the Flow Element:

a. Slide the flow element into the Dog Bone Coupler.
b. Connect the tubing from P2 on the PCA to the port on
the flow element closest to the outlet port.
c. Connect the tubing from P1 on the PCA to the port on
the flow element closest to the blower.
Step 6 Installing the Outlet Port (Refer to section 7.3.4)

Step 7 Installing the Main PCA (Refer to section 7.3.3)
Step 8 Installing the Top Enclosure (Refer to section 7.3.1)
Tubing
7.3.6 Dog Bone Coupler Replacement Procedure

Replacement Part Number 1011218 (Tubing kit)
Dog Bone Coupler Phillips screwdriver (No. 2 medium) Step 3 Remove the Outlet Port (Refer to section 7.3.4)
Tubing
Step 4 Remove the Flow Element (Refer to section 7.3.5)
Step 5 Remove the Dog Bone Coupler:
a. Slide the Dog Bone Coupler off of the Blower Assembly.
Dog Bone Coupler Step 6 Install the Dog Bone Coupler:

a. Slide the Dog Bone Coupler onto the Blower Assembly.
Step 7 Install the Flow Element (Refer to section 7.3.5)

Step 8 Installing the Outlet Port (Refer to section 7.3.4)
Procedure
7.3.7 Blower Assembly Replacement
Replacement Part Number 1022381
Blower Assembly Phillips screwdriver (No. 2 medium) Step 3 Remove the Outlet Port (Refer to section 7.3.4)

Step 5 Remove the Dog Bone Coupler (Refer to section
7.3.6)
Blower Assembly
Step 6 Remove the Blower Assembly:
3
7
5
a. 1
Remove the Blower Top Foam.
b. Remove the Bottom Enclosure.

6
Step 7 Remove the Blower Assembly:
2 4
a. Remove the protective backing from the adhesive ring
on the Blower Assembly.
b. Align the Blower Assembly air outlet with the

opening in the foam insert.
c. Firmly press the Blower Assembly into the foam

insert.
Blower Assembly Replacement (Continued)
d. Wrap the red/green/black wiring around the bottom of

the air outlet one time.
e. Place the blower top foam over the blower assembly

and press into the foam insert.
Step 8 Install the Dog Bone Coupler (Refer to section

7.3.6)
Step 10 Install the Outlet Port (Refer to section 7.3.4) 3

7
5
Step 11 Install the Main PCA (Refer to section 7.3.3) 1

6
7.3.8 Bottom Enclosure Replacement Procedure

Replacement Part Number 1011929 Step 1 Remove the Top Enclosure (Refer to section 7.3.1)
Included in Kit: Tools Required: Step 2 Remove the Main PCA (Refer to section 7.3.3)
Bottom Enclosure (w / label) Phillips screwdriver (No. 2 medium)
8 Hi - Lo x 1/2″ (x3) Step 3 Remove the Outlet Port (Refer to section 7.3.4)

Step 5 Remove the Dog Bone Coupler (Refer to section
7.3.6)
Step 6 Remove the Blower Assembly (Refer to section 7.3.7)
Step 7 Remove the Bottom Enclosure:
a. Remove the Remove the Mini Din Plug from the

Bottom Enclosure.
Bottom Enclosure
Mini DIN Plug
Bottom Enclosure Replacement (Continued)
Step 8 Replace the Bottom Enclosure:

a. Install the Mini Din Plug into the Bottom Enclosure.
Step 9 Install the Blower Assembly (Refer to section 7.3.7)
Step 10 Install the Dog Bone Coupler (Refer to section

7.3.6)
Step 12 Install the Outlet Port (Refer to section 7.3.4)
Chapter 8: Testing, Calibration, and Verification
Chapter 8:
Testing, Calibration, and
Verification
8.1 Overview ..................................................... 8-2
8.2 Run-in .......................................................... 8-2
8.3 Real-time Clock Calibration .................... 8-3
8.4 Load Serial and Model Numbers ............ 8-5
8.5 System Calibration .................................... 8-6
8.6 Current Draw Test .................................. 8-13
8.7 Manual Heated Humidifier

Test........................................................ 8-14
8.8 Performance Verification ....................... 8-15
8.9 Test Data Sheets ....................................... 8-16
Chapter 8: Testing 8.2 Run-in
8.1 Overview Before the REMstar Auto with C-Flex or REMstar Pro 2 can be calibrated,
the device must be run-in for at least 2 hours to avoid possible calibration
This chapter provides run-in, calibration, AC current draw testing, and failures.
performance verification procedures for the REMstar Auto with C-Flex and
REMstar Pro 2. Calibration and AC current draw testing are necessary only Equipment
when a repair has been made to the unit. However, these procedures may
• 0.25” Test Orifice (p/n 332353)
be used in conjunction with the performance verification to determine
whether or not the unit is functioning properly. Verification shall be
performed at periodic intervals commensurate with hospital or Homecare Procedure
Provider guidelines for preventative maintenance, between rentals, or
during normal patient usage. Step 1 Connect the test orifice to the Outlet Port of the unit.
Calibration and testing of the REMstar Auto with C-Flex and REMstar Pro 2 Step 2 Enter the therapy setup menu (refer to Chap. 4) and set the
requires the use of Respironics Utility Software. Before proceeding, log on pressure to 20 cm H2O.
to (http://servicesoftware.respironics.com) and download the Utility
Software on to your PC. Step 3 Run the unit for at least 2 hours before performing
the calibration.
8.3 Real-time Clock Calibration
The Unit Under Test (UUT) will record and track several different param-
eters (e.g. patient pressures, apnea events, when and how the device is
used, error codes, etc.) To do this in a logical manner and for a technician or
therapist to know exactly when a certain event has occurred, the REMstar
Auto with C-Flex and REMstar Pro 2 runs and records events at real-time. Click here
This time is checked and compared to your computer’s time when running
the calibration software. If the times do not match, the calibration will fail.
Therefore, you must perform the real-time clock calibration before you
proceed with the calibration.
Equipment
• SleepLink Interface Card w/cable (p/n 1007492)

• Utility Software
Procedure
Step 1 Ensure AC power is connected to the UUT.
Step 2 Connect the Sleeplink cable to communication port (1) of

your computer. Connect the other end of the cable to the
SleepLink card. Place the SleepLink card in to the UUT.
Figure 8-1
Step 3 On your computer, open the Utility Software and select, Begin Calibration
“Real-time Clock Calibration”.
Step 4 Click on the red “Set Clock / Verify Clock” button to begin
calibration (the button will turn green.)
Real-time Clock Calibration (continued)
Step 5 In the upper lefthand corner, click on the white runtime arrow. Step 6 When the program has finished, a green “PASS” indicator
The program will now set the appropriate date and time on will appear.
the UUT.
“PASS”
Indicator
Runtime
Arrow
Figure 8-3
Calibration Complete
Figure 8-2
Setting Time and Date
8.4 Main Printed Circuit Assembly (Main Step 1 Connect the UUT to a PC:
PCA) / Load Serial and Model Number a. Connect the communication cable between the SleepLink card
and the serial port COM1 PC.
NOTE: During the manufacturing process, the Serial Number is
programmed into the memory of the Main PCA. This process b. Connect the UUT to the proper AC voltage source.
gives Homecare Providers the ability to link the information
from the Encore SmartCard to a specific device for a more
complete patient record. Although this process is important for Step 2 Load the Serial and Model Number
tracking patient information, it is not necessary for the perfor-
mance of the unit. a. Click on the Start Button of your computer.
b. Select:
Programs
Respironics
Parts Needed: Tools Required:
Tools
Sleep Link Card (1007492)
Load Serial and Model Number
Communication Cable None
Utility Software (download from servicesoftware.respironics.com
c. With your mouse, click on the RUN arrow to
start the software program.
Minimum System Requirements
• Windows 95/98/2000/NT d. When prompted, enter the Serial Number of the unit. Press
enter, or click on “OK” with your mouse.
• Color Monitor with 256 colors, 800 x 600 resolution
• Windows-compatible pointing device (mouse) e. Type in the Model Number of the unit. Press
• Windows-supported serial port (COM1 - COM4) enter, or click on “OK” with your mouse.
• 2.5 MB free hard disk space
f. The software will automatically transfer the information into
the memory of the new PCA. A green PASS box will appear.
8.5 System Calibration Procedure

Step 1 Connect the RS-232 connector of the SleepLink cable to
This procedure provides instructions for the calibration of the REMstar communication port (1) of the computer. Connect the other
Auto with C-Flex and REMstar Pro 2. The results of this calibration can be end of the cable to the SleepLink card. Insert the SleepLink
printed to a local printer and used as a final test data sheet that can be card into the UUT (the card must be inserted with the word
retained as part of the device history record. “SleepLink” facing upwards).
Step 2 Connect the AC power cord to the UUT.
Step 3 Set the UUT on the REMstar Heated Humidifier and connect
the AC power cord to the Humidifier.
Equipment
• Utility Software Step 4 Connect the O2 adapter to the outlet of the UUT and occlude
• Digital Manometer (see Appendix A) the adapter.
• Windows®-compatible personal computer running
• Windows 95 or higher version software NOTE: Remove the humidifier’s reservoir if connected. All connections
Printer must be made to the outlet port of UUT.
• SmartLink card with cable. (P/N 1007492)
• Flowmeter (range: +180 to -180 LPM, 3% accuracy, 1 LPM resolu-
tion)
• Flow control valve
• Pressure pick-off adapter (O2 Enrichment Adapter)
• Pressure tubing
• Negative flow source (CPAP capable of 60 LPM)
• Smooth Bore Patient Tubing
• REMstar Heated Humidifier
System Calibration (continued)
Step 7 Start the calibration by clicking on the white runtime arrow in
the upper lefthand corner of the window.
Step 5 Connect the pressure tubing from the O2 port of the O2
adapter to the digital manometer. (Refer to figure 8-4 for
setup.) Runtime Arrow
SleepLink Card
Manometer
Figure 8-5
System Setup
Step 8 The program will then prompt the user to enter the serial
number. After typing in the serial number, click (OK). Next,
type in the model number and click (OK). Enter the user name
and hit (ENTER) on the keyboard.
O2 Adapter
Figure 8-4
w/ End Cap Step 9 The program will then run through a series of humidifier,
Pressure Setup
lighting, alarm, and display tests. Follow the instructions on
Step 6 Open the Calibration Software. the screen.
Step 10 When the prompt in Figure 8-6 appears, the program is ready
to start the pressure sensor calibration. Click on the (OK)
button.
Figure 8-7
Increase/Decrease Blower Speed
Step 12 Type in the pressure reading from the manometer and press
(ENTER) on the keyboard.
Figure 8-6
System Calibration
Step 11 Observe the manometer. If the pressure is higher than 4.00cm
H2O, click on the red button to decrease the blower speed. If
the pressure on the manometer is lower than 4.00cm H2O,
click on the green button to increase blower speed. Each time
a button is clicked, the pressure will change by approximately
0.2cm H2O. When 4.00cm H2O is achieved, click on
(DONE). Figure 8-8
NOTE: Let the pressures stabilize for at least one minute before Entering Manometer reading
making any adjustments during the calibration.
Step 13 The program will now request calibration at several higher

Patient tubing
pressures. Perform the same procedure for the remaining
different settings. Patient tubing
Step 14 After the last pressure calibration is performed, the following

prompt will appear, indicating the program is about to start Flow meter
the flow element calibration. The program will first calibrate Flow valve
positive flow.
Figure 8-10
Calibration Circuit
Step 16 Observe the flow meter. If the flow is greater than 160 LPM,
click on the red button to decrease the flow. If the flow is less
than 150 LPM, click on the green button to increase the flow.
When the UUT is delivering between 150 - 160 LPM, click on
the (DONE) button.
Figure 8-9
Flow Element Calibration
Step 15 Unblock the end of the O2 adapter. Connect a section of

patient tubing between the O2 adapter and the inlet of the
flow meter. Connect another section of patient tubing from
the outlet of the flow meter to the flow control valve (com-
pletely open the flow valve). Click on the green (OK) button
on the program window. Figure 8-11
Increase/Decrease Flow
Step 19 The program will now request several different flow settings
Step 17 Observe the flow meter and adjust the flow control valve until decreasing in value down to and including zero flow. For
150 LPM of flow is achieved. Click on the green (OK) each setting, use the flow control valve to set the flow and
button. then type in each value. After zero flow is confirmed, the
following prompt will appear.
Figure 8-12
Flow Element Calibration Figure 8-14
Step 18 Enter in the flow reading from the flow meter and press Zero Flow Confirmation
(ENTER) on the keyboard.
Step 20 The program will now calibrate negative flow. Connect
another section of patient tubing between the outlet of the
flow control valve and the outlet of the negative flow source
(refer to Figure 8-15). Turn on the negative flow source and
click the green (OK) button.
NOTE: For the negative flow source, another REMstar device may be
used with the pressure set to 20cm H2O.
Figure 8-13
Entering the Flow Meter Reading

Negative flow source
Figure 8-16
Negative Flow Value Display
Figure 8-15
System Calibration with Negative Flow Source
Step 21 The program will now calibrate the negative portion of the
flow table. Although the flow meter may not display a
negative flow, pressure against the normal direction of flow of
the device is considered a negative flow. Adjust the flow
control valve until 10 LPM is displayed on the flow meter and
click (OK). Refer to figure 8-16.
Step 22 Before entering the flow value, ensure that the negative or
minus symbol is typed in first. The software will reject a
positive value here. Figure 8-17
Entering the Negative Flow Value
System Calibration (continued) Step 28 When the pressure verification is complete, the program will
request a button test for the UUT. Press the buttons on the
Step 23 Once again, use the flow control valve to set the negative device in the order that they are numbered on the program
flows that the program requests and enter the values. screen.
Step 24 The program has now completed calibrating the flow and Step 29 When the button test has been completed and the UUT has
pressure sensor. Pressure and flow accuracy of the device successfully passed all tests, a green (PASS) prompt will
must now be verified. The program will now read the pressure appear on the computer screen. Click the (OK) button to view
and flow parameters from the device and compare these the test data sheet. Click (OK) on the print results button to
readings to the pressure and flow values that the user will print the test data sheet. Sign the sheet and retain as part of a
enter. device history record. This completes the calibration proce-
dure. The Current Draw Test must now be performed (proceed
Step 25 The program will first verify positive flows. Turn off the to section 8.5).
negative flow source and disconnect the patient tubing from
between the negative flow source and the flow valve. Com-
pletely open the flow valve. Follow the prompts on the screen
for the flow settings.
Step 26 After zero flow is confirmed, the program will verify negative
flow. Connect the patient tubing between the outlet of the
flow valve and the negative flow source. Turn on the negative
flow source and follow the prompts.
Step 27 After completion of the negative flow verification, pressure

accuracy will be checked. Turn off the negative flow source.
Disconnect the patient tubing from the UUT and occlude the
O2 port. The program will now command the UUT to produce
specific pressures. Observe the manometer and enter the
value for each pressure setting.
8.6 Current Draw Test
Step 4 Record the current reading from the multimeter in the
This procedure provides instructions for testing the current draw on the space provided on the Testing Data Sheet. Sign and date the
test sheet and retain for a device history record. This con-
REMstar Auto with C-Flex.
cludes the REMstar Auto with C-Flex Current Draw Test
Equipment
• 0.25” Test Adapter (p/n 332353) (see Appendix A)
• Multimeter
• Test Leads
NOTE: Test leads can be made by opening one lead of the power cord
and installing the proper cable ends to connect to the multi-
meter.
Step 1 Place the test adapter on the outlet of the UUT. Enter the
Setup menu and set the pressure to 20 cm H2O.
Step 2 Connect the UUT and the Multimeter (Set to Current) in

series with the hot side of the AC power cord. Connect the
AC power cord to the UUT and plug the cord into an AC
outlet.
Step 3 Turn on the UUT and allow the device to stabilize for at least
one minute.
8.7 Manual Heated Humidifier Test Step 1 Humidifier Preheat Test

a. Connect the UUT to the Heated Humidifier.
Purpose b. Set the Heated Humidifier setting to 1.
This procedure provides instructions for the Heated Humidifier System to c. Start the preheat mode and observe the following:
be tested without the test station set-up. This test is optional and may be 1. The icon appears on the CPAP display screen.
performed if the automated heated humidifier test is not performed.
2. The green LED on the front of the Heated Humidifier
is illuminated.
CAUTION: Electronic components used in this device are subject
d. Record the results (pass / fail) on the Test Data Sheet.
to damage from static electricity. Use and follow
appropriate Electro-Static Discharge (ESD) procedures. Step 2 Humidifier Heat Test
Equipment a. All of the connections remain the same as in step 1.

b. Turn the device blower on and observe that the green
• Heated Humidifier LED on the front of the Heated Humidifier is a solid
green LED.
c. Observe heater plate warms.
d. Record the results (pass / fail) on the Test Data Sheet.
8.8 Performance Verification Procedure
Step 1 Place the O2 port on the outlet of the device and connect the
The performance verification can be used as a way to determine if the pressure tubing between the test orifice and the manometer.
REMstar Auto with C-Flex and REMstar Pro 2 is functioning properly. This Occlude the O2 port on the device.
verification may be performed between rentals, during normal patient
usage, as routine maintenance, or as a screening procedure. Perform this Step 2 Enter the Setup menu and set the pressure to 4 cm H2O. Turn
procedure after the Run-in (refer to section 8.2) on the UUT and allow the unit to stabilize for at least one
minute.
Equipment
Step 3 Record the pressure reading of the manometer in the space
provided on the Testing Data Sheet.
• O2 Enrichment Attachment (p/n 312710) (see Appendix A)
• Pressure Tubing Step 4 Set the pressure on the UUT to 20 cm H2O. Allow the
• Manometer pressure to stabilize for at least one minute.
Step 5 Record the pressure reading of the manometer in the

space provided on the Testing Data Sheet.
Performance Verification
Serial No.____________________ Model No.____________________
Hours____________________
Tolerance Tolerance
CPAP Performance Verification 4cm H2O (_____) 3-5 cm H2O 20cmH2O (_____) 19-21 cm H2O
Date _____/_____/_____ Name (Print)____________________ Signature (In Ink)_____________________
Current Draw Test

Serial No.____________________ Model No.____________________
Hours____________________
Tolerance
Current Draw @ 20cm H2O (_____) <1.0 A
Date _____/_____/_____ Name (print)____________________________ Signature (In Ink) ______________________________
NOTE: Attach this form to printout of System Calibration.
Appendix A
Appendix A: Tools and

Equipment
A.1 Service Tools and Supplies ................. A-2
A.2 Acceptable Test Equipment ................ A-3
1018658 REMstar Auto with C-Flex and REMstar Pro 2 Service Manual A-1
Appendix A
Appendix A: Tools and Equipment

• Cleaning Cloth
• Digital Manometer - see Section A.2
• Digital Multimeter - see Section A.2
• Flow Meter - see Section A.2
A.1 Service Tools and Supplies • Test Leads
• Isopropyl Alcohol
You should have the following hand tools and supplies available for
troubleshooting, testing, and repairing the REMstar Auto with C-Flex and • Mild Detergent
REMstar Pro 2 systems. • Pressure Tubing
• Test Orifice (RI P/N 332353)
• Common Hand Tools:
• Whisper Swivel II (RI P/N 332113)
Flat-blade screwdriver - small
• Adjustable Flow Valve (RI P/N 1006120)
Phillips screwdriver - #2
• CPAP (for negative flow)
• Antistatic, Electro-Static Discharge (ESD)-protected
• O2 Enrichment Port (RI P/N 312710)
work station - minimum requirement is a grounded
mat and wrist strap
• Microsoft® Windows®-compatible personal computer
running Windows 95, 98, 2000, NT®, and XP® with a CD-
ROM drive
Appendix A
A.2 Acceptable Test Equipment A.2.2 Digital Multimeter
Specifications:
A.2.1 Digital Manometer*
2.5 digit readout minimum
Specifications: 0.0 - 20.0 VDC
0 - 25 cm H2O (or better) 0.0 - 25.0 VAC
±0.3 cm H2O accuracy
±0.1 cm H2O resolution Acceptable Options:
• Fluke 83 or better model
Acceptable Options: • Any commercially available multimeter
• Respironics Digital Manometer that meets the above specifications.
• TSI Certifier FA Test System, High Flow Module
(RI P/N 1012598)
• Merical DP2001 A.2.3 Flow Meter
Specifications:
• Sensym PDM 200CD
Range: +180 to -180 LPM
• Any commercially available digital manometer
± 2% accuracy
that meets the above specifications.
± 1 LPM resolution
* A water column manometer may also be used.
Acceptable Options:
• TSI Certifier FA Test System, High Flow Module
(RI P/N 1012598)
• TSI 4000 Series Flow Meter
• Any commercially available flowmeter that meets the
above specifications.
Appendix A
Appendix B
Appendix B: Schematics
Schematic Statement ............................................. B-2
Motor Driver .......................................................... B-3
Power Supply ......................................................... B-4

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

Analog Circuit ........................................................ B-7
Microprocessor...................................................... B-8
1018658 REMstar Auto with C-Flex and REMstar Pro 2 Service Manual B-1
Appendix B
Appendix B: Schematics
B.1 Schematic Statement
Schematics are supplied with this manual in direct support of the sale and
purchase of this product.
The schematics are proprietary and confidential. Do not copy the schemat-
ics or disclose them to third parties beyond the purpose for which they are
intended. Patents are pending.
The schematics are intended to satisfy administrative requirements only.

They are not intended to be used for component level testing and repair.
Any changes of components could effect the reliability of the device,
prohibit lot tracking of electronic components, and void warranties. Repairs
and testing are supported only at the complete board level.
The schematics are of the revision level in effect at the time this manual was
last revised. New revisions may or may not be distributed in the future.
Appendix B
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PA15/TXD 0 G ND
84 66 G ND +3.3V
PA16/R XD 0 PA0/TC LK3 SD A_D ISPLAY
*
TXD 0
PA3/TC LK4
69
SC L_D ISPLAY *
JP2
85 72 IN TER N ATIO N AL/D O M ESTIC

J
R 89 PA17/SC K1 PA6/TC LK5 2

86
+5V PA18/TXD 1/N TR 1 C R 20
10.0K 91 67 R 32 3
PA19/R XD 1 PA1/TIO A3 H ALL M TR _C TR _EST C
10.0K
R 29
68 90.9K BAV99L
TXD 1 PA2/TIO B3
G ND R 155 92
PA20/SC K2
.01uF
10.0K
C 76
R 75
+5V 93 70 1
+5V 10.0K PA21/TXD 2 PA4/TIO A4 BEM F +5V +5V
94 71
R XD 1 PA22/R XD 2 PA5/TIO B4
R 13 95 75 G ND
SC K
R 14 PA23/SPC K PA7/TIO A5 R AW _PW M
96 76
R 154
10.0K
M ISO 33.2 PA24/M ISO PA8/TIO B5

C R8 97 C
R 103
R 101
10.0K
10.0K
10.0K
10.0K
10.0K
33.2 G ND +5V
R 37
R 18
R 21
R 27
R 34
M O SI
N PC S0
33.2 98
99
PA25/M O SI
PA26/N PC S0/N SS PB0
139
140
C TL_H I_A * * SW 4 RAM P
N PC S1 PA27/N PC S1 PB1 C TL_LO _A
100 141 1 2
PA28/N PC S2 PB2 C TL_H I_B
101 149 SW ITCH CO ND RUBBER 3M M SPSTNO
+3.3V PA29/N PC S3 PB8 C TL_LO _B
.1uF
C 16
150 SW 5
PB9 C TL_H I_C N PC S1
117 151 1 2
VD D A PB10 C TL_LO _C
M ISO
U3
152 SW ITCH CO ND RUBBER 3M M SPSTNO
PB11 1 8
126 153 SW 6 CS VC C
+5V
1000pF
AD VR EF PB12 2 7 G ND
.1uF
C 30
C 29
154 1 2 SO H O LD
PB13 3 6
127 155 SW ITCH CO ND RUBBER 3M M SPSTNO WP SC K SC K
D AVR EF PB14 4 5
156 VSS SI M O SI
PB15
157
PB16 N M 25C 040 +5V
G ND 130 158 SW 7
G NDA PB17 O N /O FF G ND
145
PB6/AD 0TR G N W D O VF
159 * C 80
1 2
R 104
10.0K
R 102
10.0K
G ND 146 160
SW ITCH CO ND RUBBER 3M M SPSTNO
PB7/AD 1TR G M CKO C 87 Y1 SW 8
105 G ND 15pF
.1uF
C 52
XIN C 77 1 2
118 106 R 81 4.9152 M H Z
PR ESS AD 0 XO U T SW ITCH CO ND RUBBER 3M M SPSTNO
119 108 1.00K C 28 15pF
FLO W AD 1 PLLR C
120 1200pF C 23 U 14
C AD 2 R 10 G ND +3.3V
121 SW 9 1 8 G ND
AD 3 N PC S0 C S /SH D N VD D
122 170 499 R IG H T
AD 4 N R ST 120pF 1 2
123 G ND 2 7
AD 5 PR ESS CH0 C LK SC K
I_LO _SID E
BATTER Y_BU
124
125
AD 6
AD 7 N R STBU
112 R 22
CR3
* SW ITCH CO ND RUBBER 3M M SPSTNO
SW 10
FLO W
3
CH1 DO UT
6
M ISO
B XIN 32
110 1.00M 1 2 B
128 111 + C 35 4 5
.1uF
C 38
SW ITCH CO ND RUBBER 3M M SPSTNO

PP8 DA0 XO U T32 1 BATTER Y_BU VSS DIN M O SI
+8V VBU LK 129 10uF
PP7 DA1 2 Y3 25V M C P3202BI/SN
3
32.768 KH Z
BAT54
CR5
AT91M 55800-33AI 3 G ND
4 SW 11 LEFT
ZER O
.1uF
C 24
R 23
39.2K
39.2K
G ND G ND
R 31
R 24
1 2
1
Q 21 VBU LK
SW ITCH CO ND RUBBER 3M M SPSTNO +5V
BSS84LT1
C 82
C 81
* * SW 12
R 130
2.00K
1 2
G ND G ND 2 3 LS1
10.0K
10.0K
.1uF
.1uF
R 33
C 40
C 37
R 26
SW ITCH CO ND RUBBER 3M M SPSTNO 1
1.00K
R4
47.5
1
R 73
2
SW 1 HUM ID
G ND 1 2 TXD 0
+ B1 BU ZZER
G ND G ND SW ITCH CO ND RUBBER 3M M SPSTNO IR
+3.3V BR 2032-1H E C R 9 LIN K
SW 2 R1
BU ZZER Q4
1 2 ZTN 155W -03 1.00K M M BT3904LT1
G ND SW ITCH CO ND RUBBER 3M M SPSTNO
+5V +5V SW 3
.1uF
C 93
+3.3V U2 1 2 G ND
R 131 +5V
1 8 SW ITCH CO ND RUBBER 3M M SPSTNO
SENSE1 VD D G ND
ZER O R 132 2 7
R 124
10.0K
SENSE2 MR PP2 G ND
ZER O 3 6 2
PP1 W DI R ESET PP3 G ND
CR4
C 99
C 98
4 5 3
G ND R ESET N R ST
A TPS3305-33D BAV99L A
* * G ND 1 PR O D U C T LIN E:
.1uF
C 94
C -FLEX
G ND G ND
G ND
R 156 PR O C ESS: TITLE:
SPV_W D T N O TES: AU TO C -FLEX,D O M ESTIC
ZER O SCHEM ATIC
G ND 1. R EFER TO SEPAR ATE BILL O F M ATER IALS FO R AD D ITIO N AL PAR T IN FO R M ATIO N . M ICRO & DIG ITAL
2. -IN D IC ATES ITEM S N O T IN STALLED .
* DRN BY: J.KAU C IC 9-25-03 SIZE D R AW IN G N O .
S1017737
R EV.
CHK BY: EDM S EDM S D 0

SC ALE PAR T N O . SH EET OF
APPR BY: EDM S EDM S N /A 1017737 1 6
8 7 6 5 4 3 2 1
Appendix B
8 7 6 5 4 3 2 1
SEE SH EET 1
D 0:15
U 19:C
A1:A19
D 35 7 D
D0 D0 AO /N LB A0
+5V
36 8
D1 D1 A1 A1
+5V
37 9
D2 D2 A2 A2
.1uF
C3
38 10
D3 D3 A3 A3
.1uF
.1uF
C 14
C 13
39 11 U 22
D4 D4 A4 A4 U 20
11 23 G ND
A1 A0 Vcc 41 11
40 12 10 OE OE VC C
D5 D5 A5 A5 A2 A1 6 33 G ND G ND
9 15 N C S2 CS VC C
A3 A2 DQ 0 D 15 40
41 13 8 17 17 UB NW R1
D6 D6 A6 A6 A4 A3 DQ 1 D 13 WE WE 39
7 19 LB A0 D 0:15
A5 A4 DQ 2 D 11
42 14 6 21 A1:A19 1 7
D7 D7 A7 A7 A6 A5 DQ 3 D9 A14 A0 I/O 1 D0
5 24 2 8
A7 A6 DQ 4 D7 A13 A1 I/O 2 D2
47 17 4 26 3 9
D8 D8 A8 A8 A8 A7 DQ 5 D5 A12 A2 I/O 3 D4
42 28 4 10
A9 A8 DQ 6 D3 A11 A3 I/O 4 D6
48 18 41 30 5 13
D9 D9 A9 A9 A10 A9 DQ 7 D1 A10 A4 I/O 5 D7
40 16 18 14
A11 A10 DQ 8 D 14 A5 A5 I/O 6 D5
49 19 39 18 19 15
D 10 D 10 A10 A10 A12 A11 DQ 9 D 12 A6 A6 I/O 7 D3
38 20 20 16
A13 A12 D Q 10 D 10 A1:A19 A7 A7 I/O 8 D1
50 20 37 22 21 29
D 11 D 11 A11 A11 A14 A13 D Q 11 D8 A8 A8 I/O 9 D8
36 25 24 30
A15 A14 D Q 12 D6 A9 A9 I/O 10 D 10
51 21 35 27 25 31
D 12 D 12 A12 A12 A16 A15 D Q 13 D4 A2 A10 I/O 11 D 12
34 29 R2 26 32
+3.3V A17 A16 D Q 14 D2 A19 A3 A11 I/O 12 D 14
*
52 22 3 31 27 35
D 13 D 13 A13 A13 A18 A17 D Q 15 D0 A4 A12 I/O 13 D9
C A15
42
A13 I/O 14
36
D 11 C
53 23 33 R3 43 37
D 14 D 14 A14 A14 +5V BYTE 2 A16 A14 I/O 15 D 13
RY/BY 44 38
12 A1 A15 I/O 16 D 15
R 113
10.0K
10.0
54 24 N C SO CE 22
D 15 D 15 A15 A15 14 1 A17 NC
OE OE NC
43
25 WE WE 13
A16 A16 Vss 12 23
100K
R5
44 32 G ND NC A18
R 123
N R ST R ESET Vss 34 28
172 26 G ND NC PP54
OE N R D /N O E A17 A17 AM 29F400AB-90SC
R 122 33.2 173 K6R 1016C 1C -J
WE N W R 0/N W E
R 25 33.2 174 27 G ND
NW R1 N W R 1/N U B A18 A18 G ND
33.2 171 G ND
N W AIT
28
A19 A19
3
N C SO N C S0
4 31
N C S1 A20
5
N C S2 N C S2
6 32
N C S3 A21
135
C 97
C 92
N C S4
136 33
N C S5 A22
137
* * 138
N C S6
N C S7 A23
34
G ND G ND AT91M 55800-33AI +5V U 19:A +5V +3.3V
15 175
VDDIO VD D C O R E
176
C 10 VDDIO
+3.3V 16 C 11
.1uF
C 12
G ND 1
B .1uF G ND B
G N D 29 2 .1uF
G ND J4:A
VDDIO +5V 1
G ND
C9
30 131 J4:B
G ND VD D C O R E TD O 2
.1uF 132
G N D 43 VDDIO
J4:C
VD D C O R E C 25 3
.1uF
C 31
44 133
VDDIO G ND
C7 134 G ND
.1uF
.1uF
C8
G ND J4:D
45 TC K 4
.1uF G ND G ND
46
G ND J4:E
147 N R ST 5
VDDIO
G ND 59
VDDIO C 20 J4:F
148 TM S 6
C 85 G ND
60 .1uF
G ND J4:G
.1uF 161 G N D 7
G N D 73 VDDIO
VDDIO C 15 J4:H
162 JTAG SEL 8
C 18 G ND
74 .1uF
G ND G ND J4:I
N TR ST 9
.1uF G N D 87
VD D C O R E J4:J
88 109 TD I 10
VDDIO VD D BU BATTER Y_BU
C 26
.1uF
C 21
89 113
G ND G N D BU
.1uF 90 116
G ND G N D BU +3.3V
102 104 R 15
G ND VDDIO VD D PLL
100
A C 27
103 107
A
1000pF
G ND G N D PLL
.1uF
C 19
C 22
.1uF PR O D U C T LIN E:
AT91M 55800-33AI C -FLEX
G ND
PR O C ESS: TITLE:
AU TO C -FLEX,D O M ESTIC
G ND SCHEM ATIC
M IC R O ,FLASH & D EBU G C O N N EC TO R
DRN BY: SIZE D R AW IN G N O . R EV.

J.KAU C IC 9-25-03
CHK BY: EDM S EDM S D S1017737 0
8 7 6 5 4 3 2 1
Appendix B
8 7 6 5 4 3 2 1
SEE SH EET 1
+5V +5V
D D
10.0K
10.0K
R 11
R 12
+5V
+5v_M O DEM
U7
*
1 40
*
SD A_D ISPLAY SD A S23 PP10 .1uF
2 39 J5:A E3
SC L_D ISPLAY SC L S22 PP9 1
3 38 C 17
PP6 SYNC S21 PP11
4 37 J5:B +5v_M O DEM
C LK S20 PP12 2 G ND
5 36
***
VD D S19 PP13
6 35 J5:C E15
+5V O SC S18 3 2
.1uF
C 32
7 34
A0 S17 C R 21
.1uF
C 33
8 33 J5:D E2 3
A1 S16 4 R XD 1
9 32 BAV99L
A2 S15
R 17
* G ND
10
11
SA0
VSS
S14
S13
31
30
5 J5:E E4
1 +5v_M O DEM
G ND 12 29 J5:F
VLC D S12 6 G ND
13 28 G ND
**
BP0 S11
14 27
ZER O
J5:G E6
R 20
BP2 S10 7 2
15 26
BP1 S9 C R 22
16 25 J5:H E5 3
BP3 S8 8 TXD 1
17 24 BAV99L
S0 S7
G ND 18 23
S1 S6
19 22 1
S2 S5
20 21
S3 S4
PC F8566T G ND
C C
D S1
S18 1
S19 23 S17
S9 2 S10
S18 22 BP0
S8 3 C1
S17 21 S16
S7 4 S9
S16 20 S15 SM AR T C AR D
S6 5 S8 +5v_M O DEM
S15 19 S14
S5 6 S7
S14 18 S3
S4 7 S6
S13 17 S13
S2 8 S5 J6:A E14
S12 16 S1 C1
S0 9 S4
S11 15 S12 1000 O H M S @ 100 M H Z
BP3 10 S3 +5v_M O DEM
.1uF
C 78
C4 14 S11 J6:B
BP2 11 S2 C2
C3 13 S10
BP1 12 S1
C2 +5v_M O DEM
U TS-J511JV
10.0K
R 74
G ND
2
C R 24
J6:C E10 3
C3 SC L
1000 O H M S @ 100 M H Z BAV99L
+5v_M O DEM
C4 J6:D E11
1
1000 O H M S @ 100 M H Z +5v_M O DEM
J6:E E16
C5
10.0K
1000 O H M S @ 100 M H Z G ND
R7
J6:F
C6 2
B G ND B
C R 23 3
+3.3V C7 J6:G E17 SD A
1
3 4 1000 O H M S @ 100 M H Z BAV99L
U 21:A J6:H E18
2 6 9 C8
U 21:B 1
1000 O H M S @ 100 M H Z
2.49K
5 8
R 148
74LV00 U 21:C M O TO R _C U R R EN T_TR IP J6:I E12

(7=G N D ,14=+3.3V) 10 S1 SM AR T_D ETEC T
74LV00 G ND
1000 O H M S @ 100 M H Z
LM 339M (7=G N D ,14=+3.3V) 74LV00 J6:J E13
FAST_C U R R EN T S2
4 (7=G N D ,14=+3.3V)
U 1:A 1000 O H M S @ 100 M H Z
2
+8V 5 G ND
(3=VBU LK,12=G N D )
+3.3V
2.49K
R 150
R 147
2.49K
R AW _PW M
12
R 151
1.30K
.22uF
LM 339M
C1
11
U 21:D 6
13
U 1:B 1
PW M
74LV00 +3.3V
7
(7=G N D ,14=+3.3V)
G ND G ND (3=VBU LK,12=G N D )
2.49K
R 152
A A
PR O D U C T LIN E:
R 149
2.49K
C -FLEX
PR O C ESS: TITLE:
SCHEM ATIC
G ND DIG ITAL

J.KAU C IC 9-25-03
8 7 6 5 4 3 2 1
Appendix B
8 7 6 5 4 3 2 1
SEE SH EET 1
+8V
D D
1 J7:A
CO NN M 3 PIN .078
.01uF
C 48
+8V +8V
+8V
J7:B +5V
2
24.9K
R 49
CO NN M 3 PIN .078
10.0K
R 54
G ND LM 324A
3.16K
1.00K
R 64
R 53
12 G ND
1.00K
R 55
14 R 61 R 62 +5V
U 13:D
M T1 13 2.00K 30.1K
1 J7:C 11
.1uF
C 51
3 CO NN M 3 PIN .078
2 (4=+8V,11=G N D ) 13
TP8 2 U 12:D H ALL
3
4
R 65
1.00K
+8V
6
U 13:B
LM 324A
R 63 * C R 11
3
FLO W
10
LM 339M
5 G ND 7 1.00K (3=VBU LK,12=G N D )
BAV99L
6 5
(4=+8V,11=G N D )
10.0K
R 56
1
.22uF
7
10uF
C 46
C 47
24.9K
R 59
8 LM 324A
2 R 60 R 69
AIR FLO W SEN SO R U 13:A 1 2.00K 30.1K G ND
3 G ND
(4=+8V,11=G N D ) G ND G ND
G ND
.1uF
C 49
C +8V (4=G N D ,8=+8V) C

G ND LM 358A
2
1 U 11:A R 68
4.22K
R 50
3 10.0K
LM 324A
9
2.2uF
C 75
U 13:C 8
10
(4=+8V,11=G N D )
G ND
5
FLO W _O S
7
U 11:B 5
6
LM 358A 2
U 12:A PP15
4
(4=G N D ,8=+8V)
LM 339M
+5V
R 58
7
4.75K 1
U 12:B PP14
6
ZER O
R 47
2.49K
R 57
LM 339M
B C 66 B
9
.1uF G ND 14
M T2 U 12:C PP17
1 8
NC PP19 C 67
2 +5V LM 339M
VS
3 (3=VBU LK,12=G N D )
G ND .01uF
4 G ND
VO U T
M PXV5004G C 6U G ND R 42 2
3
R 67 C R 25 G ND
2.00K 1 3
U 10:A PR ESS
2 ZER O
.01uF
BAV99L
C 62
C 63
.1uF
LM 358A
(4=G N D ,8=+8V) 1
G ND G ND R 36 G ND
3.01K
10.0K
R 35
+5V
G ND
* M T3
+VS
1
2
VO
4
NC
3 5
G ND
ASD X001 7
U 10:B
A 6
LM 358A
A
G ND PR O D U C T LIN E:
G ND (4=G N D ,8=+8V)
C -FLEX
PR O C ESS: TITLE:
SCHEM ATIC
AN ALO G C IR C U IT

J.KAU C IC 9-25-03
8 7 6 5 4 3 2 1
Appendix B
8 7 6 5 4 3 2 1
R 97 SEE SH EET 1
VBU LK
10.0K VBU LK
R 84
G ND 3 1
10.0K
1 3
C TL_H I_C
4 U 8:A U 5:A PP4
R 85 2 2
6 Q 17 Q 16 LM 358A
U 5:B G ND
5 M M BT3904LT1 M M BT3904LT1 74LV08
.22uF
2.49K
C 79
PW M (4=G N D ,8=+5V) (7=G N D ,14=+3.3V)
74LV08
2.49K
(7=G N D ,14=+3.3V) G ND
R 86
90.9K
G ND +3.3V
R 82
Q 15 G ND
D 9 D
M M BT3906LT1 8
3 Q 23 U 4:C PP5
10
.1uF
C 84
R 83 4
G ND VO U T 5
232 74LV00
G ND VO U T 6
(7=G N D ,14=+3.3V)
VO U T 7
8 G ND
G ND VBU LK R 77 2 VO U T
R 78 232
1 N D S8858H
10.0K
90.9K
R 76
1 Q 19
C TL_LO _C
3 R 80 M M BT3904LT1
U 4:A Q 20
2 2.49K M M BT3904LT1
PW M
74LV00
(7=G N D ,14=+3.3V)
2.49K
R 79
Q 18
10.0K
10.0K
G ND
R 94
R 95
M M BT3906LT1
G ND
G ND G ND G ND
R 92 VBU LK PHASE_C E1:C CO NN M 3 PIN 100

1
VBU LK J1:A
10.0K 165 O H M S @ 100 M H Z
R 116
C 86
G ND
C C TL_H I_B
9
10.0K
* C
8 R 117
U 5:C Q 10 Q9
.22uF
C 91
10 2.49K M M BT3904LT1 M M BT3904LT1 G ND
PW M
PHASE_B E1:B CO NN M 3 PIN 100
74LV08 2
J1:B
(7=G N D ,14=+3.3V) 165 O H M S @ 100 M H Z
R 118
2.49K
R 114
90.9K
G ND
C 90
G ND
Q8
M M BT3906LT1 3 Q 24
*
R 115 4
G ND VO U T 5 G ND
232
VO U T 6
G ND PHASE_A E1:A CO NN M 3 PIN 100
3
VO U T 7 J1:C
165 O H M S @ 100 M H Z
VO U T 8
C 95
R 108 2
VBU LK
232 * +3.3V
*
R 109 1 N D S8858H
TP6 TP4
R 107
90.9K
10.0K
R 100
G ND
*
4 Q 11
*
C TL_LO _B
R 111 R 128 R 140 TP1
*
6 M M BT3904LT1
U 4:B Q 13
5 2.49K M M BT3904LT1 10
PW M U 1:D 13
BEM F
R 158
ZER O
C 96
74LV00
11
*
(7=G N D ,14=+3.3V) LM 339M
R 110
2.49K
G ND (3=VBU LK,12=G N D )
10.0K
Q 12
R 96
*
M M BT3906LT1 R 139 R 138
G ND G ND
*
B R 121 R 127 ZER O B
G ND
*
G ND
G ND TP2
C4
*
VBU LK
R 91 VBU LK TP7
G ND
10.0K R 144 TP5
* G ND
*
*
10.0K
12 R 120 R 126
C TL_H I_A
11 R 145
U 5:D Q3 Q2
.22uF
C 100
13 2.49K M M BT3904LT1 M M BT3904LT1
C6
PW M
*
74LV08 M TR _C TR _EST
(7=G N D ,14=+3.3V)
R 146
2.49K
R 142
90.9K
G ND
G ND
Q1 TP3 G ND
3 Q 25
*
*
M M BT3906LT1 R 143 4 R 119 R 125
G ND VO U T 5
232
VO U T 6
G ND
R 157
ZER O
7
C5
VO U T
*
VO U T 8 C R 10
VBU LK R 134 2
232 B160
R 135 1 N D S8858H
FAST_C U R R EN T G ND G ND
G ND
90.9K
R 133
10.0K
12
A
C TL_LO _A
13
U 4:D
11 R 137
2.49K
Q7
M M BT3904LT1
Q5
M M BT3904LT1
R 70 5
TP9
* A
PW M 1.00K 7 R 66 PR O D U C T LIN E:
0.12
R 28
U 8:B I_LO _SID E

2W
74LV00 R 71 6 13.7K C -FLEX

(7=G N D ,14=+3.3V) LM 358A
R 136
2.49K
1.00K
.22uF
10.0K
G ND
R 90
C 74
Q6 (4=G N D ,8=+5V) PR O C ESS: TITLE:

M M BT3906LT1 R 72 SCHEM ATIC
G ND M O TO R DRIVER
3.16K
G ND
G ND G ND G ND SIZE D R AW IN G N O . R EV.
DRN BY: J.KAU C IC 9-25-03

8 7 6 5 4 3 2 1
Appendix B
8 7 6 5 4 3 2 1
SEE SH EET 1
ISO LATIO N BAR R IER

2
J2 L2 L1
1 1 4 1 2 C R 15
D D
S14K320
L1 C 50
4 1
750K
R V1
.1uF
1/2 W
R 41
C 54
AC IN
2
L2 BR 86D L .001uF
+ C 55
P6SM B150AT3
SC H U R TER 4300.0099 2 3 4 3
F1 IC A-0885 35 m h .6A PW R G N D 3 68uF G ND
C R 17
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TP14
PR O D U C T LIN E:
TP12 TP13 TP11 TP10 C -FLEX
* G ND * * * PR O C ESS: TITLE:
SCHEM ATIC
PO W ER SU PPLY

J.KAU C IC 9-25-03
8 7 6 5 4 3 2 1
www.respironics.com
Reorder # 1018659 Revision # 1018658

TMF 7/12/04

Remstar Pro 2 and Auto

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REMstar®|Auto with C-Flex™

REMstar Auto with C-Flex and REMstar Pro 2 Service Manual

REMstar Auto with C-Flex and REMstar Pro 2 Service Manual

Chapter 8: Testing ................................................................ 8-1

1.1 System Overview........................................ 1-2

1.2 Service Notice............................................. 1-2

1.3 Technical Support Statement ................... 1-2

1.4 Training ....................................................... 1-2

Chapter 1: Introduction 1.4 Service Training

1.3 Customer Satisfaction

Phone:1-800-345-6443 Phone: 1-724-387-4000

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

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

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

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

3.3 Symbols ........................................................ 3-5

3.4 Functional Description ............................ 3-11

3.5 Theory of Operation ................................ 3-14

Chapter 3: Specifications, Features,

3.2 Specifications PHYSICAL:

Dimensions 9.5 x 6.875 x 4.5 in.

Atmospheric Pressure 83 to 102 kPascals AC Current Consumption 1.0 A maximum

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

Sound Pressure Level 30 dB(A)

Degree of Protection Against

This product is designed to conform to the following standards.

Altitude Pressure Range 83 - 102 kPascals (Automatic Altitude

Mode of Operation Continuous

Pressure 4 to 20 cm H2O (in 0.5 increments)

NOTE: Pressure accuracy measurements shall be taken at the end of a

3.4 Functional Description 3.5 Theory of Operation (Subassemblies)

This page intentionally blank.

Chapter 4: System Setup

4.1 Overview ..................................................... 4-2

4.2 Programming a SmartCard ..................... 4-2

4.3 System Setup............................................... 4-3

4.4 Heated Humidifier System Setup ............ 4-7

4.5 Changing Settings

4.6 Recommended Circuit Accessories ...... 4-12

Chapter 4: System Setup 4.2 Programming a SmartCard

4.3 System Setup

Number of nights the unit was

when either APAP or AFLE

Right User Left User LED Backlight

C-FLEX Setting Screen SETUP

4.4 Heated Humidifier System Setup 4.4.1 Humidifier Temperature Setup

4.5 Changing Settings Using a SmartCard Step 2 Verify New Settings

Insert SmartCard here

NOTE: Respironics recommends a 100 amp-hour deep cycle marine

The unit should not be operated while the vehicle is in motion.

This page intentionally blank.

5.1 Overview ..................................................... 5-2

5.2 Cleaning the System .................................. 5-2

5.3 Cleaning / Replacing the

5.4 Preventive Maintenance Schedule .......... 5-4

Chapter 5: Routine Maintenance 5.3 Cleaning / Replacing the

CAUTION: Failure to replace a dirty filter may cause the device

Figure 5-1 Figure 5-2

5.4 Preventive Maintenance Schedule

CAUTION: DO NOT place both pollen filters into the device

5.4.1 Preventive Maintenance Schedule (Factory Recommended)

Maintenance Item Verification Reference Service Interval Date

Serial Number Name Signature ______Date_/_/_