Respironics REMstar Choice User manual

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

Copyright © 1997 Respironics Inc. All rights reserved.
REMstar Choice® systems are the subject of U.S Patent #5239995 and other pending U.S. and
foreign patents. REMstar is a registered trademark of Respironics,Inc.

This manual provides service and maintenance information for the REMstar®Product
Family.
While the units look similar and share many of the same parts, the repair instructions are
not interchangeable.

REMstar Service Manual i
The REMstar Family of Nasal CPAP Systems
Table of Contents
SECTION 1 SPECIFICATIONS AND WIRING DIAGRAM
1.1 SPECIFICATIONS ............................................................................................................................1-1
1.2 THEORY OF OPERATION .............................................................................................................1-5
1.2.1 INTERNAL WIRING DIAGRAM (REMstar)...............................................................................1-6
1.2.2 INTERNAL WIRING DIAGRAM (REMstar Choice, Express, and Series II) ..........................1-7
1.2.3 INTERNAL WIRING DIAGRAM (REMstar Choice LS, Reliance) ...........................................1-9
1.3 REMSTAR PRODUCT FAMILY ..................................................................................................1-10
SECTION 2 WARNINGS, CAUTIONS, AND NOTES
2.1 WARNINGS, CAUTIONS, AND NOTES.....................................................................................2-2
SECTION 3 PREVENTIVE MAINTENANCE
3.1 PREVENTIVE MAINTENANCE ...................................................................................................3-2
3.2.1 ADJUSTING THE PRESSURE ........................................................................................................3-4
3.2.2 ADJUSTING THE PRESSURE AND RAMP TIME (REMstar Choice, Express, Series II, and
Reliance) .................................................................................................................................................3-7
3.2.3 ADJUSTING THE PRESSURE AND RAMP TIME (REMstar Choice LS)..............................3-10
3.3 ALTITUDE ADJUSTMENT ..........................................................................................................3-13
SECTION 4 TROUBLESHOOTING
4.1 TROUBLESHOOTING ....................................................................................................................4-2
4.1.1 REMSTAR AND SERIES II TROUBLESHOOTING GUIDE......................................................4-3
4.1.2 REMSTAR CHOICE AND CHOICE EXPRESS TROUBLESHOOTING GUIDE ..................4-11
4.1.3 REMSTAR CHOICE LS AND REMSTAR RELIANCE TROUBLESHOOTING GUIDE .....4-21
SECTION 5 REMOVING AND REPLACING THE COVER
5.1.1 REMOVING THE COVER (units without filter caps) ................................................................5-2
5.1.2 REMOVING THE COVER (units with filter caps) ......................................................................5-3
5.2.1 REPLACING THE COVER (units without filter caps) ...............................................................5-6
5.2.2 REPLACING THE COVER (units with filter caps) .....................................................................5-8
SECTION 6 REPAIR AND REPLACEMENT
6.1 COMPONENT LOCATIONS .........................................................................................................6-3
6.2 REPLACING THE BLOWER ..........................................................................................................6-4
6.3 REPLACING THE BLOWER TOP ASSEMBLY ...........................................................................6-7
6.4.1 REPLACING THE TRANSFORMER (REMstar) .......................................................................6-10
6.4.2 REPLACING THE TRANSFORMER (REMstar Choice Series, Series II, and Reliance) ......6-13
6.5.1 REPLACING THE MAIN CIRCUIT BOARD (REMstar) .........................................................6-16
6.5.2 REPLACING THE MAIN CIRCUIT BOARD (REMstar Choice, Series II, and Express).....6-18
6.5.2.1 REPLACING THE VARISTOR ON THE PC BOARD ..............................................................6-20
6.5.3 REPLACING THE MAIN CIRCUIT BOARD (REMstar Choice LS and Reliance) ...............6-22

REMstar Service Manual
SECTION 6 REPAIR AND REPLACEMENT (Continued)
6.6 REPLACING THE POTENTIOMETER.......................................................................................6-24
6.7.1 REPLACING THE POWER SWITCH (REMstar) ......................................................................6-26
6.7.2 REPLACING THE POWER SWITCH (REMstar Choice Series, Series II, and Reliance) .....6-27
6.8.1 REPLACING THE TIME METER ................................................................................................6-28
6.8.2 REPLACING THE TIME METER/RAMP ADJUSTMENT CIRCUIT BOARD.....................6-31
6.8.3 REPLACING THE TIME METER (Rear Panel Mounted Meter, S/N >300000)....................6-33
6.8.4 REPLACING THE RAMP ADJUSTMENT PCB (REMstar Choice S/N <300000)................6-35
6.9.1 REPLACING THE AC INLET (REMstar) ...................................................................................6-37
6.9.2 REPLACING THE AC INLET (REMstar Choice Series, Series II, and Reliance)..................6-39
6.10.1 REPLACING THE HANDLE (REMstar) ....................................................................................6-41
6.10.2 REPLACING THE HANDLE (REMstar Choice Series, Series II, and Reliance) ...................6-43
6.11 REPLACING THE COVER ...........................................................................................................6-45
6.12 REPLACING THE STICK-ON FEET ...........................................................................................6-46
6.13.1 REPLACING THE ULTRA-FINE FILTER (REMstar) ...............................................................6-47
6.13.2 REPLACING THE ULTRA-FINE FILTER (REMstar Choice Series, Series II, Reliance) .....6-48
6.14.1 REPLACING THE POLLEN FILTER (REMstar) .......................................................................6-49
6.14.2 REPLACING THE POLLEN FILTER (REMstar Choice Series, Series II, and Reliance) ......6-50
6.15 REPLACING THE FUSES .............................................................................................................6-51
6.16 REPLACING THE TIME METER/RAMP ADJUSTMENT WIRING HARNESS .................6-52
6.17 REPLACING THE UNIT CAP......................................................................................................6-54
REMSTAR REPAIR PARTS ..........................................................................................................6-55
REMSTAR PREVENTATIVE MAINTENANCE SCHEDULE.................................................6-57
SECTION 7 REPAIRS
7.1 SYSTEM ADJUSTMENT .................................................................................................................7-2
7.2 RUN-IN ..............................................................................................................................................7-2
7.3 SYSTEM FINAL ................................................................................................................................7-2
APPENDIX A REMSTAR SYSTME SCHEMATICS
A.1 WIRING DIAGRAM ...................................................................................................................... A-1
A.2 SCHEMATIC STATEMENT ......................................................................................................... A-2
APPENDIX B DATA SHEET
B.1 DATA SHEET................................................................................................................................... B-2
APPENDIX C DC OPERATION
C.1 DC OPERATION .............................................................................................................................C-2
C.2 SPECIFICATIONS ...........................................................................................................................C-3

REMstar Service Manual 1-1
Specifications and Wiring Diagram
Section 1
Specifications and Wiring Diagram
1.1 Specifications .....................................................................................................................................1-2
1.2 Theory of Operation .........................................................................................................................1-5
1.2.1 Internal Wiring Diagram (REMstar)...............................................................................................1-6
1.2.2 Internal Wiring Diagram (REMstar Choice, Express, and Series II)..........................................1-7
1.2.3 Internal Wiring Diagram (REMstar Choice LS, and Reliance) ...................................................1-9
1.3 REMstar Product Family ..................................................................................................................1-10

1-2 REMstar Service Manual
Specifications and Wiring Diagram
1.1 SPECIFICATIONS
CPAP Static Pressure Range:
Physical Dimensions:
Unit Filters:
Pressure Stability:
Electrical Requirements:
Input Voltage Settings:
Input Voltage Range:
Power Consumption:
Fuse Specification:
Unit Voltage Setting
115 VAC
230 VAC
Current Requirements:
3 – 20 cm H2O
Weight: <6.0 lbs. (2.72 kg)
Height: 9.0 in. (22.9 cm)
Width: 5.75 in. (14.6 cm)
A pollen filter and an optional 0.3 micron ultra-fine filter.
Within ±1 cm H2O at flows up to a 55 LPM leak through a six foot
section of smooth inner lumen tubing.
115 / 230 VAC; 12-24 VDC
100-130 / 200-260 VAC; 12-24 VDC
The maximum power required to operate the REMstar is
125 VA. The actual power used is dependent upon the prescrip-
tion pressure and patient’s breathing pattern. The lower the
patient’s prescription, the lower the power required. Typical
requirements are less than 100 VA.
Fuse Type
800 mA, 5 x 20 mm T Type
400 mA, 5 x 20 mm T Type
When the voltage selector switch is set to 115 VAC, the normal
steady state current is less than 700 mA, with a maximum current
draw of 800 mA. When the voltage selector switch is set to 230
VAC, the normal steady state current is less than 350 mA, with a
maximum current draw of 400 mA.
NOTE: The REMstar unit complies as a double-insulated electromedical equipment. The unit is
designed to operate safely without a grounded third wire connection in the power cord. The
standard for Health Care Facilities, NFPA 99, states that double-insulated appliances, with
two-conductor cords, may be used in the vicinity of patients (see NFPA 99, paragraph 7-
5.1.2.2).
NOTE: It is recommended that the REMstar family of products not be used on commercial airlines
due to differences in the electrical systems.

REMstar Service Manual 1-3
Specifications and Wiring Diagram
The REMstar family of products can be used in a motor vehicle
that has a working cigarette lighter and a fully charged Deep-
Cycle Battery (see below). For pressures less than 11 cm H2O,
connect the unit to the cigarette lighter using a Respironics DC
Cord. For pressures greater than 11 cm H2O, connect the unit to
the cigarette lighter using a DC Interface module.
Polarity:
Using the Respironics DC cord to a 12 V
battery, (for Pressures less than 11 cm
H2O):
Power Consumption:
Current Requirements:
Battery Size Recommended:
Using the Respironics DC Interface
Module, (for Pressures over 11 cm H2O):
Power Consumption:
Current Requirements:
Battery Size Recommended:
On the unit end of the cord, the outside of the barrel is
ground, and the inside is positive. On the cigarette lighter
adapter end, the center pin is positive and the outside tab is
ground.
40 Watts maximum
2.5 Amps DC maximum.
12 VDC Deep-cycle marine-type battery with a 24 Amp-hour
rating (minimum) for 8 hours of use.
NOTE: For proper operation, the battery voltage must
remain greater than 11.5 Volts for the duration
of unit use. As the voltage drops below this
point the unit emits a buzzing sound.
80 Watts maximum. Typical requirements are less than 50
Watts.
6.2 Amps DC maximum. Typical current requirements are 3.5
Amps DC.
12 VDC Deep-cycle marine-type battery with a 90 Amp-hour
rating (minimum) for 8 hours of use.
NOTE: For proper operation, the battery voltage must
remain greater than 11.5 Volts for the duration
of unit use. As the voltage drops below this
point the unit emits a buzzing sound.
Battery Specifications for DC Power
Operation:
WARNING: The unit must be connected to a system that has a negative ground.

1-4 REMstar Service Manual
Specifications and Wiring Diagram
Compliance to Standards
The REMstar Product family ** meets the requirements of the EU EMC Directive 89/336 EEC. The normative
documents within these requirements include:
•IEC 601-1-2
•IEC 801-2
•IEC 801-3
•IEC 801-4
•CISPIR 11
**NOTE: The original REMstar (PN 367100) unit does not meet these requirements. The IEC requirements
were not in effect at the time of unit design. REMstar met the CSA 22.2 Standard.
Noise Level: No specification is stated due to test condition variability.

REMstar Service Manual 1-5
Specifications and Wiring Diagram
1.2 Theory of Operation
The REMstar Product family is constructed of four major component assemblies: the Motor Blower Assembly,
the Printed Circuit Board Assembly, the Transformer Power Supply, and the Enclosure Housing. The CPAP
pressure and flow is generated by the motor blower assembly. This assembly generates air flow via a back-
ward vein impeller spinning in excess of 7000 RPM. The Printed Circuit Board supplies the voltage required
to power the motor and impeller. The Printed Circuit Board uses analog circuitry to rectify the voltage from
the transformer and supply it to the motor at a level correlated to the required CPAP pressure level. The
Transformer receives the AC voltage from a connection to a electrical wall outlet and steps the voltage down
to approximately 12 volts* DC for use by the printed circuit board. The Enclosure Housing insulates the
electrical components of the unit from the user.
*NOTE: The Transformer in the original REMstar steps the voltage down to approximately 18 volts DC. The
Transformer in the Choice unit steps the voltage down to approximately 12 volts DC.

1-6 REMstar Service Manual
Specifications and Wiring Diagram
1.2.1 INTERNAL WIRING DIAGRAM -
REMstar
123456
Primary
Secondary
Transformer
789101112
orange orange
gray gray
To J2 pins 8,7,6,5
8811
J2 J1
Brushless DC
Motor Controller Board
Blower
DC Motor
Pins:
1 red
2 black
3 green
4 brown
5 blue
6 orange
7 gray
8 yellow
Patient Connection
white
white black
red
Power Switch
Fuses
Internal Connections
AC Inlet
(Main Connection) DC Inlet
gray
orange
red yellow
white black
23
41
Voltage
Selector
Switch
To J2 pins 4,3
To J2 pins 1,2
violet
green
Timemeter

REMstar Service Manual 1-7
Specifications and Wiring Diagram
1.2.2 INTERNAL WIRING DIAGRAMS -
REMstar Choice, REMstar Express and Series II
123456
Primary
Transformer
789101112
orange orange
gray gray
To J2 pins 8,7,6,5
8811
J2 J1
Brushless DC
Motor Controller Board
Blower
DC Motor
Old Design Motor Pins:
1 red
2 black
3 green
4 brown
5 blue
6 orange
7 gray
8 yellow
Patient Connection
white black
Fuses
Internal Connections
AC Inlet
(Main Connection) DC Inlet
gray
orange
red yellow
white black
23
41
Voltage
Selector
Switch
To J2 pins 4,3
To J4 pins 2,3,4,5,6
violet
green Time Meter
Secondary
28 Volts DC
81
J4
Blower
ON/OFF
Switch
blue
yellow
black
green
yellow
brown
blue
Ramp
Adjustment
Switch

New Design Motor has
8-wire Ribbon Cable
*See page 1-8 for Rev 7 Controller Board Schematic
Internal Wiring Diagram, Rev 2 to Rev 6 Controller Board*
NotPresent
In Series II

1-8 REMstar Service Manual
Specifications and Wiring Diagram
*See page 1-7 for Rev 6 Controller Board Schematic
REMstar Choice, Express, and Series II
Internal Wiring Diagram, Rev 7 Controller Board*
123456
Primary
Transformer
789101112
orange orange
gray gray
To J2 pins 8,7,6,5
8811
J2 J1
Brushless DC
Motor Controller Board
Blower
DC Motor
Patient Connection
white black
Fuses
Internal Connections
AC Inlet
(Main Connection) DC Inlet
gray
orange
red yellow
white black
23
41
Voltage
Selector
Switch
To J2 pins 4,3
To J4 pins 1 to 8
Secondary
28 Volts DC
10 1
J4
Blower
ON/OFF
Switch
blue
yellow
yellow
blue
yellow
blue
yellow
blue
yellow
blue
Ramp
Adjustment
Switch

Time Meter

Time Meter/Ramp Adj. Board
Old Design Motor Pins:
1 red
2 black
3 green
4 brown
5 blue
6 orange
7 gray
8 yellow
New Design Motor has
8-wire Ribbon Cable
†There is no Ramp Adjustment
Switch on REMstar Choice units
with Serial Numbers greater
than 300000.
NotPresent
in Series II

REMstar Service Manual 1-9
Specifications and Wiring Diagram
1.2.3 INTERNAL WIRING DIAGRAM -
REMstar Choice LS and Reliance
123456 Primary
Transformer
789101112
orange orange
gray gray
To J2 pins 8,7,6,5
8811
J2 J1
Brushless DC
Motor Controller Board
Blower
DC Motor Patient Connection
white black
Fuses
Internal Connections
AC Inlet
(Main Connection) DC Inlet
gray
orange
red yellow
white black
23
41
Voltage
Selector
Switch
To J2 pins 4,3
Secondary
28 Volts DC
10 1
J4
Blower
ON/OFF
Switch
blue
yellow
6-pin jumper
2 pins empty
Rev 7 and later 
boards
81
J4 Rev 6 and earlier
boards
to 
blower
Old Design Motor Pins:
1 red
2 black
3 green
4 brown
5 blue
6 orange
7 gray
8 yellow
New Design Motor has
8-wire Ribbon Cable
to LCD
Timemeter

1-10 REMstar Service Manual
Specifications and Wiring Diagram
REMstar
Choice
X X X X X X X
Optional
X X X X X X X X X
Optional
REMstar
Reliance
X X X
Optional Optional Optional Optional
X X
Optional Optional Optional
X X X
Optional
NOTE: Any private or custom labelled unit requires the same service as the equivalent REMstar
unit. The only difference is the labelling of the filter cap and tower cover.
1.3 REMstar Product Family
Product Feature
10 Setting Ramp Time Selection 20 Minute Preset Ramp Time Short (Half) Ramp Remote Control Time Meter DC Operation International Power Carrying Case Touring Case 115 Volt Replacement Fuse Kit 230 Volt Replacement Fuse Kit Ultrafine Filter Reusable Filter Patient Instruction Video Smooth-bor Tubing (6 Foot) Lightweight Tubing (6 Foot) Power Cord Instruction Manual 1 Year Warranty 2 Year Warranty 3 Year Warrany
REMstar
X X X X
Optional Optional Optional
X X X X X X
REMstar
Choice LS
X X
Optional
X X X
Optional Optional Optional
X X
Optional
X X X X
Optional
REMstar
Choice
Express
X X
Optional
X X X
Optional Optional Optional Optional
X X
Optional
X X X X
Optional
REMstar
Series II
X X X
Optional Optional Optional Optional
X X
Optional
X X X X
Optional

REMstar Service Manual 2-1
Warnings, Cautions, Notes/Adjusting the Pressure
Section 2 Warnings, Cautions, and Notes
2.1 Warnings, Cautions, and Notes ......................................................................................................2-2

2-2 REMstar Service Manual
Warnings, Cautions, Notes/Adjusting the Pressure
2.1 WARNINGS, CAUTIONS, AND NOTES
WARNINGS
• U.S. Federal law restricts the sale or the use of this device to be on the order of a licensed physician only.
• If the patient presents a contamination risk to the unit, place a bacteria filter in-line between the unit and
the patient. The following filters are recommended:
Respirgard-II
Perma systems BAC-Trap
Other filters may cause a drop in the prescribed delivery pressure.
• All patient settings must be determined via appropriate diagnostic testing and monitoring.
• The Whisper Swivel®is designed to exhaust CO2from the patient circuit. Continuous flow is required for
safe operation. DO NOT BLOCK OR OTHERWISE TRY TO SEAL THE SLOTS ON THE WHISPER
SWIVEL.
• Oxygen supports combustion. DO NOT use Oxygen while smoking or in the presence of an open flame.
• Disinfectant residues left on the patient circuit parts shortens the useful life and may irritate the patient’s
skin. Rinse all items thoroughly after disinfection.
• To avoid electrical shock, unplug the REMstar unit before cleaning.
• To avoid electrical shock, unplug the REMstar unit before changing the fuses.
• To avoid electrical shock, unplug the REMstar unit before servicing.
• For continued protection against risk of fire, replace fuses with those of the same type and rating only.
• The unit is powered when the cord is connected to the main supply. The on/off switch enables/disables
the blower only.
CAUTIONS
• Position the unit on its base for proper operation, before connecting to the power source.
• Set the voltage selector switch to the corresponding line voltage, (in North America; 115 V), for proper
unit operation.
• Electronic components used in this unit are subject to damage by static electricity. Use proper static
discharge and grounding precautions when servicing the equipment.
NOTES
• Use only patient tubing with a smooth inner lumen and a nominal inner diameter of 3/4 in. (22 mm
fitting). The overall length of the tubing must not exceed twelve feet.

REMstar Service Manual 3-1
Preventive Maintenance
Section 3 Preventive Maintenance
3.1 Preventive Maintenance...................................................................................................................3-2
3.2.1 Adjusting the Pressure .....................................................................................................................3-4
3.2.2 Adjusting the Pressure and Ramp Time (REMstar Choice, Express, Series II, and Reliance)3-7
3.2.3 Adjusting the Pressure and Ramp Time (REMstar Choice LS) .................................................. 3-10
3.3 Altitude Adjustment .........................................................................................................................3-13

3-2 REMstar Service Manual
Preventive Maintenance
3.1 PREVENTIVE MAINTENANCE
Inspect the REMstar unit annually. After inspection, fill out the maintenance chart in the Patient Instructions
providing the patient with a record of all maintenance performed on the unit.
REMstar®Product Family Preventive Maintenance Schedule
(Factory Recommended)
Patient Dealer
Address Address
Phone Phone
Model Serial Date Purchased
Maintenance Item
Record hours on meter
Verify voltage selector
switch
Check unit pressure
Inspect fuses
Annually
Annually
Annually
Annually
Date
Service Interval