Air 10 & Lumis Series Service Manual Feb 2018

Contents How to use this manual ... 4 Introduction ... 6 Intended users of this manual ... 6 Air10/Lumis S/ST exploded view ... 7 ST-A & CS-A Alarm assembly exploded view ... 7 External device description ... 8 Air10 ... 8 AirStart ... 8 ST-A, CS-A ... 9 ST-A, CS-A rear ... 9 System description ... 10 Microprocessor controller circuit ... 10 Alarm PCB ... 11 Pneumatic block ... 11 CAM (Cellular Access Module) ... 11 Humidifier ... 12 Sensors ... 12 Power management ... 12 General inspection procedures ...13 Instructions for general inspection procedures ... 13 Equipment required ... 13 Control panel ... 14 1. Clean the flow generator ... 14 2. Record device settings ... 14 3. External examination ... 17 4. Internal examination (if necessary) ... 18 5. Replace the air filter ... 18 6. Temperature sensor test ... 19 7. CPU Watchdog test (Lumis & AirCurve CS-A devices only) ... 19 8. Pressure calibration test ... 19 9. Flow calibration test ... 20 10. Airpath leak test ... 20 11. Alarm test (ST-A & CS-A devices only) ... 21 12. Ambient light sensor check ... 21 13. Humidifier test ... 21 1

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14. Heated tube test ... 21 15. LCD test ... 22 16. Keypad test ... 22 17. LED test ... 22 18. SD card test ... 22 19. CAM registration check (only for device with a live CAM) ... 23 20. Finalise manual check results ... 23 21. Set clock ... 24 22. Reload device settings ... 24 23. Fill out product problem report ... 26 Operator safety and static precautions...27 Replacing major subassemblies ...28 Equipment required ... 28 Opening the flow generator ... 29 Replacing the dial, buttons and name plaque ... 29 Dial ... 29 Buttons ... 30 Name plaque ... 31 Replacing the air outlet ... 31 Accessing the main PCB and pneumatic block... 32 Replacing the CAM (Cellular Access Module) ... 34 Replacing the main PCB ... 37 Installing the serial number and product code ... 43 Procedure... 43 Reload settings ... 44 Recording the reloading of settings ... 44 Replacing the alarm assembly (ST-A & CS-A units only) ... 45 Replacing the pneumatic block ... 47 Replacing the swivel assembly ... 48 Replacing pneumatic block components ... 50 Replacing the venturi ... 50 Opening the pneumatic block ... 51 Removing the flow plate ... 53 Replacing the pneumatic block suspension ... 53 Refitting the flow plate ... 55 Refitting the muffler ... 56 2

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Closing the pneumatic block ... 57 Resetting the motor hours ... 59 Replacing the chassis ... 61 Closing the flow generator... 62 Replacing humidifier components ... 65 Replacement parts ...68 Pneumatic block components... 70 Other internal components ... 72 Humidifier parts ... 74 Spare parts list ... 76 Calibration procedures ...80 Equipment required ... 80 1. Pressure calibration ... 80 2. Flow calibration ... 81 Troubleshooting guide ...82 Error messages ... 82 Numbered error messages ... 83 Alarms troubleshooting (ST-A & CS-A devices only) ... 85 Recommended maintenance schedule ...86 Appendix A: Service Request form ...87 Appendix B: Determining signal strength...88 Equipment required ... 88 Procedure ... 88 Appendix C: For Germany devices only – Reset Total Used Hours ...90 Procedure ... 90

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How to use this manual Each section in this manual has been written with a specific purpose in mind. Use this guide to help you find the material which is relevant to your task at the moment. Introduction – Gives a brief overview of Air10 and Lumis devices, including a system description and an outline of the main subassemblies. General inspection and servicing – Gives the procedures to help you examine a flow generator which has been brought into a service centre. The general inspection procedures should be performed before any other work is done on the flow generator. Operator safety and static precautions – Lists procedures to be followed whenever PCBs are removed from the unit. These procedures minimise the chance of ICs being damaged by static electricity. Replacing major subassemblies – Highlights points to note when replacing subassemblies, reassembling the flow generator and indications of when recalibration is necessary. Replacement parts – Shows pictures and part numbers of all the product spare parts and subassemblies available from ResMed. Calibration procedures – Lists procedures to follow after a main PCB, motor or any part of the air circuit is replaced. Follow these procedures to calibrate the unit and restore the owner’s settings. Troubleshooting guide – Provides a comprehensive list of device error messages, along with possible causes and fixes. Recommended maintenance schedule – Provides a brief description of the maintenance required for the unit. Appendix A: Service Request Form – Fill out this form if you need to return a device to ResMed for servicing. Appendix B: Determining signal strength – List the steps to take in order to determine signal strength in a service location. Appendix C: For Germany devices only – Reset Total Used Hours – List the steps to take in order to reset Total Used Hours counter on screen. Note: Technical specifications for each device are available in the device User and Clinical Guides.

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This manual contains special terms and icons that appear in the margin to draw you attention to specific and important information.

Warning alerts you to possible injury.

Caution explains special measures for the safe and effective servicing of the device. Note: is an informative or helpful note.

Contact details To give us feedback regarding the service manual, or for further information regarding the servicing of ResMed products please contact ResMed Product Service and Support, Sydney at [email protected]

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Introduction This manual is a guide to servicing and repairing the following devices:  AirStart 10 APAP

 AirSense 10 CPAP

 AirCurve 10 VAuto

 Lumis 100 VPAP S

 AirStart 10 CPAP

 AirSense 10 Elite

 AirCurve 10 S

 Lumis 100 VPAP ST

 AirSense 10 AutoSet

 AirCurve 10 ST

 Lumis 150 VPAP ST

 AirSense 10 AutoSet for Her

 AirCurve 10 ST-A

 Lumis 100 VPAP ST-A

 AirSense 10 AUTO

 AirCurve 10 CS PaceWave

 Lumis 150 VPAP ST-A

 AirSense 10 RESPOND A

 AirCurve 10 ASV

 AirSense 10 RESPOND W

 AirCurve 10 CS-A

 Sleepmate 10 AUTO

 AirCurve 10 CS-A PaceWave

 Sleepmate 10 Elite

 AirCurve 10 CS-A TJ

Note:

The devices available vary from region to region.

It is written for ResMed service centres and authorised ResMed service agents, and gives instructions for replacing subassemblies and for recalibration as appropriate. Work at the component level will normally be carried out by ResMed.

Intended users of this manual Before attempting any repair work, please ensure that you:   

are familiar with the clinical manual and the information guides for the device have suitable electrical and mechanical training to satisfy the requirements of the relevant regulatory authorities use the correct antistatic procedures described in this manual

Use only ResMed approved parts and never use parts that have failed, show excessive wear, have been contaminated, or are ineffective for their intended use.

Note: Technical specifications for each device are available in the device User and Clinical Guides.

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Air10/Lumis S/ST exploded view

*

**

* The on-board COMMs PCBA (otherwise known as the CAM) is not included in all Air10 or Lumis devices. ** The fascia for the AirStart 10 differs from this image.

ST-A & CS-A Alarm assembly exploded view

TOP CASE

PRESSURE CONNECTION INLET SEAL

PRESSURE CONNECTION SENSOR CHASSIS INLET SEAL SPEAKER ASSEMBLY

ALARMS ST-A/CS-A PCB ASSEMBLY

BRACKET AND AMPLIFIER

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External device description Air10

1 2 3 4 5 6

5

6

Home button Screen Dial HumidAir humidifier Start/Stop button Air outlet

1

2 3

1 1 2 3

1

3

2

2

Air tubing Power inlet Filter cover

1 2

AirStart

1 2 3 4 5

4

5

SD card port Air10 modules port

6

Home button Screen Up/Select/Down buttons HumidAir humidifier Start/Stop button

1

2

3 8

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ST-A, CS-A

5

1

2

1 2 3

6

3

4

Home button Screen Up/Select/Down buttons

4 5 6

HumidAir humidifier Start/Stop button LED alarm indicator

ST-A, CS-A rear

1 2

3

5

4 1 2 3

Serial number and device number Air outlet Power inlet

9

4 5

Retention clip Air filter cover

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System description The following block diagram provides a simplified view of the Air10 and Lumis systems.

The Air10 series & Lumis comprises the following subassemblies:     

Main Controller Pneumatic block Humidifier CAM Alarm assembly (ST-A/CS-A devices only)

Note:

The CAM is not included in all Air10 or Lumis devices.

Microprocessor controller circuit The Main microprocessor comprises the main microprocessor memory, the user interface and the external interface circuitry. The main controller provides the following functions:     

All user interface input and output, including therapy settings and display of measures Supervisory control of therapy Data recording Connection via SD card to export recorded data Connection to a PC via a USB module for use in service

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Alarm PCB The alarm PCB is only present in ST-A & CS-A devices. The features of the alarm PCB are:      

Generation of auditory and visual alarm signals. Auditory and visual alarm signals test function. Management of alarm audio pause function via the User Interface. Backup power source for the power fail alarm. Independent measurement of outlet pressure. Detection of power failure alarm condition.

Pneumatic block The pneumatic block comprises:      

The blower – to deliver ventilation to the patient Silicone blower suspension - for shock and vibration protection and noise attenuation Acoustic foam to provide acoustic resistance Flow plate – differential pressure (dP) is developed across the flow plate tubes. Muffler Venturi tube

CAM (Cellular Access Module) Note: The CAM is not included in all Air10 or Lumis devices. The CAM allows wireless communication between the flow generator and ResMed’s AirView compliance management system utilising second generation (2G), third generation (3G) and soon 4G mobile cellular telecommunication systems: GSM/GPRS and CDMA. The CAM is an internal part of the flow generator. The module’s separate PCBA is connected to the flow generator main PCB via a 4-wire cable assembly.

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Humidifier The humidifier is an integrated sub-system of the main flow generator and provides heated humidification and heated tube functionality. The flow generator controls the heating of both the tubing and hotplate using commands sent to the humidifier via a system wide serial communications bus (ResBus). The humidifier sub-system electrical circuit is incorporated into the flow generator main PCB.

Sensors The sensors provide patient and machine data to the microprocessor controller. Their details are as follows: Sensor Temperature sensor Flow sensor Pressure sensor

Location Main PCB Main PCB Main PCB & Alarm PCB

Range -55°C to +130°C -70 to +180 L/min -5 to +45 cm H2O

Power management The Air10/Lumis series can be used with two different power sources:  

AC mains power External DC power supply (eg, car 12V power outlet)

Note: The isolation barrier to the patient from the mains is performed primarily by the PSU. There are no serviceable parts of the power supply, and each power supply is tested individually by the manufacturer therefore testing to IEC62353 is not required.

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General inspection procedures Instructions for general inspection procedures Carry out the procedures on the following pages to confirm that the flow generator is in good electrical and mechanical condition. These tests will highlight any major mechanical or electrical problem with the unit. Prior to completing testing it should be determined whether there is sufficient signal strength in the service centre to in order to confirm the functioning of the CAM. Refer to Appendix B: Determining signal strength on page 88 for further details. Please note the tests required will vary dependent on the device being tested.

Equipment required 

ResMed Service Software, available on the Technical services website

Note: Ensure you check the Technical Services website to confirm the latest version of service software available for use with this product.    

Air10 USB adapter Oxygen side port connector Straight adaptor Air tubing connector

Note: The above parts are available in the Service software accessories kit (ResMed part #19919) which contains: Air10 USB module and USB cable, S9 USB adapter and cable, ResScan USB adapter and cable, oxygen sideport connector, straight adapter, calibration cap and air tubing connector.   

Air10 side cover (#37303) Ambient temperature reporting source Humidity meter (we recommend the Center 310 humidity meter) Note: The humidity meter must be capable of measuring 15-40°C with an accuracy of ±1.5°C and measuring relative humidity of 10-90% with an accuracy of ± 5%.

    

SD card (#37333) 2m air tubing - standard, 19 mm inner diameter (ResMed part #14961) ClimateLineAir heated air tubing (#37296) Manometer (0-30 cm H2O range) Calibrated flow meter with flow regulation valve Note: L/min



The flow meter must be capable of measuring air flows ranging from 0 - 180 with an accuracy of 3% or better over this range.

A computer running Windows 7 or XP (32 & 64 bit for all)

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Control panel Button

Note:

Device type

Name

Description

All devices

Start/Stop button

Press to start/stop therapy. Press and hold for three seconds to enter power save mode.

All devices

Home button

Press to return to the Home screen.

AirSense, AirCurve, Lumis

Dial

Turn to navigate the menu and press to select an option. Turn to adjust a selected option and press to save your change. Operates as mute button for ST-A/CS-A devices.

AirStart

Up/Select/Down buttons

Press Up or Down to navigate the menu and press Select to choose and option. Press Up or Down to adjust an option and press Select to save your change.

Any reminders or alerts displayed on the device screen should be cleared before proceeding with the general inspection procedures.

1. Clean the flow generator Before servicing the unit it should be wiped down using a dry lint free cloth. The humidifier and air tubing can be washed in warm water using mild detergent. Do not use bleach, chlorine alcohol, or aromatic based solutions, moisturising or antibacterial soaps or scented oils to clean the device, humidifier or air tubing. Further cleaning and maintenance instructions can be found in the User Guide. Note:

If disinfecting the Air10/Lumis remove the humidifier tub and air outlet prior to disinfection. Comprehensive disinfection procedures are outlined in #378046 “AirSense 10 and AirCurve 10 reprocessing guide”. Lumis disinfection details can be found in the Lumis Clinical Guide. If decontaminating the device airpath, the side cover must be inserted.

2. Record device settings 1. With the unit disconnected from the power outlet, insert the Air10 USB adapter into the module adapter port of the flow generator.

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2. Remove the SD card from the unit. Note:

3. 4. 5. 6.

If you wish to save the patient compliance data on the SD card, download the data into ResScan. Once the SD card is reinserted in the upgraded unit all patient compliance data is erased.

Connect the flow generator to the PC via the USB cable. Connect the flow generator to the power outlet and turn it on. Allow it to complete the self-test. Open the ResMed service software. The following window will appear:

7. Press the Refresh button (as indicated above) to enable the service software to recognise the flow generator. 8. The flow generator details will then be displayed at the bottom of the screen beside the Refresh button. The calibration and tests in the Xplorer bar at the left of the screen will also change to indicate the procedures specific for that product.

9. Select Device Settings in the XPlorer bar. Note:

It will take a few seconds for the flow generator settings to be displayed.

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10. The flow generator settings will be displayed as shown below:

11. Select Save to Database in the Xplorer bar. 12. The service history dialog will then be displayed if the unit has existing records in the application database. (If there are no existing records, proceed to step 13.) Click on the Create a new Service Setting Record icon to start a new session, or select an existing session from the service history displayed:

13. The following window will then appear.

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14. At this point, you can select the name of the service agent handling the device and enter the Service Record (SR) and Repair numbers, so that this information will be included with the flow generator settings details. Note: To enter new service agent details, click on the image in the "Select service agent" window. A cursor will then appear in the "Service Agent" field, and the name can be entered. Once the service agent details are entered, any service agent names entered for that device will be available for selection in the drop down menu. If an existing session was selected, the "Select service agent" window will already be populated.

WARNING

If the device settings cannot be recorded, select the appropriate product code for the device. In the Xplorer bar click on ‘Reload Default Settings’ (this feature is available in ResMed Service Software v5.2 and onwards). Notify the patient, so they can have their settings reloaded. Some devices also require active customization – refer to Tech note 1063311 for further details.

Note: If the CAM is not working the following error message will be displayed.

Enter the device ‘About’ menu (in the Clinical menu) and confirm if the CAM details are displayed. If they are not displayed refer to the troubleshooting guide on the Technical Services website for further details. 15. Click on the Select button once the details have been entered. 16. The software will then return to the settings screen. 17. Turn off the flow generator and disconnect the Air10 USB adapter.

3. External examination Visually examine the flow generator for external damage such as:   

deformation or cracking of the upper or lower cases damaged components such as the mains power inlet damage to the interface panel or bottom decal

If either of the outside cases are fractured and require replacement, take particular care in inspecting all other components within the cases for damage.

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4. Internal examination (if necessary) WARNING Prior to assembly or disassembly ensure that power is not connected to the device.

Remove the fascia and upper case, following the instructions given in Section 5 Replacing major subassemblies. Inspect the unit for the following, recording any irregularities:    

all mechanical components are seated correctly all electrical components are mounted correctly and secured in position there are no loose terminals, loose wires or incomplete insulation on electrical components or connections there are no loose pieces of wire or other objects trapped in the PCB

Use an antistatic cloth or brush to remove dust or dirt from components and from the insides of the flow generator case. Repair or replace any missing or damaged components. Rectify any problems either identified by the user or noted during servicing. Should any major components such as the main PCB, motor or any part of the air circuit is replaced the device should be recalibrated and tested. Reassemble the flow generator.

CAUTION

Printed circuit boards can be damaged by static electricity. Please read the instructions in Section 4 Operator safety and static precautions before attempting to replace any PCBs.

5. Replace the air filter 1. Open the filter cover and remove the air filter.

2. Place the new air filter onto the cover.

3. Close the cover.

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CAUTION

Use only genuine ResMed spare parts, because the filter affects the flow characteristics of the flow generator, which in turn affects the pressure supplied to the patient. Do not wash the air filter. The air filter is not washable or reusable.

6. Temperature sensor test Note: The device shouldn’t be warmed up prior to starting the Temperature sensor test. Also ensure the Air10 side cover is not inserted when completing the test. 1. 2. 3. 4.

Select Temperature sensor test in the Xplorer bar. Set up the test equipment as instructed by the test software. Select Next and follow the steps as instructed. If the device fails this test replace the main PCB.

7. CPU Watchdog test 1. 2. 3. 4.

(Lumis & AirCurve CS-A devices only)

Select CPU Watchdog test in the Xplorer bar. Set up the test equipment as instructed by the test software. Select Next and follow the steps as instructed. If the device fails this test replace the main PCB.

8. Pressure calibration test Note: Ensure the following tests (except the Heated tube test) are completed using the standard 2 m, 19 mm inner diameter air tubing and the Air10 side cover unless otherwise specified.

1. Return to the service software and press the Start session button . 2. The following screen will then appear, indicating the existing service records for the flow generator.

3. The most recently created record (the flow generator settings recorded earlier) will be highlighted. 4. Click on the Select button

to continue recording the service results to the same record. 19

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