Stellar Cpap Service

248657/3 2016-02
Stellar series
SERVICE
ENG
Stellar™ series
INVASIVE AND NONINVASIVE
VENTILATOR
Service Manual
English
ResMed ventilation solutions

Making quality of care easy
Global leaders in sleep and respiratory medicine www.resmed.com

Manufacturer:
ResMed Germany Inc. Fraunhoferstr. 16 82152 Martinsried Germany
Distributed by:
ResMed Ltd 1 Elizabeth Macarthur Drive Bella Vista NSW 2153 Australia
ResMed Corp 9001 Spectrum Center Blvd. San Diego CA 92123 USA
ResMed (UK) Ltd (EU Authorised Representative) 96 Milton Park Abingdon Oxfordshire OX14 4RY UK
See www.resmed.com for other ResMed locations worldwide.

For patent information, see www.resmed.com/ip
© 2016 ResMed Ltd.

248657/3 2016-02
Contents
1 How to use this manual................................................................................ 4
2 Introduction ................................................................................................... 5
Intended users of this manual 5
Features of the Stellar 100 and Stellar 150 ............................ 5
Stellar model types ............................................................. 6
3 General inspection and servicing ................................................................. 7

Instructions for general inspection procedures ........................ 7
Equipment required 7
Control panel and function keys 8
LCD screen 8
1 Clean the flow generator 9
2 Record clinical settings 9
3 Internal battery remaining capacity test 11
4 Temperature sensor test 12
5 External examination 12
6 O2 connector test 13
7 Cooling fan test 13
8 DC power test 14
9 Internal examination (if necessary) 14
10 Replace the air filter 15
11 Pressure calibration test 15
12 Flow calibration test 16
13 Blower test 16
14 Humidifier test 16
15 Airpath leak test 17
16 USB port test 17
17 SpO2 port test 17
18 FiO2 port test 18
19 Keypad test 18
20 LCD test 18
21 LED test 18
22 Audible alarm test 18
23 Watchdog test 18
24 Internal battery test 19
25 Finalise manual check results 19
26 Set clock 19
27 Reload clinical settings 20
28 Fill out product problem report 21
4 Operator safety and static precautions .................................................... 22
5 Replacing major subassemblies ................................................................. 23

Outer components of the device ..........................................23
Components at rear of Type 1 device 24
Components at rear of Type 2 device 24
Opening the Stellar ............................................................25
Internal components - main PCB, power supply, battery ..........26
Replacing the main PCB 27
2 Stellar™ series Service Manual
Installing the serial number 32
Units with a service history 32
Units without a service history 33
Replacing the power supply ................................................ 34
Replacing the battery ......................................................... 36
Recovering a deeply depleted battery 37
Accessing the airpath assembly ........................................... 38
The airpath assembly ......................................................... 39
Replacing the motor 39
Replacing the muffler foam and the flow sensor 42
Installing the airpath assembly 46
The bottom case ............................................................... 46
Replacing the cable harness 47
Replacing the interface housing assembly 49
The top case ..................................................................... 50
Replacing the dial PCB 50
Closing the unit ................................................................. 52
6 Replacement parts list ................................................................................53

External components 53
Internal components 54
Air path components 55
In the top case 56
In the bottom case 57
Spare parts list .................................................................. 58
7 Calibration procedures ................................................................................60

1 Pressure calibration 60
2 Flow calibration 61
8 Troubleshooting guide ................................................................................62
9 System specifications .................................................................................67

Displayed values 69
Symbols 69
10 Recommended maintenance schedule ........................................................71
Appendix A: Service request form .......................................................................72
Appendix B: Operational diagram ........................................................................73
Contents 3
1 How to use this manual
Each of the sections in this manual have been written with a specific purpose in mind. Use this
guide to help you find the material which is relevant to your task at the moment.
2 Introduction – Gives a brief overview of the Stellar series.
3 General inspection and servicing – Gives the procedures to help you examine a device
which has been brought into a service centre. The general inspection procedures should be
performed before any other work is done on the flow generator.
4 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.
5 Replacing major subassemblies – Highlights points to note when replacing subassemblies,
reassembling the device and indications of when recalibration is necessary.
6 Replacement parts – Shows labelled pictures and part numbers of all the spare parts and
subassemblies available from ResMed.
7 Calibration procedures – Lists procedures to follow when device calibration is required.
8 Troubleshooting guide – Gives you a way to quickly locate the problem and fix it if you
know the symptoms of a faulty unit.
9 System specifications – Lists electrical and mechanical specifications of the device and air
tubing.
10 Recommended maintenance schedule – Provides a brief description of the maintenance
required for the unit.
Some countries require all medical equipment to have a periodic service to confirm that the
equipment is in good working order. Section 3, “General inspection and servicing” may
be used in this situation.
.
Appendix A: Service Request Form - Fill out this form if you need to return a device to ResMed
for servicing.
Appendix B: Operational diagram - Provides a functional block diagram of the Stellar series.
Note: Schematics of all PCBs in this device are available to authorised service centres. To
order, please contact your local ResMed office.
This manual contains special terms and icons that appear in the margins to draw your
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.
Note: If you have any feedback regarding the Stellar series service manual please contact
Technical Services, Sydney at TechSupport@resmed.com.au.

2 Introduction
This manual is a guide to servicing and repairing the Stellar series of flow generators. It is
written for ResMed distributors, and gives instructions for replacing subassemblies and for
recalibration as appropriate. Work at the component level will normally be carried out by
ResMed.
Intended users of this manual

Before attempting any repair work, please ensure that you:
• are familiar with the operating manual and the clinical manual for the 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 approved ResMed parts and never use parts that have failed, show excessive
wear, have been contaminated, or are ineffective for their intended use.
Caution • When switching off the Stellar ensure you also remove the power
cord from the device.
!
• Ensure the device is placed in such a way that the power cord can be
easily removed from the device.
• Disconnect the device from mains power when using a DC external
power supply.
• When a fuse is defective the entire subassembly should be replaced
e.g. when the fuse on a power supply is found to be defective the
power supply should be replaced.
Note: Schematics of all PCBs in this device are available to authorised service centres. To
order, please contact your local ResMed office.
Features of the Stellar 100 and Stellar 150

The Stellar 100 and Stellar 150 can deliver non-invasive ventilation for adult and pediatric
patients in the home and hospital environment. In addition to the modes provided in the Stellar
100 and 150 (CPAP, S, ST, PS, T, PAC), the Stellar 150 includes iVAPS (intelligent Volume
Assured Pressure Support) mode. iVAPS mode is designed to maintain a present target
alveolar minute ventilation by monitoring delivered ventilation, adjusting the pressure support
and providing an intelligent backup breath automatically.
Additional service features
Service menu
The Stellar series features a service menu including details such as the battery remaining
capacity, the temperature of various internal components and the time since the device was
previously serviced.
To access the service menu, hold down the dial, Monitor button and Info button on the Stellar
device simultaneously for at least three seconds. Press the Monitor button to exit the service
menu.
Service reminders
Via the service software, the service technician can enable the service reminders to be
displayed on the Stellar. Service reminders regarding the internal battery, motor and when the
next service is due will be displayed (depending on regional settings).
2 Introduction 5
Stellar model types
ResMed continually develops and improves its products. The different variations are referred
to as type numbers, such as Type 1 & Type 2.
The following table is a guide to identifying the two types of Stellar devices:
Type Product codes Characteristics

1 Stellar 150 • Original product release
24140 - Americas, 24141 - Germany, Note: Type 1 units can be upgraded to
24142 - France, 24143 - EUR G1, software version SX483-0230 and higher.
24144 - EUR G2, 24145 - UK,
24146 - Teijin, 24147 - Asia Pac,
Stellar 100
24151 - Germany, 24152 - France,
24153 - EUR G1, 24154 - EUR G2,
24155 - UK, 24156 - Asia Pac,
24157 - Americas, 24158 - Fukuda
2 Stellar 150 • SX483-0230 and higher

24141 - Germany, 24142 - France, • Support for remote alarm
24143 - EUR G1, 24144 - EUR G2, • New main PCB with some components
24145 - UK, 24146 - Teijin, 24161 - removed & sensor tube routing changed
Americas, 24162 - Asia Pac, 24165 -
• Ferrites removed from cable harness and
Brazil
Interface assembly
Stellar 100
24151 - Germany, 24152 - France, • Thinner flexible cable running from Interface
24153 - EUR G1, 24154 - EUR G2, assembly
24155 - UK, 24158 - Fukuda, 24163 • PAD printing on bottom case
- Americas, 24164 - Asia Pac
6 Stellar™ Series Service Manual

3 General inspection and servicing
Instructions for general inspection procedures
Carry out the procedures on the following pages to confirm that the unit is in good electrical
and mechanical condition. These tests will highlight any major mechanical or electrical
problem with the unit.
Note: If the device requires a software upgrade, contact your regional Technical Services
team for further details.
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.
• USB cable (part of kit #36950)

• Oxygen sideport connector (ResMed part #14915)
• Straight adaptor (ResMed part #19375)
• Calibration adaptor kit - contains calibration cap, air tubing connector and oxygen sideport
connector (ResMed part #19911)
Note: The above items are contained in the Service accessories kit (ResMed part #19919) -
S9 Adapter & USB cable, oxygen sideport connector, straight adapter, calibration
cap and air tubing connector.
• H4i heated humidifier

• Remote Alarm (ResMed part #27902)
• Remote alarm cable (ResMed part #27904)
• 2m air tubing - standard, 19 mm inner diameter (ResMed part #14961)
• Manometer (0-60 cm H2O range)
• Digital thermometer with external probe
• RPS II and DC cable (Stellar DC cable #24959) or DC power source - 24 VDC, 3 A
• Nonin Xpod connector (ResMed part #22305))
• O2 sensor (ResMed part #CAP008617)
• Calibrated flow meter with flow regulation valve
Note: The flow meter must be capable of measuring air flows ranging from 0 - 260 L/min
with an accuracy of 3% or better over this range.
Note: If you are using a flow analyser to complete the Stellar general inspection procedures
ensure it is set to gas standard STPH.
• A computer running Windows 7 (32 & 64-bit) or XP.
3 General inspection and servicing 7

Control panel and function keys
Mains power
External Monitoring
power supply menu
Internal
battery
Setup menu
Alarm
Alarm mute
button Info menu
LCD screen
Push dial
(rotate/click)
Therapy LED
Start/Stop
button
LCD screen
Warm-up feature H4i
Data storage device Ramp time
Mains power Program
DC voltage* Therapy mode
Internal
battery Patient mode
Current
Title bar screen/
number of
screens
within the
Settings menu
Scroll bar
Therapy
status bar
*Only available when an external power supply is connected.

1 Clean the flow generator
Before servicing the unit it should be wiped down using a lint free cloth and an approved
cleaning agent (Mikrozid® AF or CaviCide®).
Caution When using a cleaning agent with a high alcohol content refer to the appropriate
Material Safety Data Sheet to ensure safe handling of the cleaning agent.
!
Remove any stains from the cases. When removing any stains from the device or mask
system use soap or detergent-based cleaning solutions. Remove excess and wipe dry after
use. Do not use thinners, trichlorethylene, bleach or other solvents. Do not apply oil to any
component of the device.
2 Record clinical settings

1 With the unit disconnected from the power outlet, insert the USB adaptor into the rear of
the device and the other end to the PC.
Connecting to Type 1 Stellar
2 Connect the Stellar to the power outlet and turn it on.

3 Allow it to complete the self test.
4 Open the ResMed Service Software. The following window will appear:
XPlorer
bar
Refresh
button

5 Press the Refresh button (as indicated on the previous page) to enable the service software
to recognise the device.
6 The unit 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.
7 Select Device Settings in the XPlorer bar.
Note: It will take a few seconds for the device settings to be displayed.
8 The unit settings will be displayed as shown below:
9 Select Save to Database in the XPlorer bar.

10 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 11.) 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:
Create a new
Service Setting
Record icon

11 The following window will then appear:
Select service agent

screen
12 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 device 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 clinical settings cannot be recorded, select the appropriate product code for the
product. In the XPlorer bar, click on "Read default settings", then click on "Reload to
! flow generator". Notify the patient, so they can have their settings reloaded.
13 Click on the Select button once the details have been entered.
14 The software will then return to the settings screen.
15 Close the settings screen
Note: Further device details can also be found in the service menu. To access the service
menu hold down the dial, Monitor button and Info button on the Stellar device
simultaneously for at least three seconds. Press the Monitor button to exit the
service menu.
3 Internal battery remaining capacity test

1 Enter the Stellar service menu by holding down the dial, Monitor button and Info button
simultaneously for at least three seconds.
2 Scroll down the screen to examine the Internal Battery Remaining Capacity.
3 Confirm the remaining battery capacity is > 80%.
If the remaining battery capacity is < 80%, the battery must be replaced.

4 Temperature sensor test
1 In the service software press the Start session button .
2 The following screen will then appear, indicating the existing service records for the device.
3 The most recently created record (the device settings recorded earlier) will be highlighted.
4 Click on the Select button to continue recording the service results to the same record.
5 The "Select service agent screen", as shown on page 11, will appear once again.
6 Select the name of the service agent and enter the SR number.
7 All calibration and tests, including tests completed without service software are then listed
in the Xplorer bar.
8 Select Temperature sensor test in the XPlorer bar.
9 Set up the test equipment as instructed by the test software.
10 Select Next and follow the steps as instructed.
11 Once the test is complete, turn off the device and disconnect the USB cable.
12 If the device fails any part of the temperature sensor test (motor temperature, PCB
temperature, PSU temperature, battery temperature) replace the faulty subassembly.
Note: At the top of the screen at the beginning of each procedure is an alert reminding you
to reload the clinical settings to the unit after completing the necessary test and
calibration procedure. Click the OK button once you have read the alert.
5 External examination
1 Visually examine the Stellar for external damage such as:
• deformation or cracking of the upper or lower cases
• damaged components such as the mains power inlet, oxygen inlet and SpO2 or FiO2
connectors
• damage to the user interface or bottom decal
Where there is external damage, it is recommended that an internal examination is conducted
after completing the following manual tests.

6 O2 connector test
1 Lift the handle and pull the filter cover away in a horizontal direction.
2 Take the hold of the oxygen inlet and attempt to turn the oxygen inlet.
3 Confirm that there is no movement in the oxygen inlet.
4 If the oxygen inlet is loose, replace the inlet assembly and repeat all general inspection
procedures.
7 Cooling fan test

1 With the unit turned off, turn over the unit while holding it off the work bench.
2 Locate the fan vent on the bottom case.
3 The edge of the fan blades should be visible through the fan vent.
Fan blade
4 Press the power button at the rear of the unit.

5 Confirm the fan runs for approximately 2 seconds then stops. The alarm will sound a test
beep, then the fan will restart.
6 Turn off the unit.

8 DC power test
Caution Disconnect the Stellar from mains power when it is connected to the RPS II.
!
1 With the unit already turned off, connect the RPS II to the DC power socket in the Stellar.
2 Set the DC switch on the RPS II to ON.

3 Turn on the Stellar and confirm:
• the device powers up
• the External power supply LED is lit
• the alarm sounds and the Alarm LED is lit
• the message "External DC power in use" is displayed at the top of the Stellar screen
External power
supply LED
Alarm LED
4 Turn off the unit and disconnect the RPS II.

5 Reconnect the Stellar to mains power.
9 Internal examination (if necessary)
Caution The Stellar uses an isolated power supply, however, it is recommended that isolation
transformers are also used for added safety while working with the cases opened up
! and power switched on.
Remove the top 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 PCBs
Use an antistatic cloth or brush to remove dust or dirt from components and from the insides
of the device 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 motor, the
main PCB or any part of the air path require replacement, the general inspection procedures
should be repeated after the assembly has been replaced.
Reassemble the device.
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.
Thread-forming screws are used throughout the device. When replacing a thread-
forming screw, turn the screw anti-clockwise until it fits into the previously cut
thread. Otherwise the original thread may be stripped out.
10 Replace the air filter

1 Remove the filter cover and the filter from the rear of the device.
2 Replace the air filter.
3 Refit the filter cover.
Caution Only use genuine ResMed spare parts, because the filter affects the flow
characteristics of the device, which in turn affects the pressure supplied to the
! patient.
11 Pressure calibration test

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 device.
3 The most recently created record (the device settings recorded earlier) will be highlighted.
5 The "Select service agent screen", as shown on page 11, will appear once again.
in the Xplorer bar.
8 Select Pressure calibration test in the XPlorer bar.
11 If the device fails this test, follow the procedures outlined in Section 7 Calibration
procedures to do a full recalibration of the device, ensuring the equipment set-up is correct.
12 Flow calibration test

1 Select Flow calibration test in the Xplorer bar .
4 If the device fails this test, follow the procedures outlined in Section 7 Calibration
procedures to do a full recalibration of the device, ensuring the equipment set-up is correct.
13 Blower test
1 Select Blower test in the XPlorer bar.
4 If the device fails this test complete the Airpath leak test to determine if there is a leak in
the airpath. If the device passes the airpath leak test determine if the fault lies with the
motor, the motor connector or the main PCB.
14 Humidifier test
The Stellar is designed to integrate with the H4i heated humidifier to form a single device with
humidification unit.

1 If present, remove the H4i blind plug from the front of the device.
2 Select Humidifier test in the XPlorer bar.

3 Follow the prompts on screen to test the humidifier.
Warning The H4i can reach a maximum of 85°C.

!
4 If the device fails this test, confirm that the humidifier being used for the test is functioning
correctly. If the humifier is working properly examine the humidifier LEDs to see if they are
damaged. If they are damaged replaced the Stellar main PCB. Otherwise, determine if there
is an issue with the connection of the humidifer to the power supply.
15 Airpath leak test

1 Select Airpath leak test in the XPlorer bar .
2 Follow the steps as instructed.
3 If the Stellar fails this test, determine if there are leaks in the airpath. If there are no leaks
in the airpath recalibrate the device.
16 USB port test

1 Select USB port test in the XPlorer bar.
3 If the Stellar fails this test, determine if the fault lies with the USB port itself (in the
interface housing assembly), the flexible cable running from the interface housing assembly
or the main PCB.
17 SpO2 port test

1 Select SpO2 port test in the XPlorer bar.
3 If the Stellar fails this test, determine if the fault lies with the SpO2 port itself (in the
or the main PCB.

18 FiO2 port test
1 Select FiO2 port test in the XPlorer bar.
3 If the Stellar fails this test, determine if the fault lies with the FiO2 port itself (in the
or the main PCB.
19 Keypad test
1 Select Keypad test in the Xplorer bar.
3 If the Stellar fails this test, determine if the fault lies with the keypad (part of the top case),
dial PCB or the connection from the top case to the main PCB.
20 LCD test
1 Select LCD test in the XPlorer bar.
3 If the Stellar fails this test, replace the main PCB (which includes the LCD).
21 LED test
1 Select LED test in the XPlorer bar.
3 If the Stellar fails this test, determine if the fault lies with the LEDs (part of the top case),
dial PCB or the connection from the top case to the main PCB.
22 Audible alarm test

Note: The Remote alarm will also be tested as part of this procedure if testing a Type 2
device.
1 Select Audible alarm test in the XPlorer bar.
3 If testing a Type 1 unit and the test failed, determine if there is a fault with the interface
housing assembly, the flexible cable running from the interface housing assembly or the
main PCB.
If testing a Type 2 unit and the buzzer failed, determine if the main PCB is faulty.
If testing a Type 2 unit and the Remote Alarm failed, determine if there is a fault with the
remote alarm or remote alarm cable, the interface assembly, the flexible cable running from
the interface housing assembly or the main PCB.
23 Watchdog test
1 Select Watchdog test in the XPlorer bar.
3 If the Stellar fails this test replace the main PCB.

24 Internal battery test
1 Power off the Stellar.
2 Select Internal battery test in the XPlorer bar .
3 Follow the steps as instructed to confirm the battery capacity displayed on the flow
generator is within ±5 % of the capacity displayed in the Information and control panel.
4 If the battery capacity value displayed on the flow generator is less than 50% recharge the
device to at least 50% before returning the device to the customer.
5 Turn off the Stellar. If the device fails this test, determine if there is a fault with the
battery, the battery connection to the main PCB or with the main PCB itself.
25 Finalise manual check results

In the XPlorer bar at the left of the screen, all tests that are completed without the service
software are listed under the title "Manual Check".
1 Click on the name of each manual check.

2 For each manual check, indicate whether the unit passed or failed.
26 Set clock
Note: Ensure that the PC used to service the Stellar is set to the correct date and time prior
to pressing the Set time and date icon.
1 With the device connected to mains power, turn on the Stellar.
2 Select Set time and date in the XPlorer bar.

3 The following window will appear:
4 Select the appropriate time zone for the owner of the device, then press the Locale button.
5 Press the Select button to set the Stellar time and date.
Caution If you reset the date to one that is earlier than currently displayed on the device,
compliance data may be lost.
!
27 Reload clinical settings

1 Click on the Close session button to close the current session.
2 Select Device Settings in the XPlorer bar.
3 The Stellar settings will be displayed.
4 Select Read database, as shown below:

5 All recorded sessions for the unit will be displayed. Ensure the most recent session (in
which the clinical settings and results were recorded) is highlighted, then click the Select
button .
6 The screen will then be repopulated with the original settings.

7 Under Product Information, reset the Hours since last service to 0.
8 If the motor was replaced, reset the Motor run hours to 0.
9 Select Reload to flow generator in the Xplorer bar to load the settings back into the unit.
10 Once complete, exit the settings screen.
11 Once again, press the Start session button and ensure the most recent session (in which
the clinical settings and results were recorded) is highlighted, then click on the Select
button .
12 Click on Reload settings at the bottom of the Xplorer bar.
13 Click on the Select button to indicate that the clinical settings were successfully reloaded
into the Stellar.
14 Press the Start session button if you did not need to fill out the product problem report or
print out the test results.
28 Fill out product problem report

1 If the Stellar needs to be returned to a ResMed service centre, fill out the “ResMed Service
Request Form” on page 73 of this manual, and send it to your regional ResMed office along
with the Stellar.
2 Once again, click on the Start session button and open the session just completed.
3 At the bottom of the Xplorer bar select Complete Problem Report and click on the Pass
button to indicate that problem report was completed.
4 Click the Close session button to finish the session.

4 Operator safety and static precautions
Warning Prior to disassembly or assembly, make sure that the power is not connected to the
flow generator.
!
Integrated circuits (ICs) within the various PCBs can be badly damaged by electrostatic
discharge or transient voltages. The following procedures are recommended to avoid
component damage:
1 Work benches where handling and repairs are done must have surfaces of suitable
conducting material connected via a 1 Mresistor to an electrical ground.
Note: It is also recommended that the area under and also in front of the work bench be
coated with a suitable conductive floor paint or covered with a conductive floor mat.
Conductive paint coating or floor mat must be connected to an electrical ground.
2 Soldering irons or solder baths must be at the same reference (ground) potential as the
work bench.
3 A wrist strap must be worn by service personnel working at the bench. The wrist strap
must have a conductive lead (1 M) connected to the bench surface. Alternatively, a heel
grounding strap to ground the operator to the floor may be used. (Such a wrist or heel strap
should not create an electrical hazard for the wearer).
4 Handling of ICs should be kept to a minimum. If handling is required, avoid directly
touching the leads. The recommended procedure is to first touch the container in which the
ICs are stored, or the PCB in which they are mounted, before touching the ICs. Service
personnel should take every precaution that the items will see the same reference potential
when moved.
5 All ICs and PCB assemblies containing ICs should be stored in antistatic bags until use.
6 Service personnel should wear clothing which minimizes the build up of static charges.
Cotton is preferable to wool or synthetic fibres.
7 Service personnel should avoid electrostatic build up through the movement of air over
plastic material.
8 Plastic materials should wherever possible be kept away from the ICs as they develop and
maintain high levels of static charge.
22 Stellar ™ series Service Manual

5 Replacing major subassemblies
This section contains instructions and points to be aware of as you replace major
subassemblies and reassemble the Stellar.
Equipment required
• Torx T10 screwdriver
• Adjustable wrench
• Dial removal tool (ResMed part #R190-750)
Caution When a main PCB, motor or any part of the air path is replaced, the device must be
recalibrated and tested. Repeat the tests in Section 3 General inspection and
! servicing.
Printed circuit boards can be damages by static electricity. Please read the
instructions in Section 4 Operator safety and static precautions before attempting to
replace any PCBs.
Thread-forming screws are used throughout the device. When replacing a thread-
forming screw, turn the screw anti-clockwise until it fits into the previously cut
thread, otherwise the original thread may be stripped out.
Outer components of the device
Handle
LCD
Control panel
AC connection
for H4i humidifier
Air outlet
5 Replacing major subassemblies 23

Components at rear of Type 1 device
Air filter cover
Oxygen inlet
AC power
socket
FiO2 sensor
connection
Power on/
XPOD oximeter stand-by
connection switch
Data DC power socket

communication
ports
Components at rear of Type 2 device
Air filter cover
Oxygen inlet
AC power
Remote alarm socket
connection
XPOD oximeter Power on/

connection stand-by
switch
FiO2 sensor Data DC power socket

connection communication
ports

Opening the Stellar
1 From the rear of the unit, lift the handle and pull the filter cover away in a horizontal
direction.
2 Remove the filter.

3 Turn the unit over and remove the five screws circled below, using the Torx T10
screwdriver.
4 Turn the unit back over and gently lift up the top case.

5 The dial PCB in the top case is connected to the main PCB via the flexible cable. Release
the lock holding the cable on the main PCB:
Dial PCB
Flexible cable
Main PCB
Internal components - main PCB, power supply, battery

With the top case removed, the main PCB, power supply and battery are visible.
Flexible cable from

Inlet assembly Interface housing assembly
Type 1 unit
LCD
Flow sensor cable

Battery harness
Pressure sensors
Battery cable
Power supply
cable
Power supply
Main PCB
Note: Take care not to damage the humidifier

LEDs when handling the main PCB.

Flexible cable from
Inlet assembly Interface housing assembly
Type 2 unit
LCD
Battery Pressure sensors
Battery cable
Power supply
cable
Flow sensor cable
harness
Power supply
Main PCB
Note: Take care not to damage the humidifier

LEDs when handling the main PCB.
Replacing the main PCB

1 Disconnect the power supply cable harness and battery cable from the side of the main
PCB.
2 Disconnect the motor cable harness from the front of the main PCB.
3 Near the top of the main PCB, disconnect the flow sensor cable harness and the two
silicone tubes from the sensors.
4 Pull up on the connector clip and disconnect the flexible cable sitting behind the LCD.
5 Disconnect the fan cable harness from under the rear of the LCD.
LCD
Battery
Fan cable harness
6 Remove the two screws attaching the main PCB to the chassis (circled below).
Type 1 unit
7 Take the new PCB and fit it on the chassis, ensuring it is sitting correctly on the two
locating posts.
8 Refit the two screws removed earlier.
Note: If using a pneumatic screwdriver, set the torque to 0.6 Nm ± 0.10 Nm.
9 Reconnect the battery cable and the power supply wiring harness to the main PCB. Ensure
the power supply cables are routed beside the ferrite and are not overlapping. Flatten the
wires on top of the power supply connector to prevent them touching the top case.
Type 1 unit
Power supply cables

beside ferrite

10 Confirm the flexible cable between the LCD and main PCB is sitting under the LCD.

 
11 Reconnect the motor cable harness at the front of the main PCB.
12 On the other side of the PCB, reconnect the flow sensor cable harness. The cable should be
oriented toward the back of the device. (For Type 1 units it should be routed behind the leg
of the electronic chassis.) Push any excess cable into the bottom case.
13 Reconnect the flexible cable at the rear of the main PCB. Close the connector clips while
holding the flexible cable in place.
Type 1 unit
Flexible cable
Flow sensor cable harness
The flow sensor cable harness

connector in a Type 2 unit is
located further forwards from
the pressure sensors.
Note: Ensure that the flexible cable is inserted perpendicularly into the connector, not at an
angle.
Flexible cable in Type 1 device Thinner flexible cable in Type 2 device

14 Reconnect the fan cable harness under the rear of the LCD.
15 For a Type 1 unit - refit the silicone tubes to the pressure sensors:
• take the tube from on the left of the patient connector and insert it on the pressure
sensor at the top of the main PCB. Tuck this tube under the bottom right hand corner of
the LCD
• fit the tube on the right of the patient connector and insert it on the remaining pressure
sensor
• route the tubes as shown below:
Tube route
Ensure the tubes are not pinched.

 


For a Type2 unit - refit the silicone tubes to the pressure sensors:
• take the tube from on the left of the patient connector and insert it on the pressure
sensor at the top of the main PCB. Fit the tube on the right of the patient connector and
insert it on the remaining pressure sensor
• route the tubes as shown below:
• Tuck both tubes under the bottom right hand corner of the LCD.
Ensure the tubes are not pinched.

 

Installing the serial number and product code
If the main PCB has been replaced the unit’s serial number and product code needs to be re-
installed.The following flow chart outlines this procedure.
Procedure
16 Connect the unit to the PC and open the service software.
17 Select Device Settings in the XPlorer bar .

18 The flow generator settings screen will be displayed.
19 Enter the unit’s serial number (found on the base of the unit) and select the appropriate
product code.

20 Select Read Default Settings in the Xplorer bar. The default settings for that product code
will be displayed on the settings screen.
21 Select Reload Device Settings to load the default settings to the device.
22 Exit the settings screen.
23 Click the Start session button . Any existing records for the unit will be displayed on
screen. Ensure the most recent record is highlighted.
Note: If no previously recorded session exists for the unit enter the service record details as
prompted.
24 Complete the calibrations and tests required when the main PCB has been replaced.
25 Finally, reload settings to the device (as outlined below).
Reload settings
26 A device:
• which has had the clinical settings recorded can have those settings reloaded to the unit
following the procedures from “27 Reload clinical settings” on page 20.
• A device without previously recorded settings requires the product code default settings to
be reloaded.
- Select Device Settings in the XPlorer bar.
- Select the appropriate product code for the unit from the drop down menu, then click on
Read Default Settings.
- The screen will then be populated with the units default settings.
- Click on Reload to flow generator to load them into the unit.
- Exit the Settings screen.
Recording the reloading of settings
27 Once again, press the Start session button and ensure the most recent session (in
which the clinical settings and results were recorded) is highlighted, then click on the
Select button .
28 Click on Reload settings at the bottom of the Xplorer bar.
29 Click on the Select button to indicate that the clinical settings were successfully
reloaded into the flow generator.
Press the Stop session button if you do not need to fill out the product problem report or
print out the test results.

Replacing the power supply
1 From the main PCB, disconnect the:
• power supply wiring harness
• motor cable harness
• flow sensor cable harness
• 2 silicone tubes from sensors
• flexible cable behind the LCD
• fan cable under the LCD
2 Disconnect the power supply wiring harness AC cable from the right side of the power
supply.
3 Disconnect the main wiring harness DC cable from the left side of the power supply.
Power supply wiring harness
Main wiring harness DC cable
Main wiring harness AC cable
4 Gently lift the electronic chassis, with main PCB and power supply, up from the bottom
case.
5 Remove the two screws which attach the power supply to the chassis.
6 Gently disconnect the power supply from the two snaps (circled) at the top and pull the
power supply away from the chassis.
Screws

7 Take the new power supply and slide it into the mounting slots at the base of the chassis
and the bottom case, then click it into place.
Mounting slots
Mounting slots in chassis base
8 Refit the 2 screws.

9 Reconnect the main wiring harness DC cable and the AC cable to the power supply. Ensure
the AC cable is inserted into the slots in the bottom case.
DC cable
AC cable
For Type 1 units, locate the ferrites towards the connector, as shown below:
Ferrites
10 Reconnect the battery cable and the power supply wiring harness to the main PCB. Ensure
the power supply cables are routed beside the ferrite and are not overlapping. Flatten the
wires on top of the power supply connector to prevent them touching the top case.
Power supply cables

beside ferrite

Replacing the battery
Note: If the remaining capacity of the internal battery is <80% (as described in “3 Internal
battery remaining capacity test” on page 11) the battery must be replaced. After
replacing the battery, repeat the tests in Section 3 General inspection and
servicing.
1 Disconnect the battery cable from the main PCB.
2 Push down on the catch at the top of the battery, then pull the battery cage away from the
chassis.
3 Take the new battery and cage assembly and gently push it into the battery cage. The
battery cables should be sticking out towards to top of the battery cage (which has the
catch on top).
4 Slide the battery cage into the chassis and push forward on the 2 tabs at the top of the
cage to engage the catch on the battery cage to the chassis.
5 Reconnect the battery cable to the main PCB.

Recovering a deeply depleted battery
When the battery is deeply depleted ( 5%) it can take several hours to charge it to a 15-20%
charge level.
To determine if a battery is deeply depleted complete the following steps:
1 Confirm the device fails to turn on using the internal battery.
2 Connect the device to AC mains (leave the device turned off) and confirm the Battery
Charging yellow LED is not flashing.
3 While connect to AC mains turn on the device. After the device completed the self test
confirm the Internal Battery Indicator on the Stellar screen has a yellow "X" displayed over
the top, as shown below:
If these conditions are met, the internal battery is deeply depleted. Complete the procedure
below to recharge the battery.
4 Turn off the device (if left on at step 3) and leave it connected to AC mains.
5 Confirm the Battery Charging yellow LED is flashing.
Note: If the yellow LED is not flashing the battery cannot be charged and should be
replaced.
6 Leave the device on AC mains (though still turned off) for several hours to reach a charge
level of 15-20%.
Note: To check the charge level turn on the device an examine the charge level on the
Stellar screen. Turn off the device after checking.
7 Once a level of 15-20% charge is reached it should take approximately one hour to reach
100% charge. (The device should still be turned off during this time.)

Accessing the airpath assembly
The airpath assembly is located under the electronic chassis.
To remove the electronic chassis, follow steps 1-4 of “Replacing the power supply” on page
34.
Inlet assembly
Type 1 unit
Switch
Flow sensor
Main wiring
harness DC cable
Blower assembly
Fan
AC cable
Patient connector
Motor connector
1 Lift the airpath assembly away from the bottom case.

The airpath assembly
Muffler housing
Inlet assembly
Blower housing
Flow sensor
Motor cable
Bump stops (circled)
Patient connector
Hose clamps
Replacing the motor

Note: After replacing the motor, ensure you reset the unit’s "motor run hours" to 0 when
reloading the unit’s clinical settings. For further detail, refer to “27 Reload clinical
settings” on page 20.
1 Pull the outlet seal and patient connector away from the blower housing.
2 Pull the inlet assembly away from the flow sensor.

3 Remove the three screws from the front of the blower housing.

4 Separate the blower housing from the muffler housing.
5 The foam pieces in the muffler housing can be removed and replaced if required.
6 Remove the main seal from the motor housing.
Main seal
7 The motor, attached to the main seal, is now visible.

8 Pull the motor away from the main seal.
Blower suspension
9 The motor suspension, sitting on top of the motor, can also be removed and replaced if
needed.
10 Take the replacement motor and place it on the main seal. Align the openings on the motor
with the corresponding holes in the main seal.

11 Turn the main seal over and confirm that the silicone of the main seal is flush with the
motor openings.
Motor openings
12 Gently push the motor cable harness into the channel on the main seal, ensuring there is
some slack in the cable harness.
13 Place the blower housing over the motor, ensuring that the motor cable harness is sitting
correctly in the locator of the blower housing.
14 If the flow sensor and muffler foam does not require replacement, proceed directly to step
25 on page 43.

Replacing the muffler foam and the flow sensor
15 Remove the foam from the muffler housing.
16 Pull the flow sensor away from the muffler housing.

17 Remove the flow sensor seal from the sensor.
18 Take the new flow sensor and install it in the seal.

19 Take the flow sensor (in the seal) and align it to the muffler housing as shown below:
20 Push the flow sensor into the muffler housing. If needed, use a twisting action to fully
insert the sensor into the housing.

21 Ensure the flow sensor is inserted correctly, with the sensor visible, and the seal is
completely through the housing and not pinched.
22 Take the replacement muffler foam, and insert the outlet muffler foam into the smaller
section of the muffler housing.
23 Insert the inlet muffler foam over the flow sensor.
24 Ensure the muffler foam is inserted correctly, with the holes in the foam align to the
corresponding holes in the muffler housing.




25 Fit the blower housing to the muffler housing.
26 Install the three screws removed earlier, in the following order:
3 2
27 If removed earlier, refit the 3 bump stops to the housing.

Note: Ensure the bump stop (located on the long pin next to the flow sensor) is inserted all
the way to the muffler housing.
28 Take the outlet seal and insert it over the outlet.

29 Take a hose clamp and place it over the rear channel in the seal.
30 Tighten the hose clamp.
31 Place the second hose clamp on the outlet seal (do not tighten!) and orient to the bottom
left of the first hose clamp, as shown below:
Tightened hose clamp
Second hose clamp

(do not tighten!)
32 Attach the pressure sensor tubing to the patient connector.

33 Insert the patient connector, lining up the nozzles on the patient connector with the mating
feature on the outlet seal (circled). Confirm that the patient outlet is aligned with the ridge
on the blower outlet (see arrow).
34 Tighten the second hose clamp (sitting under the patient connector).
Second hose clamp
35 Take the inlet assembly and twist it onto the flow sensor seal, until it is fully inserted.

Installing the airpath assembly
1 Take the airpath assembly and gently lower it into the bottom case.
2 Ensure the flexible cable from the interface housing and the fan cable is clear.
3 Ensure the screw bosses on the inlet assembly are sitting correctly on the locators on the
bottom case.
4 Ensure the patient connector aligns to the front screw bosses on the bottom case.
Type 1 unit
Flexible cable clear of

Inlet assembly airpath assembly
screw bosses
Fan cable clear of

airpath assembly
Patient connector sitting on

front screw bosses
The bottom case

With the airpath assembly removed, the parts located in the bottom case are visible.
1 The airpath suspension can be replaced if required.
Type 1 unit
Airpath suspension

2 The fan assembly can also be replaced if required. When fitting a new fan assembly, ensure
you orientate the assembly in the bottom case as shown below, with the fan cable routed
under the retainer closest to the switch.
Caution When handling the fan ensure you hold the frame. Do not push/press on the fan body.
!

 
Replacing the cable harness
1 Remove the main wiring harness DC cable harness from under the retainers, and the AC
cable harness from the slots at the side of the bottom case.
2 Press the four clips at the top and bottom of the power connector to release it from the
bottom case.
Clips
Clips

3 Pull the power connector with cable harness forward to remove it from the bottom case.
4 Take the new cable harness and power connector and feed it through the hole in the
bottom case.
5 Engage the power connector, ensuring the switch is sitting on the right side of the power
connector, as shown below:
6 Route the cables in the bottom case as shown below.
For type 1 units locate the ferrite next to the screw boss.
Ferrite location and AC

cables behind post

Replacing the interface housing assembly
1 Pull back on the two clips holding the interface housing assembly, and pull the assembly up
from the bottom case.
Type 1 interface housing assembly
Type 2 interface housing assembly
2 Take the replacement interface housing assembly and gently install it in the bottom case.
Insert the interface housing at a slight angle to ensure the FiO2 and SpO2 connectors are
not damaged.
3 Click the assembly into place. Ensure the housing clip clicks into place, as shown below:

 
Type 1 unit

The top case
On the underside of the top case sits the dial PCB.
Flexible cable which runs

Dial PCB to main PCB
Replacing the dial PCB

1 Remove the dial from the top case, using the dial removal tool.
2 Release the lock and remove the flexible cable which connects to the main PCB.
3 Release the lock and remove the keypad flexible cable.

4 Turn the top case over and unscrew the nut on the dial PCB encoder, using a torque-limited
screwdriver including long nut.
5 Take the new dial PCB and remove the nut from the encoder.
Note: Ensure that the washer remains on the base of the encoder.
Washer
6 Fit the dial PCB to the top case, ensuring the PCB sits on the locating posts as shown
below:
7 Turn the top case over and fix the nut (removed in step 5) to the encoder.
8 Place the dial on the encoder.
9 Once again, turn over the top case and insert the keypad flexible cable into the lock, then
engage the lock.
10 Take the large flexible cable and insert it in the lock, with the metal contacts on the cable
facing the PCB.

Closing the unit
1 Place the top case beside the bottom case assembly.
2 Take the flexible cable from the top case and install it in the lock on the main PCB.
Note: Ensure the flexible cable is not at an angle, and is inserted fully in the lock.

 
3 Place the top case on the bottom case.
4 Turn the unit over and install the five screws in the following order.
3 2
5 4

6 Replacement parts list
Note: Type 2 spare parts, except for the bottom case, cannot be used in Type 1 products.
Refer to the Technical Services website for the latest Stellar spare parts available.
External components
Top case (including handle, membrane
keypad and chrome frame)
Stellar 150 (ROW) 19540

Stellar 150 (Americas) 19547
Stellar 150 (Teijin) 19550
Stellar 100 (ROW) 19544
Stellar 100 (Americas) 19546
Stellar 100 (Fukuda) 19658
Bottom case, Type 2 (Americas) 19593

Bottom case, Type 2 (ROW) 19594
Note: A Type 2 bottom case can be fitted to Type 1 units.
Base pad & decal kit (ROW) 19517

Base pad & decal kit (Americas) 19549
Note: For instructions on replacing the decal and serial

number, refer to tech note 1063224.
Dial R360-775
Screw (for case) Z2021

Type PT, Self tapping 3 x 25 mm,
Torx pan head
6 Replacement parts list 53

Internal components
Main PCB (with LCD)
Stellar 150 (Type 1) 19524

Stellar 150 (Type 2), Japan 19686
Stellar 100 (Type 2), Japan 19687
Power supply 19521
Screw (for PCBs) Z2019

PT Type DG, Self tapping, 3 x 7 mm,
pan head with Torx recess
Electronic chassis 19519
Sensor tube x 1 (Type 1) 19522

Sensor tube x 1 (Type 2) 19596

Battery (with cage) 19520
Battery cage R241-7038
Air path components

Inlet assembly 19523
Flow sensor 19300

Flow sensor cable harness R261-7146
Flow sensor seal (circled) 19525
Patient connector R241-7025
Outlet seal 19528
Hose clamp R241-7054

Motor enclosure assembly 19529
(including blower housing, muffler
housing, inlet muffler foam, outlet
muffler foam, bump stops, main seal,
screws)
Motor with enclosure assembly 19530

(including motor, blower housing,
muffler housing, inlet muffler foam,
outlet muffler foam, bump stops,
main seal, screws)
Muffler foam 19689
Screw (for blower assembly) Z2032

Self tapping 3 x 20 mm, Torx pan
head
Motor 19531
Motor suspension 19532
In the top case

Dial PCB (Type 1) 19541
(with flexible cable)
Dial PCB (Type 2) 19659


In the bottom case
Cable harness with switch (Type 1) 19538
Cable harness with switch (Type 2) 19587
Airpath suspension 19539
Interface PCB assembly, Type 1 19542

Interface PCB assembly, Type 2 (ROW) 19595
Interface PCB assembly, Type 2 (Americas) 19657
Fan (with suspension) 19535
Caution When handling the fan ensure you hold the frame. Do not push/press on the fan body.
!

 
 6 Replacement parts list 57
Spare parts list
Part number Part description (in alphabetical order)
19539 Airpath suspension
19517 Base pad and decal kit (ROW)
19549 Base pad and decal kit (Americas)
19520 Battery (with cage)
R241-7038 Battery cage
19593 Bottom case, Type 2 (Americas)
19594 Bottom case, Type 2 (ROW)
19538 Cable harness with switch (Type 1)
19587 Cable harness with switch (Type 2)
R360-775 Dial
19541 Dial PCB, Type 1 (with flexible cable)
19659 Dial PCB, Type 2 (with flexible cable)
19519 Electronic chassis
19535 Fan (with suspension)
19300 Flow sensor
R261-7146 Flow sensor cable harness
19525 Flow sensor seal
R241-7054 Hose clamp
19523 Inlet assembly
19542 Interface PCB assembly (with flexible cable), Type 1
19595 Interface PCB assembly, ROW (with flexible cable), Type 2
19657 Interface PCB assembly, Americas (with flexible cable), Type 2
19686 Main PCB, with LCD, Type 2, Japan (Stellar 150)
19687 Main PCB, with LCD, Type 2, Japan (Stellar 100)
19524 Main PCB, with LCD, Type 1 (Stellar 150)
19531 Motor
19529 Motor enclosure assembly
19530 Motor with enclosure assembly
19532 Motor suspension
19689 Muffler foam
19528 Outlet seal
R241-7025 Patient connector
19521 Power supply
Z2032 Screw (for blower assembly) Self tapping 3 x 20 mm, Torx pan head

Z2021 Screw (for case) Type PT, Self tapping 3 x 25 mm, Torx pan head
Z2019 Screw (for PCBs) PT Type DG, Self tapping 3 x 7 mm, pan head with Torx recess
19522 Sensor tube x 1, Type 1
19596 Sensor tube x 1, Type 2
19658 Top case (Stellar 100, Fukuda) - including handle, membrane keypad and chrome
frame
19540 Top case (Stellar 150, ROW) - including handle, membrane keypad and chrome
frame
19544 Top case (Stellar 100, ROW) - including handle, membrane keypad and chrome
frame
19550 Top case (Stellar 150, Teijin) - including handle, membrane keypad and chrome
frame
19547 Top case (Stellar 150, Americas) - including handle, membrane keypad and chrome
frame
19546 Top case (Stellar 100, Americas) - including handle, membrane keypad and chrome
frame

7 Calibration procedures
All calibration procedures should be carried out whenever the main PCB, motor or any part of
the air path is replaced.
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.
• USB cable (part of kit #36950)

• Oxygen side port connector (ResMed part #14915)
• Straight adaptor (ResMed part #19375)
• Calibration adaptor kit - contains calibration cap, air tubing connector and oxygen sideport
connector (ResMed part #19911)
Note: Service accessories kit #19919 contains - S9 USB adapter and cable, oxygen
sideport connector, straight adapter, calibration cap and air tubing connector.
• 2m air tubing - standard, 19 mm inner diameter (ResMed part #14961)

• Manometer (0-60 cm H2O range)
• Calibrated flow meter with flow regulation valve
Note: The flow meter must be capable of measuring air flows ranging from 0 - 260 L/min
with an accuracy of 3% or better over this range.
Note: If you are using a flow analyser to complete the Stellar calibration procedures ensure
it is set to gas standard STPH.
• A computer running Windows 7 (32 & 64-bit) or XP.
Caution The Stellar clinical settings must be recorded before any calibration procedure is
performed. Refer to the instructions provided in Section 3 General inspection and
! servicing. If the clinical settings can not be recorded, reset the unit to the factory
default settings, and notify the patient.
1 Pressure calibration
1 With the unit still switched off, connect the Stellar to the PC via the USB cable.
2 Turn on the unit and allow it to complete the self test.
3 Return to the service software and press the Start session button .
4 The following screen will then appear, indicating the existing service records for the Stellar.

5 The most recently created record (the Stellar settings recorded earlier) will be highlighted.
7 The “Select service agent screen”, as shown on page 11, will appear once again.
in the Xplorer bar.
10 Select Pressure calibration in the XPlorer bar.

12 Select Next and follow the steps as instructed until the calibration is complete.
2 Flow calibration
Caution The pressure calibration must be performed before the flow calibration.
!
1 Select Flow calibration in the XPlorer bar.
3 Select Next and follow the steps as instructed until the calibration is complete.
Once the calibrations are complete, repeat the tests found in Section 3 General inspection and
servicing.
If the unit continually fails the calibration, check the following:
• the test set-ups are correct
• the calibration cap is securely attached and there are no leaks in the air delivery system
• the unit has no excess noise or vibration, which may be caused by a problem with the
blower.
If the unit continues to fail, send the device with service request form (found on page 73 of
this manual) to ResMed for further servicing.
7 Calibration procedures 61
8 Troubleshooting guide
Note: The performance tests in the service software are a valuable tool in determining the
possible cause of flow generator problems.
Caution When the main PCB or motor is replaced, the flow generator must be recalibrated and
tested. Repeat the tests found in Section 3 General inspection and servicing.
!
If any other components are replaced, repeat the relevant test in Section 3 General
inspection and servicing.
Note: Refer to the Technical Support Website for the latest Stellar troubleshooting
information.
Problem/Cause Action
The following message is displayed on the LCD: "Apnea!"
• No inspiration detected for a set apnea interval • Check alarm settings
• Unit out of calibration • Check calibration
The following message is displayed on the LCD: "Attention High Temp! [42]"
• High motor temperature (> 100oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Ensure unit not covered
• Blocked filter • Replace filter
• Blocked inlet or outlet • Check for blockages at inlet and outlet
• Faulty motor temperature sensor • Replace motor
• High battery temperature (> 50oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Ensure unit is not covered
• Cooling fan fault • Check cooling fan
• Faulty internal battery temperature sensor • Replace internal battery
• High PSU temperature (> 85oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Faulty PSU temperature sensor • Replace PSU
• High PCB temperature (> 85oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Faulty main PCB temperature sensor • Replace main PCB

The following message is displayed on the LCD: "Blocked Tube!"
• Blocked hose or air path • Remove obstruction
• Issue with flow sensor connection • Confirm flow sensor connected properly
• Faulty flow sensor • Replace flow sensor
The following message is displayed on the LCD: "Circuit disconnected!"
• Air tubing disconnected from device • Check air tubing connection
• Flow sensor cable issue • Confirm flow sensor cable connected properly
• Check flow sensor cable function. Replace if faulty
• Faulty flow sensor • Replace flow sensor
The following message is displayed on the LCD: "Disconnected XPOD!"
• XPOD disconnected during therapy • Check connection
The following message is displayed on the LCD: "Finger Sensor Failure!"
• Improper sensor attachment • Check sensor attachment on patient
• SpO2 and pulse outside of specified range • Check alarms settings
• Faulty sensor • Replace sensor
The following message is displayed on the LCD: "High FiO2 Level!"
• Measured FiO2 level higher than set threshold • Check alarm settings
The following message is displayed on the LCD: "High Leak!"
• High mask leak (> 40 L/min) • Check mask fitting

• Check air tubing connection
The following message is displayed on the LCD: "High Pressure!"
• Mask pressure exceeds set threshold • Check alarm settings
• Unit out of calibration • Recalibrate the unit
The following message is displayed on the LCD: "High Respiratory Rate!"
• Patient breath rate exceeds set maximum threshold • Check alarm settings
The following message is displayed on the LCD: "High Temperature! [10]" (continued over page)
• High motor temperature (> 120oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Blocked filter • Replace filter
• Blocked inlet or outlet • Check for blockages at inlet and outlet
8 Troubleshooting guide 63
• Faulty motor temperature sensor • Replace motor
The following message is displayed on the LCD: "High Temperature! [11]"
• High battery temperature (> 59oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Faulty internal battery temperature sensor • Replace internal battery
• High PSU temperature (> 90oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Faulty PSU temperature sensor • Replace PSU
• High PCB temperature (> 90oC for 10 seconds) • Ensure ambient temperature conditions within specified
operating range
• Faulty main PCB temperature sensor • Replace main PCB
The following message is displayed on the LCD: "Humidifier Over Pressure!"

Note: This alarm is only displayed in units with software versions earlier than SX483-0222.
• H4i in use and IPAP or CPAP set to  25 cmH2O • Check settings - H4i cannot be used with treatment
pressure set to25 cmH2O
• Unit has software version earlier than SX483-0222 • Upgrade device to latest software version
The following message is displayed on the LCD: "Internal Battery Empty!"
• Battery in use with low charge state (< 15%) • Connect device to mains power
• Faulty battery • Replace internal battery
The following message is displayed on the LCD: "Internal Battery Low!"
• Internal battery in use with low charge state • Connect device to mains power
(< 30%)
The following message is displayed on the LCD: "Keypad Failure!"
• Buttons on control panel pressed for longer than 10 • Ensure keypad buttons are not jammed
seconds • Check buttons function
• Faulty connection between main PCB and dial PCB • Check flexible cable connected properly
• Replace flexible cable
• Replace main PCB
• Replace dial PCB
• Faulty keypad • Replace top case (with keypad)

The following message is displayed on the LCD: "Low FiO2 Level!"
• Measured FiO2 level lower than set threshold • Check alarm settings
The following message is displayed on the LCD: "Low Minute Ventilation!"
• Minute ventilation lower than set threshold • Check alarm settings
The following message is displayed on the LCD: "Low Pressure!"
• Calculated mask inspiratory pressure below IPAP/ • Check air tubing connection
CPAP setting • Check alarm settings
The following message is displayed on the LCD: "Low Respiratory Rate!"
• Patient breath rate below set minimum threshold • Check alarm settings
The following message is displayed on the LCD: "Low SpO2 Level!"
• Measure SpO2 level lower than set threshold • Check alarm settings
• Check sensor connections
• Improper sensor attachment • Check sensor attachment on patient
The following message is displayed on the LCD: "Non-Vented Mask!"
• Non-Vented mask in use • Ensure leak port included in circuit
• Blocked leak port / mask vent • Ensure leak port / mask vent unobstructed
The following message is displayed on the LCD: "O2 Sensor Disconnected!"
• FiO2 cell disconnected • Check connection
• Faulty FiO2 cell • Replace FiO2 monitoring sensor
The following message is displayed on the LCD: "Over Pressure!"
• High mask pressure (> 59 cmH2O) • Check air tubing

• Perform Learn Circuit
• Pressure sensor tube not connected properly • Reconnect pressure sensor tube
• Faulty pressure sensor tube • Replace pressure sensor tube
• Blockage in air outlet • Remove blockage from air outlet
• Unit of out calibration • Check calibration
• Sensor fault • Replace main PCB
The following message is displayed on the LCD: "System Failure! [6]" (continued over page)
• Motor fault • Check motor cable connections

• Replace motor
• Pressure sensor tube not connected properly • Reconnect pressure sensor tube
8 Troubleshooting guide 65
• Faulty pressure sensor tube • Replace pressure sensor tube
• Blockage in air outlet • Remove blockage from air outlet
• Sensor fault • Replace main PCB
The following message is displayed on the LCD: "System Failure! [7]"
• Faulty pressure sensor • Check pressure sensor tube

• Software system failure • Power cycle the device

• Check software version. Reinstall or update software
• Calibration data corrupted • Recalibrate the unit
• Air inlet filter blocked • Remove blockage from air inlet filter
• Blockage in air path between the motor and • Remove blockage

pressure measurement points
• Device internal temperature is too low for the • Ensure hat ambient temperature is above 5°C. If device
device to start/deliver therapy has been stored below 5°C, allow sufficient time for
device to acclimatise. Once acclimatised, power-cycle
device.dx
• Self test fail due to faulty internal components • Check RTC battery
• Check motor cable and connections
• Check backup battery
• Faulty flow sensor • Check flow sensor connection

• Replace flow sensor
• Faulty cooling fan • Check cooling fan
• Internal battery disconnected • Check internal battery connections
• Faulty internal battery • Replace battery
• Software failure • Power cycle the device

• Check software version. Reinstall or update software

9 System specifications
Operating pressure range • IPAP: 2 cm H2O to 40 cm H2O (in S, ST, T, PAC mode)
• PS: 0 cm H2O to 38 cm H2O (in S, ST, T, PAC mode)
• EPAP: 2 cm H2O to 25 cm H2O (in S, ST, T, iVAPS, PAC mode)
• CPAP: 4 cm H2O to 20 cm H2O (in CPAP mode only)
• Min PS: 0 cm H2O to 20 cm H2O (in iVAPS mode)
• Max PS: 0 cm H2O to 30 cm H2O (in iVAPS mode)
Note: iVAPS mode is only available in Stellar 150
Maximum single fault pressure 60 cm H2O (in all modes)
Maximum breathing resistance under 2 cm H2O at 30 L/min;

single fault 7.2 cm H2O at 60 L/min
Therapy pressure tolerance IPAP: ± 0.5 cm H2O ± 10% of set pressure (end of inspiration)
EPAP/PEEP: ± 0.5 cm H2O ± 4% of set pressure
CPAP: ± 0.5 cm H2O or ± 10% of set pressure
Test condition: T mode, IPAP: 40 cm H2O, EPAP: 2 cm H2O, Rise
Time: MIN, Fall Time: MIN, Ti: 4.0 sec, Respiratory Rate: 10 bpm,
with ResMed calibration cap.
Flow accuracy ± 5 L/min or 20% measured value, whichever is greater

Test condition: T mode, IPAP: 40 cm H2O, EPAP: 2 cm H2O, Rise
Time: MIN, Fall Time: MIN, Ti: 4.0 sec, Respiratory Rate: 10 bpm,
with ResMed calibration cap.
Maximum flow >200 L/min at 20 cm H2O
Inspiratory trigger (nominal) The minimum flow required to initiate IPAP by ASL5000 simulator
characteristics with chronically weak efforts (R20, C20, BPM20):
• For Very High setting: 2.4 L/min
• For High setting: 4.2 L/min
• For Medium setting: 6.0 L/min
• For Low setting: 10.2 L/min
• For Very Low setting: 15.0 L/min
Accuracy ± 20% or +2.0-1.5 L/min whichever is greater.
When test with IPAP = 15 cm H2O, EPAP = 5 cm H2O, Rise Time =
Min, 2 m air tubing, Ultra Mirage mask, zero leak.
Expiratory trigger (nominal) The expiratory cycle occurs at the following flow rates:
characteristics • For Very High setting: 50% of peak inspiratory flow
• For High setting: 35% of peak inspiratory flow
• For Medium setting: 25% of peak inspiratory flow
• For Low setting: 15% of peak inspiratory flow
• For Very Low setting: 8% of peak inspiratory flow
Accuracy ± 10%/-25% or ± 1.3 L/min whichever is greater.
When test with IPAP = 15 cm H2O, EPAP = 5 cm H2O, Rise Time =
Min, 2 m air tubing, Ultra Mirage mask, zero leak.
Sound pressure level 29 dB(A) as measured according to ISO 17510-1:2002.

32 dB(A) with uncertainty of 3 dB(A) as measured according to ISO
17510-1:2007.
Alarm volume range 45 dB - 85 dB at 1 metre (3 steps: low, medium, high)
9 System specifications 67
Data storage 7 days of respiratory flow, calculated therapy pressure, SpO2, pulse
rate, breath-by-breath data (EPAP, pressure support, minute
ventilation, leak, respiratory rate, tidal volume, inspiration time,
expiration time, spontaneously or machine triggered or cycled breaths)
365 days of 5th-, 50th-, 95th- percentile data (leak, SpO2, minute
ventilation, tidal volume, respiratory rate, I:E, pressure support, AHI,
AI)
Dimensions (L X W x H) 230 mm x 170 mm x 120 mm
Weight 2.1 kg
Air outlet 22 mm taper, compatible with ISO 5356-1:2004

Anesthetist & Respiratory Equipment - Conical Connectors
Pressure measurement Internally mounted pressure transducer
Flow measurement Internally mounted flow transducer
Power supply AC 100-240V, 50-60Hz, 2.2 A, max. 65 W
External DC Power Supply (isolated) 24V, 3 A
Internal Battery Lithium-Ion battery, 14.4V, 1.6 Ah, 23 Wh

Operating hours: 2 hrs. with a new battery under normal conditions
(see below).
Patient type: home chronic; pressure: IPAP/EPAP 15/5 cm H2O; mask
type: Ultra Mirage; air tubing: 2 m; leak: 0; respiratory rate: 20 bpm;
battery capacity: 100%
Patient type: hospital acute; pressure: IPAP/EPAP 20/5 cm H2O; mask
type: Ultra Mirage; air tubing: 2 m; leak: 0; respiratory rate: 45 bpm;
battery capacity: 100%
Housing construction Flame retardant engineering thermoplastic
Environmental conditions • Operating temperature: 0°C to + 35°C

Stellar 100/150 • Operating humidity: 10%-95% non-condensing
• Storage and transport temperature: -20°C to +60°C (+50°C*)
• Storage and transport humidity: 10%-95% non-condensing
• Air pressure; 680hPa to 1100hPa; Altitude: 3000 m
Note: The performance may be limited below 800 hPa.
*NONIN XPOD
Electromagnetic compatibility Product complies with all applicable electromagnetic compatibility

requirements (EMC) according to IEC60601-1-2, for residential,
commercial and light industry environments.
Air filter Electrostatic fibre mesh with TPE frame structure. Bacterial filtration
efficiency of 99.540% on area weight 100g/m2
Air tubing Flexible plastic, 2 m or 3 m length (22 mm diameter)
SlimLine air tubing Flexible plastic, 1.83 m length (15 mm diameter)
IEC60601-1 classifications • Class II (Clause 3.14 - double insulation). This adherence means the
need for a protective earthing (ie, an earthed plug) is not necessary.
• Type BF
• Continuous operation
Air travel requirements Medical-Portable Electronic Devices (M-PED) that meet the Federal
Aviation Administration (FAA) requirements of RTCA/DO-160 can be
used during all phases of air travel without further testing or approval
by the airline operator. ResMed confirms that the Stellar meets RTCA/
DO-160 requirements.
This device is not suitable for use in the presence of a flammable anesthetic mixture.

Displayed values
Value Range Accuracy Display

Resolution
Flow sensor in devicea
Leakb,c 0-120 L/min ± 12 L/min or ± 20%, whichever is greater 1 L/min
Tidal volumeb,c 50-3000 mL ± 20% or 30 mL, 10 mL

whichever is greater
Respiratory rate 5-60 bpm ± 1 bpmd 1 bpm
Minute ventilationb 0.6-60 L ± 0.5 L or 20%, 0.1L

whichever is greater
Ti 0.0-4 sec ± 0.1 sec or ± 10%, whichever is greater 0.1 sec
Pressure 0-40 cm H2O IPAP: ± 0.5 cm H2O ± 10% of set pressure 0.1 cm H2O
(end of inspiration); EPAP or PEEP: ± 0.5 cm
H2O ± 4% of set pressure; CPAP: ± 0.5 cm
H2O ± 10% of set pressure
a. Results may be inaccurate in the presence of leaks and may be affected by vent characteristics.
b. Results are expressed at STPH (Standard Temperature Pressure, ambient humidity)
c. Results may be inaccurate in the presence of leak and supplemental oxygen > 10 L/min. If necessary for therapy, use
external monitoring.
d. Results may be inaccurate if the tidal volume is below 50 mL.
Note: The manufacturer reserves the right to change these specifications without notice.
Pressure may be displayed in cm H2O or hPA.
Symbols
The following symbols may appear on the Stellar, power supply unit, air tubing or packaging.
Follow instructions for use; Class II equipment; Type BF equipment; Bell (Remote alarm);
IP31 Device is protected against solid foreign objects of 2.5 mm diameter and greater and vertically falling
water drops; Caution; General warning sign (see H4i connector plug and AC connection on the
device); Standby or preparatory state for a part of equipment; Connection for oxygen supply;
max 30 l/min (max 30 l/min); Data communication port; CE labeling in accordance with EC
+ 60 °C
+ 140 °F
directive 93/42/EEC, class II b; - 20 °C

- 4 °F
Temperature limitation for storage and transport; Handle with care;
Maximum humidity; Keep dry; Manufacturer; Upside; Catalogue number;
Serial number; Batch code; Do not re-use; Use by date; Keep away from sunlight;
Do not use if package is damaged; Latex-free

LATEX
9 System specifications 69
Environmental information This device must be disposed of in accordance with the laws and regulations of
the country in which disposal occurs.
The crossed-out wheeled bin symbol indicates that the product bearing this symbol may not be disposed
of together with general household waste, but instead requires separate disposal. This requirement for
separate disposal is based on the European Directive 2002/96/EC for electrical and electronic equipment,
and the European Directive 2006/66/EC for batteries. You can hand in the product at a municipal collection
point, for example. This reduces the impact on natural resources and prevents contamination through the
release of hazardous substances.
Batteries containing more than 0.0005 percent of mercury by mass, more than 0.002 percent of cadmium
by mass or more than 0.004 percent of lead by mass are marked below the crossed-bin symbol with the
chemical symbols (Hg, Cd, Pb) of the metals for which the limit is exceeded.
For further information regarding product disposal, please contact your local ResMed office or visit our
website at www.resmed.com
Dispose of used air filters and air tubing according to the directives in your country.

10 Recommended maintenance schedule
The Stellar series are intended to provide safe and reliable operation when operated in
accordance with the instructions provided by ResMed. ResMed recommends that the device
be inspected and serviced by an authorised ResMed Service Centre if there is any sign of wear
or concern with device function. If the remaining capacity of the internal battery is <80% (as
described in “3 Internal battery remaining capacity test” on page 11) the battery must be
replaced, otherwise, service and inspection of the device generally should not be required
during the five year design life of the unit.
The air filter should be replaced at least every six months. Regular cleaning recommendations
are provided in the User Manual. All of these procedures can be carried out by the owner.
Some countries require all medical equipment to have a periodic service to confirm that the
equipment is in good working order. Section 3 General inspection and servicing may be used
in this situation.
10 Recommended maintenance schedule 71

Appendix A: Service request form
ResMed Service Request Report
Today’s date: Product description: Flow generator
Date of awareness: Mask
(ResMed only)
Other
Reported by:
Product code:
Company name:
Product name:
Country:
Serial/Lot number:
Contact details
Email: Quantity
(Lot control items only)
Phone:
Mask type:
Equipment owner:
Pressure settings:
Patient:
Hourmeter reading:
Service centre:
Under warranty? Yes No
Additional owner
information: Humidifier? Yes No
SmartStart? Yes No
Date of product purchase:

Date problem occurred?
If purchase date is unknown, please indicate below the
When did the fault occur?
time the product was used before the problem occurred:
Out of box failure with distributor
< 3 months 1 - 2years
Out of box failure with patient
3 - 6 months 2 - 5 years
In use by distributor
6 - 12 months > 5 years
In use by patient
Is this device being returned to ResMed? Unknown
Yes No Other
Injury reported? Yes No
Death reported? Yes No
Problem description:
Effect on user:
Service details
ResMed reference number Distributor reference number (if applicable) Signature
AF305-009-01

Appendix B: Operational diagram
Room air in Flow sensor Blower To patient Humidifier
O2 Pressure Safety Optical

FiO2 Interface sensor Pressure sensor
assembly sensor
SpO2
USB and alarm
ports
Mains
Power supply Keypad
power
Controller LCD
Internal battery
pack Dial
Cooling fan
Appendix B: Operational diagram 73

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ResMed ventilation solutions

Global leaders in sleep and respiratory medicine www.resmed.com

See www.resmed.com for other ResMed locations worldwide.

© 2016 ResMed Ltd.

3 General inspection and servicing ................................................................. 7

4 Operator safety and static precautions .................................................... 22

5 Replacing major subassemblies ................................................................. 23

6 Replacement parts list ................................................................................53

7 Calibration procedures ................................................................................60

8 Troubleshooting guide ................................................................................62

9 System specifications .................................................................................67

10 Recommended maintenance schedule ........................................................71

Appendix A: Service request form .......................................................................72

Appendix B: Operational diagram ........................................................................73

! Warning alerts you to possible injury.

Note is an informative or helpful note.

4 Stellar™ series Service Manual

Intended users of this manual

Features of the Stellar 100 and Stellar 150

Additional service features

Type Product codes Characteristics

2 Stellar 150 • SX483-0230 and higher

6 Stellar™ Series Service Manual

• USB cable (part of kit #36950)

• H4i heated humidifier

• A computer running Windows 7 (32 & 64-bit) or XP.

3 General inspection and servicing 7

Data storage device Ramp time

Mains power Program

DC voltage* Therapy mode

*Only available when an external power supply is connected.

8 Stellar™ series Service Manual

2 Record clinical settings

Connecting to Type 1 Stellar

2 Connect the Stellar to the power outlet and turn it on.

3 General inspection and servicing 9

9 Select Save to Database in the XPlorer bar.

10 Stellar™ series Service Manual

Select service agent

3 Internal battery remaining capacity test

3 General inspection and servicing 11

12 Stellar™ series Service Manual

7 Cooling fan test

4 Press the power button at the rear of the unit.

3 General inspection and servicing 13

2 Set the DC switch on the RPS II to ON.

4 Turn off the unit and disconnect the RPS II.

9 Internal examination (if necessary)

10 Replace the air filter

11 Pressure calibration test

12 Flow calibration test

16 Stellar™ series Service Manual

2 Select Humidifier test in the XPlorer bar.

Warning The H4i can reach a maximum of 85°C.

15 Airpath leak test

16 USB port test

17 SpO2 port test