278065 Astral Service Manual

278065/3 2014-12
Astral series
SERVICE
Astral™series
Life support ventilators
ENG
Respiratory care solutions Respiratory care solutions

Service Manual
Making quality of care easy Making quality of care
Englisheasy
Manufacturer:
ResMed Ltd 1 Elizabeth Macarthur Drive Bella Vista NSW 2153 Australia
Distributed by:
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
© 2014 ResMed Ltd.

278065/3 2014-12
Contents
Foreword ........................................................................................................................... 7
Intended users of this manual 7
Recommended maintenance schedule . . . . . . . . . . . . . . . . . . . . . .7
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Training requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1 General instructions .............................................................................................10

General advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrostatic discharge precautions . . . . . . . . . . . . . . . . . . . . . . . 11
2 Function and operation .........................................................................................12

External device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Internal device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Technical description 15
System description 16
Main PCB 16
Power Block 16
Main Controller 17
Pneumatic Controller 17
Hardware Alarm Controller 17
Pneumatic Block 18
Sensors 19
Top case assembly 19
Operation of the ventilator 20
Operation with a single or double circuit - valve ventilation 25
1/ Inspiration 25
2/ Start of expiration 26
3/ Expiration 27
Safe states 28
Description of functions and sub-assemblies . . . . . . . . . . . . . . . . . 28
Oxygen management 28
Power management 28
Internal battery charging 28
Power switching 29
Device standby and shutdown 29
Automatic shutdown 29
Forced shutdown 29
Device counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Contents 3
3 Test and calibration procedures .......................................................................... 31
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Service software kit - #19688 31
PC and software 31
Measurement tools 31
Test set-up equipment 32
Accessories 32
Connecting the Astral to the service software . . . . . . . . . . . . . . . .32
Test procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.1 Cleaning the device 33
3.2 Visual inspection 34
External examination 34
Internal examination 34
3.3 External battery interface test 35
3.4 ResBus interface test 35
3.5 Set time and date 35
3.6 Record device settings 36
3.7 Determine ventilation hours 38
3.8 Peep hours check 38
3.9 Learn circuit 39
3.10 Temperature sensor test 40
3.11 Heated flex test 40
3.12 Final assembly leak test 41
3.13 NRV check 41
3.14 Safety valve test 41
3.15 PEEP blower test 41
3.16 Pressure calibration test 41
3.17 Flow calibration test 42
3.18 Quick flow check 42
3.19 Blower test 42
3.20 Outlet pressure model test 42
3.21 Cooling fan test 43
3.22 Alarm test 43
3.23 Maximum pressure test 43
3.24 Remote alarm test 43
3.25 USB port test 43
3.26 Low flow O2 port test 43
3.27 SpO2 port test 44
3.28 LCD test 44
3.29 LED test 44
3.30 Keypad test 44
3.31 Internal battery test 44
3.32 Super capacitor test 44
3.33 Current consumption test 45
3.34 Electrical safety test 45
3.35 Finalise manual check results 46
3.36 Reload device settings 46
Calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3.37 Pressure calibration 48
3.38 Flow calibration 48
3.39 Outlet pressure model 49
4 Astral™ series service manual

Completion of test and calibration procedures . . . . . . . . . . . . . . . 49
Device service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Entering Clinical mode 50
Entering Service mode 50
Resetting the device to factory default settings 51
Deleting patient data 51
Calibration and test procedures required when parts are replaced . . 52
4 Preventative maintenance ....................................................................................54

Astral two year maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Two year maintenance test procedures 55
Confirming screw torque 55
End of preventative maintenance test procedures 56
5 Corrective maintenance ........................................................................................57

Equipment required 57
Screws used in the Astral 57
Opening the Astral . . . . . . . . . . . . . . . . . . . . . . . ........... 58
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 60
Battery storage 61
Top case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 62
Forced shutdown 65
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Motor capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Buzzer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pneumatic block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Thermistor, inlet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Outlet tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Low pressure O2 adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Tee tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Heated flex cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Main PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Installing the device serial number and product code 82
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Expiratory flow sensor, membrane and adapter . . . . . . . . . . . . . . . 88
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Closing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Astral external battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Replacing the battery inside the external battery 95
Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 97
6 Troubleshooting guide ..........................................................................................99

Learn circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Learn circuit troubleshooting flow chart . . . . . . . . . . . . . . . . . . . 101
Further device information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Device error log 102
Contents 5
Therapy alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
System failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7 Technical specifications .....................................................................................113

General technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . 113
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Time parameters 115
Volume and flow parameters 116
Pressure parameters 116
Other parameters 117
Accuracy of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Appendix A: Resmed forms ..........................................................................................120

ResMed Service Request Report . . . . . . . . . . . . . . . . . . . . . . . . 120
Astral two year maintenance form . . . . . . . . . . . . . . . . . . . . . . . 121
35,000 hour preventative maintenance form . . . . . . . . . . . . . . . . 122
Appendix B: Pneumatic block components .................................................................123

Equipment required 123
Opening the pneumatic block . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Pneumatic block sensor PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
PEEP control tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
PEEP turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
NRV assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Volute assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Aluminium housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Closing the pneumatic block . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Pneumatic block spare part list . . . . . . . . . . . . . . . . . . . . . . . . . 139

Foreword
This manual is a guide to servicing and repairing the Astral series devices. It is written for
ResMed service centres and authorised ResMed service agents, and gives instructions for regular
maintenance of Astral devices, replacing subassemblies and for recalibration and testing 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 user manual and the clinical manual for the device
• have completed Astral service training
• 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.
Recommended maintenance schedule

The Astral is intended to provide safe and reliable operation when operated in accordance with
the instructions provided by ResMed. The Astral should be inspected and serviced by an
authorised ResMed service centre according to the maintenance schedule found in chapter 4
Preventative maintenance on page 54.
ResMed also 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.
Note: If the Astral needs to be returned to ResMed the log files should be captured for
investigation. Contact TechSupport@resmed.com.au for the steps required to capture
the log files.
Regular cleaning recommendations, which can be carried out by the device owner, are provided
in the Clinical and User Manuals.
Note: All units with a serial number prior to 22141103741 should be reworked to the latest
Astral build standard, which requires replacement of the main PCB, bottom case,
chassis and expiratory adapter cover. See tech note #1063301 for the rework
procedures.
Foreword 7
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.
1 General instructions – Outlines requirements when servicing Astral devices. Ensure the
requirements are read prior to servicing the device.
2 Function and operation – Provides technical information describing how the device functions.
3 Testing and calibration procedures – Lists all the test and calibration procedures that are
required as part of servicing the Astral. Also contains information for the cleaning and
disinfection of the device.
4 Preventative maintenance - Provides the preventative maintenance schedule with related kits
and testing.
5 Corrective maintenance - Lists the disassembly / reassembly procedures needed for the major
subassemblies, along with their spare part details. A complete list of Astral spare parts is also
included.
6 Troubleshooting guide - Provides a complete list of Astral error messages along with possible
fixes.
7 System specifications - Lists electrical and mechanical specifications of the device and air
tubing.
Appendix A: ResMed forms - Contains forms to fill out for the two year maintenance and 35,000
hour maintenance. Also includes Service Request Form - fill out this form if you need to return
a device to ResMed for servicing.
Appendix B: Pneumatic block components - Lists the disassembly / reassembly procedures
needed for the pneumatic block parts, along with their spare part details.
Training requirements
The maintenance procedures described in this manual must be performed by competent
technicians who have been trained in the maintenance of Astral devices and are ResMed
certified.
There are three levels of training.The following table shows the training requirements for each
level:
Training level
Training Topics/Modules Level 1 Level 2 Level 3
Device overview









Intended use
Technical specifications
Device operation
Alarms (Basic)
Alarms (Advanced & Troubleshooting)
Principle of Operations & Hardware
Disassembly/Assembly (excluding
pneumatic block)
Cleaning/ Preventative maintenance
Incoming inspection/Full performance

tests
Calibration
Disassembly/Assembly of pneumatic
block

The following table shows which of the Astral maintenance procedures may be performed at
each level of training:
Training level
Maintenance procedures Level 1 Level 2 Level 3
Acceptance tests









Safety checks
Service testing and calibration
Corrective maintenance outside of

pneumatic block
Preventative maintenance and
pneumatic block replacement
Pneumatic block rework/servicing
Definitions
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 Astral service manual please contact Technical
Services, Sydney at TechSupport@resmed.com.au.
Foreword 9
1 General instructions
Warning Prior to disassembly or assembly, make sure that the power is not connected to the
ventilator.
!
General advice
Under no circumstances shall the manufacturer be liable for the damage caused to the device by:
• Servicing or modifications that do not comply with the manufacturer’s procedures or
performed without prior authorization from the manufacturer
• Servicing or modifications performed by unauthorised person.
Power supply
• The device must be connected to the mains supply with an Astral 90W mains supply pack
and cable.
Note: If the Astral power supply requires replacing, the replacement must be recorded in the
appropriate service reporting system. This record must include the serial number details
of the replacement (new) power supply.
• The electrical installation must comply with the local regulation standard.
• If there are any doubts regarding electrical disruption of mains supply the device must run on
the internal battery.
• It is strongly recommended the internal battery is replaced every two years.
Electromagnetic compatibility
• This device many be affected by interference from electromagnetic fields exceeding 20 V/m.
• The user should take the necessary precautions to ensure the specified electromagnetic
compatibility (EMC) limits are not exceeded. In particular, where the device is used in the
presence of short waves or high frequency generators, such as defibrillators, diathermy,
electrosurgery or radiology devices, cell phones etc., interference may occur if the energy
emitted is higher than the levels stipulated in Directive 93/42 EC.
Storage and transport

• During transport the device should be packed appropriately to prevent damage. It is
recommended the device is placed in its storage bag in order to offer maximum protection
against accidental splash.
• Keep the device away from direct sunlight.
• Do not expose the device to violent impact.
• Do not start the ventilator up immediately after storage or transport in conditions other than
the recommended operating conditions.
• If the ventilator has been stored in extreme conditions (>50°C or <-10°C) allow adequate
time for the device to acclimatise to the current conditions.

Recycling
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.
For further information regarding product disposal, please contact your local ResMed office or
visit our website at www.resmed.com
Dispose of used air s and air tubing according to the directives in your country.
Electrostatic discharge precautions

Integrated circuits (ICs) within the various PCBs can be badly damaged by electrostatic discharge
or transient voltages. The following procedures are recommended to avoid component damage:
1 Work benches where handling and repairs are done must have surfaces of suitable conducting
material connected via a 1 MΩ resistor to an electrical ground.
2 The area under and also in front of the work bench must be coated with a suitable conductive
floor paint, or alternatively covered with a conductive floor mat. The conductive paint coating
or floor mat must be connected to an electrical ground.
3 Soldering irons or solder baths must be at the same reference (ground) potential as the work
bench.
4 A wrist strap must be worn by service personnel working at the bench. The wrist strap must
have a conductive lead (1 MΩ) connected to the bench surface. Alternatively, a heel
grounding strap to ground the operator to the floor may be used. (Such a wrist or heel strap
should not create an electrical hazard for the wearer).
5 Handling of ICs should be kept to a minimum. If handling is required, avoid directly touching
the leads. The recommended procedure is to first touch the container in which the ICs are
stored, or the PCB in which they are mounted, before touching the ICs. Service personnel
should take every precaution that the items will see the same reference potential when
moved.
6 All ICs and PCB assemblies containing ICs should be stored in antistatic bags until use.
7 Service personnel should wear clothing which minimizes the build up of static charges.
Cotton is preferable to wool or synthetic fibres.
8 Service personnel should avoid electrostatic build up through the movement of air over plastic
material.
9 Plastic materials should wherever possible be kept away from the ICs as they develop and
maintain high levels of static charge.
1 General instructions 11
2 Function and operation
External device description
Power source indicators

(AC, DC, internal battery)
Touch screen
Alarm mute/reset button

Therapy on/off indicator
Constant green - device is on
but not ventilating
Alarm bar Flashing blue - Device is
ventilating and Ventilation LED
Flashing red - high priority alarm
setting is "On". Otherwise is
Flashing yellow - medium priority "Off"
alarm
Constant yellow - Low priority
alarm
Adapter port
Inspiratory port
Handle (to patient)
USB connector
Mini USB
Ethernet
connector
connector
Remote control/ SpO2 sensor

Remote alarm five connector
pin connector
Device on/off
push button
Air inlet
(including DC power
hypoallergenic inlet
filter)
Low flow Data
oxygen input connector
(up to 30 L/min) cover

Internal device description
Top case
assembly
Expiratory
flexible
Screw - main PCB cable*
to chassis
Expiratory valve PCB
Main PCB pressure tube assembly
PEEP extension
tube assembly
Chassis - LP
Motor capacitor O2 sensor

assembly connector
wire harness
Low pressure tubing

5mm ID x 8mm OD
Expiratory pressure
sensor filter
CPC O2
coupler Expiratory
body and flow sensor
o-ring
Expiratory
interface
seal
Buzzer housing assembly

Pneumatic block
O2 low pressure port Expiratory valve

assembly
O2 inlet seal
Expiratory adapter
Battery connector assembly
Fan mount assembly

Bottom case
Screw - bottom case O2

to top case/chassis sensor
cover
Battery pack assembly Screw - O2 sensor

cover to bottom case
Battery cover
Expiratory cover
assembly
* The Expiratory flexible cable is only in Astral 150 devices. It is replaced by the Heated flex cable in newer Astral 150
devices. Heated flex cable functionality is included with SX544-0300 and will only work in devices where the heated
flex cable in installed.
2 Function and operation 13
Remote alarm
wire harness
SpO2 connector
wire harness
Thermistor
probe DC power
assembly (in connector
air inlet seal) wire harness
Power button
wire harness
Screw - chassis
to top case Data
connector
cover
Outlet tube
& seal
Plug outlet Inlet filter

tube (optional) assembly
O2 sensor & Screw - pneumatic

adapter pack block to O2 low
pressure port
Pneumatic
block
Screw - battery cover

to bottom case

Theory of operation
Technical description
The Astral device provides continuous or intermittent ventilatory support for patients weighing
more than 5 kg (11 lb) who require mechanical ventilation. The Astral device is intended to be
used in home, institution/hospital and portable applications for both invasive and non-invasive
ventilation.
There are two versions of the Astral ventilator:
• Astral 100
• Astral 150
The following table details the differences between Astral 100 and Astral 150
Feature Astral 100 Astral 150
Internal battery
Single limb with expiratory valve
Single limb intentional leak

Circuit
Double limb
Preset programmes 2 4
Leak therapy modes
Valve therapy modes
Apnea ventilation
Therapy
Manual breath button
Sigh breath (pre-programmed)
SpO2 monitoring Optional Optional
FiO2 monitoring Optional
O2 Oxygen inlet Low flow Low flow

System description
The following block diagram provides a simplified view of the Astral ventilator system. Due to
the relative complexity of the device, this diagram shows only limited interconnections.
Astral
Main Controller Pneumatic Controller
Internal
External Patient
Battery
Interfaces
Pneumatic Ambient
Main micro- Main Blower
Power In Power Block HAC micro- temperature
processor Control
processor sensor
Patient Circuit
Atmospheric
User Interface Safety PEEP Blower
User Interface pressure Patient
Control Circuit Control
sensor interface
Airpath nebulizer
Outlet
Pressure
sensor
O2 input port Filter

Flow control Outlet flow
Inlet Blower Patient outlet
module sensor
Filter Humidification
system
Safety valve O2 Cell
watertraps
Double circuit
pneumatic valve Single circuit
pneumatic
valve Tubes
Proximal Proximal
Expiratory
pressure Peep blower I/E Valve exhalation
Flow sensor
sensors valve
Exhalation
valve
Optional link
Optional Mandatory
Pneumatic link
Component Component
Electrical link
Figure 1 – Astral system block diagram
The Astral ventilator comprises three complex sub-assemblies: main PCB, a pneumatic block
(including a sensor PCB) and a top case assembly.
Main PCB
The main PCB hosts four subsystems:
• the Power Block;
• the Main Controller;
• the Pneumatic Controller;
• the Hardware Alarm Controller.
Power Block
The power block provides for conversion of the available DC supply to the required internal
operating voltages for use by the main blower, PEEP blower, electro-valves, electronic
subsystems, user interface (including LCD) and external interfaces.
The power block utilises external power when available, or the internal battery, when external
power is unavailable. When external power is available, the power block provides for
recharging of the internal battery.
The internal power rails are segregated between core ventilation rails and peripheral device
rails to prevent peripheral circuit failures from halting ventilation.

Main Controller
The Main Controller is comprised of the main microprocessor & associated 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
• alarm management
The Main Controller also manages the following external interfaces:
• connection to an external Nonin Oximeter for monitoring of patient SpO2 levels
• connection via USB to export recorded data
• connection to a PC via a USB interface for use in service
• connection to a PC via an Ethernet interface for use in service
Pneumatic Controller
The Pneumatic Controller is comprised of an independent microprocessor, main & PEEP blower
control, ambient temperature and pressure sensors, and safety circuit.
The Pneumatic Controller provides control and monitoring of all pneumatic functions including:
• delivery of target inhalation pressure
• delivery of target inhalation flow
• control of exhalation pressure
• sequencing of valves
• acquisition and conditioning of all sensor signals
• derivation of patient measures
• leak compensation
• circuit compensation
Within the Pneumatic Controller a hardware circuit is implemented, such that a single
command from the Hardware Alarm Controller will force all pneumatic controls to their safe
state (“Safe states” on page 28).
Hardware Alarm Controller

The Hardware Alarm Controller (HAC) monitors activities of the Main Controller, Pneumatic
Controllers and pneumatic circuit. Should either controller trigger an alarm, detect a fault, or
operate abnormally, the HAC will immediately trigger an Alarm Condition, and if necessary
raise a safety assert signal, to set all pneumatic controls to their safe state.
When the pneumatic circuit detects excessively high outlet pressure, high blower temperature,
high blower current, high valve control current or an unexpected PB micro watchdog reset the
HAC will raise an alarm and raise an assert.
Under alarm conditions the HAC controls the device LEDs and buzzers to create appropriate
priority alarm. Where applicable, it ensures connection to a remote alarm module or nurse call
system for remote enunciation of alarms.
Forced shutdown can be instigated by pressing the on/off and alarm mute/reset button
buttons for 10 seconds continuously, then releasing the buttons.

Pneumatic Block
The pneumatic block comprises:
• a main blower dedicated to deliver ventilation to the patient
• a PEEP blower dedicated to maintaining a positive expiratory pressure
• a flow control module comprising the flow control valve (FCV), the pressure release valve
(PRV) and the non-return valve (NRV)
• an I:E valve used to control the expiratory valve, which in turn controls the inspiratory and
expiratory times
• a valve
• a sensor PCB
Pneumatic block exploded view

Sensors
The table below lists and provides information on the sensors.
Sensor Location Range

Peep valve sensor Pneumatic block -10 to 120hPa
Inspiratory flow sensor Pneumatic block -70 to 200 L/min
Outlet pressure sensor Pneumatic block -10 to 120hPa
Proximal pressure sensor Main PCB -10 to 120hPa
Trigger pressure sensor Main PCB -2 to 40hPa
Expiratory flow sensor Expiratory cradle 0 to 300 L/min
Atmospheric pressure sensor Main PCB 400 - 1200hPa
Chemical sensor measuring the oxygen Inspiratory outlet 0 to 100%

concentration of the air delivered to the
patient (optional)
Ambient temperature sensor Air inlet -40 to 90°C
Main blower temperature sensor Blower -20 to 150°C
Refer to operation diagrams to identify sensors.
Top case assembly

Astral top case assembly hosts the major part of user interface input and output. It is
comprised of:
• a bezel with decal for the LCD
• a membrane keypad, including the alarm mute/reset button, system indicators LEDs and an
ambient light sensor
• a touch panel (touch screen) and visual alarm indicators
• an LCD module with gaskets
• an adapter board (PCB)
• a top case
The Astral touch screen is a 5-wire analog resistive touch panel compatible with the 7-inch
LCD display size. It includes a touch controller to interface the Main board microprocessor
with the touch screen. It is powered by 3.3Vdc power source and contains 128 Bytes of
onboard EEPROM which is used to store touch calibration data. It communicates with the
Main board microprocessor via an I2C channel. The touch-screen calibration data are therefore
stored in the touch screen driver chip.
The LCD display is a 7.0 inch WVGA (800 x 480 RGB dots) LCD module with a TTL interface
that can be driven directly by the LCD controller on the Main board microprocessor. The digital
circuitry for the LCD display is powered from the local 3.3V rail on the adapter board. The LED
Backlight internal to the LCD display consists of 3 strings of 8 white LEDs, a total of 24 LEDs.
The adapter board acts to connect all electrical interfaces (membrane keypad, LCD and touch
panel) into a single connection to connect it to the Astral main PCB. It also provides:
• 5Vdc power source for the alarm mute/reset button and for the system indicator LEDs
• 3.3Vdc power source for the ambient light sensor

Operation of the ventilator
The main blower draws air from the inlet, via the flow control module, and delivers it to the
outlet. Air pressure and flow are measured at the outlet via sensors. Air is directed to the
patient via one of three ventilator breathing circuit:
• Single limb circuit with expiratory valve
• Single limb circuit with intentional leak
• Double limb circuit (exhaled gas returns to the device for monitoring). (Astral 150 only)
During valve ventilation, the PEEP blower and I:E valve are used to deliver a control pressure
to a pneumatic expiratory valve. This valve may be located proximal to the patient (as in a
single limb circuit with valve), or remotely from the patient (as in a double limb circuit).
The expiratory cradle (pictured in figure 5) adapts the ventilator for use with different
breathing circuits.
A double limb adapter can be fitted to the cradle for use with a double limb circuit. This
adapter incorporates an expiratory valve and flow element as per figure below.
2 3 4
1 2 1
3
4
Figure 2 – Double limb adapter

Alternatively a single limb adapter can be fitted to the expiratory cradle for use with single
limb circuit with expiratory valve. This adapter provides pneumatic interconnections with the
pneumatic expiratory valve located proximal to the patient as per figure & table below.
Figure 3 – Single limb adapter
Patient expiratory Expiratory valve Expiratory flow Expiratory flow

pressure control Port 3 Port 4
A -> 2 B -> 1 Blocked Blocked

Pressure at the patient connector is measured using a pressure sensor. A second pressure
sensor monitors the same point but at higher sensitivity in order to improve detection of
patient inspiratory effort.
Alternatively, a blank adapter can be fitted to the expiratory cradle for use with single limb
leak circuits. In the Astral 150, the double limb adapter can also be used in combination with
a single limb leak circuit.
Figure 4 - Single limb leak adapter (blank adapter)
The following diagram shows the main airpath components, the position of the control valves
and status of subassemblies when the device is powered off.
Figure 5 – Device powered off - double circuit

For safety reasons, the valve allows the patient to breathe spontaneously regardless of the
status of the ventilator. Exhalation is possible via the expiratory valve. Expired air is prevented
from returning into the ventilator by the non-return valve.
On detection of a blocked expiratory valve, both the flow control and pressure release valves
are activated to open the non-return valve. This allows expired air from the patient to be
returned to atmosphere via the ventilator.
The following diagram shows the device connected with a single circuit adapter.
Figure 6 – Device with a single circuit - leak ventilation

Operation with a single circuit - leak ventilation
At the start of ventilation, the flow control valve is deactivated, enabling the main blower to
freely draw air from the inlet and deliver it at the required pressure to the outlet. Patient
inspiratory pressure is regulated via the outlet pressure. The circuit resistance determined
during circuit test is included in the regulation: pressure drop along the circuit is compensated
in accordance with the flow measured at the outlet.
Figure 7 - Leak ventilation - inspiratory phase

The degree to which the non-return valve is opened, is self-regulated by the inspiratory flow.
At the peak of inspiratory flow, the flow control valve is activated, locking the non-return
valve in its present open position. The ventilator remains in this state during exhalation.
Typically exhaled air is driven to atmosphere via the intentional leak vent at the regulated
expiratory pressure delivered by the main blower.
Figure 8 - Leak ventilation - expiratory phase

Operation with a single or double circuit - valve ventilation
To provide ventilation via a dual or single limb circuit with valve, the ventilator transitions
through three distinct states:
1/ inspiration
2/ start of expiration
3/ expiration
1/ Inspiration
At the start of inspiration, the flow control valve is deactivated, enabling the non-return valve
to open as wide as needed to satisfy the inspiratory flow. The I:E valve is also activated
routing outlet pressure to the expiratory valve in order to fully close it.
If the prescribed therapy specifies a positive expiratory pressure, the PEEP blower is driven to
the required set point, in preparation for the expiratory phase.
Figure 9 - Valve ventilation - start of inspiration

2/ Start of expiration
At the start of expiration, the I:E valve is deactivated, delivering the PEEP set point pressure to
the pneumatic exhalation valve. As the patient breaths out the exhalation valve is opened to
the desired expiratory pressure. At the same time, the non-return valve may be momentarily
closed to restrict airflow and allow the main blower to quickly reduce speed. This significantly
reduces the peak air flow out of the exhalation valve.
Figure 10 - Valve ventilation - start of expiration

3/ Expiration
During expiration, the non-return valve is again opened, allowing air flow through the
ventilator to properly maintain the desired expiratory pressure target. This is achieved by
driving the main blower to deliver a specified flow, to ensure the exhalation valve is
maintained in a stable open position even after the patient has completed exhalation.
Figure 11 - Valve ventilation - expiration

Safe states
In the event of a system fault being detected the various parts of the pneumatic system are
placed in the following safe state while the system is energised:
Function Safe state

Main blower Off
PEEP blower Off
Non Return Valve (Flow Control) Activated
Pressure Release Valve Activated
I:E valve Deactivated
Description of functions and sub-assemblies
Oxygen management
Up to 30 L/min supplemental oxygen can be added into Astral’s oxygen inlet at the rear of the
device. Once ventilation has started, low pressure oxygen is added and mixed with ambient air
at the inlet to the main blower. The oxygen flow rate is controlled by the user before it
reaches the inside of the Astral. Monitoring supplemental oxygen is achieved using:
• integrated FiO2 sensor
• Low FiO2 and High FiO2 alarms, available when the oxygen sensor is installed
Power management
The Astral device can be used with four different power sources:
• AC Mains power
• Astral External battery (#27918)
• Internal battery
• External DC power supply (eg, car 12V power outlet)
For more information on power supplies and sources see the Clinical Guide.
Note: If the Astral power supply requires replacing, the replacement must be recorded in
the appropriate service reporting system. This record must include the serial number
details of the replacement (new) power supply
Internal battery charging

Internal battery charging is automatically activated when the device is powered by AC mains
or DC mains power, in operating or standby mode. When the internal battery is fully charged,
the charging mode is deactivated.
For more information on internal battery charging see the Clinical Guide.

Power switching
Information on power source in use can be viewed via the Power source indicators when
switching from one power source to another. The Information bar at the top of the touch
screen also displays power status information:
• system battery status - in use during ventilation, or charging while device is operating or in
standby
Note: If an External battery is connected, the capacity of the External Battery will be added
to the Run Time indicator on the Information bar of the Astral interface (this may
take a couple of minutes). The total will be the sum of the Astral internal battery plus
either one or two external batteries.
• power alarms:
Power disconnected when the power source is changed from an external source to the
internal battery
Using internal battery when the device is powered on and is using battery power
Device standby and shutdown

When the device is not ventilating, it can be switched off by pressing the On/Off button and
confirming the command on the touch screen:
• if powered by internal battery, the device is fully powered off once command is confirmed
• if powered by mains power, the device transitions to standby once the power off command
is confirmed. The device will remain in standby for 5 minutes before powering off.
• if powered by the Astral External battery, the device transitions to standby once the power
off command is confirmed. It will remain in standby for 10 minutes if powered by a single
external battery. It will remain in standby for 15 minutes if powered by two external
batteries.
Automatic shutdown
Forced shutdown
When a forced shutdown of the device is required complete the following steps.
1 Disconnect any external power source (such as AC mains or external battery).
2 Press and hold the green on/off button and the alarm mute/reset button for at least 10
seconds. After 10 seconds the alarm bar will flash yellow.
3 Release both buttons. The Astral will then power off.

Device counters
Important device usage information can be found via the Info screen.
To access the device information enter the Information menu and select the Device tab.
Scroll down the screen to observe usage details for:

• Patient hours
• Pneumatic block ventilation hours
• Peep blower hours
• Hours since last service
• Total machine hours
Along with information specific to that device including:
• Device product code
• Serial number
• Software details

3 Test and calibration procedures
Equipment required
Service software kit - #19688

The Astral Service Software kit (#19688) contains the following parts:
• USB Ethernet adapter (#25923)
• Ethernet cable - CAT5E, 2M (#25919)
• 22mm inlet adapter (#R270-7431)
• Expiratory valve assembly (#R270-120)
• USB cable (#629051)
• USB stick (#R241-7168)
• O2 coupling insert (#Z373)
• 2 x 19 cm air tubing - 19 mm inner diameter, 190.5 mm long (#R160-754)
• Double patient circuit [air tubing], 1.6 m, 22 mm flex tube (#21308) - kit includes 22F safety
cap
• Air tubing connector (#R04S011)
• Oxygen side port connector (#Z305)
• ResMed leak valve (#R249-102)
• Silicone tubing (to connect to O2 coupling insert)
Note: At the time of publication not all components of the service software kit were available.
If your kit is incomplete, please contact TechSupport@resmed.com.au.
PC and software
• 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.After installation of the Service
Software ensure you install the Astral device driver.
• A computer running Windows XP/7 (32/64 bit), with at least three USB ports
Measurement tools
• Electrical safety analyser e.g. Rigel 288
• FlowAnalyser (PF-300 or equivalent)
The accuracy requirements of the flow analyser are as follows:
Measurement Range Accuracy
Low flow ± 20 L/min ±2% or 0.05 L/min
High flow ± 300 L/min ±2% or 0.1 L/min
Differential pressure ± 150 mbar ±0.75% or 0.1 mbar
Atmospheric pressure 0 - 1150 mbar ±1% or 5 mbar
Temperature 0 - 100° C ±1.75% or ±0.5°C
Note: A ±2% accuracy is acceptable for Low flow and High flow during preventative
maintenance procedures. An accuracy of ±1.75% is required for all other testing and
calibration
Note: When viewing values on the flow analyser screen disregard any negative sign (-) when
reading absolute value.
Note: Zero calibration must be performed on the flow analyser before every Astral service.
3 Test and calibration procedures 31

Test set-up equipment
• Siemens test lung, 1L (ResMed part #BAL007641)
• S9 service device (#19938)
• Flow regulation valve
• Soft tip stylus
Accessories
• Remote alarm (#27902)
• Remote alarm cable (#27904)
• Nonin XPOD® oximeter Type 3012
• Astral External Battery (#27918)
• Oxygen sensor (#27935)
Caution If the target flow cannot be achieved in any of the following test and calibration
procedures complete the “3.19 Blower test” on page 42 to help locate the source of the
! device issue.
Connecting the Astral to the service software

Note: The internal battery must be installed when testing or calibrating the Astral.
Ensure the Astral driver is installed on the PC with the Service Software.
1 With the Astral disconnected from the power outlet insert the USB cable into the rear of the
device and the other end of the cable to the PC.
2 Connect the Ethernet cable to the rear of the device and the other end to the PC.
USB cable
Ethernet cable
Note: Instructions for setting up the ethernet connection to the PC can be found in the
Service Software User Guide.
3 Connect the Astral to the power outlet and press the green power button turn it on.
4 Allow the Astral to complete the self test.

5 Open the ResMed service software. The following window will appear:
6 Press the Refresh button (highlighted above) to enable the service software to recognise the
device.
7 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.
Test procedures
3.1 Cleaning the device

Regular cleaning recommendations are provided in the clinical and user manuals.
Prior to any servicing the unit should be cleaned using an anti-bacterial solution on a clean, non-
dyed disposable lint free cloth. The following cleaners and disinfectants are compatible for use
when cleaning the external surfaces of the unit:
• Actichlor Plus
• Bleach (1:10) (May also be known as ’dilute hypochlorite’).
• Isopropanol
• CaviCide*
• Mikrozid*
* Suitable for cleaning on a monthly basis only
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.
!
Note: The Astral can be decontaminated using Hydrogen Peroxide (H2O2) vapor or ozone.
This can be done up to 15 times with H2O2 vapor or 7 times with ozone throughout
the expected service life of the Astral (8 years). Decontamination should involve 15
minutes gassing, then 30 minutes dwell, followed by aeration (the length of aeration
depends on the room size).
For information regarding cleaning of multi-patient use devices refer to the Astral
Clinical Manual.

Once the device has been cleaned install a new air filter. The procedure for replacing the air filter
can be found in “Air filter” on page 91.
Caution Do not wash the air filter. The air filter is not washable or reusable.
!
3.2 Visual inspection
External examination
Visually examine the Astral 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.
Internal examination
Whenever the unit is opened as part of a preventative or corrective maintenance a visual internal
examination should also be performed.
Inspect the unit for the following recording any irregularities and fixing them as appropriate:
• there is no contamination within the air inlet or outlet tube, or elsewhere within the device
• all mechanical components are seated correctly
• all electrical components are mounted correctly and secured in position
• there are no loose wires or loose terminals on electrical components or connections
• there are no loose pieces of wire or other objects trapped in the PCB
• there is no dust on the isolation barriers
Note: If there is dust on the isolation barriers, gently remove the dust using an ESD brush.
(The isolation barriers are the dark green strips surrounding the islands of circuits
around the rear connectors).

3.3 External battery interface test
1 Connect the Astral External Battery to the Astral DC power inlet.
2 Confirm the DC LED is illuminated.
DC cable from Astral External Battery
3 If the DC LED does not light up determine if the fault lies with the power inlet (on the chassis)
or with the main PCB.
3.4 ResBus interface test

1 Connect the AC power cable to mains power and to the Astral.
2 Confirm the AC power source indicator is illuminated.
AC cable running from mains power
3 If the AC power source LED does not light up determine if the fault lies with the power inlet
(on the chassis) or with the main PCB.
3.5 Set time and date

Note: Ensure the PC used to service the Astral is set to the correct date and time.
1 With the device connected to the service software, select Set time and date in the Xplorer
bar, or click on the Set time and date icon.
2 The following window will appear:

3 Select the appropriate time zone for the owner of the device, then press the Locale button.
4 Press the Select button to set the Astral time and date.
3.6 Record device settings

Info on connecting and turning on device here
1 Select Device Settings in the XPlorer bar, or click on the Device Settings Dialog icon at the
top of the screen.
Note: It will take a few seconds for the device settings to be displayed.
2 The settings will be displayed as shown below:
3 Select Save to Database the XPlorer bar.

4 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 5. 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:

5 The following window will then appear:
6 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 device settings cannot be recorded, reset to the default settings after completing
the device tests. Notify the customer that the device has been reset to default settings.
! Refer to page 50 for instructions on resetting to default settings.
7 Click on the Select button.

8 The software will then return to the settings screen.
9 Close the settings screen.

3.7 Determine ventilation hours
Note: Do not refer to the device Service mode when determining ventilation hours. In some
versions of the device software the ventilation hours are incorrectly described as
"Patient hours".
1 Select Device Settings in the XPlorer bar, or click on the Device Setting Dialog icon at the top
of the screen.
2 The unit settings will be displayed.
3 In the Product Information column note the ventilation hours (highlighted below) for the
device.
4 If the ventilation hours displayed is > 35,000 the pneumatic block must be replaced.
Note: When examining the ventilation hours to determine if the pneumatic block should be
replaced, consider if the device will reach the 35,000 hour benchmark well before the
next scheduled maintenance.
3.8 Peep hours check

1 With the Device settings screen still displayed from the ventilation hours check, examine the
Product Information column to note the Peep hours (highlighted below) for the device.
2 If the value of the PEEP hours displayed is > 35,000 the pneumatic block must be replaced.
Note: When examining the PEEP hours to determine if the pneumatic block should be

3.9 Learn circuit
In order to confirm the device function, the Astral 150 devices need to complete the Learn
circuit twice, using first the Double circuit then the Single Circuit.
Astral 100 devices complete the Learn circuit once, testing the Single Circuit.
1 Enter the Astral Clinical mode (instructions for entering Clinical mode can be found on
page 50.
2 Select the Setup menu, then the Setup Assistant sub-menu.
3 Press the Start button.
4 A warning message will be displayed. Select Continue.

5 Select the Paediatric patient type.
6 The Select Circuit type screen is then displayed. Select the Double Circuit for the Astral 150.
Select Single with leak for the Astral 100 (or if completing the second Learn Circuit for Astral
150 devices).
7 The Learn Circuit screen will then be displayed. Press the Start button.
8 Follow the prompts to attach and test the circuit.
9 If the Learn Circuit was successful you will then be prompted to select a required ventilation
mode. Select any mode, as this mode will be changed once the original device settings are
reloaded.

10 The default settings for the mode are then displayed.
11 Exit the Clinical mode.
12 A test result screen is displayed if any of the tests fail.
The following icons are used to report the Learn Circuit results:
Icon Description
OK Learn Circuit has passed
Caution! Learn Circuit has failed.
Warning!
13 If the device fails the Learn circuit examine the results on the device screen to determine the
location of the issue. Press the Confirm button and service the device as is required.
Further Learn Circuit troubleshooting information can be found in Section 6 Troubleshooting
guide, where a Learn circuit troubleshooting flow chart is provided.
3.10 Temperature sensor test

The temperature sensor test will test both the ambient temperature sensor and the motor
temperature sensor.
1 Select Temperature sensor test in the Xplorer bar, or click on the Perform temperature sensor
test icon.
2 Set up the test equipment as instructed by the service software.
3 Select Next and follow the steps as instructed.
4 If the device fails the Temperature sensor test examine the results screen to determine if the
fault is with the ambient temperature sensor or the motor temperature sensor. If the ambient
temperature sensor is faulty replace the temperature sensor (thermistor). If the motor
temperature sensor is at fault determine if the fault is with the pneumatic block (Level 2
service technician), the volute assembly (Level 3 service technician) or the connection to the
main PCB.
3.11 Heated flex test

The Heated flex test is only completed on Astral150 devices with SX544-0300 and above where
the heated flex cable is present.
1 Select Heated flex test in the Xplorer bar, or click on the Perform heated flex test icon.
4 If the device fails the Heated flex test confirm the heated flex cable is connected properly to
the expiratory flow sensor and the main PCB. Otherwise, determine if the heated flex cable,
expiratory flow sensor or main PCB is faulty and replace the faulty component.

3.12 Final assembly leak test
1 Select Final assembly leak test in the Xplorer bar, or click on the Perform final assembly leak
test icon.
4 If the device fails the Final assembly leak test confirm the CPC connector was closed. If it
was not closed, repeat the Final assembly leak test with the CPC connector closed. If the
CPC connector was open, determine if the fault lies with:
• the CPC connector (on the chassis)
• the device not being assembled correctly
3.13 NRV check

1 Select NRV check in the Xplorer bar, or click on the Perform NRV check icon.
4 The software will indicate if the device has successfully completed the test.
5 If the device fails the NRV check the service software will indicate the potential cause for the
failure. Replace the pneumatic block (Level 2 service technician) or replace the faulty
component within the pneumatic block (Level 3 service technician).
3.14 Safety valve test

1 Select Safety valve test in the Xplorer bar, or click on the Perform safety valve test icon.
4 If the device fails the Safety valve test replace the pneumatic block (Level 2 service
technician) or replace the volute assembly (Level 3 service technician).
5 .
3.15 PEEP blower test

1 Select PEEP performance test in the Xplorer bar, or click on the Perform PEEP performance
test icon.
4 If the device fails the PEEP performance test replace the pneumatic block (Level 2 service
technician). A Level 3 service technician can open the pneumatic block to determine if the
fault lies within the PEEP turbine, the PEEP valve tubing, the I/E valve or the sensor PCB.
3.16 Pressure calibration test

1 Select Pressure calibration test in the Xplorer bar, or click on the Perform pressure calibration
test icon.
4 If the device fails the pressure calibration test complete the pressure calibration (“3.37
Pressure calibration” on page 48) then repeat the pressure calibration test.
5 If the device has passed the pressure calibration test after recalibration, ensure you
immediately complete the outlet pressure model and outlet pressure model tests.

6 If the device fails the pressure calibration test again determine if the fault lies with the main
PCB or the sensor PCB (part of the pneumatic block, which can only be opened by Level 3
service technicians) and replace as appropriate. Then complete the required calibration and
test procedures.
3.17 Flow calibration test

1 Select Flow calibration test in the Xplorer bar, or click on the Perform flow calibration test
icon.
4 If the device fails the flow calibration test complete the flow calibration (“3.38 Flow
calibration” on page 48) then repeat the flow calibration test.
5 If the device has passed the flow calibration test after recalibration, ensure you immediately
complete the outlet pressure model and outlet pressure model tests.
6 If the device fails the flow calibration test again replace the pneumatic block (Level 2
technician) or the sensor PCB (Level 3 service technician). Then complete the required
calibration and test procedures.
3.18 Quick flow check

1 Select Flow calibration test in the Xplorer bar, or click on the Perform quick flow check icon.
4 If the device fails the quick flow check perform the flow calibration and repeat the flow
calibration test. If the flow calibration test fails replace the pneumatic block (Level 2
technician) or the sensor PCB (Level 3 technician).
3.19 Blower test

1 Select Blower test in the Xplorer bar, or click on the Perform blower test icon.
4 If the device fails the Blower test replace the pneumatic block (Level 2 service technician). A
Level 3 service technician can determine if the fault lies with connection of the blower to the
main PCB, the volute assembly, the valves (part of the aluminium housing) or the sensor PCB
3.20 Outlet pressure model test

Note: The Outlet pressure model test must be run whenever the Outlet pressure model is
completed.
1 Select Outlet pressure model test in the Xplorer bar, or click on the Perform outlet pressure
model test icon.
4 If the device fails the Outlet pressure module test the device should be recalibrated (complete
the pressure calibration, flow calibration and outlet pressure model) and then complete the
pressure calibration test, flow calibration test and outlet pressure model test.

3.21 Cooling fan test
1 Select Cooling fan test in the Xplorer bar, or click on the Perform cooling fan test icon.
4 If the device fails the Cooling fan test determine if the fault lies with the cooling fan or the
main PCB.
3.22 Alarm test

1 Select Alarm test in the Xplorer bar, or click on the Perform alarm test icon.
4 If the device fails the Alarm test determine if the fault lies with the buzzer or the main PCB.
3.23 Maximum pressure test

1 Select Maximum pressure test in the Xplorer bar, or click on the Perform maximum pressure
test icon.
4 If the device fails the Maximum pressure test determine if there is a fault with the main PCB.
3.24 Remote alarm test

1 Select Remote alarm test in the Xplorer bar, or click on the Perform remote control test icon.
4 If the device fails the Remote alarm test, determine if the fault lies with the remote control
connector on the chassis or the main PCB.
3.25 USB port test

1 Select USB port test in the Xplorer bar, or click on the Perform USB port test icon.
4 If the device fails the USB port test, determine if the fault lies with the USB connector on the
main PCB.
3.26 Low flow O2 port test

1 Select Low flow O2 port test in the Xplorer bar, or click on the Perform low flow O2 port test
icon.
4 If the device fails the Low flow O2 port test, determine if the fault lies with the oxygen (CPC)
connector on the chassis or with the main PCB.

3.27 SpO2 port test
1 Select SpO2 port test in the Xplorer bar, or click on the Perform SpO2 port test icon.
4 If the device fails the SpO2 port test, determine if the fault lies with the SpO2 port connector
on the chassis or the main PCB.
3.28 LCD test

Note: It is recommended you use a soft tip stylus when completing the steps for the touch
screen calibration and calibration test.
1 Select LCD test in the Xplorer bar, or click on the Perform LCD test icon.
4 Once the software test is complete, enter the Information screen and press the Device tab.
5 Press the down button to scroll down the device details, in order to confirm the touch screen
is functioning correctly.
6 If the device fails the LCD test determine if the flexible cable from the top case is connected
properly to the main PCB, or whether the top case or main PCB are faulty.
3.29 LED test

1 Select LED test in the Xplorer bar, or click on the Perform LED test icon.
4 If the device fails the LED test determine if the flexible cable from the top case is connected
properly to the main PCB, or whether the top case or main PCB are faulty.
3.30 Keypad test

1 Select Keypad test in the Xplorer bar, or click on the Perform keypad test icon.
4 If the device fails the keypad test determine if the flexible cable from the top case is
connected properly to the main PCB, or whether the top case or main PCB are faulty.
3.31 Internal battery test

1 Select Internal battery test in the Xplorer bar, or click on the Perform internal battery test
icon.
3 Select Next and follow the steps as instructed
4 If the device fails the internal battery test determine if the battery, battery connector (on the
bottom case) or the main PCB are faulty and replace as appropriate.
3.32 Super capacitor test

1 Select Super capacitor test in the Xplorer bar, or click on the Perform super capacitor test
icon.
4 If the device fails the Super capacitor test replace the main PCB.

3.33 Current consumption test
1 Select Current consumption test in the Xplorer bar, or click on the Perform current
consumption test icon.
4 If the device fails the Current consumption test determine if the fault lies with the battery, top
case, main PCB or the pneumatic block (the volute assembly or PEEP blower.) For Astral 150
devices the fault may lie with the heated flex cable (where installed).
3.34 Electrical safety test

Using the Rigel 288 (or equivalent) complete both the Equipment leakage current test and the
Insulation resistance test in accordance with IEC 62353.
While in standby mode the following points on the Astral should be tested:
Bottom case test points
Rear panel test points
If you are using a probe to test the unit ensure you test the ground pin of each port. The ground
pins are as follows:
Remote alarm - pin 2 SpO2 - pin 2 DC input - pin 1

The outer metal rims of both the Ethernet port and the USB mini port are the ground test points.
3.35 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 device passed or failed.
3.36 Reload device settings

Note: When the main PCB has been replaced you may be unable to reload the device settings.
Warning If the device settings cannot be restored, reset to the default settings after completing
! the device tests. Notify the customer that the device has been reset to default settings.
Refer to page 50 for instructions on resetting to default settings.
1 Click on the Close session button to close the current session.

top of the screen.
3 The Astral settings will be displayed.
4 Select Read Database, as shown below:

5 All the recorded sessions for the device 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 In the Product Information column of the settings screen reset the "Hours since last service"
field to zero.
8 If no components were changed in the device proceed to step 10.

9 If any of the following parts have been replaced enter the serial number details for the newly
installed components:
• main PCB
• pneumatic block
• top case
10 Select Reload Device Settings in the Xplorer bar to reload the settings to the device.
11 Once complete, exit the settings screen.

Calibration procedures
3.37 Pressure calibration

Note: The “3.39 Outlet pressure model” on page 49 must be run whenever the pressure or
flow calibrations are completed.
1 Select Pressure calibration in the Xplorer bar, or click on the Perform pressure calibration icon.
4 If the device fails the pressure calibration, examine the results displayed by the service
software to determine the location of the device issue.
Pressure calibration failure Pressure calibration pass
3.38 Flow calibration

Note: The “3.39 Outlet pressure model” on page 49 must be run whenever the pressure or
flow calibrations are completed.
1 Select Flow calibration in the Xplorer bar, or click on the Perform flow calibration icon.
4 If the device fails the flow calibration determine if there is a problem with the connection of
the PAFS or VAMPS cable to the main PCB or the connection of the pneumatic block to the
main PCB. Alternatively, there could be a fault lies with the sensor PCB - replace the
pneumatic block (Level 2 technician) or the sensor PCB (Level 3 technician).
Flow calibration pass Flow calibration failure

3.39 Outlet pressure model
Note: The Outlet pressure model must be run whenever the pressure or flow calibrations are
completed.
1 Select Outlet pressure model in the Xplorer bar, or click on the Perform outlet pressure model
icon.
4 If the device fails the outlet pressure model complete both the pressure and flow calibrations
followed by the pressure calibration test and the flow calibration test. Following this repeat
the outlet pressure model then outlet pressure model test to highlight any problems with the
device.
Completion of test and calibration procedures

Once all the test and calibration procedures for the device have been finished:
1 Ensure the inlet adapter has been removed from the device and replaced with the air filter.
2 Ensure the expiratory adapter present in the unit at the beginning of the service has been
reinstalled in the device.
3 Fill out the ResMed Service Request Report in Appendix A if the device needs to be returned
to a ResMed service centre.
Note: If the Astral needs to be returned to ResMed the log files should be captured for
investigation. Contact TechSupport@resmed.com.au for the steps required to capture
the log files.

Device service mode
The Astral Service mode enables the technician to:
• reset the device to default factory settings
• delete patient data
• examine raw and calibrated values while the device is running.
To enter the Astral service mode you must first enter the device clinical mode.
Entering Clinical mode
1 From the patient home screen press and hold the padlock icon for three seconds.
2 The following window will then be displayed:
3 Select either "20 minutes" or "Unlimited".
Entering Service mode

1 While in the Clinical mode select the Information menu.
2 Once in the Information menu hold down the Mute button for at least 10 seconds.
3 When the blue bar is visible at the top of the screen you have entered Service mode.
Note: Do not refer to the device Service mode when determining ventilation hours. In some
versions of the device software the ventilation hours are incorrectly described as
"Patient hours".

Resetting the device to factory default settings
1 Enter the Setup menu and select the Device config. tab.
2 With the Device config. screen displayed select the Reset tab.
3 The following screen will be displayed:
4 Press the Reset button.

5 Confirm that you wish to reset the device to default settings.
Deleting patient data

1 In the Information menu, select the Events tab, then select the Delete tab.
2 Select Delete. All patient data and event logs will be deleted and patient hours will be reset to
zero.

Calibration and test procedures required when parts are replaced
The following calibration and test procedures are required whenever a part is replaced in the
Astral as part of corrective maintenance.
Upon receipt of a device which requires corrective maintenance complete the following
procedures prior to opening the device.
Initial inspection procedures

3.9 Learn circuit
Caution If the target flow cannot be achieved in any of the test and calibration procedures
complete the “3.19 Blower test” on page 42 to help locate the source of the device
! issue.
After determining the issue with the device and replacing any faulty components, complete the
following calibration and test procedures in the order given below, prior to returning the device
to the customer.
Calibration and test procedures Notes

3.10 Temperature sensor test Required if the pneumatic block has been replaced or the
device has been disassembled.
3.11 Heated flex test Only required for Astral 150 devices with SX544-0300
and above where the heated flex cable is present
3.12 Final assembly leak test Required if the device has been opened.
3.37 Pressure calibration Required if the pneumatic block, main PCB or sensor PCB
was replaced
3.38 Flow calibration Only required if any part of the pneumatic block is
replaced -(not if the entire pneumatic block was replaced)
3.39 Outlet pressure model Only required if Pressure calibration and/or Flow
calibration have been completed.
3.13 NRV check Required if the pneumatic block has been replaced or
components within the pneumatic block replaced.
3.14 Safety valve test Required if the pneumatic block has been replaced or
components within the pneumatic block replaced.
3.17 Flow calibration test Only required if the flow calibration has been completed.

Calibration and test procedures Notes
3.18 Quick flow check This test is not required if the flow calibration test has
been completed.
3.19 Blower test
3.21 Cooling fan test Required when the cooling fan is replaced.
3.22 Alarm test
3.24 Remote alarm test Only required if the main PCB has been replaced.
3.25 USB port test Required if main PCB has been replaced or if there is a
fault in data transfer.
3.26 Low flow O2 port test Only required when the low pressure O2 adapter has been
disconnected from the pneumatic block or the chassis.
3.27 SpO2 port test Only required if the main PCB has been replaced.
3.28 LCD test Only required if the main PCB or top case has been
replaced.
3.29 LED test
3.30 Keypad test
3.9 Learn circuit
3.34 Electrical safety test Required when the device has been opened.

4 Preventative maintenance
Preventative maintenance is required every two years, and is to be performed by a service
technician with training level 2 or above.
Note: All units with a serial number prior to 22141103741 should be reworked to the latest
Astral build standard, which requires replacement of the main PCB, bottom case,
chassis and expiratory adapter cover. See tech note #1063301 for the rework
procedures
Astral two year maintenance

The following parts are replaced as part of the two year maintenance for the Astral:
Part number Part
19620 Internal battery
27935 Oxygen sensor (if device currently has one fitted)
For Astral 100
27939 Air inlet filter
Part of Single Limb
27941 Expiratory adapter (Single limb valve adapter)
Valve Kit (19641)
19614 Expiratory adapter membrane and pressure sensor filter
For Astral 150
27939 Air inlet filter
Part of Double Limb
27940 Expiratory valve (Double limb adapter)
Kit it (#19642)
19614 Expiratory adapter membrane & pressure sensor filter
The following flow chart outlines the regular maintenance procedures required every two years
or when the Vent hours or PEEP hours exceed 35,000 hours:

Two year maintenance test procedures
To begin the preventative maintenance these test procedures must be completed, in the
following order, to examine device function.
All test procedures can be found in Section 3 Test and calibration procedures starting page 31.
Note: The device settings do not need to be recorded (test 3.6) and then reloaded (test 3.36)
when the device is being prepared for a new patient.
Initial inspection procedures

(Internal examination and dusting of isolation
barriers not required for 2 year inspection)
3.9 Learn circuit
Note: When examining the ventilation hours to determine if the pneumatic block should be
Note: After completing the Learn circuit you may wish to examine Astral Information menu or
the device error log (via the service software) if you are concerned with device
function.
Confirming screw torque

If the device did not need to be opened at the two year maintenance the case screws need to be
examined to confirm they are still within the specified torque range - 0.2 ± 0.05 Nm torque.
Using an adjustable or pre-setable Torque screwdriver (details on page 57) examine the following
screws:
• Bottom case screws (including screw at base of the battery well) - page 93
• Oxygen sensor cover screws - page 93
• Battery cover screw - page 94
Adjust the screws as appropriate so they are at the correct torque setting of 0.2 ± 0.05 Nm.
4 Preventative maintenance 55
End of preventative maintenance test procedures
After the replacement of the components required as part of the two year preventative
maintenance the following test procedures must be performed in the following order:
End of preventative maintenance test procedures

3.11 Heated flex test (Astral 150 devices with SX544-0300 and higher only
where the heated flex cable is present)
3.18 Quick flow check
3.19 Blower test
3.22 Alarm test
3.29 LED test
3.30 Keypad test
3.9 Learn circuit
If the device required replacement of the pneumatic block, cooling fan or any faulty components,
ensure you complete the required tests listed in “Calibration and test procedures required when
parts are replaced” on page 52.

5 Corrective maintenance
Where corrective maintenance is required for an Astral, ensure you record the device clinical
settings prior to opening the device. The steps for recording the clinical settings can be found in
Section 3 Test and calibration procedures.
After installing replacement parts in the Astral refer to “Calibration and test procedures required
when parts are replaced” on page 52 to determine the tests required for the device.
Note: When replacing the top case, pneumatic block or main PCB ensure you record the serial
number of the replacement spare part in your service reporting/recording system.
Caution Printed circuit boards can be damaged by static electricity. Please read the instructions
“Electrostatic discharge precautions” on page 11 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
Equipment required
• Adjustable or pre-setable Torque screwdriver (such as the Lindstrom PS501-2 Pre Set
Precision Torque Screwdrivers - 7-70 cNm[Ncm], or the Stahlwille 760/7.5 Torsiometer
Torque Screwdriver - 15-75 cNm)
• Screwdriver bit, TX8
• Screwdriver bit, TX10
Note: The screw driver blade needs to be at least 65 mm long, with a diameter no larger than
5 mm.
Screws used in the Astral

A number of different screws are used throughout the Astral. The screws mentioned in the
following chapter are available in a kit - part #19651 (they are not available separately).
Kit #19651 contains the following:
Part number Quantity Description

Z2039 5 Thread forming, (Tx8)2.5 x 8 mm, Torx plus (silver)
Z2051 9 M3 x 20 mm Pan Head (T10) Ni/Black with Nylok
Z2053 4 M3 x 8 mm Pan Head (T10) Ni/Black with Nylok
Z2055 3 M3 x 10 mm Pan Head (T10) Ni with Nylok (silver)
Caution Torque control is required when fixing screws to the external cases.
!
5 Corrective maintenance 57
Opening the Astral
Note: Before opening the unit ensure the device is shutdown (not in standby). To shutdown,
remove mains power from the device. Press the green On/Off switch at the rear of the
device and follow the instructions on the screen.
1 Remove the filter from the rear of the unit.
2 Turn the unit upside down. Push on the button and pull away the expiratory valve cover, as
shown below:
Note: The dial is not present on the

expiratory cover of newer model
Astral devices.
3 Remove the two screws from the cover of the oxygen sensor enclosure (Z2053 - part of
screw kit #19651), and remove the cover (if there is an oxygen sensor present in the unit).

4 Using the tab at the side, pull up on the oxygen sensor and disconnect the sensor cable from
the unit. (if there is an oxygen sensor present in the unit).
5 Remove the screw (Z2053) from the battery cover.

6 Remove the battery cover and pull out the battery.
7 Remove the screw at the base of the battery compartment (Z2053) then remove the eight
screws from the bottom case assembly:
8 The bottom case assembly (#19611) can now be pulled away from the unit and replaced if
required. (If replacing the bottom case also remove the expiratory flow sensor, membrane and
filter from the case.)
Note: The bottom case assembly includes the 8 way connector for the battery and base
decals for both the Astral 100 and Astral 150. The base decals for the US (#19645) are
available separately.
If replacing the bottom case the serial number of the device needs to be retained. For
instructions regarding installation of a serial number decal onto a new bottom case
refer to tech note 1063224.
Caution Ensure the correct base decal is placed on the unit when the bottom case is replaced.
!
Battery
Spare part: Internal battery - 19620
Battery cover - 19619
Caution Ensure there is no O2 supply connected and there are not high levels of O2 inside the
! unit prior to replacing the battery.
Note: Before opening the unit ensure the device is shutdown (not in standby). To shutdown,
remove mains power from the device. Press the green On/Off switch at the rear of the
device and follow the instructions on the screen.
The battery is replaced every two years as part of the two year maintenance procedure. The
battery should also be replaced when there is a noticeable reduction in usage time.
1 Using a Tx10 screwdriver bit, remove the screw (Z2053) from the battery cover.
Battery cover
2 Remove the battery cover from the device.

Note: At this point the battery cover can be replaced if required.
3 Remove the battery from the device.
4 Take the new battery and install it in the unit, taking care not to damage the pins on the 8
way connector (circled).

Caution When installing a new battery, discard any battery that has been dropped or shows
signs of being dropped, such as dents on the battery casing
!
5 Refit the battery cover to the unit, as shown below, and slide it into place.
6 Screw the battery cover into place, using a Tx10 bit with 0.2 ± 0.05 Nm torque.
Battery storage
When storing Astral batteries ensure:
• the battery is recharged every six months
• the battery is not stored in a depleted charge state. Charge the battery to 50% when
storing.
Top case
Spare part: Top case assembly - 19606
Top case assembly (USA) - 19773
Top case assembly (Fukuda) - 19803
Top case decal (150) - 19643
Top case decal (100) - 19644
Top case decal (100SC) - 19794
Note: When installing a new top case on the device ensure you record the serial number of
the new top case in the device service record. The top case serial number can be found
on the flexible cable - see the image on the following page.
To replace the top case, the expiratory adapter membrane must be removed from the device. For
information regarding the expiratory membrane refer to “Expiratory flow sensor, membrane and
adapter” on page 88.
1 To disconnect the top case flexible cable from the main PCB gently pull up on the top case
flexible cable, to avoid damaging the main PCB connector and the top case connector.

2 Using a Tx10 screwdriver bit remove the three screws (Z2055 - part of screw kit #19651)
which attach the chassis to the top case (one of these screws can be found at the base of the
air inlet).
Air inlet
3 Pull the chassis away from the top case, taking care to feed the flexible cable and connector
through the slot in the chassis to avoid damage.
4 Take the replacement top case and stick the appropriate decal (Astral 150 or Astral 100) in
the recess on the case, in the location shown:
Caution Ensure the correct product type decal is stuck to the top case.
!
5 Turn the top case over and place it on the work surface as shown below:
Top case serial number
6 Take the chassis and place it over the top case, while at the same time feeding the flexible
cable through the slot in the chassis.
7 Lift the flexible cable to visually align the flexible cable connector with the PCB connector.
8 Once they are aligned, gently press the connector into place. Do not force the connector.
9 Gently rock the connector stiffener to ensure it is fully inserted. The connector should be
firmly held in place.

10 Refit the three screws (Z2055) removed earlier in the following order, using a Tx10 bit with
0.2 ± 0.05 Nm torque.
3
2
Forced shutdown
Where the touch screen is unresponsive and you need to power off the device, complete the
following steps.
1 Disconnect any external power source (such as AC mains or external battery).
2 Press and hold the green on/off button and the alarm mute/reset button for at least 10
seconds. After 10 seconds the alarm bar will flash yellow.
3 Release both buttons. The Astral will then power off.
Cooling fan
Spare part: Cooling fan assembly - 19610
1 Disconnect the fan cable from the connector on the main PCB.
Fan connector
2 Take the new fan and connect it to the main PCB.

Note: Take care not to press or touch the fan blades.
3 Insert the fan into the chassis with the cable routed underneath the fan (between the two slot
rails). Sit the fan on the slot rails as shown below:

Motor capacitor
Spare part: Motor capacitor - 19608
1 Move the fan assembly away from the motor capacitor to access the motor capacitor cable.
2 Pull the capacitor from its slot in the chassis.
3 Disconnect the motor capacitor cable from the main PCB.
4 Take the new motor capacitor and slot it into the chassis.
5 Connect the capacitor cable to the main PCB.
6 Tuck the excess capacitor cable into the slot shown below, so it does not obstruct the screw
boss (circled) in the chassis.
7 Refit the fan assembly.
Buzzer assembly
Spare part: Buzzer assembly - 19607
1 Disconnect the buzzer cable from the connector on the main PCB.
2 Pull the buzzer assembly away from the rear of the device chassis.
3 Fit the new buzzer to the chassis. Begin by pressing firmly on the left side of the buzzer
housing then press the rest of the buzzer into place, ensuring the entire perimeter of the
buzzer is pressed fully onto the chassis.
4 Take the new buzzer assembly and connect it to the main PCB.
5 Route the cable from the buzzer assembly under the cable holder on the chassis and connect
it to the main PCB.
Cable holder

Pneumatic block
Spare part: Pneumatic block assembly - 19623
Note: When installing a new pneumatic block in the device ensure you record the serial
number of the new pneumatic block in the device service record.
1 If needed, move the cooling fan and the motor capacitor out of the way of the pneumatic
block.
2 Disconnect the PEEP extension tube (at the front of the unit) from the chassis.
3 Turn the unit around and disconnect the following cables from the main PCB:
• 10 pin PAFS cable running from the pneumatic block
• 8 pin VAMPS cable running from the pneumatic block
Note: Disengage the PAFS and VAMPS cable by pressing in the small tab on the connector
while gently pulling the connector away from the main PCB.
• Thermistor cable
• Blower cable
Blower cable
10 pin PAFS cable
8 pin VAMPS cable
Thermistor cable
4 Use a Tx8 screwdriver bit to remove the two screws (Z2039 - part of screw kit #19651) that
attach the low pressure O2 adapter to the pneumatic block. Hold the low pressure O2 adapter
while removing the screws, as shown below:
5 Gently lift upwards on the pneumatic block and disconnect the low pressure O2 adapter.
6 While pulling upwards on the pneumatic block the inlet assembly (with thermistor) and outlet
tube will also be removed from the chassis.
Outlet tube
Inlet assembly
7 Remove the inlet assembly and outlet tube from the pneumatic block.
Note: For information regarding the replacement of the outlet tube refer to page 73.
8 Take the new pneumatic block assembly and install the inlet assembly. Ensure it is installed
correctly, as shown below:

9 Install the outlet tube, with the O2 sensor interface facing upwards, as shown below:
10 Place the pneumatic block over the chassis and connect the blower cable to the PCB.
11 While lowering the pneumatic block connect the low pressure O2 adapter.
Note: Ensure the thermistor is sitting under the low pressure tube.
Low pressure O2 adapter
Thermistor
12 While lowering the pneumatic block ensure the inlet assembly and outlet tubes slide into
position and are sitting flush with the chassis.
13 Connect the PEEP extension tube to the chassis.

14 Take the two screws removed at step 4 and screw the low pressure O2 adapter to the
pneumatic block, using a Tx8 bit. Hold the O2 adapter while installing the screws.
15 Connect the 8 pin PAFS and 10 pin VAMPS cables to the main PCB.
16 Reconnect the thermistor cable to the main PCB.
17 If needed, refit the cooling fan (see “Cooling fan” on page 66) and the motor capacitor (see
“Motor capacitor” on page 67) into position in the chassis.
18 Finally, confirm the thermistor is sitting in the correct position in the inlet assembly. Details
regarding the location of the thermistor in the inlet assembly can be found on the following
page.
Thermistor, inlet assembly
Spare part: Inlet assembly (seal and grid) - 19621
Thermistor - 19609
Thermistor Inlet assembly
1 The inlet assembly (with thermistor) is removed from the device along with the pneumatic
block. See page 70 for further details.
2 Remove the inlet assembly from the pneumatic block.
3 Take the inlet assembly and pull the thermistor out from the inlet seal.
4 Take the new thermistor and insert it in the hole at the side of the inlet seal.
5 Just the tip of the thermistor should be sitting in the area between the outer grid ring and
inner grid ring, as shown below:
Area where thermistor

tip should be sitting
6 Part of the red thermistor probe should also be visible on the outside of the inlet seal.
7 Refit the inlet assembly to the pneumatic block. See page 70 for further details.

Outlet tube
Spare part: Outlet tube (with seal) - 19622
1 The outlet tube is removed from the device along with the pneumatic block. See page 70 for
further details.
2 Remove outlet tube from the pneumatic block.
3 Install the new outlet tube, with the O2 sensor interface facing upwards, as shown below.
Ensure the silicone seal has not been twisted out of position during assembly.
Low pressure O2 adapter
Spare part: Low pressure adapter - 19615
1 The low pressure O2 adapter is easily replaced when the pneumatic block has been removed
from the device. See “Pneumatic block” on page 69 for further details.
2 Pull the low pressure O2 adapter from the CPC connector.
3 Take the new adapter and insert it on the CPC connector, ensuring it has been inserted
completely onto the adapter port.

Tee tubing
Spare part: Silicone tubes kit - 19603
(also includes PEEP extension tube assembly)
With both the top and bottom cases removed the Tee tubing can be replaced.
1 Turn over the chassis to expose the main PCB.
2 Disconnect the Tee tubing from the chassis and the ports on the main PCB.
3 Fit the new Tee tubing to the chassis and the main PCB. Ensure each port is fully inserted into
the tubes to ensure effective sealing.
Heated flex cable
Spare part: Heated flex cable - 19793
With both the top and bottom cases removed the heated flex cable can be replaced.
1 Remove the expiratory flow sensor from the chassis.
2 Turn over the chassis to expose the main PCB.

3 Disconnect the heated flex cable from the main PCB and the small PCB on the cable from the
sensor.
Connection to sensor
Connection to main PCB
4 Pull the cable out from the cavities in the chassis.

5 Turn the chassis back over. Take the new heated flex cable and insert it through the cavities
in the chassis, as shown below:
6 Feed the tab at the end of the cable so it is sitting under the main PCB.
7 Re-insert the flow sensor into the chassis (it will sit over the heated flex cable).
8 While holding the flow sensor in place turn the chassis back over. Bend over the heated flex
cable and insert the PCB into the sensor (through the hole in the chassis) and connect the end
of the cable to the main PCB.
Main PCB
Spare parts: Main PCB (Astral 100) - 19653
Main PCB (Astral 150) - 19600
Expiratory flexible cable - 19602
PEEP extension tube - part of kit 19603
Note: When installing a new main PCB in the device ensure you record the serial number of
the new main PCB in the device service record.
The device serial number and product code also need to be installed on the new main
PCB. See “Installing the device serial number and product code” on page 82 for
installation procedures.
Note: If the main PCB is replaced and the device settings could not be recorded the internal
battery must also be replaced. After installation check the Battery install date. If the
following date is displayed (1/1/2050) please contact your local ResMed office for
assistance.
With the both the top and bottom cases removed, the main PCB can be replaced.
1 Disconnect all components currently connected to the top of the main PCB, following the
instructions provided in this manual.
2 Turn over the chassis to expose the PCB.
3 Disconnect the Tee tubing (circled) from the chassis and the main PCB.
Expiratory flexible cable Heated flex cable
4 Disconnect the expiratory flexible cable or the heated flex cable from the main PCB.

5 Disconnect the oxygen sensor plug cable from the PCB.
6 Use the Tx8 screwdriver bit to remove the following three screws (Z2039).
7 Lift the main PCB from the chassis.

Note: With the main PCB removed, the PEEP extension tube (part of kit #19603) can be
replaced.
8 Take the new main PCB and fit it on the chassis, using the board locators (highlighted below)
to ensure it is in the correct position.
9 Ensure the PEEP extension tube assembly and flexible cable are not pinned under the PCB.
10 Fit the three screws removed at step 3 in the following order:

11 Connect the expiratory flexible cable, or the heated flex cable to the PCB.
Note: At this point the expiratory flexible cable (#19602) can be replaced if required. Refer to
“Heated flex cable” on page 76 if you need to replace the heated flex cable.
12 Refit the Tee tubing as shown below. Ensure each port is fully inserted into the tubes to
ensure effective sealing.
13 Connect the oxygen sensor plug cable to the main PCB and insert the cable into ribs on the
chassis.
After the main PCB has been replaced the following behaviour is observed once the device is
powered on:
• System Error 75 will be displayed, as the pressure sensors have not yet been calibrated.
Recalibration of the device will remove the error message.
• If System Error 65 is displayed after replacing the main PCB contact
TechSupport@resmed.com.au.
Installing the device serial number and product code
If the main PCB has been replaced the device serial number and product code needs to be
installed.
1 Once the device has been completely reassembled connect the unit to the PC and open the
service software, following the instructions “Connecting the Astral to the service software”
on page 32.
top of the screen.
3 The settings will be displayed.
4 Enter the unit’s serial number (found on the base of the unit) and select the appropriate
product code.
5 Select Reload Device Settings in the Xplorer bar.

6 Exit the settings screen.
7 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 begin a new session.
8 Complete the calibration and test procedures required when the main PCB has been replaced
as outlined in Section 3 Test and calibration procedures.
9 Reload the clinical settings to the unit following the procedures from “3.36 Reload device
settings” on page 46.
10 Finally, reset the device time and date following the procedures from “3.5 Set time and date”
on page 35.

Chassis
Spare part: Chassis - 19605 (includes buzzer, oxygen sensor cable,
remote interface cable, SpO2 sensor cable,
power button cable, power connector
cable, data connector cover and low flow
oxygen input)
Chassis decals (ROW) - 19772

Chassis decals (USA) - 19771 (includes air inlet decal)
Air inlet decal (EUR1) - 19786
Air inlet decal (FRA) - 19790
Air inlet decal (APAC) - 19791
Air inlet decal (Japan) - 19792
To replace the chassis, the following parts need to be removed from the device:
• bottom case • main PCB

• top case • PEEP extension tube
• pneumatic block (with outlet tube and inlet assembly) • expiratory flexible cable/ heated flex cable
• cooling fan • expiratory flow sensor
• motor capacitor • pressure sensor filter
• low pressure O2 adapter • expiratory adapter membrane
1 Once the chassis has been replaced stick the air inlet decal to the side of the chassis, in the
location shown below:
Caution Ensure you attach the air inlet decal that is appropriate for the device region.
!
The air inlet decals for each region and the languages displayed on these decals are as follows:
Part number Region Languages displayed

19771 (Chassis decals USA English, French (Canadian), Spanish (LA), Portuguese (LA)
including air inlet decal)
19786 EUR1 Portuguese (EU), Spanish (EU), Czech, Polish

19787 EUR2 Swedish, Norwegian, Finnish, Danish
19788 EUR3 German, French (EU), Italian, Dutch
19789 EUR4 Italian, English, Turkish, Greek
19790 FRA French
19791 APAC English, Chinese Simplified, Chinese Traditional
19792 Japan Japanese, English
2 After placing the air inlet decal on the device, two more decals need to be placed at the rear
of the chassis. Place the "Power On/Off" decal and the "O2" decals in the locations shown
below:
O2 decal (ROW) Power On/Off decal (ROW)
O2 decal (US) Power On/Off decal (US)

Oxygen sensor
Spare parts: Oxygen sensor cover (ROW) - 19650
Oxygen sensor cover (USA) - 19617
Plug outlet tube and lip seal - 19616
Note: The oxygen sensor is available as

an accessory - #27935
The oxygen sensor is supplied with the Astral 150, and is available as an optional accessory for
the Astral 100.
1 Turn the Astral over and remove the two screws (Z2053) from the cover of the oxygen
sensor enclosure, using a Tx10 screwdriver bit.
2 Remove the cover to reveal the oxygen sensor.

3 Using the tab at the side, pull up on the oxygen sensor and disconnect the sensor cable from
the unit.
4 Take the replacement oxygen sensor. Examine the seal on the oxygen sensor to confirm it is
in good condition.
Oxygen sensor with original seal Oxygen sensor with new lip seal
Note: Leak through the flow ventilation seal could affect ventilation accuracy.
5 Ensure the polarity features on the connector are oriented correctly before gently inserting the
connector into the chassis. (The red cable from the oxygen sensor is the cable closest to the
front of the Astral.)
Note: Pins can be damaged if alignment is incorrect.
Connector orientation
Caution Prior to fitting the oxygen sensor cover ensure there are no foreign objects trapped
within the oxygen sensor well.
!
6 With the cable connected, insert the sensor into the unit.
7 Push down on the tab to secure it into place. If it is a tight fit, wiggle the tab side to side a
little as you push downwards.

8 Carefully tuck the cables to the side of the sensor.
Cables tucked
to the side
Tab
9 Fit the oxygen sensor cover to the bottom case and refit the two screws (Z2053), using a
Tx10 bit, with 0.2 ± 0.05 Nm torque.
Note: The sensor cover will not go on correctly if the sensor is not installed properly.
Expiratory flow sensor, membrane and adapter
Spare parts: Expiratory flow sensor - 27936
Pressure sensor filter - 27937
Expiratory adapter membrane - 19614
Expiratory adapter cover (ROW) - 19649
Expiratory adapter cover (USA) - 19613
Double limb adapter - 27940
Single limb valve adapter - 27941
Single limb leak adapter - 27942
Expiratory flexible cable - 19602
Note: For details regarding the replacement of the expiratory flexible cable refer to page 51.
For details regarding the replacement of the heated flexible cable refer to page 76.
1 Turn the Astral over.
2 Press and hold the eject button while pulling forwards on the cover.
Note: The dial is not present on the

expiratory adapter cover of newer
model Astral devices.
3 The adapter is now visible. Lift up the adapter to remove it from the device.

4 Sitting under the adapter is the expiratory adapter membrane. Pull up on the tab to remove it
from the chassis.
Note: When the expiratory adapter membrane is removed, the pressure sensor filter may stick
to the membrane.
If the filter needs replacing, remove the filter from the membrane and place the new
filter in the chassis, as shown below:
Pressure sensor filter
5 Sitting in the base of the chassis is the expiratory flow sensor. Use the tab at the side of the
sensor to remove it from the chassis.
6 Take the replacement expiratory flow sensor and insert it in the chassis, taking care not to
bend the sensor pins.
7 Refit the expiratory adapter membrane to the chassis, followed by the adapter.
Note: If installing a new expiratory adapter membrane ensure an expiratory pressure sensor
filter is installed in the unit. See page 89 for details.
8 Slide the adapter cover into place over the expiratory adapter and allow it to "click" into
place.
9 Ensure the cover sits flush with the case.
 
10 Turn the dial clockwise until it clicks.

Air filter
Spare parts: Inlet filter pack - 27939
(includes filter cover, muffler & four filters)
Caution Do not wash the air filter. The air filter is not washable or reusable.
!
1 Remove the filter from the rear of the device by turning it in an anti-clockwise direction then
pulling it away from the device.
2 Pull out the air filter and muffler from the cover and discard the filter (and muffler if required).
3 Insert the new air filter into the muffler and insert both into the filter cover.
4 Refit the filter cover to the Astral, turning it in a clockwise direction until it is securely in
place.
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.
!
Closing the unit
1 Before fitting the bottom case to the unit confirm:
• the three screws which attach the chassis to the top case are present
• the inlet assembly is present
• the expiratory pressure sensor filter and expiratory flow sensor are present
• the thermistor is present and in the correct position
• the PEEP extension tube is connected to the chassis
• the cooling fan is present and oriented correctly
• the motor capacitor cable is not obstructing the screw boss
PEEP extension tube

connected to chassis
Expiratory flow
sensor (under
membrane)
Third screw
(under
membrane)
Expiratory
pressure sensor
filter
Motor capacitor
cable and
screw boss
Thermistor
Cooling fan
Inlet assembly
2 Fit the bottom case to the unit. Using a small amount of force, push down on the case to
ensure the device is sealed and the case engages on the chassis.
3 Examine the fan mount assembly and confirm it is clearly visible against the bottom case.
 
4 Fit the nine screws in the following order (screws 1-8 are Z2051, screw 9 is Z2053), using a
Tx10 bit with 0.2 ± 0.05 Nm torque.
8 4
1
5
6
3 2
7
5 Refit the oxygen sensor. Details for refitting the oxygen sensor can be found on page 86.
6 Fit the oxygen sensor cover to the bottom case and refit the two screws (Z2053), using a
Tx10 bit, with 0.2 ± 0.05 torque.
Caution Ensure there is no O2 supply connected and there are not high levels of O2 inside the
! unit prior to replacing the battery.
7 Install the battery in the device ensuring it is oriented correctly.
8 Refit the battery cover to the unit, as shown below, and slide it into place.
9 Screw the battery cover into place (using screw Z2053), using a Tx10 bit, with 0.2 ± 0.05
torque.
10 If removed previously, fit the expiratory adapter to the unit.
11 Slide the adapter cover into place over the expiratory adapter.
12 Ensure the cover sits flush with the case.
 
13 Turn the dial clockwise until it clicks.
14 Turn the unit over.
15 Insert the inlet filter and twist it until it "clicks" into place.

Astral external battery
The Astral external battery (#27918) is
available as an accessory.
Note: If the Astral external battery is replaced, the replacement must be recorded in the
appropriate service reporting system. This record must include the serial number details
of the replacement (new) external battery.
To determine the amount of charge left in the Astral external battery press the On button. The
Battery Level Check indicator will be displayed for five seconds.
Indicator External battery status

DC on/off LED
Constant blue Battery turned on
Charging LEDS
Flashing green Charging
Constant green Fully charged
Four green continuous Greater than 90% (approximate)
Three green continuous 65% to 90% (approximate)
Two green continuous 40% to 65% (approximate)
One green continuous 10% to 45% (approximate)
One green flashing Less than 10% (approximate)
One amber flashing Less than 5% (approximate)
It is recommended that the external battery is returned for servicing every two years. At the two
year service the battery inside the external battery should be replaced.
Replacing the battery inside the external battery
Caution When installing a new battery, discard any battery that has been dropped or shows
signs of being dropped, such as dents on the battery casing.
!
Note: When the battery inside Astral external battery is replaced, the replacement must be
recorded in the appropriate service reporting system. This record must include the serial
number details of the replacement (new) internal battery and the external battery into
which it was placed.
1 Turn over the Astral external battery pack and remove the screw indicated below:
2 Slide back the battery cover and lift it away from the unit, exposing the Astral battery inside.
3 Remove the Astral battery from inside the external battery pack.
4 Insert the new Astral battery into the external battery, oriented as shown below:
5 Refit the cover to the base of the external battery and screw it into place.

Spare parts list
Note: Spare parts are not always available at the time of publication. Contact
TechSupport@resmed.com.au if you require information regarding the timing of the
release of spare parts.
Refer to the Technical Support website for the latest Astral spare parts available.
Green cells indicate part that are in the pneumatic block.
Blue cells indicate parts that are available as accessories.
Part number Part description (in alphabetical order)

19786 Air inlet decal (EUR1)
19790 Air inlet decal (FRA)
19791 Air inlet decal (APAC)
19792 Air inlet decal (Japan)
19624 Aluminium housing
19688 Astral Service kit
19645 Base decal 150 (USA)
19619 Battery cover
19611 Bottom case assembly (Bottom case moulding, connector housing 8 way).
19639 Bottom lid
19607 Buzzer assembly
19635 Cable harness 1
19605 Chassis
19771 Chassis decal (USA)
19610 Cooling fan assembly (Fan, fan mount)
27940 Double limb adapter (Expiratory valve)
19649 Expiratory adapter cover (ROW)
19613 Expiratory adapter cover (USA)
19614 Expiratory adapter membrane
19602 Expiratory flex cable
27936 Expiratory flow sensor
27918 External battery
19793 Heated flex cable
19621 Inlet assembly (Inlet seal and grid)
27939 Inlet filter pack (Filter, filter cover)
19620 Internal battery
19615 Low pressure connector/adapter
19600 Main PCB (Astral 150)
19653 Main PCB (Astral 100)
19608 Motor capacitor
19632 NRV assembly
19650 O2 sensor cover (ROW)
19617 O2 sensor cover (USA)
19616 O2 sensor plug and o-ring
19622 Outlet tube (with seal)
19652 PEEP assembly kit
19623 Pneumatic block assembly
19637 Pneumatic block sensor PCB
19626 Pneumatic block silicone kit
27937 Pressure sensor filter
19651 Screw kit, Final assembly (5 x Z2039, 9 x Z2051, 4 x Z2053, 3 x Z2055)
19640 Screw kit, Pneumatic block (8 x Z2054, 4 x Z2039)
19641 Single limb valve kit
19642 Double limb kit
19603 Silicone tubes kit (Tee tubing)
27942 Single limb leak adapter (Expiratory adapter)
27941 Single limb valve adapter
19609 Thermistor
19606 Top case assembly
19803 Top case assembly (Fukuda)
19773 Top case assembly (USA)
19643 Top case decal (Astral 150)
19644 Top case decal (Astral 100)
19794 Top case decal (Astral 100SC)
19638 Top lid
19627 Volute assembly
Note: The screws used in the Astral are not available as separate spare parts - they are only
available in screw kits #19651 and #19640.

6 Troubleshooting guide
Note: Refer to the Technical Support website for the latest Astral troubleshooting
information.
Learn circuit
When troubleshooting a device fault it is highly recommended that you run the Learn Circuit.
The Learn Circuit takes the device through a number of tests determining the impedance and
compliance characteristics of the circuit. It also checks and calibrates the oxygen cell and
expiratory flow sensors.
The resulting information available after the completion of the Learn Circuit provides valuable
information regarding possible faulty components. A breakdown of the tests run during the
Learn circuit is provided in the flow chart below:
6 Troubleshooting guide 99
For the steps required to perform the Learn Circuit refer to “3.9 Learn circuit” on page 39.
Once the Learn circuit is complete you can examine the device screen to help determine the
location of issues with the device.
The following icons are used to report the Learn circuit results:
Icon Description
OK Learn Circuit has passed
Caution! Learn Circuit has failed.
Warning!
Learn circuit troubleshooting

When examining the Learn Circuit results screen you will note the results are divided into the
following sections:
• Learn circuit
• Device test
• Oxygen sensor
Note: The oxygen sensor test details will indicate "Oxygen sensor missing" if there is no
oxygen sensor in the device.
• Expiratory flow sensor
Note: As there is no expiratory flow sensor in the Astral 100 this field is not displayed on
the Astral 100 screen.
By examining the pass/fail details of each of these sections you can begin to troubleshoot the
reasons for any device issues. See the Learn circuit troubleshooting flow chart on the
following page for the steps to take when examining the reasons for Learn circuit failures.

Learn circuit troubleshooting flow chart

Further device information
Further device information can also be found via the Information menu, in the Events sub-
menu. The Events sub-menu contains information regarding specific alarms, settings and
system events for the device.
Device error log

Where there are concerns with device function, the device error log can also be examined,
using the service software.
1 Select Diagnostics>Error Logs.
2 In the Error log screen select Print and navigate to the Alarm events screen. The following
kind of information is then displayed and can be used to determine issues with the device.

Therapy alarms
Problem/Cause Action
The following message is displayed on the LCD: Internal Battery inoperable

Alarm priority: High
Description: The battery is inoperable
• A battery is not in the device • Install battery in device
• Faulty battery • Replace battery
• Faulty 8 way connector • Replace bottom case
The following message is displayed on the LCD: Battery 1 fault (Battery 1 indicates the external battery
connected directly to the Astral)
Alarm priority: Low
Description: External battery 1 is connected but faulty
• Faulty external battery • Replace external battery
• Faulty power inlet • Replace device chassis
The following message is displayed on the LCD: Battery 2 fault (Battery 2 indicates the external battery
connected directly to Battery 1)
Alarm priority: Low
Description: 2 external batteries are connected and Battery 2 is faulty
• Faulty external battery • Replace external battery
The following message is displayed on the LCD: Circuit fault

Description: Circuit impedance does not match actual circuit impedence
• Circuit impedence does not match actual circuit • Run Learn circuit
• Pressure sensor fault (proximal or outlet pressure • Run pressure calibration test to determine location of
sensor) faulty sensor.
• Replace affected subassembly (main PCB or sensor PCB)
• Flow sensor fault • Run Quick flow test to determine location of faulty
sensor.
• Replace affected subassembly
The following message is displayed on the LCD: Critically low internal battery
Description: Very low battery charge while device is powered internally or externally
• Low charge on battery • Check battery charge & connect unit to external power
source
The following message is displayed on the LCD: Device overheating

Alarm priority: Medium
Description: Main PCB temperature exceeds 85°C for 60 seconds
• Device in inappropriate location • Move device to cooler location
• Foreign object in air inlet • Remove object from air inlet
• Dirty air filter • Replace air filter
• Foreign object in cooling fan inlet or outlet • Remove object from cooling fan inlet or outlet
• Inappropriate circuit/settings combination • Change settings/circuit combination

Device overheating continued...
• Faulty main PCB temperature sensor • Replace main PCB
• Faulty main PCB • Replace main PCB
The following message is displayed on the LCD: Incorrect circuit

Description: Vented expiratory module missing
• Incorrect expiratory adapter installed for circuit type • Connect appropriate adapter
• Peep valve control line not reconnected • Connect peep valve control line
• Peep valve pressure sensor failure • Replace pneumatic block (Level 2 technician)
• Replace sensor PCB (Level 3 technician)
• Peep motor failure • Replace pneumatic block(Level 2 technician)

• Replace PEEP assembly (Level 3 technician)
The following message is displayed on the LCD: Last self-test failed

Description: Device detected fault during circuit test
Run Learn Circuit to determine any issues with the device. If the device successfully completed the Learn Circuit run
the following tests to determine the location of the device issue:
• Alarm test
• LED test
The following message is displayed on the LCD: Low internal battery

Description: While running on the battery the battery time is less than or equal to 20 mins.
• Low charge on battery • Connect device to external power
The following message is displayed on the LCD: No FiO2 monitoring

Description: This alarm indicates the absence (at start of ventilation) or loss (during ventilation) of O2 monitoring, if
the Low and/or High FIO2 alarms are used.
• Check oxygen sensor and connections • Fix connections or replace oxygen sensor as appropriate
• Replace main PCB
The following message is displayed on the LCD: NV mask

Description: Alarm indicates non vented or blocked mask
• Non vented mask attached • Change mask
• Blocked mask vents • Unblock mask vents
• Incorrect mask selection • Change mask selection
• Learn circuit has not been performed • Perform Learn circuit
• Unit out of calibration • Calibrate unit

The following message is displayed on the LCD: Pressure Line disconnected
Description: With a circuit type of "Single with valve" the proximal pressure line is disconnected.
• Faulty connections to sensors (t-tubing) • Reconnect tubing to sensors
• Faulty pressure sensors • Replace main PCB
The following message is displayed on the LCD: Unexpected restart

Description: Device unexpectedly restarts
• View alarm details prior to this reset to determine cause for restart
The following message is displayed on the LCD: Power disconnected

Alarm priority: Low
Description: Loss of external power while device is operating
• Faulty AC adapter • Replace AC adapter
• Faulty connectors • Replace power cord
• Problem with mains supply power • Use alternate power source

System failures
Note: Where there are failures with the sensors or the motor it is recommended that you
first complete the "Learn Circuit" then examine the Error log to determine the origin
of any system failures. It is also recommended that the unit is then recalibrated to
see if this resolves the system failure.
The following message is displayed on the LCD: "System fault - 34"

Description: Total power failure when device is powered internally
• Flat battery • Recharge battery or replace if needed

Description: Program data is read from NV memory, and program data fails CRC
• Program data is corrupted • Contact Technical Services, Sydney, for further

information
• Main PCB has been replaced

Description: Software task failure
• Software task fault • Replace the main PCB

Description: Pneumatic block calibration data read from NV memory, and pneumatic block is not calibrated
• Pneumatic block out of calibration • Recalibrate device
• Replace pneumatic block
• Main PCB has been replaced and pressure sensors • Recalibrate device
have not yet been calibrated

Description: Alarm system failure - Invalid HAC response
• Fault with the hardware alarm controller • Replace main PCB

Description: Data transfer CRC failure

Description: Incorrect outlet pressure measurement
• Calibration issue • Recalibrate (estimated outlet pressure model)
• Faulty outlet pressure sensor • Replace pneumatic block
• Faulty I/E valve • Replace pneumatic block (Level 2 technician)

• Replace aluminium housing (Level 3 technician)
• Faulty outlet flow sensor • Complete circuit test

Description: Monitoring failure - Pressure Sensors 1
• Faulty pressure sensors (at least 3 of the 4) • Recalibrate device

Description: Monitoring failure - Pressure Sensors 2
• Faulty pressure sensors • Recalibrate device

Description: Trigger pressure measurement incorrect
• Trigger pressure sensor failure • Recalibrate device

Description: Invalid atmospheric pressure measurement (atmospheric pressure is too high [>1150 hPa] or too low
[<500 hPa])
• Faulty atmospheric pressure sensor • Recalibrate device

Description: Invalid ambient temperature measurement (ambient temperature is too high [>80°C] or too low [<-
30°C])
• Thermistor disconnected • Reconnect thermistor
• Faulty thermistor • Replace thermistor

Description: Invalid request to stop therapy
• Software fault • Replace main PCB

Description: Incorrect proximal pressure measurement
• Calibration issue • Recalibrate device
• Faulty proximal pressure sensor • Replace main PCB

Description: Main blower temperature sensor fault
• Faulty thermistor • Replace thermistor
• Faulty blower • Replace pneumatic block (Level 2 technician)

• Replace volute assembly (Level 3 technician)
The following message is displayed on the LCD: "System fault - 132

Alarm priority: Low
Description: Trigger Pressure measurement incorrect (not in use)
• Trigger pressure sensor fault (on main PCB) • Recalibrate device

Alarm priority: Low
Description: PEEP Valve Pressure measurement incorrect
• PEEP valve pressure sensor fault • Recalibrate device
• Replace pneumatic block (Level 2 technician)


Alarm priority: Low
Description: NV memory corruption (non critical data)
• Software fault • Contact Technical Services, Sydney, for further

information

Description: Loss of communication with pneumatic block
• Cables from pneumatic block not connected properly • Connect pneumatic block cables to main PCB
to main PCB
• Faulty pneumatic block • Replace pneumatic block

Description: Pneumatic block refusing breath state change

Description: Loss of control data

Description: Wrong alarm priority (detected by PB)
• Hardware alarm controller fault • Replace main PCB

Description: PB software receives an invalid request to enter a mode or state.

Description: PB software receives command to perform a circuit test when NOT in CIRCUIT TEST mode.

Description: Failure to start ventilation

Description: Maximum inspiratory or expiratory limit exceeded

Description: Failure of main PCB software watchdog signal
• Hardware alarm controller failure • Replace main PCB

Description: PB software has detected that the motor has stalled and could not be restarted after 3 attempts.
• Blower cable from pneumatic block not connected to • Reconnect blower cable to main PCB
main PCB
• Motor capacitor cable not connected to main PCB • Reconnect motor capacitor cable to main PCB
• Faulty motor • Replace pneumatic block(Level 2 technician)


Description: Main blower failure - hardware over temperature


Description: Main blower over current limit is exceeded


Description: Electro-valve over current limit is exceeded
• Electro-valve fault in pneumatic block • Replace pneumatic block (Level 2 technician)

• Replace aluminium housing (Level 3 technician)

Description: Super capacitor fault
• Fault with super capacitor • Replace main PCB

Alarm priority: Low
Description: Internal battery is present but cannot be charged
• Faulty 8 way connector • Replace bottom case

Description: Outlet flow sensor data implausible
• Excessive electromagnetic interference • Remove source of electromagnetic interference
• Faulty expiratory flow sensor • Replace expiratory flow sensor
• Faulty flow sensor • Replace pneumatic block(Level 2 technician)


Description: The safety assert signal test performed during start up or circuit test fails
• Faulty pneumatic block • Replace pneumatic block

Description: The pneumatic block software has not successfully communicated with the processor software for one
second

Description: Critical outlet pressure sensor failure
• Faulty outlet pressure sensor • Replace pneumatic block(Level 2 technician)


Description: Loss of communication with outlet flow sensor
• Faulty outlet pressure sensor • Replace pneumatic block(Level 2 technician)


Description: Power to Sensor Board compromised - 3V3 Rail low
• Issue with cable connection to sensor PCB • Examine cable connections to sensor PCB and fix as
appropriate (Level 3 technician)
• Faulty sensor PCB • Replace pneumatic block(Level 2 technician)


Description: Persistent software fault - device has had > 3 unexpected restarts in 1 minute.

Description: The UI finds that the critical settings held by the TM, PB or TC are not correct

Description: Outlet flow sensor stuck
• Faulty outlet sensor • Replace pneumatic block(Level 2 technician)


Description: Pneumatic block has not received all preventilation data.

Description: Calibration corrupted.
• Calibration fault • Recalibrate device

Description: The blower temperature reading is <-15°C
• Faulty blower • Replace pneumatic block(Level 2 technician)


Description: MB watchdog alarm

Description: PB watchdog alarm

• Software processor fault

Description: MB & PB watchdog alarm

Alarm priority: Low
Description: Peep blower failure
• Faulty PEEP blower or peep valve pressure sensor in • Replace pneumatic block(Level 2 technician)
pneumatic block • Replace PEEP assembly (Level 3 technician)

7 Technical specifications
General technical specifications
Operating pressure range Single limb with valve or double limb with valve:
Expiratory: 3 cm H2O
Inspiratory: 50 cm H2O
Single limb with intentional leak:
Expiratory: 2 cm H2O
Inspiratory: 50 cm H2O
CPAP: 3 to 20 cm H2O
Maximum working pressure limit: 10 to 55 cm H2O
Forced cycling occurs if the Pressure alarm limit is exceeded
Operating tidal volume range (volume Adult patient type: 100 to 2500 mL
control modes) Paediatric patient type: 50 to 300 mLa
Maximum single fault pressure 60 cm H2O (in all modes)
Breathing resistance under single faulta Circuit type:

Paediatric (at 15 L/min)
Inspiration: 2.2 cm H2O
Expiration: 2.4 cm H2O
Adult (at 30 L/min)
Inspiration: 5.7 cm H2O
Expiration: 4.2 cm H2O
Operational range for circuit resistance Paediatric patient setting:

and complianceb Circuit resistance range (circuit with intentional leak):
0 to 8 cm H2O at 60 L/min
Circuit resistance range (circuit with valve):
Circuit compliance range:
0 to 4 mL/cm H2O
Adult patient setting:
Circuit resistance range (circuit with intentional leak):
Circuit resistance range (circuit with valve):
Circuit compliance range:
0 to 4 mL/cm H2O
Maximum flow 220 L/min

Inspiratory trigger (nominal) Inspiratory trigger occurs when patient flow exceeds trigger setting.
characteristics Double limb with valve (flow trigger): 0.5 to 15.0 L/min
Single limb with valve or Double limb with valve:
1.6 to 10.0 L/min (in five steps)c
Single limb with intentional leak: 2.5 to 15.0 L/min (in five steps)
Expiratory cycle (nominal) Cycle occurs when inspiratory flow declines to the set percentage of peak
characteristics inspiratory flow.
Single limb with valve or Double limb with valve: 5 to 90%
Single limb with intentional leak: 8 to 50 % (in five steps)
Sound pressure level 35 ± 3 dBA as measured according to IEC80601-2-12:2011
Sound power level 43 ± 3 dBA as measured according to IEC80601-2-12:2011
Alarm volume range 59 - 89 dBA (in five steps)
Data storage 7 days of high-resolution airway pressure, respiratory flow and delivered volume
(sampled at 25 Hz).
7 days of breath-related therapy data (sampled at 1 Hz)
365 days of statistical data per program.
Dimensions (L x W x H) 285 mm x 215 mm x 93 mm (11.22" x 8.47" x 3.66")
7 Technical specifications 113

Weight 3.2 kg (7.1 lb)
Inspiratory port / double limb adapter 22 mm (0.87") taper, compatible with ISO 5356-1:2004 Anaesthetic &
Respiratory Equipment - Conical Connectors
Pressure measurement Internally mounted pressure transducers
Flow measurement Internally mounted flow transducers
Power supply AC 100-240V, 50-60 Hz, 90 W 3.75 A continuous, 120 W/ 5A peak
115V/400 Hz
External DC battery supply 12 - 24V DC 90 W, 7.5 A/3.75 A
Internal battery Lithium-Ion battery, 14.4. V, 6.6 Ah, 97 Wh
Operating hours: 8 h with a new battery under normal conditions (see below).
Test conditions: Adult, P(A)CV mode, P insp: 20 cm H2O, PEEP: OFF,
Rate: 15 bpm, Ti: 1.2 sec
Note: Time may vary with environmental conditions.
Total lifetime: 3,000 hours of operation on internal battery.
Housing construction Flame retardant engineering thermoplastic
Environmental conditions Operating temperature: 0° to 40°C (+32°F to +104°F)
Charging temperature: 5°C to 35°C (+41°F to +95°F)
Operating humidity: 5 - 93% non-condensing
Storage and transport temperature: -25° to 70°C (-13°F to +158°F) - for up to
24 hours
Storage and transport temperature: -20° to 50°C (-4°F to +122°F) - for
greater than 24 hours
Note: Storing the Astral at temperatures exceeding 50°C (+122°F) for
extended periods will accelerate battery ageing. This will not affect the safety of
the battery or the device.
Storage and transport humidity: 5 - 93% non-condensing
Air pressure: 1,100 hPa to 700 hPa
Altitude: 3000m (9,843 ft)
Note: The performance may be limited below 800 hPa/2000m.
IP22 (Protected against finger sized objects. Protected against dripping water
when tilted up to 15 degrees from specified orientation.)When placed
horizontally on flat surface, or vertically with handle up.
IP21 (Protected against finger sized objects and against vertically dripping
water.) When placed on a desktop stand.
Oxygen measurement Internally mounted oxygen sensor.
1,000,000 % hours at 25°C (77°F)
Electromagnetic compatibility This product complies with all applicable electromagnetic compatibility
requirements (EMC) according to IEC60601-1-2, for residential, commercial and
light industry environments.
It is recommended that mobile communication devices are kept at least one
metre away from the device.
For further details see the "Guidance and manufacturer’s declaration -
electromagnetic emissions and immunity" in the Clinical manual.
Aircraft use 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 Astral meets the Federal Aviation Administration
(FAA) requirements (RTCA/DO-160G, section 21, category M) for all phases of
air travel.
IATA classification for internal battery: UN 3481 - Lithium-Ion batteries
contained in equipment

Automotive use Product complies with ISO 16750-2 "Road Vehicles - Environmental Conditions
and Testing for Electrical and Electronic Equipment - Part 2: Electrical Loads" -
2nd Edition 2006, Tests 4.2, 4.3.1.2, 4.3.2, 4.4, 4.6.1 and 4.6.2. The
functional status classification shall be Class A.
Product complies with ISO7637-2 "Road Vehicles - Electrical Disturbance by
Conduction and Coupling - Part 2 Electrical Transient Conduction Along Supply
Lines Only" - 2nd Edition 2004, Section 4.4 Transient Immunity Test. The
functional status classification shall be Class A to test level III and Class C to
test level IV.
Data connections The Astral device has three data connections ports (USB connector, mini USB
connector, and the Ethernet port). Only the USB connector is for customer use.
The USB connector is compatible with the ResMed USB stick.
Recommended patient circuit Refer to www.resmed.com
components and compatible
accessories
IEC60601-1 classifications Class II (double insulation)
Type BF
Continuous operation
Suitable for use with oxygen
Applied parts Patient interface (Mask, endotracheal tube or tracheostomy tube)
Oximeter
Operator position The device is designed to be operated within arm’s length. An operator should
position their line of sight within an angle of 30 degrees from a plane
perpendicular to the screen.
The Astral device complies with IEC60601-1:2005 legibility requirements.
This device is not suitable for use in the presence of a flammable anaesthetic mixture.
a. The International ventilator standard indicates that Paediatric patient type is intended to be used for a patient receiving less
than 300 mL, however Astral permits adjustment of ’Vt’ setting parameter up to 500 mL for cases where ’Vt’ is set such
that it compensates for leak in the breathing circuit.
b. Limits are the sum of device and circuit impedance.
c. Individual configurations may be more sensitive.
Note: The manufacturer reserves the right to change these specifications without notice.
A list of symbols which appear on the device can be found in the device clinical manual.
Refer to the clinical manual for Astral standards compliance details.
Monitoring
This section specifies the monitored parameters of the Astral device. Monitored therapy parameters are only
displayed during ventilation. Other parameters (eg, battery charge level and oximetry data) are monitored even
when not ventilating.
The Astral device monitors the following parameters:
Time parameters
Parameter Updates Units Range Resolution Accuracy
Ti End of inhalation sec 0 to 10 0.01 ±(20 ms + 5%)
Te End of exhalation sec 0 to15 0.01 ±(20 ms + 5%)
I:E End of breath N/A 1:9.9 to 9.9:1 0.1 ±10%
Resp. rate End of breath 1/min 0 to 99 1 ±1/min

Volume and flow parameters
Flow Continuous L/min -250 to +250 0.1 ±1L/min or 10%

whichever is greater
Vti End of inhalation mL 0 to 3000 1 10 mL or 10%, whichever

is greater
Vte End of breath mL 0 to 3000 1 For double limb circuit: 10

mL or 10%, whichever is
greater
For single limb with
intentional leak: 15 mL or
15%a, whichever is
greater
Mvi End of breath L 0 to 99 0.1 ±15% (VTI >=100 mL)
Mve End of breath L 0 to 99 0.1 ±15% (VTE >=100 mL)
Peak Inspiratory End of inhalation L/min 0 to 250 0.1 ±1 L/min or 15%,

Flow (PIF) whichever is greater
Measured Once per second L/min 0 to 250 1 N/A

Unintentional Leak
(for intentional leak
circuits)
Measured End of breath % 0 to 100 1 N/A

Unintentional Leak
(for double limb
circuit with
expiratory valve)
a. When Resp. rate ≥ 8/min and Pressure ≤ 40 cm H2O.
Pressure parameters
Pressure Continuous cm H2O to hPa 0 to 99 0.1 ±(0.5 hPa + 4% of

or mbar actual pressure)
PIP End of inhalation cm H2O to hPa 0 to 99 0.1 ±15%

or mbar
PEEP End of exhalation cm H2O to hPa 0 to 30 0.1 ±(0.5 hPa + 4% of

Avg. P End of breath cm H2O to hPa 0 to 99 0.1 ±(0.5 hPa + 4% of


Other parameters
RSBI End of breath 1/min-L 0 to 999 1 N/A
% Spont. Trig. Start of inhalation % 0 to 100 1 N/A
% Spont. Cyc. End of inhalation % 0 to 100 1 N/A
Measured Battery Once per minute HH:MM N/A 1 min N/A

Time
Measured Battery Once per minute % 0 to 100 1 N/A

Charge Level
FiO2a End of inhalation % 18 to100 1 ±(2.5% + 2.5% of

actual oxygen
concentration)
SpO2 Once per second % SpO2 0 to 100 1 Refer to Nonin Xpod 3012
technical specifications at
www.nonin.com
Pulse rate Once per second 1/min 18 to 321 1 Refer to Nonin Xpod 3012
technical specifications at
www.nonin.com
a. FiO2 monitoring automatically compensates for atmospheric pressure variation.
Notes:
• All flow and volumes are measured at BTPS conditions.
• To achieve specified accuracies, a successful Learn Circuit must be performed prior to measurement
testing. Specified accuracies exclude mask compliance.
• Pressure may be displayed in cm H2O, hPa or mbar. The conversion factor of the pressure units is 1.
This means the displayed pressure will have the same values regardless of the unit selected.

Accuracy of Controls
The following table shows the setting range and accuracy for the adjustable parameters.
Parameter Range Resolution Accuracy
Delivered pressure 2 to 50 cm H2O ± (0.5 cm H2O + 5% of

target)
IPAP 4 to 50 cm H2O 0.2 cm H2O N/A
EPAP 2 to 25 cm H2O 0.2 cm H2O N/A
CPAP 3 to 20 cm H2O 0.2 cm H2O N/A
PEEP Off, 3 to 20 cm H2O 0.2 cm H2O N/A
PS 2 to 50 cm H2O 0.2 cm H2O N/A
P Control 2 to 50 cm H2O 0.2 cm H2O N/A
Vt (Tidal volume) Adult: 100 to 2500 mL 10 mL (Adult) Valved circuits: ± 12 mL or

Paed: 50 to 300 mLa 5 mL (Paed) 10%, whichever is greater
Resp. rate Adult: Off, 2 to 50 bpm 1 bpm ± 2%

Paed: Off, 5 to 80 bpm
Ti (Inspiration time) (A)CV, V-SIMV (mandatory 0.1 sec (Adult) ± (20ms + 5% of setting)
breaths: 0.3 to 3.0 sec 0.05 sec (Paed)
P(A)CV, P-SIMV (mandatory
breaths): 0.2 to 5.0 sec
P(A)C: 0.3 to 4.0 sec
PIF (Peak Inspiratory Flow) (A)CV, V-SIMV (mandatory 1 L/min N/A

breaths):
Adult: 10 to 120 L/min
Paed: 5 to 60 L/min
Cycle (expiratory trigger) 5 to 90%, Auto 5% N/A
Trigger (inspiratory trigger) ACV, P(A)CV: 0.5 L/min N/A

Off, 0.5 to 15 L/min
V-SIMV, PSIMV, PS, CPAP:
0.5 to 15 L/min
Inspiratory Pressure Trigger (A)CV, P(A)CV: N/A

Off, Very Low to Very High
PS, P-SIMV, V-SIMV CPAP:
Very Low to Very High
Trigger sensitivity - Vented (S)T, P(A)C: N/A

Very Low to Very High, Off
CPAP: Very Low to Very High
Rise Time Min, 150 to 900 msec 50 ms N/A
Flow shape Constant, 75, 50 25% N/A
Ti Min PS: 0.2 to 4.0 sec 0.1 sec (Adult) N/A

(S)T: 0.1 to 4.0 sec 0.05 sec (Paed)
Ti Max 0.3 to 4.0 sec 0.1 sec (Adult) N/A

0.05 sec (Paed)
Cycle Sensitivity Very Low to Very High N/A
Apnoea Interval Adult: 15 to 120 sec 1 sec ±50 msec

Paed: 5 to 30 sec

Parameter Range Resolution Accuracy
Apnoea Resp Rate Adult: 4 to 50 bpm 1bpm ±2%

Paed: 12 to 80 bpm
Apnoea Ti When Volume Breath option is 0.1 sec (Adult) ±(20 ms + 5% of setting)
set to Ti. 0.05 sec (Paed)
If Apnoea Response is (A)CV
+ Alarm: 0.3 to 3 sec
If Apnoea Response is P(A)CV
+ Alarm: 0.2 to 5 sec
Apnoea Vt If Apnoea Response is (A)CV 10 mL (Adult) Valved circuits: ±10 mL or

+ Alarm: 5 mL (Paed) 10%, whichever is greater
Adult: 100 to 2500 mL
Paed: 50 to 300 mLa
Apnoea flow shape Constant N/A
Apnoea PIF When Volume Breath is set to 1 L/min N/A

PIF.
If Apnoea Response is (A)CV
+ Alarm:
Adult: 10 to 120 L/min
Paed: 5 to 60 L/min
Apnoea P control When Apnoea Response is 0.2 cm H2O ±(0.5 cm H2O + 5% of

P(A)CV + Alarm: target)
2 to 50 cm H2O
Manual Breath Magnitude 100 to 250% 10% N/A
Sigh Interval 3 to 60 min 1 min N/A
Sigh Magnitude 120 to 250% 10% N/A
a. The International ventilator standard indicates that Paediatric patient type is intended to be used for a patient receiving less
than 300 mL, however Astral permits adjustment of ’Vt’ setting parameter up to 500 mL for cases where ’Vt’ is set such
that it compensates for leak in the breathing circuit
Notes: All flow and volumes are measured at BTPS conditions.

To achieve specified accuracies, a successful Learn Circuit must be performed prior to measurement
testing.
Delivered pressure is regulated at the patient port.

Appendix A: Resmed forms
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

Astral two year maintenance form
Product type: Product code:
Serial number: Software version:
Cleaning the device: Pass  Fail  Maximum pressure test: Pass  Fail 
Visual inspection: Pass  Fail  LED test: Pass  Fail 
External battery test: Pass  Fail  Keypad test: Pass  Fail 
ResBus interface test: Pass  Fail  Internal battery test: Pass  Fail 
Set time and date: Pass  Fail 

Super capacitor test: Pass  Fail 
Record device settings: Pass  Fail 

Current consumption Pass  Fail 
test:
Determine ventilation hours: hours Learn circuit: Pass  Fail 

PEEP hours check: hours Finalise manual check Pass  Fail 
results:
Learn circuit: Pass  Fail  Reload device settings: Pass  Fail 
Confirm screw torque: N/A  Pass  Fail 
Parts replaced
Heated flex test: N/A  Pass  Fail 
Oxygen sensor  N/A 
PEEP blower test: Pass  Fail  Serial number:
Internal battery 
Pressure calibration test: Pass  Fail  Air inlet filter 
Quick flow check: Pass  Fail  Expiratory adapter membrane 
Blower test Pass  Fail  Pressure sensor filter 
Outlet pressure model test: Pass  Fail  Expiratory adapter (Single limb valve)  N/A 
Alarm test: Pass  Fail  Expiratory valve (Double limb adapter)  N/A 
Any further servicing done on the device?

(Please include details regarding any other parts replaced and their replacement serial numbers where appropriate)
Service reference number Technician name Signature Date
Appendix A: Resmed forms 121

35,000 hour preventative maintenance form
Product type: Product code:
Serial number: Software version:
Cleaning the device: Pass  Fail  Alarm test: Pass  Fail 
Internal inspection and dusting: Pass  Fail  Max. pressure test: Pass  Fail 
Visual inspection: Pass  Fail  Low flow O2 port test: Pass  Fail 
External battery test: Pass  Fail  LED test: Pass  Fail 

ResBus interface test: Pass  Fail  Internal battery test: Pass  Fail 
Set time and date: Pass  Fail  Super capacitor test: Pass  Fail 
Record device settings: Pass  Fail  Current consumption test: Pass  Fail 
hours
Determine ventilation hours: Learn circuit: Pass  Fail 
hours
hours
PEEP hours check: Electrical safety test: Pass  Fail 
Learn circuit: Pass  Fail 
hours Finalise manual checks: Pass  Fail 
Temperature sensor test: Pass  Fail  Reload device settings: Pass  Fail 
Heated flex test: N/A  Pass  Fail 
Parts replaced
Final assembly leak test: Pass  Fail 
Oxygen sensor  N/A 
Pressure calibration: Pass  Fail  Serial number:
Internal battery 
Outlet pressure model: Pass  Fail 
Serial number:
Pneumatic block 
NRV check: Pass  Fail 
Cooling fan 
Safety valve test: Pass  Fail 
Air inlet filter 
PEEP blower test: Pass  Fail 
Expiratory adapter 
Pressure calibration test: Pass  Fail  membrane
Quick flow check: Pass  Fail  Pressure sensor filter 

Blower test: Pass  Fail  Expiratory adapter  N/A 
(Single limb valve)
Outlet pressure model test: Pass  Fail 
Expiratory valve  N/A 
Cooling fan test: Pass  Fail  (Double limb adapter)
Any further servicing done on the device?

(Please include details regarding any other parts replaced and their replacement serial numbers where appropriate)
Technician name Signature Date

Service reference number

Appendix B: Pneumatic block components
Caution Only service technicians with Level 3 training are to replace components within the
pneumatic block.
!
Equipment required
• Adjustable or pre-setable Torque screwdriver (such as the Lindstrom PS501-2 Pre Set
Precision Torque Screwdrivers - 7-70 cNm[Ncm], or the Stahlwille 760/7.5 Torsiometer
Torque Screwdriver - 15-75 cNm)
• Screwdriver bit, Tx8
• Screwdriver bit, Tx10
Note: When replacing the sensor PCB, PEEP turbine or volute assembly ensure you record the
serial number of the replacement spare part in your service reporting/recording system.
Opening the pneumatic block

1 With the pneumatic block removed from the chassis, remove outlet tube from the pneumatic
block assembly. If also attached, remove the inlet assembly.
Outlet tube
Inlet assembly
2 Turn the pneumatic block over and remove the three screws (Z2054 [Tx10] - part of kit
#19640) from the top lid.
3 Remove the top lid (#19638) from the assembly.

Note: The top lid can be replaced if required.
Appendix B: Pneumatic block components 123

Pneumatic block sensor PCB
Spare part: Pneumatic block sensor PCB - 19637
Note: When installing a new sensor PCB in the device ensure you record the serial number of
the new sensor PCB in the device service record.
1 With the top lid removed the pneumatic block sensor PCB is visible.
2 Remove the four screws (Z2039 [Tx8] - part of kit #19640) from the PCB using a Tx8
screwdriver bit.
3 Disconnect the blue and yellow cables from the top of the sensor PCB.
4 Gently lift up the PCB to expose the cables connected underneath.
PEEP turbine cable
Yellow electrovalve cable
5 Disconnect the PEEP turbine cable and the yellow electrovalve cable from the PCB.

6 While holding the PCB gently pull up on the cable harnesses to pull the grommet free of the
chassis.
Grommet
Note: With the sensor PCB removed the grommet (part of kit #19626) can be replaced if
required.
7 Remove the two cable harnesses (with grommet) from the sensor PCB.
Note: At this point cable harness 1 (10 pin PAFS cable - part #19635) and cable harness 2 (8
pin VAMPS cable - part #19636) can be replaced.
8 Take the new sensor PCB and connect the cable harnesses (with grommet).
9 Connect the PEEP turbine cable and the yellow electrovalve cable to the PCB base.
Note: Do not bend the cable headers when connecting the cables to the PCB.
10 Carefully push the sensor PCB into place on the assembly, ensuring the pressure and flow
sensors (on the underside of the PCB) engage with the seal volute sensor.
11 Slot the grommet into place in the pneumatic block chassis.
12 Tuck the PEEP turbine cable and the yellow electrovalve cable next to the silicone tubing.
13 Confirm the silicone is sitting correctly under the PCB and that no wires are obstructing the
screw boss.
Cables tucked
next to tubing
Screw boss

14 Using a Tx8 bit refit the four screws (Z2039) to the sensor PCB in the following order:
2
4
15 Reconnect the blue and yellow cables to the top of the sensor PCB. Push the blue and yellow
cables away from the screw boss, towards the PCB, to avoid pinching the cables when the
top case in installed.

PEEP control tube
Spare part: part of Pneumatic block silicone kit - 19626
With the sensor PCB removed the PEEP control tube can be replaced.
1 Lift up the blower cable and pull the PEEP control tube away from the blower.
2 Pull the PEEP control tube off the pressure port.
3 Take the new PEEP control tube and insert it onto the pressure port.
4 Lift up the blower cable. Wind the tube around the blower, ensuring it sits behind the clip
next to the blower.
5 Ensure the tubing sits in the groove circled below, with the elbow outside of the pneumatic
block box.
Blower cable
Clip
Tube attached to
pressure port

PEEP turbine
Spare part: PEEP assembly kit - 19652
Note: When installing a new PEEP turbine in the device ensure you record the serial number of
the new PEEP blower in the device service record.
1 With the sensor PCB removed the PEEP assembly can be accessed.
2 To pull the PEEP assembly away from the pneumatic block, pull up on the PEEP inlet/EV
moulded tube and the volute sensor seal.
PEEP inlet/EV moulded tube
Volute sensor seal
3 Take the new PEEP assembly and slot it into the volute assembly, as shown below:

4 Push the PEEP inlet/EV moulded tube onto the electrovalve with the blue wire and the
pressure port beside it.
Pressure port
Moulded tube on electrovalve

with blue wire
5 Push the volute sensor seal onto the five areas on the volute assembly shown below:

NRV assembly
Spare part: NRV assembly - 19632
1 Turn the pneumatic block over and remove the five screws (Z2054 [Tx10] - part of kit
#19640) from the bottom lid of the Astral housing and remove the lid from the assembly.
2 Disconnect the moulded NRV inlet elbow from the NRV assembly.
Moulded NRV inlet elbow
Note: At this point the moulded NRV inlet elbow (part of kit #19626) can be replaced if
required.
3 Rotate the NRV anti-clockwise to unlock it from the volute.
Note: The force to unlock the NRV is quite high until the clips are disengaged.

4 Fit the new NRV assembly into the volute base. The port of the NRV should be aligned with
the raised section in the volute.
5 Rotate the assembly clockwise until it clicks into place.
6 The pressure port on the NRV should be aligned with the moulded NRV inlet elbow.
7 Fit the moulded NRV inlet elbow to the NRV assembly.
8 Using a Tx10 bit refit the five screws in the following order:
4
3
1 5
Note: The bottom lid (#19639) can be replaced if required.

Volute assembly
Spare part: Volute assembly - 19627
(including PEEP control tube and main blower heat
sink)
Note: When installing a new volute assembly in the device ensure you record the serial
number of the new blower in the device service record.
1 With the sensor PCB and the PEEP turbine removed from the pneumatic block the volute
assembly can be replaced.
2 Turn the pneumatic block over and remove the five screws (Z2054 [Tx10] - part of kit
#19640) from the bottom lid of the Astral housing and remove the lid from the assembly.
3 Disconnect the moulded NRV inlet elbow from the NRV assembly.
Moulded NRV inlet elbow
4 Turn the unit back over.

5 Disconnect the PEEP control tube from the pressure port and pull it away from the retaining
clip.
EV-NRV tube
Main blower heat sink
PEEP control tube
6 Remove the EV-NRV tube from the electrovalve with the yellow cable.
7 Remove the main blower heat sink from the top of the blower.
8 Remove the integrated seal from the air outlet and the port at the rear.
9 Remove the volute assembly from the unit.

10 Remove the EV-NRV tube from the volute assembly.
Note: At this point the moulded EV-NRV tube (part of kit #19626) can be replaced if required.

11 The new volute will be supplied with the PEEP control tube as shown below. Disconnect the
PEEP control tube from the electrovalve.
12 Insert the new volute assembly into the pneumatic box block, taking care to feed through the
moulded NRV inlet elbow through the hole in the housing.
13 Fit the integrated seal to the air outlet and the port at the rear, and ensure the seal is sitting
correctly on the aluminium housing.
14 Connect the EV-NRV tube to the electrovalve with the yellow cable.

15 Tuck the tubing behind the retaining clip. Guide the PEEP tube around the blower and into the
channel shown below:
Retaining clip
16 Turn the assembly over and confirm the volute is sitting on the groove of the seal (as
highlighted below):
17 Connect the moulded NRV elbow to the NRV assembly.

4
3
1 5
Note: The bottom lid (#19639) can be replaced if required.

Aluminium housing
Spare parts: Aluminium housing - 19624
(includes I/E and FC electro valve, and pressure relief
electro valve)
1 With the volute assembly removed the aluminium housing can be replaced.
2 Remove the integrated seal from the aluminium housing.
Note: At this point the integrated seal (part of kit #19626) can be replaced if required.
3 Take the new aluminium housing and insert the integrated seal. When installing the seal
ensure it is seated correctly in the pneumatic box block.
 

Closing the pneumatic block
1 If not refitted previously, fit the bottom lid to the pneumatic box block.
4
3
1 5
Note: The bottom lid (#19639) can be replaced if required. If replacing the bottom lid the
serial number of the pneumatic block needs to be retained. For instructions regarding
installation of the serial number decal onto a new bottom lid refer to tech note
1063224.
3 Confirm that all cables and tubes are in the correct place and will not be crushed by the top
lid (particularly the PEEP control tube and PEEP turbine cable).
PEEP control tube
PEEP turbine cable
4 Place the pneumatic block top lid on the assembly.

5 Using a Tx10 bit fix the screws into the lid in the following order:
2
3
6 Refit the outlet tube and inlet assembly to the pneumatic block prior to installing the
pneumatic block in the unit. Steps for refitting both the inlet assembly and outlet tube can be
found on page 71.

Pneumatic block spare part list
Refer to the Technical Support website for the latest Astral spare parts available.
The following spare parts are available for the pneumatic block.
Part number Part description (in alphabetical order)

19624 Aluminium housing
19639 Bottom lid
19632 NRV assembly
19652 PEEP assembly kit
19637 Pneumatic block sensor PCB
19626 Pneumatic block silicone kit
19640 Screw kit, Pneumatic block (8 x Z2054, 4 x Z2039)
19638 Top lid
19627 Volute assembly
Note: The screws used in the pneumatic block are not available as separate spare parts - they
are only available in screw kit #19640.

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278065/3 2014-12

Respiratory care solutions Respiratory care solutions

For patent information see www.resmed.com/ip

© 2014 ResMed Ltd.

1 General instructions .............................................................................................10

2 Function and operation .........................................................................................12

4 Astral™ series service manual

4 Preventative maintenance ....................................................................................54

5 Corrective maintenance ........................................................................................57

6 Troubleshooting guide ..........................................................................................99

7 Technical specifications .....................................................................................113

Appendix A: Resmed forms ..........................................................................................120

Appendix B: Pneumatic block components .................................................................123

6 Astral™ series service manual

Intended users of this manual

Recommended maintenance schedule

Alarms (Advanced & Troubleshooting)

Principle of Operations & Hardware

Incoming inspection/Full performance

8 Astral™ series service manual

Service testing and calibration

Corrective maintenance outside of

! Warning alerts you to possible injury.

Note is an informative or helpful note.

Storage and transport

10 Astral™ series service manual

Electrostatic discharge precautions

Power source indicators

Alarm mute/reset button

Remote control/ SpO2 sensor

12 Astral™ series service manual

Motor capacitor O2 sensor

Low pressure tubing

Buzzer housing assembly

O2 low pressure port Expiratory valve

Fan mount assembly

Screw - bottom case O2

Battery pack assembly Screw - O2 sensor

Plug outlet Inlet filter

O2 sensor & Screw - pneumatic

Screw - battery cover

14 Astral™ series service manual

Feature Astral 100 Astral 150

Single limb with expiratory valve

Single limb intentional leak

Leak therapy modes

Valve therapy modes

Sigh breath (pre-programmed)

SpO2 monitoring Optional Optional

FiO2 monitoring Optional

O2 Oxygen inlet Low flow Low flow

2 Function and operation 15

O2 input port Filter

Figure 1 – Astral system block diagram

16 Astral™ series service manual

Hardware Alarm Controller

2 Function and operation 17

Pneumatic block exploded view

18 Astral™ series service manual

Sensor Location Range

Inspiratory flow sensor Pneumatic block -70 to 200 L/min

Outlet pressure sensor Pneumatic block -10 to 120hPa

Proximal pressure sensor Main PCB -10 to 120hPa

Trigger pressure sensor Main PCB -2 to 40hPa