I also support you in finding a solution.
From what you say it looks like he wants to find a solution too, so I would add my voice to getting a decent data capable machine with as many of the extra features as you can i.e.
Data capable, Auto pressure adjusting, Exhale pressure relief, Humidifier, heated tube, Start up pressure ramp to name the ones I most enjoy.
After you get a data capable machine , get the Sleepyhead software, read the data and own the treatment. we can help you understand what it is telling you and as indicated already. With this data you can quickly start to understand what is causing the issues.
Also- do not accept the first mask if he cannot keep it on. Sounds like he has real mask issues and they are real, not "just in your head" or "needing some time to settle down". If a mask is not working for you, you know almost from the first night though it is usually fair to give it a week - there are plenty of masks to choose from.
When he is at the next sleep study get him to try several different masks through the night - they should have a range of the different types to try. I refused the nasal pillows at my first study as the thought of the prongs in my nostrils turned me off - but now that is my preferred mask. Get him to give all the mask styles a go that could possibly work for him (Caveat - if he is a mouth breather then any nasal type will be out etc)
I personally have 4 different masks I use for different reasons (when I have allergies, when I have a cold etc) which I know will work for those times. It is trial and error from what I can figure out to find a mask that will work. Everyone is different. If your insurance will not spring for it, have a look at our suppliers list ( http://www.apneaboard.com/forums/Thread-CPAP-Supplier-List
- I have used 1 and 10 and found them good - others use other suppliers and are happy as well) and try one or 2 - Search this forum as there are extensive threads on the various more popular masks to give a clue before you part with the coin.