Fresenius 2008, 2008H Troubleshooting guide
FRESENIUS 2008H
HEMODIALYSIS SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 507082 Rev. B
FRESENIUS USA, INC.
2637 Shadelands Drive, Walnut Creek, CA 94598
800-227-2572 or 925-295-0200
TECHNICAL SUPPORT FOR HEMODIALYSIS SYSTEMS
Press 5 when the automated system answers.
AUTOMATED PHONE SYSTEM MENU
Press To Reach
1 An individual 4-digit extension
5 Technical Support
6 Spare Parts Ordering
0 Operator
USEFUL EXTENSION AND FAX NUMBERS
Technical Support
Receptionist X7003 FAX 925-988-1969
Technical Training
Receptionist X7264 FAX 925-988-1969
Spare Parts
Receptionist X7004 FAX 925-988-1969
REGIONAL EQUIPMENT SPECIALIST: __________________________________
FRESENIUS 2008H
HEMODIALYSIS SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 507082 Rev B
Copyright 1998, 1999 Fresenius USA, Inc.
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
TABLE OF CONTENTS
USING THE TROUBLESHOOTING GUIDE........................................................................................................1
THE 'ORDER' OF TROUBLESHOOTING ...........................................................................................................2
INITIAL CHECKS .................................................................................................................................................3
SAFETY CHECKS ...............................................................................................................................................4
EQUIPMENT NEEDED ........................................................................................................................................4
SECTION 1 - FLOW ERRORS IN DIALYZE MODE............................................................................................6
SECTION 2 - NO WATER..................................................................................................................................23
SECTION 3 - FLOW ERRORS IN CLEANING PROGRAMS ............................................................................25
SECTION 4 - TEMPERATURE PROBLEMS.....................................................................................................33
SECTION 5 - CONDUCTIVITY PROBLEMS.....................................................................................................46
SECTION 6 - CONCENTRATE PUMP 'END OF STROKE' (EOS) ERRORS..................................................52
SECTION 7 - COND OFFSET REF OR COND OFFSET FAILURES ...............................................................54
SECTION 8 - FILLING PROGRAM PROBLEMS...............................................................................................55
SECTION 9 - TMP PROBLEMS ........................................................................................................................57
SECTION 10 - PRESSURE HOLDING TESTS FAILING..................................................................................60
SECTION 11 - NEGATIVE PRESSURE TESTS ...............................................................................................62
SECTION 12 - INDUCED POSITIVE PRESSURE TESTS ...............................................................................65
SECTION 13 - DEAERATION PROBLEMS ......................................................................................................66
SECTION 14 - UF PUMP PROBLEMS..............................................................................................................67
SECTION 15 - BLOOD LEAK PROBLEMS .......................................................................................................69
SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE ........................................................................72
SECTION 17 - CHECKING THE SENSOR BOARD CABLE.............................................................................74
SECTION 18 - MANUAL BALANCING CHAMBER VALVE LEAK TESTS .......................................................76
SECTION 19 - TESTING FOR A LEAKING BALANCING CHAMBER DIAPHRAGM.......................................79
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
PREFACE
This troubleshooting guide has been developed with the help of many customers and Fresenius personnel. It
is a combination of known techniques and excellent feedback from people that actually work with the
equipment.
The intent of the 2008H Troubleshooting Guide is to provide you with an aid in the diagnosis of common
problems. Since this document is only a guide and may not provide the most up-to-date solutions for every
conceivable problem, we recommend contacting our Technical Services Support line should additional
assistance be required.
WARNING: Before using this guide you must read pages 1 through 4 which outline Using the
Troubleshooting Guide, Order of Troubleshooting, Initial Checks, Safety Checks and Equipment
Needed. Never troubleshoot with a patient connected to the machine. If possible, remove the
machine from the treatment area when it is being serviced. Always tag the machine to ensure it is not
accidentally returned to service before the service work is completed.
Always fully test a machine (in accordance to the Technicians Manual P/N 490004 or Operators
Manual P/N 490005) when maintenance and/or repairs have been completed. This is to include
confirmation of conductivity, pH and Temperature with a calibrated device.
Should additional technical assistance be needed, technical support is provided 24 hours a day, seven days a
week at our toll free number (800) 227-2572.
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
USING THE TROUBLESHOOTING GUIDE
1. The equipment technician should have knowledge of clinical Hemodialysis and operational theory of the
Fresenius system. A minimum of Level I training is necessary! Incorrect troubleshooting can result in
injury or death to the troubleshooter and patient.
2. The equipment technician should have knowledge of the test equipment, especially the multimeter. Refer
to the meter's operational manual as necessary.
3. The troubleshooting procedures are written in 'flow chart' style that systematically eliminates possible
areas of failure. Read each procedure carefully before moving on. You will be prompted to the next
procedure or to possible solutions. Pay careful attention to CAUTIONS and NOTES.
4. Many of the troubleshooting procedures are performed at the DISTRIBUTION BOARD.
a) Inside the distribution board are several numerically identified 'male' connector positions. Male pins are
arranged vertically and are numbered 1 through 5 (from top to bottom).
b) Each hydraulic component has a 5-pin female connector dedicated to numeric distribution board
positions as specified in the HYDRAULIC FLOW DIAGRAM. For example, flow pump #21 plugs into
position [P21, FLOW-P]. Valve 43 plugs into position [V43], etc. Except for the heater, acid pump, and
bicarb pump, you can plug and unplug connectors into the distribution board with the power on.
NOTE: There are several unused positions including; x4 [PH-PR] (pH probe, optional), x13 [COND-POS]
(on-line clearance, optional), x44 [NTC-POS] (on-line clearance, optional), V14, V15, x19 [AIR-SEP], V23
and x40 [V42]. Be CAREFUL not to accidentally plug a connector into one of these.
FEMALE CONNECTOR
DISTRIBUTION BOARD
PIN 1
PIN 5
5. If unsuccessful please call Technical Services at 1-800- 227- 2572.
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 1
THE 'ORDER' OF TROUBLESHOOTING
Troubleshoot in the following order:
1. No Water
2. Flow Errors
3. Temperature
4. Conductivity
5. TMP
6. Blood Leak
7. Pressure Holding Test Failures
NOTE: Before beginning we recommend that you perform INITIAL CHECKS (page 3). This is especially
important if someone has been working on the machine before you!
1. NO WATER (debug screen 5, !WATER = "1" either constantly or intermittently). Without water hydraulic
operation is not possible.
2. FLOW ERRORS (debug screen 5, FLWERR = "1" either constantly or intermittently), will effect
Temperature, Conductivity, TMP and Blood Leak. If a FLOW ERROR is present troubleshoot it before
being concerned with any other alarms.
3. FLOW ERRORS turn the heater off and result in TEMPERATURE problems. Before troubleshooting any
TEMPERATURE problem assure that the machine is free of flow errors (debug screen 5, FLWERR = "0"
constantly).
4. CONDUCTIVITY is temperature compensated. Without stable temperature CONDUCTIVITY will not be
stable. Before troubleshooting CONDUCTIVITY problems, assure that TEMPERATURE is normal and
remaining constant from the main dialysis screen.
5. Before troubleshooting TMP problems assure that there are no flow errors present (debug screen 5,
FLWERR = "0" constantly). Assure also that TEMPERATURE and CONDUCTIVITY are normal and
remaining constant from the main dialysis screen.
6. Before troubleshooting PRESSURE HOLDING TEST FAILURES assure that there are no flow errors
present (debug screen 5, FLWERR = "0" constantly). Assure also that TEMPERATURE and
CONDUCTIVITY are normal and remaining constant from the main dialysis screen.
7. Before troubleshooting BLOOD LEAK problems assure that there are no flow errors present (debug
screen 5, FLWERR = "0" constantly). Assure also that TEMPERATURE and CONDUCTIVITY are normal
and remaining constant from the main dialysis screen.
FUNCTIONAL BOARD SOFTWARE DISCLAIMER
Functional board software may effect the TROUBLESHOOTING GUIDE. With the exception of
CONDUCTIVITY PROBLEMS this guide is compatible with functional software up to 8.02
Page 2
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
INITIAL CHECKS
1. Turn the power OFF and slide the card cage forward. Check that all five boards are pushed down into the
motherboard and are 'locked' in.
2. Check that the sensor and actuator cables are plugged tightly into *both ends. Check also for bare wires
or other damage along their entire length.
* Both cables run into the distribution board and terminate at the SENSORS and ACTUATOR connectors
respectively (see DISTRIBUTION BOARD diagram below).
3. Check that the power logic board cable is plugged tightly into the power logic board.
4. Check that the PGND (power ground) wire is plugged into the distribution board (see DISTRIBUTION
BOARD diagram below).
5. Close the card cage. IMPORTANT NOTE! Do NOT troubleshoot with the card cage open! Turn the
machine ON and return to the operating mode (DIALYSIS, RINSE, etc) where the problem is occurring.
6. Allow 10 minutes for stabilization.
ACTUATOR CABLE SENSOR CABLE
MOTHER BOARD
POWER LOGIC
CABLE
CARD CAGE, TOP VIEW
SENSORS CONNECTOR ACTUATOR CONNECTOR PGND WIRE
DISTRIBUTION BOARD
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 3
SAFETY CHECKS
Before placing the machine back into service:
1. Remove all test equipment (jumpers, 'dummy' connectors, etc) from the distribution board and make sure
that all hydraulic components are plugged in.
2. If you have been troubleshooting TEMPERATURE problems turn the heater breaker switch off and
assure that the TEMP display falls to 33°C and that the bypass condition exists.
3. If you have been troubleshooting CONDUCTIVITY problems drop the acid and bicarb lines into water and
assure that the COND display falls to 10.0 and that the bypass condition exists.
4. Check that AUDIO ALARMS are working properly.
5. Perform alarm and pressure holding tests.
EQUIPMENT NEEDED
- Fresenius gauge kit (part # 150034)
- Fresenius test (temperature) 'dummy connectors' (part # 190060)
- Graduated cylinder (1000 ml)
- Buret 0 - 25cc (part # 290104)
- 60 ml syringe
-Flashlight
- Jumper wire
- Independently calibrated temperature, conductivity, and pressure meters
- Voltmeter (recommended Fluke "70" series)
- Clip-on meter leads (recommended Fluke TL24 Flexible test leads with AC80 pin grabbers)
* Non-standard meter probes (recommended Fluke TP80 probes)
* Non-standard meter probes assure safe voltage measurement in 'tight' areas when shorting other pins or
connectors is a concern. Fluke TP80 meter probes include a slip-on cap that fits over the lead to 'isolate'
the measuring point and prevent shorting.
FLUKE TP80 METER PROBES (WITH SLIP ON CAP)
Page 4
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
UPPER POWER
SUPPLY
SHUNT DOOR
HANSEN
CONNECTORS
EXTERNAL FLOW
INDICATOR #75
DIALYSATE LINE
FILTER #73
UF PUMP #22
BALANCING
CHAMBER #68
HEATER BREAKER
SWITCH
ON/OFF SWITCH
DISTRIBUTION BOARD
(INSIDE COVER)
HEATER
CONNECTOR
INPUT WATER
FILTER
FILTER
VENT LINE
DRAIN LINE
CONDUCTIVITY CELL #7
VALVE #25
Note: On Later version,
Valve 25 may be on the
front side of hydraulics
DIALYSATE PRESSURE
TRANSDUCER #9
REGULATOR #78
FLOW PUMP #21
NTC #2
NTC #3
CFS TRANSDUCER #10
ORIFICE #48
LOADING PRESSURE
REGULATOR #65
VALVE 39
DEAERATION PUMP #29
DIAGRAM A REAR VIEW
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 5
SECTION 1 - FLOW ERRORS IN DIALYZE MODE
F- 1.0.0 CHECK LOADING PRESSURE
a) Assure that the vent tube is not 'pinched' (see diagram A, page 5) .
b) Insert a *loading pressure gauge TIGHTLY into the ACETATE/ACID port. Peak pressure?
1) 0 to 10 psi Call up debug screen 5. If !WATER = "1" proceed to NO WATER (page 23)
otherwise proceed to F- 2.0.0
2) 17 to 25 psi Allow two minutes (if necessary) for the symptoms to appear. See F- 3.0.0
3) Greater than Attempt to calibrate loading pressure to +19 psi peak per CALIBRATION
25 psi PROCEDURES, section 2.13. If not successful a bad loading pressure
regulator #65 is indicated (see diagram A, page 5).
* If the gauge does not read 0 psi at atmosphere compensate for this during loading pressure checks.
F- 2.0.0 CHECK FOR A RUNNING DEAERATION PUMP
Make sure that flow is on (FLOW ON/OFF LED is off). Depending upon the pump:
1. Motors with brushes The deaeration pump's motor shaft can be accessed from the front side of the
machine (see FRONT VIEW diagram below). If the shaft is *rotating the pump is running. Is the deaeration
pump running?
Yes See F- 14.0.0 (page 12).
No See F- 18.0.0 (page 16) to check the DEAERATION PUMP.
* Rotation is CCW (from the front of the machine). If rotating CW the motor is running backwards
2. Motors without brushes Remove the CLEAR tubing from the deaeration pump's input nozzle (see REAR
VIEW diagram below). If the pump is running you will hear 'gurgling'. Is the deaeration pump running?
Yes See F- 14.0.0 (page 12).
No See F- 18.0.0 (page 16) to check the DEAERATION PUMP.
DEAERATION
MOTOR SHAFT
(WITH BRUSHES)
DEAERATION
INPUT NOZZLE
FRONT VIEW REAR VIEW
Page 6
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
F- 3.0.0 CHECK DEBUG ERRORS
CAUTION Do NOT attempt to reset other alarms during this check!
Call up debug screen 5 and watch !WATER and FLWERR for two minutes. Proceed accordingly:
1) !WATER and FLWERR = "0" constantly. See F- 3.0.1
2) !WATER = "1" constantly or intermittently. See NO WATER (page 23).
3) FLWERR = "1" constantly or intermittently. See F- 4.0.0
F- 3.0.1 FLOW ERROR NOT PRESENT
- If COND is CONSTANTLY high. Watch FLWERR for several minutes. If it goes to "1" see F- 4.0.0
- If COND is drifting from normal to high. Wait until the BYPASS LED is off and watch FLWERR for 30
seconds. If it goes to "1" see F- 6.0.0.
- If conductivity remains normal. If FLWERR remains " 0" constantly a flow error is not indicated.
- If conductivity remains low and FLWERR remains "0" a flow error is NOT present.
F- 4.0.0 CHECK FOR FILLING PROGRAM
Call up debug screen 7. Is FILACT "1" or "0"?
"1" See F- 4.0.1
"0" See F- 5.0.0
F- 4.0.1 FILLING PROGRAM PRESENT
a) At the top of chamber #69 is a two-pin female connector that plugs onto two male probes (see diagram,
below). Unplug both sides of the connector and connect the female ends together. FILACT should now = 0.
b) Return to debug screen 5 and watch for 3 minutes. Does FLWERR go to "0" and REMAIN?
Yes See F- 4.0.2.
No Plug the female connector back onto the probes and see F- 5.0.0.
TWO-PIN FEMALE
CONNECTOR
MALE PROBES
CHAMBER # 69
FLOW PUMP
MOTOR SHAFT
FRONT VIEW
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 7
F- 4.0.2 CHECK FLOW PUMP
From the front side of the machine you can see the flow pump's motor shaft (see FRONT VIEW diagram,
previous page). Turn the flow off. Is the shaft rotating?
Yes Replace the actuator board.
No See F- 16.0.0 (page 14).
F- 5.0.0 CHECK FOR A *VALVE ERROR
Proceed with this step ONLY if FILACT and !WATER are both = "0" continuously.
From DIALYZE MODE return to debug screen 5. Watch VLVERR VERY carefully for two full minutes. If a
valve error is present VLVERR 'blinks' momentarily to "1" (about every 60 seconds). If a valve error is present
VLVERR goes to "1" for ONLY a second. If you look away you may miss it! Does VLVERR ever 'blink' "1"?
Yes See F- 5.0.1
No See F- 6.0.0
* VALVE ERRORS indicate either high or low current in a particular 'valve circuit'.
F- 5.0.1 LOCATING THE VALVE ERROR
Listen carefully in the area of the hydraulics (you may need to remove them from the machine). You should
be able to hear a continuous, dull, 'thudding'. Proceed step-by-step and follow the given instructions.
1) From DIALYZE MODE open the shunt door. If the 'thudding' stops a VALVE 25 is causing the error. Note
this (valve 25 is the problem) and see TROUBLESHOOTING VALVE ERRORS (page 30). If the 'thudding'
continues proceed to step 2.
2) Turn the flow off. If the 'thudding' stops a BALANCING CHAMBER VALVE is causing the error. Note this
(balancing chamber valve is the problem) and see TROUBLESHOOTING VALVE ERRORS (page 30). If
the 'thudding' continues proceed to step 3.
3) The 'thudding' continues with the shunt door open and flow off. VALVE 30 or 26 is causing the error. Note
this (valve 30 or 26 is the problem) and see TROUBLESHOOTING VALVE ERRORS (page 30).
Troubleshoot BOTH valves.
Page 8
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
F- 6.0.0 CHECK FLOW ERROR 'IN BYPASS'
Open the shunt door to cause bypass. Return to debug screen 5 and watch FLWERR for one full minute.
Does FLWERR go to "0" constantly or does it still = "1" (either constant or intermittent)?
"0" constantly See F- 6.0.1
Still = "1" Close the shunt door and see F- 7.0.0
F- 6.0.1 CHECK FLOW ERROR 'OUT OF BYPASS'
a) Leave the shunt door open and return to the main DIALYSIS screen.
b) Allow TEMP and COND to become normal.
c) Close the shunt door (bypass LED should turn off) and return to debug screen 5. Wait 30 seconds. Does
FLWERR = "1"?
Yes See F- 17.0.0 (page 15).
No A flow error is not indicated.
F- 7.0.0 CHECK FOR A RUNNING FLOW PUMP
CAUTION Do NOT attempt to reset other alarms during this check!
a) At this time NOTE if FLWERR = "1" constantly or intermittently for future use.
b) From the FRONT of the machine you can see the flow pump's motor shaft (see FRONT VIEW diagram
below). If the shaft *rotating?
Yes See F- 8.0.0
No See F- 18.0.0 (page 16) to check the FLOW PUMP.
* Rotation is CCW (from the front of the machine). If rotating CW the motor is running backwards
FLOW PUMP
MOTOR SHAFT
FLOW PUMP
OUTPUT NOZZLE
FRONT VIEW REAR VIEW
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 9
F- 8.0.0 CHECK FLOW PUMP CONTROL
Turn the flow off and check the flow pump's motor shaft again. Still rotating?
Yes Replace the actuator board (pump driver (IC18) possibly shorted).
No a) Turn the flow on.
b) FLWERR may = "0" for a few seconds after turning flow on. Ignore this! As noted
previously (step F- 7.0.0) was FLWERR = "1" constant or intermittent?
Constant See F- 10.0.0
Intermittent See F- 9.0.0
F- 9.0.0 CHECK FOR NO WATER
Turn the flow on and call up debug screen 5 and carefully watch !WATER for two minutes. Does !WATER go
to "1" at any time during this time interval?
Yes See NO WATER (page 23).
No See F- 9.0.1
F- 9.0.1 CHECK FLOW PUMP PRESSURE
a) Tee a pressure gauge between the flow pump's output nozzle and the WHITE tubing (see REAR VIEW
diagram, previous page).
b) Turn the flow on at a 500 flow rate. Does pressure peak to 14 psi or greater?
Yes See F- 13.0.0 (page 12)
No Three possibilities: 1) Bad actuator board; 2) Bad flow pump head; 3) Bad flow pump motor.
F- 10.0.0 CHECK DRAIN FLOW
a) Having a bucket handy and go to end of the drain line. Hold it UP, at a 45 degree angle, over the bucket.
CAUTION! Holding the drain line lower than 45 degrees makes this test invalid!
b) Watch for 20 seconds. Flow may be intermittent and this is normal. Is there any flow through the drain line?
Yes See F- 10.1.0
No See F- 11.0.0
Page 10
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
F- 10.1.0 DETERMINING DRAIN FLOW
Normal Fresenius drain output 'pulses' in 30 ml increments, stops completely, and then 'pulses' out again. Is
drain flow 'pulsing' or 'continuous' (never stops)?
Pulsing See F- 13.0.0 (next page).
Continuous Three possibilities: 1) Partial restriction to drain (check the drain line first for
restrictions); 2) Balancing chamber valve remaining open (run automated valve leak
test from SERVICE/DIAGNOSTICS); 3) Leaking balancing chamber diaphragm (see
TESTING FOR A LEAKING BALANCING CHAMBER DIAPHRAGM).
F- 11.0.0 CHECK FLOW TO (DRAIN) VALVE 30
CAUTION! During this procedure there will be spillage. Move the hydraulics away from the cabinet to prevent
spillage into the cabinet!
a) Turn the flow off and remove the INPUT tube from valve 30 (see TOP VIEW diagram below). Point it AWAY
from the hydraulics.
b) Turn the flow on. Is there good 'pulsing' flow here?
Yes Turn flow off and attach the tubing to valve 30. See F- 11.1.0
No See F- 12.0.0
VALVE 30INPUT TUBE
TOP VIEW
REAR OF MACHINE
F- 11.1.0 CHECK VALVE 30
a) Turn the flow on.
b) Remove the drain line from the back of the machine. Is there good 'pulsing' flow here?
Yes The drain line is restricted.
No A problem is indicated with VALVE 30 or the actuator board. NOTE this and see
TROUBLESHOOTING VALVES (page 29).
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 11
F- 12.0.0 CHECK FLOW TO FLOW PUMP
Proceed with this step if you are VERY sure that VLVERR (debug screen 5) is always "0".
Place the machine into RINSE and remove the CLEAR tube from the flow pump's INPUT nozzle (see diagram
below). Good flow here?
Yes A problem is indicated with VALVE 26 or the actuator board. NOTE this and see
TROUBLESHOOTING VALVES (page 29).
No Replace the actuator board. If the flow error continues there may be two bad valves
(remaining closed) on the balancing chamber.
DEAERATION PUMP
INPUT NOZZLE
FLOW PUMP
INPUT NOZZLE
REAR VIEW
F- 13.0.0 CHECK CFS SIGNAL
Making sure that flow is on call up debug screen 11 and watch ACFS (in vdc). SIX possibilities:
1) Constant flow error and ACFS remaining between 3 and 7. See F- 21.0.0 (page 20).
2) Constant flow error and ACFS remaining between 8 and 11. See F- 23.0.0 (page 22).
3) Constant flow error and ACFS remaining between 0 and 3. See F- 20.0.0 (page 18).
4) Intermittent flow error and ACFS remaining between 3 and 7. See F- 21.0.0 (page 20).
5) Intermittent HIGH FLOW error. Call up debug screen 10 and watch CFS for a couple of minutes. If CFS
intermittently 'bounces' to about 10 replace the CFS transducer (#10). If the problem continues check for a
bad connection at the sensor board cable on both sides (especially the distribution board side, unplug the
cable and check the male pins for corrosion ). There may also be an intermittent open in the sensor cable or
a problem with the sensor or actuator boards.
6) Intermittent flow error and ACFS 'bouncing' (about every 9 seconds) from between 0 and 3 to about 5. A
problem is indicated with a BALANCING CHAMBER VALVE. See F- 19.0.0 (page 16).
F- 14.0.0 LOW LOADING PRESSURE, DEAERATION PUMP RUNNING
NOTE: This procedure checks for water in the hydroblock and proper float functional.
a) Stop the deaeration pump by unplugging it from distribution board position P20, DEAR-P.
b) If you haven't done so remove the CLEAR (input) tube from the deaeration pump's nozzle (see REAR VIEW
diagram, above). Is there flow from the tube?
Page 12
Yes See F- 14.0.1
No See F- 15.0.0
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
F- 14.0.1 CHECK INCOMING WATER
Allow this flow to continue for about three minutes (you may need a bucket). You should hear water entering
the hydroblock in cycles as the float falls and rises. Does flow remain continuous?
Yes See F- 14.0.2
No See F- 15.0.0
F- 14.0.2 CHECK LOADING PRESSURE REGULATOR
a) Plug the deaeration pump back into the distribution board (P20, DEAR-P) and assure that it starts running
i.e. the motor shaft rotates. Allow one minute and check if loading pressure returns to normal (19 ± 1 psi). If
it does there may be an intermittent problem with the float. Continue to part b otherwise.
b) Tightly clamp the solid tubing between the loading pressure regulator and the hydroblock (see diagram
below). Is there a drastic increase of loading pressure?
Yes A problem is indicated with the loading pressure regulator.
No A problem is indicated with the deaeration pump head.
F- 15.0.0 CHECK HYDROBLOCK
a) Clamp the vent tube and remove the orifice from the hydroblock (see diagram below). Check if it is plugged.
If plugged this is the problem.
b) Re-install the orifice and REMOVE the clamp from the vent tube.
c) Turn the power off.
d) Loosen (but don't remove) the screws that mounts the float into the hydroblock (see diagram below).
CAUTION Don't pull on the float's wiring harness or you may break it! Carefully remove the float from the
hydroblock.
FLOAT (FULLY DOWN ON SHAFT)
HEATER
VENT TUBE
HYDROBLOCK
LOADING PRESSURE
REGULATOR
SOLID TUBING
(CLAMP HERE)
ORIFICE
e) Unplug the float from distribution board position FLOAT-SW. Check inside the distribution board for bent
broken or corroded male pins.
Fresenius 2008H Troubleshooting Guide
Page 13
P/N 507082 Rev. B
f) Very carefully open the cover on the female connector (see diagram below). Note that pins 2 and 5 are
(
)
missing. Clip meter leads onto pins 1 and 3 (pin 1 = top of the 100 ohm resistor, pin 3 = middle pin).
CAUTION! Be careful to clip onto the correct pins!
PIN 1 (TOP PIN)
100 OHM RESISTOR
PIN 2 (MISSING)
PIN 3 (MIDDLE PIN)
MISSING
PIN 5
FEMALE FLOAT DISTRIBUTION
BOARD CONNECTOR
g) With the float FULLY DOWN on the shaft you should read approximately 100Ω, FULLY UP an 'open' (OL).
Move the float FULLY UP and DOWN twenty times while watching the transition on the meter. It should go
from OL to 100Ω everytime! If the float checks out good see F- 15.0.1
F- 15.0.1 CHECK INCOMING WATER
a) Plug the float's connector back into the distribution board (position FLOAT-SW).
b) Hold the float in its FULLY UP position. Turn the power on and wait until the SELECT PROGRAM screen is
up.
c) Looking into the hydroblock's float cavity turn the power on. CAUTION Avoid overflow during this step!
Move the float to its FULLY DOWN position. Is the water level rising?
Yes See F- 15.0.2
No Two possibilities: 1) *Bad sensor board cable; 2) Bad actuator board.
* The sensor cable can be checked for continuity. Note that you are checking the FLOAT connection and see
CHECKING THE SENSOR BOARD CABLE (page 74).
F- 15.0.2 CLEARING AN AIR LOCK
a) Connect a 60 ml syringe to the clear INPUT tubing of the deaeration pump and draw on it. You may have to
pull five or six syringes full of air before water flows continuously by itself. If you are not able to make water
flow continuously it may be indicative of a 'stripped' orifice.
b) Re-connect the INPUT tubing to the deaeration pump and plug the deaeration pump back into the
distribution board (P20, DEAR-P). Assure that it starts running i.e. the motor shaft rotates. Allow a few
minutes for loading pressure to return to normal. NOTE: Recurring air locks may be indicative of a bad
deaeration pump head, motor or a 'stripped' orifice.
F- 16.0.0 TROUBLESHOOTING 'FILLING PROGRAM' FLOW ERRORS
During FILLING PROGRAMS the dialysate pressure transducer #9 determines the presence of flow.
a) Plug the connector back onto the probes.
b) Remove the dialysate lines from the shunt door and drop them into a bucket of water on the floor.
c) IMPORTANT Close the shunt door.
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Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
d) Call up debug screen 9 and wait 30 seconds. Is PDIA between 4.0 and 6.0 vdc?
Yes See F- 16.0.1
No See TM- 2.0.1, TMP PROBLEMS (page 58).
F- 16.0.1 CHECK VALVE 43
CAUTION! During this procedure there will be spillage. Move the hydraulics away from the cabinet to prevent
damage.
a) Place the machine into RINSE.
b) Clamp and remove the tubing from the valve 43's output nozzle (see diagram below).
VALVE 43
OUTPUT NOZZLE
HYDRAULICS, TOP VIEW
c) Call up debug screen 20. When V43= 1 the actuator board is sending a signal to open valve 43. This occurs
every two minutes for several seconds. When V43= 1 is there flow from valve 43's nozzle?
Yes Flow errors sometimes occur if a FILLING PROGRAM is prolonged.
No A problem is indicated with VALVE 43 or the actuator board. NOTE this and see
CHECKING VALVES (page 28).
F- 17.0.0 TROUBLESHOOTING FLOW ERRORS 'OUT OF BYPASS'
A problem is indicated in the 'out of bypass' circuit which includes the external dialysate filter (73), valves 24
and 25. CAUTION! There will be spillage during this procedure. Make sure the card cage is closed!.
a) Place the machine into RINSE.
b) Open the shunt door and remove the RED dialysate line. Is there flow from the shunt door?
Yes a) Stop RINSE by pulling the red concentrate connector from its port
b) Check the external dialysate line filter #73 (see diagram A, page 5). If the filter is clean a
problem is indicated with VALVE 25 or the actuator board. NOTE this and see
TROUBLESHOOTING VALVES (page 29).
No A problem is indicated with VALVE 24, the actuator board or actuator cable. NOTE this and
see CHECKING VALVES (page 28).
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 15
F- 18.0.0 TROUBLESHOOTING PUMPS
Proceed ONLY with the pump of interest.
a) Make sure that flow is on and the proper flow rate is selected as directed in the table below.
b) Unplug the noted pump from the distribution board. Check, inside the distribution board, for bent, broken,
or corroded male pins.
c) Measure dc voltage, inside the distribution board, between male pins 1 and 5 (top and bottom).
PUMP
DISTRIBUTION
BOARD
POSITION
FLOW
RATE
(ml/min)
VOLTAGE
RANGE
BAD
16 vdc or greater Replace the pump head
DEAERATION P20, DEGAS-P 500
Two Possibilities:
Less than 16 vdc
1
1.
Actuator cable
2. Actuator board
12 vdc or greater Replace the pump head
FLOW P21, FLOW-P 800
Less than 12 vdc
Two Possibilities:
2
1.
Actuator cable
2. Actuator board
1
The actuator cable can be checked for continuity. Note that you are checking DEAERATION PUMP
connections and see CHECKING THE ACTUATOR BOARD CABLE (page 72).
2
The actuator cable can be checked for continuity. Note that you are checking FLOW PUMP connections
and see CHECKING THE ACTUATOR BOARD CABLE (page 72).
F- 19.0.0 TROUBLESHOOTING BALANCING CHAMBER VALVES
A balancing chamber valve may be remaining open or closed at all times.
a) Check that all balancing chamber valves are plugged into the distribution board at their proper positions
(V31 through V38). If ok proceed.
b) Turn the power off and swap in a good actuator board.
c) Put the machine back into dialyze mode. Call up debug screen 5 and watch FLWERR for several minutes.
If the flow error is still intermittent see F- 19.0.1.
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P/N 507082 Rev. B
VALVE 34
(BEHIND VALVE 32)
VALVE 32
VALVE 33
(BEHIND VALVE 31)
VALVE 31
VALVE 37
(BEHIND VALVE 35)
VALVE 35
(BEHIND VALVE 36)
HYDRAULICS, REAR VIEW
F- 19.0.1 CHECKING VALVES 36 AND 38
NOTE: The previous actuator board is good.
a) Turn the machine off and then back on. Wait until the SELECT PROGRAM screen is up.
b) IMPORTANT! Do NOT place the machine into dialyze mode. From SELECT PROGRAM is there flow to the
drain?
Yes Using a metal clamp tightly clamp the solid tubing at balancing chamber valve 36 (see
diagram, above). If flow stops replace valve 36. If not replace valve 38.
VALVE 36
VALVE 38
No See F- 19.0.2
F- 19.0.2 CHECKING VALVE 32
Unplug valves 32 and 36 from the distribution board (V32 and V36). Plug 36 into 32's position and visa versa.
If there is flow to the drain replace valve 32. If not carefully plug both valves back into their proper distribution
positions and see F-19.0.3
F- 19.0.3 CHECKING VALVE 34
Unplug valves 34 and 38 from the distribution board (V34 and V38). Plug 34 into 38's position and visa versa.
If there is flow to the drain replace valve 34. If not carefully plug both valves back into their proper distribution
board positions and see F-19.0.4.
Fresenius 2008H Troubleshooting Guide
Page 17
P/N 507082 Rev. B
F- 19.0.4 CHECKING FOR CLOSED BALANCING CHAMBER VALVES
Place the machine into dialyze mode and TIGHTLY clamp the clear tubing at valve 31 (see diagram, above).
From debug screen 5, does FLWERR now go constant "1"?
Yes Referencing the flow diagram, the problem is a valve in the right-side balancing chamber.
See F- 19.0.5
No FLWERR remains intermittent. Referencing the flow diagram, the problem is a valve in the
left-side balancing chamber. See F- 19.0.6
F- 19.0.5 'RIGHT-SIDE' VALVE BAD
a) Turn the power off and unplug valves 37 and 34 from the distribution board (positions V37 and V34).
b) Plug valve 37 into 34's position (V34), leaving valve 34 unplugged.
c) IMPORTANT! Do NOT place the machine into dialyze mode. From SELECT PROGRAM check drain flow.
Is there strong flow to the drain?
Yes Note that either valve 38 or 34 is not opening and see F- 19.0.7
No Note that either valve 37 or 33 is not opening and see F- 19.0.7
F- 19.0.6 'LEFT-SIDE' VALVE BAD
a) Turn the power off and unplug valves 35 and 32 from the distribution board (positions V35 and V32).
b) Plug valve 35 valve 32's position (V32), leaving valve 32 unplugged.
c) IMPORTANT! Do NOT place the machine into dialyze mode. From SELECT PROGRAM check drain flow.
Is there strong flow to the drain?
Yes Note that either valve 32 or 36 is not opening and see F- 19.0.7
No Note that either valve 35 or 31 is not opening and see F- 19.0.7
F- 19.0.7 CHECK FOR A 'MECHANICALLY STICKING' VALVE
a) Check the noted valve's distribution board connector position for bent, broken or corroded male pins.
b) Carefully plug all valves back into their proper distribution board position.
c) Place the machine into dialyze mode and call up debug screen 7. FILACT MUST = "0" to continue.
d) If the valve bodies are clear check the valve plungers for movement and replace the one that is not moving.
If the valve bodies are solid, swap one of the valves and check for flow errors.
F- 20.0.0 ACFS BETWEEN 0 AND 3
The CFS transducer is acting like a 'short'. Turn flow off. Does ACFS go to between 3 and 7?
Yes IMPORTANT turn flow on and return to F- 7.0.0 (the CFS transducer is good).
Page 18
No See F- 20.0.1
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
F- 20.0.1 CHECK CFS CIRCUIT
Unplug the CFS transducer from the distribution board (position CFS). Check, for bent, broken or corroded
male pins. Is ACFS between 8 and 11?
Yes See F- 20.0.2
No ACFS remains between 0 and 3. See F- 20.0.7
F- 20.0.2 CHECK SENSOR BOARD CFS VALUE
Leave the transducer unplugged and call up debug screen 10. Is CFS between 8 and 11?
Yes See F- 20.0.3
No Replace the sensor board.
F- 20.0.3 CHECK FOR A LEAKING BALANCING CHAMBER VALVE
a) Plug the CFS transducer back into the distribution board and assure that ACFS returns to between 0 and 3.
b) Turn the flow on and push SET to return to the DIALYSIS screen. Is TMP pegged at +60?
Yes See F- 20.0.4
No Replace the CFS transducer (see diagram, next page).
F- 20.0.4 CHECK FOR A LEAKING BALANCING CHAMBER VALVE
a) Push and release the RESET button on the front panel. The message "ADJUST TMP?" appears.
b) Immediately push and HOLD the RESET button. After the "ADJUSTING TMP" message is gone does TMP
return to +60 or remain relatively stable?
+60 See F- 20.0.5
Stable Replace the CFS transducer (see diagram, next page).
F- 20.0.5 CHECK FOR A LEAKING BALANCING CHAMBER VALVE
a) Place the machine into SERVICE/DIAGNOSTICS.
b) Select and enter #11 VALVE LEAK TEST. Wait until the "READY" message appears.
c) Push SET TWICE to start the test. Is a leaking valve indicated?
Yes Note the leaking valve and see F- 20.0.6
No Replace the CFS transducer (see diagram, next page).
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 19
F- 20.0.6 CHECK FOR SHORTED VALVE DRIVER
a) Unplug the NOTED valve from the distribution board.
b) Measure dc voltage, inside the distribution board, between male pins 1 and 5 (top and bottom). One volt or
greater?
Yes Replace the actuator board.
No Replace the indicated leaking valve.
F- 20.0.7 TROUBLESHOOTING THE CFS CIRCUIT
Leave the transducer unplugged for now and call up debug screen 10. Is CFS also between 0 and 3?
Yes See F- 22.0.0
No Between 8 and 11. Replace the actuator board.
F- 21.0.0 ACFS BETWEEN 3 AND 7
The CFS transducer is not switching the balancing chamber valves properly.
Clamp the solid tubing between the output of the CFS transducer and regulator #78 (see diagram below).
Does ACFS go to below 2 now?
Yes Replace regulator #78 (see diagram below).
No See F- 21.0.1
FLOW PUMP OUTPUT
NOZZLE
REAR VIEW
CLAMP TUBING HERE
CFS TRANSDUCER
REGULATOR #78
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Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
F- 21.0.1 CHECK FLOW PUMP PRESSURE
1) Remove the clamp.
2) Turn the flow off and tee a psi gauge between the flow pump's output nozzle and the SOLID tubing (see
diagram on previous page).
3) Turn the flow on at a 500 flow rate. Does pressure peak to 14 psi or greater?
Yes See F- 21.0.2
No Three possibilities: 1) Bad actuator board; 2) Bad flow pump head; 3) Bad flow pump motor.
F- 21.0.2 CHECK CFS CIRCUIT
Unplug the CFS transducer from the distribution board (position CFS) and check for bent, broken or corroded
male pins. Is ACFS between 8 and 11?
Yes See F- 21.0.3
No ACFS remains between 3 and 7. See F- 21.0.4
F- 21.0.3 CHECK SENSOR BOARD CFS VALUE
Leave the CFS transducer unplugged and call up debug screen 10. Is CFS between 8 and 11?
Yes a) Plug the CFS transducer back into distribution board (position x10, CFS).
b) If CFS remains between 3 and 7 and the flow error is still present there are four
possibilities: 1) Bad actuator board; 2) Bad flow pump head; 3) Bad flow pump motor
motor; Bad CFS transducer (see diagram, previous page).
No Replace the actuator board.
F- 21.0.4 TROUBLESHOOTING THE CFS CIRCUIT
Leave the transducer unplugged for now and call up debug screen 10. Is CFS also between 3 and 7?
Yes See F- 22.0.0
No Between 8 and 11. Replace the actuator board.
F- 22.0.0 CHECK SENSOR BOARD CABLE
a) Turn the power off and unplug the 34-pin ribbon cable from the top of the sensor board [card cage, smallest
board, right hand side].
b) Turn the power on.
c) Push the SET button ONCE to enter the VERIFY CONCENTRATE screen
d) Call up debug screen 11. Is CFS between 8 and 11 now?
Yes Unplug both sides of the 34-pin ribbon cable from the sensor and distribution board's
SENSORS connector. Look for bent male pins inside each connector. If ok replace the 34-pin
ribbon cable.
No Three possibilities: 1) Bad sensor board; 2) Bad actuator board; 3) Bad functional board;
Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
Page 21
F- 23.0.0 ACFS BETWEEN 8 AND 11
An CFS transducer is acting 'open'. There are several possibilities that may cause this symptom.
Call up debug screen 10. Is CFS also reading between 8 and 11?
Yes See F- 23.0.1
No Replace the actuator board.
F- 23.0.1 CHECK CFS TRANSDUCER FOR AN 'OPEN'
a) Unplug the CFS transducer from distribution board position CFS. Check, inside the distribution board, for
bent, broken or corroded male pins.
b) Plug the 34 degree Fresenius temperature 'dummy connector' into the CFS's distribution board position
(CFS). Does CFS go to between 0 and 2?
Yes
1
Replace the CFS transducer (see diagram, page 20).
No Two possibilities: 1) 2Bad sensor board cable; 2) Bad sensor board.
1
Before replacing the transducer, check if there is a pig tail extension in the cable between the transducer
and the distribution board. If present make sure it is plugged in properly using the 'key' on the pig tail
connector. The pig tail is not present in all cases.
2
The sensor cable can be checked for continuity. Note that you are checking CFS TRANSDUCER
connections and see CHECKING THE SENSOR BOARD CABLE (page 74) .
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Fresenius 2008H Troubleshooting Guide
P/N 507082 Rev. B
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