Fresenius 2008K Schematic Diagrams
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FRESENIUS 2008K
HEMODIALYSIS SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 507298 Rev. C
FRESENIUS MEDICAL CARE
NORTH AMERICA
2637 Shadelands Drive, Walnut Creek, CA 94598
800-227-2572 or 925-295-0200
REGIONAL EQUIPMENT SPECIALIST: ___________________________________
FRESENIUS 2008K
HEMODIALYSIS SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 507298 Rev C
Copyright 2002 - 2010 Fresenius Medical Care North America
TABLE OF CONTENTS
USING THE TROUBLESHOOTING GUI
THE 'ORDER' OF TROUBLESHOOTING .......................................................................................................... 2
INITIAL CHECKS ................................................................................................................................................ 3
FINAL CHECKS .................................................................................................................................................. 4
EQUIPMENT NEEDED....................................................................................................................................... 4
SECTION 1 - FLOW ERRORS IN DIALYZE MODE .......................................................................................... 6
TROUBLESHOOTING MOTORS .............................................................................................. 23
SECTION 2 - NO WATER................................................................................................................................. 24
SECTION 3 - FLOW ERRORS IN CLEANING PROGRAMS........................................................................... 26
TROUBLESHOOTING VALVES ................................................................................................ 30
TROUBLESHOOTING VALVE ERRORS.................................................................................. 31
SECTION 4 - TEMPERATURE PROBLEMS.................................................................................................... 39
SECTION 5 - CONDUCTIVITY PROBLEMS.................................................................................................... 55
SECTION 6 - CONCENTRATE PUMP 'END OF STROKE' (EOS) ERRORS ................................................. 61
SECTION 7 - COND OFFSET REF OR COND OFFSET FAILURES.............................................................. 63
SECTION 8 - FILLING PROGRAM PROBLEMS.............................................................................................. 64
SECTION 9 - TMP PROBLEMS ....................................................................................................................... 69
SECTION 10 - PRESSURE HOLDING TESTS FAILING................................................................................. 72
SECTION 11 - NEGATIVE PRESSURE TESTS .............................................................................................. 77
SECTION 12 - INDUCED POSITIVE PRESSURE TESTS .............................................................................. 80
SECTION 13 - DEAERATION PROBLEMS ..................................................................................................... 81
SECTION 14 - UF PUMP PROBLEMS............................................................................................................. 83
SECTION 15 - BLOOD LEAK PROBLEMS...................................................................................................... 86
SECTION 16 - CHECKING ACTUATOR BOARD CABLE ............................................................................... 88
SECTION 17 - CHECKING SENSOR BOARD CABLE.................................................................................... 90
SECTION 18 - MANUAL BALANCING CHAMBER VALVE LEAK TESTS ...................................................... 92
SECTION 19 - TESTING FOR A LEAKING BALANCING CHAMBER DIAPHRAGM...................................... 96
DE....................................................................................................... 1
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
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 2008K 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 490049 or Operators
Manual P/N 490042) 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 2008K Troubleshooting Guide
P/N 507298 Rev. C
USING THE TROUBLESHOOTING GUIDE
1. We assume that the troubleshooter is qualified and has been trained to work on Fresenius machines.
Incorrect troubleshooting can result in injury or death!
2. We assume that the troubleshooter has the necessary test equipment and knows how to use it.
3. Troubleshooting procedures are written in ‘flow chart’ style that systematically narrows in on and locates
the problem. Each procedure is critical so take the time to read each one thoroughly and then proceed
EXACTLY as directed. Trying to hurry, skipping steps, or second guessing will lead to error. Don’t assume
anything! Pay particular attention to CAUTIONS and NOTES.
4. Most hydraulic components (valves, pumps, etc) can be checked at the DISTRIBUTION BOARD. Each
component has a numerically labeled connector ‘position’. Referring to the HYDRAULIC FLOW DIAGRAM
flow pump #21 plugs into position [P21, FLOW-P], valve 43 plugs into position [V43], etc.
NOTE: Except for the heater (CAUTION! High Voltage), sensor cable, actuator cable, acid pump, bicarbonate
pump or blood leak detector it is okay to unplug connectors with the power on.
CAUTION! Unplugging the sensor cable, actuator cable, acid pump, bicarbonate pump and the blood leak
detector with the power on may cause damage. Disconnecting the heater with the power on may cause
electrocution!
Figure 1 – Distribution Board
PIN 1
PIN 5
Figure 2 – Female Connector
5. If unsuccessful please call Technical Services at 1-800- 227- 2572.
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
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
importa
1. A NO WATER alarm turns flow off. Clear NO WATER alarms before concerning yourself with other
2. Do not concern yourself with FLOW ERRORS if a NO WATER alarm is also present. Troubleshoot a NO
3. Do not concern yourself with a TEMPERATURE problem if a FLOW ERROR is also present. Flow errors
4. Do not concern yourself with CONDUCTIVITY problems if a TEMPERATURE problem is also present.
5. Do not concern yourself with a TMP problem if other hydraulic alarms (i.e. conductivity, temperature, flow)
6. Do not concern yourself with a BLOOD LEAK problem if other hydraulic alarms (i.e. conductivity,
CAUTION! Before placing the machine back into service always perform FINAL CHECKS (p
nt if someone has been working on the machine before you!
hydraulic alarms.
WATER alarm first and the FLOW ERROR will probably clear itself.
turn the heater off. Troubleshoot the FLOW ERROR first and the TEMPERATURE problem will probably
clear itself.
Conductivity is temperature compensated. Troubleshoot TEMPERATURE problems first and a
CONDUCTIVITY problem will probably clear itself.
are also present. Troubleshoot other hydraulic problems first and the TMP problem will probably clear.
temperature, flow) are also present. Troubleshoot other hydraulic problems first and the BLOOD LEAK
problem will probably clear.
age 4).
Page 2
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
INITIAL CHECKS
1. If the electronic card cage has been previously moved from the cabinet:
Check that all five boards are pushed down into the motherboard and locked in place.
Check that the power logic board cable is plugged in.
Check that the power cable is plugged into the power connector (see Figure 3 below).
Check that the sensor and actuator cables (see Figure 3 below) are plugged into the distribution board.
2.
Check that the PGND (power ground) wire is plugged into the distribution board (see Figure 4 below). A
3.
loose PGND cau
4. Check cables for worn insulation (bare wires) or other signs of damage (like screw holes). Replace if
damaged.
5. NEVER troubleshoot with the card cage open!
ses unpredictable symptoms.
ACTUATOR CABLE SENSOR CABLE
POWER CONNECTOR
MOTHER BOARD
POWER LOGIC
CABLE
Figure 3 – Card Cage (Top View)
SENSORS CONNECTOR ACTUATOR CONNECTOR PGND WIRE
Figure 4 – Distribution Board
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 3
FINAL CHECKS
Before placing the machine back into service:
1. Remove all troubleshooting equipment (jumpers, 'dummy' connectors, etc) from the distribution board and
make sure that all hydraulic components are plugged in properly.
2. If you were troubleshooting FILLING PROGRAMS or FLOW ERRORS make sure that the female
connectors on chamber #69 are plugged in properly (brown wire on top).
3. Turn the heater breaker switch off. Allow eight minutes and assure that the Temperature display falls to
less than 30 and that the machine goes into bypass (valve #24 closes, no flow through the external
indicator).
4. Drop the acid and bicarbonate lines into water. Allow eight minutes and assure that the Conductivity
display falls to 10.0 mS/cm and that the machine goes into bypass (no flow through the external
indicator).
5. Check that AUDIO ALARMS are working properly.
6. IMPORTANT! Perform alarm and pressure holding tests. Do NOT place the machine back into service
until all tests have pass.
EQUIPMENT NEEDED
- Fresenius gauge kit (part # 150034)
- Fresenius test (temperature) 'dummy connectors' (part # 190060)
- 60 ml syringe
- Flashlight
- Jumper wire
- Independently calibrated temperature, conductivity, and pressure meters
- Voltmeter
- Fluke TP80 meter probes. These probes have a slip-on cap that fits over the lead to 'isolate' the
measuring point and assures safe voltage measurements in ‘tight’ areas when shorting other pins or
connectors is a concern.
Page 4
Figure 5 - Fluke TP80 Meter Probes (with slip on cap)
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
POWER SUPPLY
SHUNT DOOR
DIALYZER QUICK
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 #20
Figure 6 – Machine Rear View
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 5
SECTION 1 - FLOW ERRORS IN DIALYZE MODE
F- 1.0.0 CHECK LOADING PRESSURE
a) Assure that the vent tubing (back of machine) is not 'pinched' (see Figure 6, page 5).
b)
Assure that dialysate flow is on (flow on/off LED off).
1
TIGHTLY insert a 2loading pressure gauge into the red ACETATE/ACID port. Proceed accordingly:
c)
0 to 10 psi. See F- 15.0.0, LOW LOADING PRESSURE (pa
ge 19).
10 to 17 psi. Calibrate loading pressure per CALIBRATION PROCEDURES. If
unsuccessful, the loading pressure regulator #65 (see Figure 6, page 5)
may be bad.
18 to 25 psi. See F- 2.0.0
Greater than 25 psi Calibrate loading pressure per CALIBRATION PROCEDURES. If
unsuccessful the loading pressure regulator #65 (see Figure 6, page 5)
may be bad.
1
If the gauge is not in the port correctly you will always read low pressure!
2
If the gauge does not read 0 psi at atmosphere compensate for this when reading it.
F- 2.0.0 CHECK DEBUG ERRORS (NO WATER AND FLOW ERROR)
a) Lift the shunt door to force bypass (bypass LED on). This should be done even if the machine is already in
bypass!
NOTE Unless instructed do NOT
try to reset alarms while troubleshooting flow errors.
b) Call debug screen 0. Intermittent problems are easily missed with a ‘quick look’ so watch for two minutes
or
until you see either a NO WATER alarm or a flow error (FLOW ERROR = “1”). Proceed accordingly:
NO WATER alarm (intermittent or constant). See SECTION 2 - NO WATER (p
age 24).
FLOW ERROR = “0” (constant). See F- 2.0.1
Page 6
FLOW ERROR = “1” (intermittent or constant). See F- 3.0.0
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
F- 2.0.1 FLOW ERROR NOT INDICATED (FLOW ERROR = “0”)
a) Leaving the shunt door open push the blue HOME screen button to return to the Home screen. Allow
Temperature and Conductivity to come out of alarm state.
NOTE: If the Temperature or Conductivity windows (in the main screen) are RED an alarm is present.
When alarms clear the windows turn yellow.
NOTE: Conductivity alarm limits can be adjusted: 1) Push the Conductivity data button to go to the
Dialysate screen. Select either Alarm Position or Alarm Width by pushing the appropriate blue
screen button 2) Adjust the limits using the UP or DOWN arrow keys. 3) Push the CONFIRM key.
4) Push the blue HOME screen button to return to the Home screen.
NOTE: If Temperature and Conductivity alarms do not clear and you are sure that FLOW ERROR = “0”
constant do NOT continue troubleshooting flow errors!
b) Close the shunt door. Assure that the machine is ‘out of bypass’ (bypass LED turns off). Is there flow
through the external flow indicator (is the bob rising)?
Yes See F- 2.0.2
See F- 14.0.0, TROUBLESHOOTING FLOW ERRORS ‘OUT OF B
No
F- 2.0.2 CHECK FLOW ERROR ‘OUT OF BYPASS’
YPASS’ (page 18).
Call debug screen 0. Intermittent problems are easily missed with a ‘quick look’ so watch FLOW ERROR for
five minutes
or until you see FLOW ERROR = “1”. Proceed accordingly:
FLOW ERROR = “0” (constant). Stop here! A flow error is not present.
FLOW ERROR = “1” (intermittent or constant). See F- 14.0.0, TROUBLESHOOTING FLOW
ERRORS ‘OUT OF BYPASS’ (page 18).
F- 3.0.0 CHECK FOR FILLING PROGRAM
Call debug screen 1. FILACT = "1"?
Yes Proceed to SECTION 8 - FILLING PROGRAM PROBLEMS (pag
e 64)
No See F- 4.0.0
F- 4.0.0 CHECK FOR A VALVE ERROR (VERR)
NOTE: Valve errors are caused by electrical current problems in a ‘valve circuit’. If present, VERR (debug
screen 1) increases (to a maximum of 255). If not present VERR remains 0.
Call debug screen 1. VERR is in the lower right corner. Is VERR = “0”?
Yes See F- 4.0.1
No
NOTE that you are in DIALYSIS program and proceed to TROUBLESHOOTING VALVE
ERRO
RS (page 31)
F- 4.0.1 CHECK FLOW ERROR “IN BYPASS”
Open the shunt door to cause bypass. Go to debug screen 0 and watch Flow Error for one minute. Does
Flow Error remain “0” constantly or does it still = “1” (either constant or intermittent)?
“0” constant See F- 2.0.2
Still = “1”
Close the shunt door and see F- 5.0.0
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 7
Section 1 – Flow Errors in Dialyze Mode
F- 5.0.0 CHECK FOR A RUNNING FLOW MOTOR
The flow pump’s motor shaft can be viewed from the front of the hydraulics (see Figure 7). Is the shaft
rotating count
er-clockwise (viewed from the FRONT!)?
Yes See F- 6.0.0
See TROUBLESHOOTING MOTORS (p
No
age 23) to check the FLOW MOTOR.
FLOW
MOTOR SHAFT
Figure 7 – Hydraulics (Front View)
F- 6.0.0 CHECK FLOW PUMP CONTROL
Turn dialysate flow off (flow on/off LED on) and check the flow pump's motor shaft again. Still rotating?
Yes Replace the actuator board (shorted driver).
No See F- 7.0.0
F- 7.0.0 DETERMINE DRAIN FLOW
Normal Fresenius flow 'pulses' in 30 ml (approximately) increments when the balancing chamber valves cycle
and ‘stops completely’ in between. Determine flow ‘type’ as defined below:
Normal: 30 ml - Stops completely - 30 ml - Stops completely – etc
Abnormal: Continuous flow (never stops, i.e. cannot distinguish 30 ml increments)
OR
30 ml – continuous – 30 ml – stops completely - etc
None: No drain output
a) IMPORTANT: Turn dialysate flow on (flow on/off LED off).
b) Go to end of the drain tubing. Hold the tubing so that the opening is pointed UPWARD!
(at about 45
degrees). CAUTION!! If the opening is held DOWNWARD this test is invalid.
c) Watch drain flow for 30 seconds. Proceed accordingly:
Normal: See F- 8.0.0 (page 12)
Abnorm
al or None: See F- 7.0.1
Page 8
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
F- 7.0.1 CHECK (DRAIN) VALVE #30 INPUT
a) Turn dialysate flow off (flow on/off LED on) and remove (drain) valve 30’s INPUT tubing (see Figure 8).
Point the tubing’s o
utput AWAY from the hydraulics! Have a bucket ready to catch any output.
b) Turn dialysate flow on (flow on/off LED off). Proceed accordingly:
Normal: See F- 7.0.2
Abnorm
al or None: See F- 7.0.3
VALVE 30
INPUT
TUBING
Figure 8 – Hydraulics (Top View)
F- 7.0.2 CHECK VALVE #30 OUTPUT
a) Turn flow off (flow on/off LED on) and reconnect the tubing to valve 30.
b) Remove the tubing from bottom (drain) port at the rear of the machine (see Figure 9). Have a bucket ready
to c
atch any output.
Figure 9 - Hydraulics (Rear View)
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
DRAIN PORT
Page 9
Section 1 – Flow Errors in Dialyze Mode
c) Turn flow on (flow on/off LED off). Proceed accordingly:
Normal: The drain tubing or the drain itself is restricted. Locate and repair.
Abnormal or None: A problem is indicated with the actuator board or VALVE 30. NOTE this
and proceed to TROUBLESHOOTING VALVES (page 30).
F- 7.0.3 CHECK FILLING PROGRAM FUNCTION
a) Unplug the air sensor connector from distribution board position x6, AIR-SEN.
b) Wait 30 seconds and call debug screen 1. Does FILACT = “1”?
Yes A) Plug the connector back into the distribution board (position x6, AIR_SEN), allow
30 seconds, and assure that FILACT = “0”; B) See F– 7.0.4
No
Using a flashlight, check inside the distribution board for ‘white’ corrosion (indicative of
spillage). If no corrosion, two possibilities: 1) Bad sensor board; 2) Bad function board.
F- 7.0.4 CHECK ‘IN BYPASS’ FLOW
For this procedure a bucket 1/2 filled with water is needed.
a) Plug the acid and bicarbonate concentrate connectors into their ports. The screen returns to the SELECT
PROGRAM screen.
b) Reconnect the tubing to valve 30.
c) Place the machine into RINSE.
d) Open the shunt door (COVER OPEN message) and remove both quick connectors. Drop the RED quick
connector into the bucket. Hold the BLUE quick connector over the bucket such that the opening is held
UPWARD!
(at about 45 degrees). CAUTION!! If the opening is held DOWNWARD this test is invalid.
e) IMPORTANT leave the shunt door open!
f) Watch flow here for 30 seconds and NOTE flow ‘type’ (Normal, Abnormal, None) for later use. Proceed to
step F- 7.0.5
®
F- 7.0.5 DETERMINING DIASAFE
The DIASAFE
®
filter looks like a dialyzer that is mounted in the bottom compartment under the hydraulics.
FILTER
Also, there is a ‘test valve’ on the rear panel.
a) Unplug the acid connector from its port to INTERRUPT rinse then plug it back in.
b) Place the quick connectors back into the shunt and close the door.
®
c) Does this machine have a DIASAFE
filter?
Yes See F- 7.0.6
No
See F- 7.0.8
Page 10
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
®
F- 7.0.6 CHECK THE DIASAFE
a) If the DIASAFE
®
filter and its quick connector o-rings have not been replaced in the last 90 days do so now
and see F- 7.0.7. If it has been repla
FILTER
ced see part b.
b) Assure that the ‘test valve’ is set in DIALYZE position. If not, set it there, and see F– 7.0.7. If already in
DIALYZE position see p
c) Check for tubing restrictions at the DIASAFE
art c
®
filter. Clear all restrictions and see F- 7.0.7. If not restricted
see step F- 7.0.8
F- 7.0.7 TROUBLESHOOTING THE DIASAFE
®
FILTER
a) Return to the SELECT PROGRAM screen by reconnecting the acid and bicarbonate concentrate
connectors to their ports on the front of the machine.
b) Place the machine into RINSE for three minutes.
c) Remove the acid and bicarbonate concentrate connectors from their ports and plug them back into
concentrate.
®
d) If the DIASAFE
F- 7.0.8 DETERMINE FLOW PROBLEM
As noted, in step F- 7.0.4 a
filter was the problem the flow error will clear. Return to step F- 2.0.0.
bove, was flow through the BLUE quick connector:
Normal: A problem is indicated with the actuator board or VALVE 26. NOTE this and proceed
to TROUBLESHOOTING VALVES (page 30).
Abnorm
None: Possibly two balancing chamber valves stuck closed! Try replacing the actuator
al: See F- 7.0.9
board.
F- 7.0.9 CHECK BALANCING CHAMBER VALVES AND BALANCING
CHAMBER DIAPHRAGM
Perform SECTION 18 - MANUAL BALANCING CHAMBER VALVE LEAK TESTS (page 92) on the balancing
cham
ber valves (V31 through V38). Did the leak test indicate a leaking valve?
Yes See F- 7.1.1
Possible leaking balancing chamber diaphragm. Perform SECTION 19 - TESTING FOR A
No
LEAKING BALANCI
NG CHAMBER DIAPHRAGM (page 96).
Fresenius 2008K Troubleshooting Guide
Page 11
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
F- 7.1.1 CHECK FOR A SHORTED VALVE DRIVER
a) Unplug the indicated leaking valve from the distribution board (see Figure 10 below). Using a flashlight,
che
ck inside the distribution board, for ‘white corrosion’ (indicative of spillage).
b) If no corrosion: measure volts dc, inside the distribution board, BETWEEN male pins 1 and 5 (top and
bottom). Place the red lead at pin 5 (bottom). Greater than one volt?
Yes Replace the actuator board (shorted driver).
No Replace the indicated leaking balancing chamber valve.
BALANCING CHAMBER
VALVE POSITIONS
Figure 10 – Distribution Board
F- 8.0.0 CHECK CFS TRANSDUCER SIGNAL (ACFS)
Call debug screen 0. Intermittent problems are easily missed with a ‘quick look’ so watch ACFS (in volts) for
two minutes
or until you have determined the symptom. Proceed accordingly:
ACFS remaining between 3.0 and 7.0. See F- 9.0.0 (page 13)
ACFS remaining between 7.0 and 12. See F- 10.0.0 (page 14*)
ACFS remaining between 0 and 3.0. See F- 11.0.0 (page 14)
ACFS cycling from about 4 (4.0 to 5.5) to about 2 (0 to 3.0). See F- 13.0.0 (p
ACFS intermittently going to between 7 and 12. See F- 10.0.0 (pa
ge 14)
age 17).
Page 12
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
F- 9.0.0 ACFS BETWEEN 3.0 AND 7.0 - CHE
CK FLOW PUMP PRESSURE
The CFS signal is not switching the balancing chambers properly.
a) Turn dialysate flow off and tee a psi gauge between the flow pump's output nozzle and the WHITE tubing
(see Figure 11 below, for gauge location).
Turn the dialysate flow on (flow on/off LED off) and set to 500 ml/min. Does pressure peak to 14 psi or
b)
greater?
Yes See F- 9.0.2
See F- 9.0.1
No
CLAMP HERE
REGULATOR #78
FLOW PUMP
OUTPUT
Figure 11 - Hydraulics (Rear View)
F- 9.0.1 CHECK FLOW RELIEF PRESSURE REGULATOR #78
With a metal hemostat TIGHTLY clamp regulator #78 at the location specified in the Figure 11 above. Does
flow pump p
F- 9.0.2 CHECK CFS CIRCUIT
a) Unplug the CFS transducer from distribution board position CFS. Using a flashlight, check inside the
distribution board, for ‘white’ corrosion (indicative of spillage).
b) If no corrosion: inside the distribution board there should be five male pins. Check for bent or broken male
pins.
c) If all pins are okay: is ACFS between 7.0 and 10?
ressure peak to 14 psi or greater now?
Yes Calibrate FLOW RELIEF PRESSURE per CALIBRATION PROCEDURES. If unsuccessful
regulator #78 may be malfunctioning.
No Three possibilities: 1) Bad actuator board; 2) Bad flow pump head; 3) Bad flow pump motor
Yes See F- 9.0.3
See F- 12.0.0 (page 16)
No
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 13
Section 1 – Flow Errors in Dialyze Mode
F- 9.0.3 CHECK SENSOR BOARD CABLE
a) Plug the CFS transducer back into the distribution board.
If ACFS remains between 7 and 10 make sure that you have plugged in properly.
If ACFS starts cycling from about 4 (4.0 to 5.5) to about 2 (0 to 3.0) and if the flow error is still
present return to F- 2.0.0
b)
Have you tried calibrating FLOW RELIEF PRESSURE during this troubleshooting session?
Yes Three possibilities: 1) Bad CFS transducer (see Figure 6, page 5); 2) Bad flow pump head;
3) Bad flow m
otor (try new brushes)
No Try calibration FLOW RELIEF PRESSURE per CALIBRATION PROCEDURES and return to
F- 2.0.0. If F
F- 10.0.0 ACFS BETWEEN 7.0 AND 10 – CHECK CFS CIRCUIT
LOW RELIEF PRESSURE was the problem, the flow error will clear.
The CFS transducer is acting ‘open’.
a) Unplug the CFS transducer from distribution board position CFS. Using a flashlight, check inside the
distribution board connector for ‘white’ corrosion (indicative of spillage).
b) If no corrosion: inside the distribution board there should be five male pins. Check for bent or broken
male pins.
c) If all pins are okay: plug the 34degree temperature ‘dummy connector’ into distribution board position CFS
(this simulates a good transducer). From debug screen 0, does ACFS go to 0?
Yes See F- 10.0.1
Possible: 1)
No
1
The sensor board cable can be checked for continuity. Note that you are checking CFS TRANSDUCER
connections and proceed to SECTION 17 - CHECKING SENSOR BOARD CABLE (pag
F- 10.0.1 CHECK CFS TRANSDUCER
1
Bad sensor board cable; 2) Bad sensor board; 3) Bad actuator board
e 90).
Plug the CFS transducer back into the distribution board. Does ACFS start cycling from about 4 (4.0 to 5.5)
to about 2 (0 to 3.0)?
Yes The CFS transducer seems to be working okay. Return to F- 2.0.0 but if you return he
re
replace the CFS transducer (see Figure 6, page 5)
Bad CFS transducer (see Figure 6, page 5).
No
F- 11.0.0 ACFS BETWEEN 0 AND 3.0 – CHECK FLOW PUMP ‘DEAD HEAD’
The CFS transducer is acting ‘shorted’.
Turn dialysate flow off (flow on/off LED on). Is ACFS between 4.0 and 7.0?
Yes The CFS transducer is good! Return to F- 2.0.0.
No
See F- 11.0.1
Page 14
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
F- 11.0.1 CHECK CFS CIRCUIT
a) Unplug the CFS transducer from distribution board position CFS. Using a flashlight, check inside the
distribution board for ‘white’ corrosion (indicative of spillage).
b) If corrosion not present: Inside the distribution board there should be five male pins. Check for bent or
broken male pins.
c) If all five pins are okay: is ACFS between 7.0 and 10?
Yes See F- 11.0.3
See F- 12.0.0
No
F- 11.0.3 CHECK FOR A LEAKING BALANCING CHAMBER VALVE
a) Plug the CFS transducer back into the distribution board. If ACFS remains between 7 and 12 make sure
that you have plugged the transducer in properly.
b) Turn dialysate flow on (flow on/off LED off).
c) Push the blue HOME screen button to return to the main dialysis screen. Does the digital TMP reading
have positive (+) sign (example +220 mmHg)?
Yes See F- 11.0.4
Replace the CFS transducer (see Figure 6, page 5).
No
NOTE: TMP readin
gs with no sign (example 220 mmHg) indicates that venous pressure is greater than
dialysate pressure. If TMP readings have a positive sign (example +220 mmHg) dialysate pressure is greater
than venous pressure.
F- 11.0.4 CHECK FOR (+) POSITIVE TMP
a) Push and release the RESET key. The message "RESET TO ADJUST TMP" appears.
b) Immediately push and HOLD the RESET key. After the "ADJUSTING TMP" message is gone does TMP
return to a positive (+) value or remain relatively stable?
Returns positive (+) See F- 11.0.5
ns stable Replace the CFS transducer (see Figure 6, page 5).
Remai
F- 11.0.5 CHECKING BALANCING CHAMBER VALVES
Perform SECTION 18 - MANUAL BALANCING CHAMBER VALVE LEAK TESTS (page 92) on the balancing
cham
ber valves (V31 through V38). Did the leak test indicate a leaking valve?
Yes See F- 11.0.6.
Replace the CFS transducer (see Figure 6, page 5).
No
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 15
Section 1 – Flow Errors in Dialyze Mode
F- 11.0.6 CHECK FOR A SHORTED VALVE DRIVER
Remain in DIAGNOSTICS for this procedure.
a) Unplug the NOTED leaking balancing chamber valve from the distribution board. Using a flashlight, check
inside the distribution board for ‘white’ corrosion (indicative of spillage).
b) Measure volts dc, inside the distribution board, BETWEEN male pins 1 (top) and 5 (bottom). Place the
meter’s red lead at pin 5. Greater than one volt?
Yes Replace the actuator board (shorted driver).
No Replace the NOTED leaking balancing chamber valve
F- 12.0.0 CHECK SENSOR BOARD CABLE
a) Turn the power off, slide the electronic card cage out, and unplug the sensor board’s ribbon cable (see
Figure 3, page 3).
b)
Check, inside the sensor board connector, for bent or broken male pins.
c) If pins are okay: leaving the cable unplugged, turn the power on.
d) Return to debug screen 0. Ignore all alarms! Is ACFS between 7.0 and 10?
Yes A) Unplug the sensor board ribbon cable from the distribution board SENSORS connector
(see Figure 12 below); B) Using a flashlight, che
ck inside the distribution board’s SENSORS
connector for ‘white’ corrosion (indicative of spillage) and for bent or broken male pins; C) If
no corrosion and all pins are okay: replace the sensor board ribbon cable.
No Possible: 1) Bad sensor board; 2) Bad actuator board.
Page 16
Figure 12 – Distribution Board
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
BALANCING CHAMBER
VALVE POSITIONS
Section 1 – Flow Errors in Dialyze Mode
Figure 13 - Hydraulics (Rear View)
F- 13.0.0 ACFS CYCLING - CHECK BALANCING CHAMBER VALVES (STUCK CLOSED)
a) Assure that all balancing chamber valves are plugged into the distribution board at their proper position (see
Figure 12, page 16 and Figure 13 above).
b)
IMPORTANT: Set dialysate flow rate to 500 ml/min.
NOTE: Flow errors caused by a balancing chamber valve not opening are predictably cyclic.
c) Call debug screen 0 and watch ACFS for one minute
where it remains for 3 seconds to about 2 volts (0 to 2.8 volts) where it remains for ten seconds?
Yes A balancing chamber valve is not opening. See F- 13.0.1
No
F- 13.0.1 CHECK THE ACTUATOR BOARD
Return to step F- 2.0.0
Have you already tried replacing the actuator board during this troubleshooting session?
Yes See F- 13.0.2
No
Try replacing the actuator board and return to F- 2.0.0.
the flow error will clear.
. Is ACFS cycling from about 4 volts (4.0 to 5.5 volts)
If the actuator board is the problem
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 17
Section 1 – Flow Errors in Dialyze Mode
F- 13.0.2 TROUBLESHOOTING A ‘MECHANICALLY’ CLOSED BALANCING CHAMBER VALVE
a) Using a metal hemostat tightly clamp balancing chamber valve #35 as close to the valve as you can. From
the rear valve #35 is in the lower, left side (see Figure 13, page 17).
b)
Wait 30 seconds. From debug screen 0 does ACFS remain between 0 and 2.8 and FLOW ERROR = “1”
constant?
Yes Valve #33 or #34 or #37 or #38 is not opening.
No Flow Error remains intermittent: Valve #31 or #32 or #35 or #36 is not opening.
F- 14.0.0 TROUBLESHOOTING FLOW ERRORS 'OUT OF BYPASS'
A restriction is indicated in the 'out of bypass' circuit, which includes the *DIASAFE
®
filter (if present), external
dialysate filter #73, valve #24 and valve #25.
®
*The DIASAFE
filter looks like a dialyzer that is mounted in the bottom compartment under the hydraulics.
Also, there is a ‘test valve’ on the rear panel
Normal Fresenius flow pulses in 30 ml (±1ml) increments when the balancing chamber valves cycle and
‘stops completely’ in between. During the following procedure determine flow ‘type’ as defined below:
Normal: 30 ml - Stops completely - 30 ml - Stops completely – etc
Abnormal: Continuous flow (never stops, i.e. cannot distinguish 30 ml increments)
None: No output
®
F- 14.0.1 CHECK V24 AND THE DIASAFE
FILTER (IF PRESENT)
a) Plug the acid and bicarbonate concentrate connectors into their ports. The machine returns to the SELECT
PROGRAM screen.
b) Place the machine into RINSE. Have a bucket ready to catch any output.
c) With a bucket ready to catch any output, open the shunt door (COVER OPEN message) and remove the
RED quick connector.
d) IMPORTANT Leave the door open! There should be flow through the shunt door port. Proceed accordingly:
®
Normal: See F- 14.0.2 (valve #24 and the DIASAFE
filter (if present) are okay)
Abnormal or None: See F- 14.0.3
F- 14.0.2 CHECK EXTERNAL DIALYSATE FILTER #73
a) Unplug the acid connector from its port to INTERRUPT rinse then plug it back in.
b) Place the quick connectors back into the shunt and close the door.
c) Check the external dialysate filter #73 (see Figure 6, page 5) for restrictions.
If filter #73 is okay: a problem is indicated with the actuator board or VALVE 25. NOTE this and proceed to
d)
TROUBLESHOOTING VALVES (page 30).
Page 18
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
®
F- 14.0.3 CHECK V24 AND THE DIASAFE
FILTER
a) Unplug the acid connector from its port to INTERRUPT rinse then plug it back in.
b) Place the quick connectors back into the shunt and close the door.
®
c) Does this machine have the DIASAFE
filter?
Yes See F- 14.0.4
No
A problem is indicated with the actuator board, actuator cable, or VALVE 24. NOTE this and
proceed to TROUBLESHOOTING VALVES (page 30).
F- 14.0.4 CHECK DIASAFE
a) If the DIASAFE
®
filter and its quick connector o-rings have not been replaced in the last 90 days do so now
and see F- 14.0.5. If
®
FILTER
it has been replaced, proceed to part b.
b) Assure that the ‘test valve’ is set in DIALYZE position. If not set it there and see F- 14.0.5. If already set i
DIALYZE position proceed to part c.
®
c) Check for tubing restrictions at the DIASAFE
filter. Clear all restrictions and see F- 14.0.5. If not restricted
proceed to part d.
d) A problem is indicated with the actuator board or VALVE 24. NOTE this and proceed to
TROUBLESHOOTING VALVES (page 30).
®
F- 14.0.5 TROUBLESHOOTING THE DIASAFE
FILTER
a) Return to the SELECT PROGRAM screen by reconnecting the acid and bicarbonate concentrate
connectors to their ports on the front of the machine.
b) Place the machine into RINSE for three minutes.
c) Remove the acid and bicarbonate concentrate connectors from their ports and plug them back into
concentrate.
®
d) If the DIASAFE
F- 15.0.0 LOADING PRESSURE LOW (0 to 10 psi) /CHECK DEAERATION PUMP
filter was the problem the flow error will clear. Return to step F- 2.0.0.
The deaeration pump's motor shaft can be viewed from the front of the hydraulics (see Figure 14, page 20).
Is
the shaft rotating counter-clockwise (from the FRONT!)?
n
Yes See F- 15.0.1
See TROUBLESHOOTING MOTORS (p
No
age 23) to check the DEAERATION MOTOR.
Fresenius 2008K Troubleshooting Guide
Page 19
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
FLOW
MOTOR SHAFT
HYDRAULICS (FRONT VIEW) HYDRAULICS (REAR VIEW)
Figure 14
F- 15.0.1 LOADING PRESSURE LOW - DEAERATION MOTOR RUNNING
NOTE: This procedure checks for water in the hydro block.
a) Turn flow off (flow on/off LED on). Call debug screen 0 and wait until DEAP = 255 (indicates deaeration
motor is off).
b) Remove the CLEAR (input) tubing from the deaeration pump's nozzle (see Figure 14 above). Hold it below
the pump. Is there continu
ous (never stops) flow from this tubing?
Yes See F- 15.0.2
See F- 15.0.5
No
F- 15.0.2 CHECK INCOMING WATER
a) Allow flow to continue from the tubing (use a bucket to catch it).
b) Call debug screen 0. When the float’s bob drops, incoming water valve #41 is energized open. This is
indicated when the circle (next to the valve) turns solid blue. Normally (if the incoming water circuit is okay)
valve #41 will open for about one second per cycle.
c) Intermittent water problems are missed with a ‘quick look’. Watch specifically (and carefully) for a NO
WATER alarm for two minutes
Yes Reconnect the tubing to the deaeration pump and see SECTION 2 - NO WATER (pa
. Is a NO WATER alarm ever present?
ge 24).
No See F- 15.0.3
F- 15.0.3 RECHECK LOADING PRESSURE
a) Reconnect the tubing and turn flow on (flow on/off LED off).
b) Wait 30 seconds. Does loading pressure return to normal (18 to 25 psi)?
Yes Problem maybe solved. If low loading pressure symptoms repeat: 1) Possible bad deaeration
pump head; 2) Possible bad deaeration motor (try brushes); 3) Possible bad (intermittent)
float switch; 4) Possible stripped orifice fitting or bad orifice o-rings.
No See F- 15.0.4
Page 20
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Section 1 – Flow Errors in Dialyze Mode
F- 15.0.4 CHECK DEAERATION PUMP AND LOADING PRESSURE REGULATOR
While watching the loading pressure gauge, tightly clamp the white tubing between the loading pressure
regulator #65 and the hydroblock (see Figure 15 below). Does loading pressure increase to greater than
20 psi
?
Yes The loading pressure regulator #65 (see Figure 15 below) is bad.
Two possibilities: 1) Deaeration pump head; 2) Deaeration motor brushes (see brush
No
replacement process in the PREVENTATIVE MAINTENANCE manual).
F- 15.0.5 CHECK THE ORIFICE AND FLOAT
a) Reconnect the tubing and turn the water OFF.
b) Clamp the hydro block vent tube (see Figure 15 below). Unscrew and pull the o
block (see Figure 15 below). If the small opening, at the end of the shaft, is plugged thi
rifice (#48) from the hydro
s is the problem!
FLOAT (FULLY DOWN ON SHAFT)
HEATER
VENT TUBE
ORIFICE (#48)
LOADING PRESSURE
REGULATOR #65
Figure 15 – Hydroblock
SOLID TUBING
(CLAMP HERE,
Step F- 15.0.4)
c) Re-install the orifice (don’t over tighten!) and UNCLAMP the vent tube.
d) Remove the float (see Figure 15 above). CAU
TION! Don't pull on the wiring harness!
e) Holding the float FULLY UP turn the water ON.
f) CAUTION Avoid overflow during this step! Looking into the hydro block’s float cavity move the float bob
FULLY DOWN. Is the water level rising?
Yes a) Turn the water off and reinstall the float; b) Turn the water on and see F- 15.0.7
See F- 15.0.6
No
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
Page 21
Section 1 – Flow Errors in Dialyze Mode
F- 15.0.6 CHECK THE FLOAT CIRCUIT
a) Turn the water off.
b) Unplug the float from distribution board position FLOAT-SW. Using a flashlight, check inside the distribution
board for ‘white’ corrosion (indicative of spillage).
c) If no corrosion: inside the distribution board there should be five male pins. Check for bent or broken
male pins.
d) If all pins are okay: place a jumper wire, inside the distribution board, BETWEEN male pins 1 and 3 (top
and middle). This simulates a ‘closed’ float switch. IMPORTANT! Make VERY sure of a good jumper
connection!
e) Call debug screen 0. Is the circle next to valve #41 solid blue (indicating valve #41 is energized)?
Yes The float is bad. Replace it and see F 15.0.7
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
SECTION 17 - CHECKING SENSOR BOARD CABLE (page 90).
F- 15.0.7 CLEARING AN AIR LOCK
There should be flow through the hydro block unless an air lock is present.
a) Assure that the water in ON.
b) Connect a 60 ml syringe (with plunger) to the deaeration pumps clear INLET tubing and draw on the
plunger. You may have to pull several syringes full of air before you achieve continuous flow. If unable to
achieve continuous flow (after five or six tries) the orifice fitting may be 'stripped'.
c) Reconnect the tubing to the deaeration pump nozzle and turn flow on.
d) Allow loading pressure to return to normal (18 to 25 psi).
NOTE: Recurring air locks may be indicative a 'stripped' orifice fitting, bad orifice o-rings or bad (intermittent)
float switch.
Page 22
Fresenius 2008K Troubleshooting Guide
P/N 507298 Rev. C
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