Fresenius 4008 Technical manual

4008 E / 4008 B / 4008 H / 4008 S

!!

!

Caution!

These Operating Instructions in pdf­format are for information only.
They are not a replacement for the
Operating Instructions supplied with
the machine/device and options.

Hemodialysis system

Technical Manual

Edition: 5/03.09

Part no.: M40 618 1

Software 4.5/5.3 and higher

CareFreseniusMedical

Important information on the Technical Manual

How to use the Technical Manual

Identification The document can be identified by the following information on the title page and

on the labels, if any:
– Edition of the technical document
– Part number of the technical document

Page identification The page identification 1-3, for example, refers to: chapter 1, page 3.

Editorial information The editorial information 1/01.05, for example, refers to the 1

2005.

Changes Changes to the Technical Manual will be released as new editions or supple-

ments. In general: This manual is subject to change without notice.

Significance of the Explanation of the Caution and Note symbols used:
safety precautions

Caution

Advises the operator against certain procedures or actions that could cause
damage to the equipment or may have adverse effects on operators and
patients.

Note

☞

Informs the operator that if the steps are not followed as described, a specific
function will be executed incorrectly or will not be executed at all, or will not
produce the desired effect.

st

edition, January

Fresenius Medical Care 4008 5/03.09 (TM) 0-1

Important information on the system

Technician’s qualification

Purpose This Technical Manual is intended for service technicians and is to be used for

first studies (to acquire a basic knowledge) and for reference purposes (for TSC,
Maintenance and repair). The Technical Manual, however, does not replace the
training courses offered by the manufacturer.

Requirements Knowledge of the current Operating Instructions for the respective system.

Background experience in mechanics, electrical and medical engineering.

Precautions for working on the system

Authorized persons Assembly, extensions, adjustments, modifications or repairs may only be carried

out by the manufacturer or persons authorized by him.

Test equipment and The activities described in this technical document require the availability of the
accessories necessary technical test equipment and accessories.

Specifications For the specifications of the respective system, refer to the current Operating

Instructions. Observe the information on the specifications.

Precautions Before turning power on, repair any visible damage.

Prior to opening the system and when working on the open system, the following
precautions have to be observed:
– Protect the components against ingress of fluids.
– Do not touch live parts (e.g. connectors of the power cable or heater).
– Disconnect and connect all jacks, connectors and components only when the

system is turned off.

ESD precautions When repairing the system and replacing spare parts, observe the applicable

ESD precautions.

Hygienic measures The system and the consumables are generally considered to be contaminated

and must therefore be sufficiently disinfected by the responsible organization as
specified by the manufacturer.

0-2 Fresenius Medical Care 4008 5/03.09 (TM)

Addresses

Please address any inquiries to:

Manufacturer Fresenius Medical Care AG & Co. KGaA

D-61346 Bad Homburg
[phone]
www.fmc-ag.com

Service Fresenius Medical Care
Central Europe Deutschland GmbH

Geschäftsbereich Zentraleuropa
Kundendienst / Servicecenter
Steinmühlstraße 24
61352 Bad Homburg
Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

International Fresenius Medical Care
service Deutschland GmbH

Service Support International
Hafenstraße 9
D-97424 Schweinfurt
Germany
Phone: [phone] (hotline)
Fax: [phone]

Local service

Fresenius Medical Care 4008 5/03.09 (TM) 0-3

0-4 Fresenius Medical Care 4008 5/03.09 (TM)

Table of contents

Section Page

1 Description of system functions and malfunctions ................................................. 1-

1.1 Description of the T1 test ............................................................................................... 1-3

1.2 Functional description of the modules ............................................................................ 1-78

1.3 Functional description of the hydraulic unit .................................................................... 1-83

2 Technical Safety Checks / Maintenance .................................................................... 2-

2.1 Technical Safety Checks and Maintenance

for 4008 hemodialysis systems and options .................................................................. 2-3

2.2 TSC report ...................................................................................................................... 2-25

3 Adjustment instructions .............................................................................................. 3-

3.1 Overview of the DIP switches in the 4008 ...................................................................... 3-9

3.2 Calibration mode ............................................................................................................ 3-13

3.3 Hydraulics ....................................................................................................................... 3-15

3.4 Air detector ..................................................................................................................... 3-31

4 Calibration program ..................................................................................................... 4-

5 Diagnostics program.................................................................................................... 5-

5.1 General notes ................................................................................................................. 5-3

5.2 Menu structure ................................................................................................................ 5-5

5.3 Reading the analog inputs of CPU I ............................................................................... 5-7

5.4 Reading the analog inputs of CPU II .............................................................................. 5-9

5.5 Reading the digital inputs of CPU I ................................................................................ 5-10

5.6 Reading the digital inputs of CPU II ............................................................................... 5-15

5.7 Writing the analog outputs of CPU I ............................................................................... 5-19

5.8 Writing the analog outputs of CPU II .............................................................................. 5-20

5.9 Writing the digital outputs of CPU I ................................................................................ 5-21

5.10 Writing the digital outputs of CPU II ............................................................................... 5-27

5.11 Writing/Reading the digital outputs of CPU I.................................................................. 5-30

5.12 ONLINE

5.13 HPU ................................................................................................................................ 5-32

6 Setup menu ................................................................................................................... 6-

6.1 Overview Setup menu settings ....................................................................................... 6-3

6.2 Overview ......................................................................................................................... 6-7

6.3 Main menu 4008 E/B ...................................................................................................... 6-9

6.4 Main menu 4008 H/S ...................................................................................................... 6-37

7 Miscellaneous ............................................................................................................... 7-

plus

™ module ..................................................................................................... 5-31

Fresenius Medical Care 4008 5/03.09 (TM) 0-5

Section Page

8 Circuit diagrams and circuit descriptions ................................................................. 8-

8.1 Block diagram 4008 ........................................................................................................ 8-3

8.2 Block diagram of voltage supply .................................................................................... 8-4

8.3 Block diagram of screen 4008 H/S ................................................................................. 8-5

8.4 Connection layout diagram ............................................................................................. 8-6

8.5 P.C.B. LP 450-2 Level detector control (LD) .................................................................. 8-9

8.6 P.C.B. LP 493 Blood leak detector ................................................................................. 8-11

8.7 P.C.B. LP 624 Control board (BP).................................................................................. 8-12

8.8 P.C.B. LP 630 Motherboard ........................................................................................... 8-13

8.9 P.C.B. LP 631 CPU 1 ..................................................................................................... 8-14

8.10 P.C.B. LP 632 CPU 2 ..................................................................................................... 8-16

8.11 P.C.B. LP 633 Input board ............................................................................................. 8-18

8.12 P.C.B. LP 634 Output board........................................................................................... 8-20

8.13 P.C.B. LP 635 Display board.......................................................................................... 8-22

8.14 P.C.B. LP 636 External connectors................................................................................ 8-24

8.15 P.C.B. LP 950 Control board (HEP) ............................................................................... 8-25

8.16 P.C.B. LP 644-4 Display board (HEP)............................................................................ 8-26

8.17 P.C.B. LP 645 Position sensor membrane pump........................................................... 8-27

8.18 P.C.B. LP 649-2 Display board (4008 B/S) .................................................................... 8-28

8.19 P.C.B. LP 742 Interference filter..................................................................................... 8-30

8.20 P.C.B. LP 748 Display board (BP) ................................................................................. 8-31

8.21 P.C.B. LP 763 Multi interface board (COMMCO III) ...................................................... 8-32

8.22 P.C.B. LP 922 Display board (4008 S)........................................................................... 8-33

8.23 P.C.B. LP 923 Traffic light (4008 H/S) ........................................................................... 8-34

8.24 P.C.B. LP 924 Display board (4008 H) .......................................................................... 8-35

8.25 P.C.B. LP 941 Hydraulics processor .............................................................................. 8-36

8.26 Heater board (power supply unit 4008) .......................................................................... 8-37

8.27 Power board (power supply unit 4008) .......................................................................... 8-38

0-6 Fresenius Medical Care 4008 5/03.09 (TM)

Table of contents
1 Description of system functions and malfunctions

Section Page

1.1 Description of the T1 test ............................................................................................ 1-3

1.1.1 T1 test flow diagram, serial program steps .................................................................... 1-3

1.1.2 T1 test flow diagram, parallel program steps ................................................................. 1-5

1.1.3 Description of the T1 test incl. error messages .............................................................. 1-7

1.1.4 Description of system errors during the cleaning programs .......................................... 1-53

1.1.5 Error messages after turning power on .......................................................................... 1-70

1.1.6 Error messages during dialysis ...................................................................................... 1-71

1.2 Functional description of the modules ...................................................................... 1-78

1.2.1 Blood pump (arterial) ...................................................................................................... 1-78

1.2.2 Blood pump (Single-Needle), optional ........................................................................... 1-79

1.2.3 Heparin pump ................................................................................................................. 1-80

1.2.4 Air detector ..................................................................................................................... 1-82

1.3 Functional description of the hydraulic unit ............................................................. 1-83

Fig.: Flow diagram

1.3.1 Description of the hydraulic unit ..................................................................................... 1-85

1.3.2 Theory of operation of the balancing chamber .............................................................. 1-87

1.3.3 Central delivery system option ....................................................................................... 1-91

1.3.4 Program sequences during the cleaning programs ....................................................... 1-92

Fig.: Flow chart of cleaning programs – overview

.......................................................................................................... 1-83

.......................................................... 1-92

Fresenius Medical Care 4008 5/03.09 (TM) 1-1

1-2 Fresenius Medical Care 4008 5/03.09 (TM)

1.1 Description of the T1 test

1.1.1 T1 test flow diagram, serial program steps

MODULE

T1

START T1 TEST

TEST

BYPASS

TEST OK?no

yes

TEST

OPT. DETECTOR

TEST OK?no

yes

TEST

BLOOD SYSTEM

TEST OK?no

yes

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

TEST

ACCUMULATOR

TEST OK?no

yes

TEST

BLOOD LEAK DETECTOR

TEST OK?no

yes

TEST

TEMPERATURE

TEST OK?no

yes

NEG. PRESSURE

HOLDING TEST

TEST OK?no

yes

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

TEST

VENOUS PRESSURE

TEST OK?no

yes

TEST

AIR DETECTOR

TEST OK?no

yes

TEST

DISPLAY

TEST OK?no

yes

TEST

ARTERIAL PRESSURE

TEST OK?no

yes

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

POS. PRESSURE

HOLDING TEST

TEST OK?no

yes

TEST

UF-FUNCTION

TEST OK?no

yes

TEST

CONDUCTIVITY

TEST OK?no

yes

Basic hydraulics Advanced hydraulics

TEST

DIASAFE/HDF FILTER

TEST OK?no

yes

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

STORAGE

ERROR NUMBER

TEST DIASAFE PLUS /

ONLINE PLUS /

HPU TEST

STORAGE

ERROR NUMBER

1

Fresenius Medical Care 4008 5/03.09 (TM) 1-3

1

T1 TEST

UNSUCCESSFUL

no

RETURN

yes

DIALYSIS START KEY

INCORRECT

TEST STEP

TEST OK?no

yes

FURTHER
INCORRECT
TEST STEPS

no

RETURN

yes

ERROR

DISPLAY

NEXT INCORRECT

TEST STEP

1-4 Fresenius Medical Care 4008 5/03.09 (TM)

1.1.2 T1 test flow diagram, parallel program steps

/

MODULE

T1

START T1 TEST

TEST

OPT. DETECTOR

TEST OK

?

no

STORAGE

ERROR NUMBER

TEST

BLOOD SYSTEM

yes

TEST OK

?

1 1 1 1

STORAGE

ERROR NUMBER

TEST

VENOUS PRESSURE

TEST OK

?

STORAGE

ERROR NUMBER

TEST

AIR DETECTOR

TEST OK

?

STORAGE

ERROR NUMBER

yes

no

yes

no

yes

no

1 1

TEST

BYPASS

TEST OK

?

no

STORAGE

ERROR NUMBER

TEST

TEMPERATURE

TEST OK

?

no

STORAGE

ERROR NUMBER

NEG. PRESSURE

HOLDING TEST

TEST OK

?

no

STORAGE

ERROR NUMBER

TEST

DISPLAY

yes

TEST OK

?

STORAGE

ERROR NUMBER

yes

TEST

BLOOD LEAK DETECTOR

yes

TEST OK

?

STORAGE

ERROR NUMBER

TEST

ACCUMULATOR

yes

TEST OK

?

no

STORAGE

ERROR NUMBER

yes

no

yes

no

TEST

ARTERIAL PRESSURE

TEST OK

?

no

STORAGE

ERROR NUMBER

yes

POS. PRESSURE

HOLDING TEST

TEST OK

?

no

STORAGE

ERROR NUMBER

TEST

CONDUCTIVITY

TEST OK

?

no

STORAGE

ERROR NUMBER

TEST

DIASAFE/HDF FILTER

TEST OK

?

no

STORAGE

ERROR NUMBER

yes

yes

ERROR NUMBER

yes

1

TEST

UF-FUNCTION

TEST OK

?

no

STORAGE

Conductivity?

yes

yesno

TEST

CONDUCTIVITY

TEST OK

?

no

STORAGE

ERROR NUMBER

POS. PRESSURE

HOLDING TEST

TEST OK

?

no

STORAGE

ERROR NUMBER

TEST

UF-FUNCTION

TEST OK

?

no

STORAGE

ERROR NUMBER

yes

yes

Basic hydraulics Advanced hydraulics

TEST

TEST

DIASAFE/HDF FILTER

DIASAFE/HDF FILTER

yes yes

TEST OK

?

1 1

no

STORAGE

ERROR NUMBER

TEST DIASAFE PLUS

ONLINE PLUS /

HPU-TEST

Fresenius Medical Care 4008 5/03.09 (TM) 1-5

1

T1 TEST

UNSUCCESSFUL

no

RETURN

yes

DIALYSIS START KEY

INCORRECT

TEST STEP

TEST OK?no

yes

FURTHER
INCORRECT
TEST STEPS

yes

RETURN

no

ERROR

DISPLAY

NEXT INCORRECT

TEST STEP

1-6 Fresenius Medical Care 4008 5/03.09 (TM)

1.1.3 Description of the T1 test incl. error messages

● Prerequisites for starting and running the test

Error message Description

Power failure Power failure while the test is in progress

Dialines not conn The dialysate lines are not in the interlock shunt.

Shunt Cover open The interlock shunt is open.

Connect Conc.Line
Wrong conc. supply The concentrate connector is in the rinse chamber, or concen-

trate is not connected at all. The error message depends on the
central delivery system preselected in the setup menu.

Blood Sensed by OD The optical detector senses blood in the system.

Flow alarm Line to or from the dialyzer kinked, malfunctions in the hydraul-

ics.

Water alarm Water supply interrupted.

XXX not calibrated A valid calibration value is missing in the NOVRAM.

● Overview of the individual test steps

Bypass test ..................................................................................................................... 1-8

Optical detector test ....................................................................................................... 1-10

Blood system test ........................................................................................................... 1-12

Venous pressure system test ......................................................................................... 1-16

Air detector test .............................................................................................................. 1-18

Display test ..................................................................................................................... 1-22

Arterial pressure system test .......................................................................................... 1-24

Battery test ..................................................................................................................... 1-26

Blood leak test ................................................................................................................ 1-28

Temperature test ............................................................................................................ 1-30

Negative pressure holding test ....................................................................................... 1-32

Positive pressure holding test ........................................................................................ 1-34

UF function test .............................................................................................................. 1-39

Conductivity test ............................................................................................................. 1-42

Diasafe/HDF filter test .................................................................................................... 1-44

Online plus / Diasafe plus filter / HPU test ..................................................................... 1-48

Fresenius Medical Care 4008 5/03.09 (TM) 1-7

● Bypass test

H_REL_W
EM_H_OFF

V24_EN
V24B_EN

CI

V26
V24B
V24

V24

V24B

V26

X631/A20

X631/A21

X632/B27

X632/B28

X632/A4

X632/A5

X632/A6

X632/B22

X632/C26

X632/C25

X632/A6

X632/A9

X632/A10

X639/A12
X639/A17

C22

A18

X634R/

X634R/

V26

X634R/

X634R/

A23

V24

V24B

V26

X634L/C25

X634L/C12

X634L/A25

HOT_RINSE

C24

X639/
A20

X632/A26

Test description:

Check of the following functions:
– Heater relay
– Bypass (electric)
– Check of the temperature range changeover

Illustration:

LP 632

CPU 2

LP 639

(4008E/H)

Power

Logic

LP 647

(4008S/B)

LP 631

CPU 1

LP 635

(4008 E)

Display

LP 924

(4008 H)

LP 630

Mother

board

LP 649

(4008 B)

board

LP 922

(4008 S)

Testgenerierung/Generation of Test

Rueckmeldung/Acknowledgement

LP 633

Input

board

DATA BUS

LP 634

Output

board

1-8 Fresenius Medical Care 4008 5/03.09 (TM)

Error description:

Error message Description

F 01 Bypass The heater relay is switched off.

– Acknowledgement (H_REL_W, X639/A12) → X632/A10, 0 V are

missing.

F 02 Bypass The heater relay cannot be switched off by CPU2.

– Acknowledgement (H_REL_W, X639/Y12) → X632/A10, 12 V are

missing.

– Control line (EM_H_OFF, X632/A9) → X639/A17, 12 V are missing.

F 03 Bypass The temperature measurement range is set to hot rinse.

– Control line (HOTRINSE, X634R/C24) → X639/A20, 0 V are miss-

ing.

– Acknowledgement (HOTRINSE, X634R/C24) → X632/A26, 0 V are

missing.

F 04 Bypass The extended bypass cannot be correctly switched by CPU2 (V24 = off,

V26 = on, V24B = off).
– Acknowledgement (V24, X637/C1) → X632/A4, 24 V are missing.
– Acknowledgement (V26, X637/C2) → X632/A6, 0 V are missing.
– Acknowledgement (V24B, X637/C23) → X632/A5, 24 V are miss-

ing.

F 05 Bypass The extended bypass cannot be correctly switched off by CPU2 (V24 =

on, V26 = off, V24B = on).
– Acknowledgement (V24, X637/C1) → X632/A4, 0 V are missing.
– Acknowledgement (V26, X637/C2) → X632/A6, 24 V are missing.
– Acknowledgement (V24B, X637/C23) → X632/A5, 0 V are missing.

F06 Bypass CPU1 fails to set the temperature control to hot rinse.

– Control line (HOTRINSE, X634R/C24) → X639/A20, 12 V are miss-

ing.

– Acknowledgement (HOTRINSE, X634R/C24) → X632/A26, 12 V

are missing.

F 07 Bypass The extended bypass cannot be correctly switched by CPU1 (V24 = off,

V26 = on, V24B = off).
– Acknowledgement (V24, X637/C1) → X632/A4, 24 V are missing.
– Acknowledgement (V26, X637/C2) → X632/A6, 0 V are missing.
– Acknowledgement (V24B, X637/C23) → X632/A5, 24 V are miss-

ing.

F08 Bypass CPU1 fails to reset the temperature control to dialysis.

– Control line (HOTRINSE, X634R/C24) → X639/A20, 0 V are miss-

ing.

– Acknowledgement (HOTRINSE, X634R/C24) → X632/A26, 0 V are

missing.

F09 Bypass The extended bypass cannot be correctly switched off by CPU1 (V24 =

on, V26 = off, V24B = on).
– Acknowledgement (V24, X637/C1) → X632/A4, 0 V are missing.
– Acknowledgement (V26, X637/C2) → X632/A6, 24 V are missing.
– Acknowledgement (V24B, X637/C23) → X632/A5, 0 V are missing.

F95 Bypass System error

Fresenius Medical Care 4008 5/03.09 (TM) 1-9

● Optical detector test

Test description:

Attenuation of the optical detector.
Check of the acknowledgement of the optical detector.

Illustration:

LP 632

CPU 2

B27

A20

LP 631

CPU 1

LP 635

(4008 E)

LP 924

(4008 H)

X632/B28

X631/A21

Display

board

X632/C16

X632/C15

X632/A30

LP 649

(4008 B)

LP 922

(4008 S)

LP 630

Mother

board

LDSA

ODSA

OD_OUT

X633L/C7

LP 633

Input

board board

X633L/C8

OD_IN

DATA BUS

X351/5

Pven

X351/7

X351/10

LP 634

Output

Testgenerierung/Generation of Test

Rueckmeldung/Acknowledgement

1-10 Fresenius Medical Care 4008 5/03.09 (TM)

Error description:

Error message Description

F01 opt. Detector CPU1 interprets the optical detector in a different way than does CPU2.

– Acknowledgement (OD_OUT, X633L/C7) → X632/A30 and the

digital input of P.C.B. LP 633 measure different levels.

F02 opt. Detector CPU2 fails to recognize blood in the system.

– Acknowledgement (OD_OUT, X633L/C7) → X632/A30, 0 V are

missing.

– Detuning (ODSA, X632/C15) → X351/7 not 12V.

F03 opt. Detector CPU1 fails to recognize blood in the system.

– Acknowledgement (OD_OUT, X633L/C7) → digital input on P.C.B.

LP 633.

– Detuning (ODSA, X632/C15) → X351/7 not 12V.

F04 opt. Detector CPU2 recognizes that the optical detector senses opaque fluid (re-

quired because of the test in the cleaning program).
– Acknowledgement X632/A30 not 12V.
– AD28 defective.

F96 opt. Detector System error.

Fresenius Medical Care 4008 5/03.09 (TM) 1-11

● Blood system test

Test description:

Check of the following functions:
– Blood alarm acknowledgement
– Blood pump switch-off

Illustration:

X632/B27

X631/A20

LP 632

CPU 2

LP 631

CPU 1

X632/C10

X632/C14

X632/C21

X632/B11

X632/A11

X632/A15

X632/B28

X631/A21

LP 630

Mother

board

CLP_CTL

LDA2

BL_AL

BPSB_VEN

BPSB_ART

SN_ART

X633L/
C13

DATA BUS

LP 633

Input

board

A13

X633L/

X634L/

C15

X634L/

A14

A15

LP 634

(4008E/H)

Output

board

LP 647

(4008S/B)

BPST_ART

BPSST_A

X634L/

B14

B15

BPSST_V

X634L/

C14

LP 635

(4008 E)

Display

LP 924

(4008 H)

LP 649

(4008 B)

board

LP 922

(4008 S)

Testgenerierung/Generation of Test

Rückmeldung/Acknowledgement

X348a/2

X348a/6

X348a/3

X348a/1

X348/V6

X348/V3

X348/V1

Pven

X351/8

X351/6

1-12 Fresenius Medical Care 4008 5/03.09 (TM)

Error description:

Error message Description

F09 Bloodsystem Acknowledgement that CPU2 recognizes that the arterial blood pump

is inactive (BP not running).
– Acknowledgement (BPSB_ART, X348a/6) → X632/A11, 12 V miss-

ing.

– Control line (BPSST_ART, X634L/B14) → X348a/1, 12 V missing or

(BPST_ART, X634L/A14) → X348a/3, 12 V are missing.

F10 Bloodsystem Acknowledgement that CPU1 recognizes that the arterial blood pump

is inactive (BP not running).
– Acknowledgement (BPSB_ART, X348a/6) → X633L/A11, 12 V are

missing.

– Control line (BPSTT_ART, X634L/B14) → X348a/1, 12 V missing or

(BPST_ART, X634L/A14) → X348a/3, 12 V missing.

– Level is raised during the T1 test.

F11 Bloodsystem The arterial blood pump cannot be stopped by CPU1.

CPU2 recognizes that the arterial blood pump remains active.
– Control line (BPSST_ART, X634L/B14) → X348a/1, 0 V missing,

as well as (BPST_ART, X634L/A14) → X348a/3, 0 V missing.

– Acknowledgement (BPSB_ART, X348a/6) → X632/A11, 0 V are

missing.

– The level is raised during the T1 test, or the up/down key on the air

detector is blocked and the level is constantly raised.

F12 Bloodsystem The arterial blood pump cannot be stopped by CPU1.

CPU1 recognizes that the arterial blood pump remains active.
– Control line (BPSST_A, X634L/B14) → X348a/1, 0 V missing,

as well as (BPST_ART, X634L/A14) → X348a/3, 0 V missing.

– Acknowledgement (BPSB_ART, X348a/6) → X633L/A11, 0 V are

missing.

F13 Bloodsystem

Applicable for SW 4.91/2.91 and higher if SN, ONLINE-HDF or
4008 HDF pump is connected (= ADKS active)

Acknowledgement that CPU2 detects that the pump is inactive (pump
is not running).
– Acknowledgement (BPSB_VEN, X348V/6) → X632/ B11, 12V

missing

– Control line (BPSST_VEN, X634L/B15) → X348V/1, 12V missing or

(BPST_VEN, X634L/A15) → X348V/3, 12V missing

– Transistor T9 on P.C.B. LP 754 defective
– IC5 on P.C.B. LP 632 defective
– In 4008 HDF an HDF treatment was performed, followed by a

cleaning program with the substituate pump running, then the T1
test has been re-started.
The substituate pump must be switched off because otherwise the
test step will fail to be passed (problem was corrected with SW 3.20
in 4008 H/S systems: the substituate pump will be switched off
automatically on starting a cleaning program).

Fresenius Medical Care 4008 5/03.09 (TM) 1-13

F14 Bloodsystem

Applicable for SW 4.91/2.91 and higher if SN, ONLINE-HDF or
4008 HDF pump is connected (= ADKS active)

Acknowledgement that CPU1 detects that the pump is inactive (pump
is not running).
– Acknowledgement (BPSB_VEN,X348V/6) → X633L/A13, 12V

missing

– Control line (BPSST_VEN, X634L/B15) → X348V/1 not 12V or

(BPST_VEN, X634L/A15) → X348V/3 not 12V

– IC16 on P.C.B. LP 633 defective
– P.C.B. LP 633 recognizes Single-Needle pump although it is not

connected.

F15 Bloodsystem

F16 Bloodsystem

Applicable for SW 4.91/2.91 and higher if SN, ONLINE-HDF or
4008 HDF pump is connected (= ADKS active)

CPU1 fails to stop the corresponding blood pump.
CPU2 detects that the pump remains active.
– Control line (BPSST_VEN, X634L/B15) → X348V/1, 0V missing as

well as (BPST_VEN, X634L/A15) → X348V/3 not 0V

– Acknowledgement (BPSB_VEN, X348V/6) → X632/B11, 0V miss-

ing
– Transistor T9 on P.C.B. LP 754 defective
– IC5 on P.C.B. LP 632 defective
– During the test the lines are inserted on the corresponding pump

using the Start/Stop key.
– P.C.B. LP 633 recognizes Single-Needle pump although it is not

connected.

Applicable for SW 4.91/2.91 and higher if SN, ONLINE-HDF or
4008 HDF pump is connected (= ADKS active)

CPU1 fails to stop the corresponding blood pump.
CPU1 detects that the pump remains active.
– Control line (BPSST_VEN, X634L/B15) → X348V/1 not 0V as well

as (BPST_VEN, X634L/A15) → X348V/3 not 0V
– Acknowledgement (BPSB_VEN, X348V/6) → X633L/A13 not 0V
– IC16 on P.C.B. LP 633 defective
– P.C.B. LP 633 recognizes Single-Needle pump although it is not

connected.

F17 Bloodsystem

Applicable for SW 4.91/2.91 and higher if SN, ONLINE-HDF or
4008 HDF pump is connected (= ADKS active)

Although the recognition of the venous blood pump (ADKS) is not
acknowledged, the 24-V supply voltage of the pump can be switched
off.
– Acknowledgement line (ADKS, X348V/7) → X633L/A10 not 12V
– Acknowledgement (BPSB_VEN, X348V/6) → X633L/A13 not 12V
– Acknowledgement (BPSB_VEN, X348V/6) → X632/B11 not 12V
– Online-HDF has already been switched on during the T1 test.
– IC16 on P.C.B. LP 633 defective.

1-14 Fresenius Medical Care 4008 5/03.09 (TM)

F18 Bloodsystem

Applicable for SW 5.00/4.10 and higher, check of the BPUS signal

(CPU, P.C.B. LP 632)

At the beginning of the test step a maximum of 40s may pass until

rotation has stopped.If the blood pump is being activated, the rotation

stop alarm must have been cleared.

– Acknowledgement line (BPUS, X348A/8) → X632/A13 not 0V

– Acknowledgement line (BPUS, X348A/8) → X632/A13 not 12V

– Blood pump speed is set to “0”: preset speed during the T1 test.

F19 Bloodsystem

Applicable for SW 5.00/4.10 and higher, check of the BPUS signal

(CPU, P.C.B. LP 631 via LP633)

At the beginning of the test step a maximum of 40s may pass until

rotation has stopped. If the blood pump is being activated, the rotation

stop alarm must have been cleared.

1. Acknowledgement line (BPUS, X348A/8) → X633L/A12 not 0V

2. Acknowledgement line (BPUS, X348A/8) → X633L/A12 not 12V

F20 Bloodsystem Check of the actual arterial BP rate.

The actual rate of the arterial BP is not zero. The actual rate of the

arterial BP does not increase.

If SN is installed: The actual rate of the venous BP is not zero. The

actual rate of the venous BP does not increase.

– Acknowledgement line (BPR_ART, X348A/10) → X633L/B3 not 0V

or acknowledgement line (BPR_ART, X348A/10) → X632/A14 not
0V

– Acknowledgement line (BPR_ART, X348A/10) → X633L/B3 no

increase or acknowledgement line (BPR_ART, X348A/10) → X632/
A14 no increase

If SN is installed:

– Acknowledgement line (BPR_VHDF, X348V/10) → X633L/B4 not

0V

– Acknowledgement line (BPR_VHDF, X348V/10) → X633L/B4 no

increase

F95 Bloodsystem System error.

Fresenius Medical Care 4008 5/03.09 (TM) 1-15

● Venous pressure system test

X

X

Test description:

Verification of the lower limit by checking the venous zero point.
The upper limit is tested by detuning the venous pressure unit in positive direction.
(The venous line clamp is closed during the test.)

Illustration:

LP 632

X632/C16

LDSA

CPU 2

PV_DET

P_VEN

Input

LP 633

LP 634

Output

632/B27

X632/C18

X632/C17

X632/B28

boardboard

X634R/C18

VENT_V

631/A20

LP 631

CPU 1

X631/A21

LP 630

X633L/B5

DATA BUS

Mother

board

LP 635

(4008 E)

LP 649

X351/1

(4008 B)

X351/2

P

VEN

Display

board

LP 924

(4008 H)

LP 922

(4008 S)

X351/4

X351/10

Testgenerierung/Generationof Test

Rueckmeldung/Acknowledgement

1-16 Fresenius Medical Care 4008 5/03.09 (TM)

Error description

Error message Description

F01 Venous CPU1 (input board) shows a venous zero point deviation of more than

±12 mmHg (60 s).

– Control (VENT_VALVE, X634R/C18) → X351/1 of the vent valve in

the LD is defective.

– Acknowledgement (P_VEN, X351/4) → X633L/B5 that the voltage

value is outside the zero point tolerance.

– P-venous has not been calibrated.

F02 Venous CPU2 shows a venous zero point deviation of more than ±12 mmHg

(60 s).

– Control (VENT_VALVE, X634R/C18) → X351/1 of the vent valve in

the LD is defective.

– Acknowledgement (P_VEN, X351/4) → X632/C17, the voltage

value is outside the zero point tolerance.

– P-venous has not been calibrated.

F03 Venous With detuning in positive direction, the achieved change in the venous

display is less than 100 mmHg (7 s).

– The test detuning is defective (PV_DET, X632/C18) → X351/2.

– Acknowledgement (P_VEN, X351/4) → X633L/B5, the change in

voltage is too low.

– P-venous has not been calibrated.

F04 Venous The deviation in the measured value between CPU1 and CPU2 is

higher than ±12 mmHg (if Pven > 100 mmHg).

– Acknowledgement (P_VEN, X351/4) → X633L/B5 and X632/C17

measure different voltage values.

– P-venous has not been calibrated.

F95 Venous System error.

Fresenius Medical Care 4008 5/03.09 (TM) 1-17

● Air detector test

Test description:

– Test of the air detector by checking the alarm state.
– Switch-off of the venous line clamp in the air detector module.

Illustration:

1-18 Fresenius Medical Care 4008 5/03.09 (TM)

Error description:

Error message Description

F01 Airdetector CPU1 interprets the air detector signal in a different way than does

CPU2.

– Acknowledgements (LDA1, X351/14) → X632/C13 and X633L/C10

recognize different signal levels.

F02 Airdetector The air detector alarm is not recognized by CPU2.

– Acknowledgement (LDA1, X351/14) → X632/C13, 0 V are missing.

– Transmission weakening (LDSA, X632/C16) → X351/10, 12 V are

missing.

F03 Airdetector Air detector clamps acknowledgement (CPU2) activated (clamp

closed).

– Acknowledgement (LDA2, X351/6) → X632/C14, 24 V are missing.

– Clamp control (CLP_CTL, X634L/C14) → X351/8, 12 V are missing.

– Clamp control (CLP_CTL, X632/C10) → X351/8, 12 V are missing.

F04 Airdetector Air detector clamps acknowledgement (CPU1) activated (clamp

closed).

– Acknowledgement (LDA2, X351/6) → X633L/C13, 24 V are miss-

ing.

– Clamp control (CLP_CTL, X634L/C14) → X351/8, 12 V are missing.

– Clamp control (CLP_CTL, X632/C10) → X351/8, 12 V are missing.

F05 Airdetector The blood alarm signal has not been cleared (indicates an alarm).

– Acknowledgement (BL_AL, X634L/C15) → X632/C21, 12 V are

missing.

If the HDF option is used, this signal is not tested (special function).

F06 Airdetector Closing of the air detector clamp via the CPU2 control line was not

possible.

– Clamp control (CLP_CTL, X632/C10) → X351/8, 0 V are missing.

– Acknowledgement (LDA2, X351/6) → X632/C14, 0 V are missing.

F07 Airdetector Opening of the air detector clamp via the CPU2 control line was not

possible.

– Clamp control (CLP_CTL, X632/C10) → X351/8, 12 V are missing.

– Acknowledgement (LDA2, X351/6) → X632/C14, 24 V are missing.

F08 Airdetector Closing of the air detector clamp via the CPU1 control line was not

possible, or CPU2 acknowledgement is incorrect.

– Clamp control (CLP_CTL, X634L/C14) → X351/8, 0 V are missing.

– Acknowledgement (LDA2, X351/6) → X632/C14, 0 V are missing.

Fresenius Medical Care 4008 5/03.09 (TM) 1-19

F09 Airdetector Closing of the air detector clamp via the CPU1 control line was not

possible, or CPU1 acknowledgement is incorrect.
– Clamp control (CLP_CTL, X634L/C14) → X351/8, 0 V are missing.
– Acknowledgement (LDA2, X351/6) → X633L/C13, 0 V are missing.

F10 Airdetector The blood alarm message is missing.

– Acknowledgement (BL_AL, X634R/C15) → X632/C21, 0 V are

missing.

If the HDF option is used, this signal is not tested (special function).

F11 Airdetector Air detector clamps acknowledgement (CPU2) activated (clamp

closed).
– Acknowledgement (LDA2, X351/6) → X632/C14, 24 V are missing.
– Clamp control (CLP_CTL, X634L/C14) → X351/8, 12 V are missing.
– Clamp control (CLP_CTL, X632/C10) → X351/8, 12 V are missing.

F12 Airdetector Air detector clamps acknowledgement (CPU1) activated (clamp

closed).
– Acknowledgement (LDA2, X351/6) → X633L/C13, 24 V are miss-

ing.
– Clamp control (CLP_CTL, X634L/C14) → X351/8, 12 V are missing.
– Clamp control (CLP_CTL, X632/C10) → X351/8, 12 V are missing.

F13 Airdetector The blood alarm signal has not been cleared (indicates alarm).

– Acknowledgement (BL_AL, X634L/C15) → X632/C21, 12 V are

missing.

If the HDF option is used, this signal is not tested (special function).

F14 Airdetector Raise level key on the air detector is constantly active.

– Acknowledgement (LEVEL_UP, X351/3) → X632/C11 not 0V.

F15 Airdetector Acknowledgement of the supply voltage for the ultrasonic output stage

not between 6.5 and 13.5 V after 3 seconds.
– Adapter board AD28 not connected
– Acknowledgement (X351/11 → X633L/25A jumper to X633L/B7)

not 12V.
– Relay on AD28 failed to drop.

F16 Airdetector Acknowledgement of the supply voltage for the ultrasound output stage

not >14.5V after 3 seconds.
– Adapter board AD28 not connected.
– Acknowledgement (X351/11 → X633L/25A jumper to X633L/B7)

not 16V/24V.
– Relay on AD28 is not controlled.
– No 10-Hz signal at ALARM_REST (X351/12)

1-20 Fresenius Medical Care 4008 5/03.09 (TM)

F17 Airdetector Acknowledgement of the supply voltage for the ultrasound output stage

not between 6.5 and 13.5 V after 3 seconds.

– Adapter board AD28 not connected

– Acknowledgement (X351/11 → X633L/25A jumper to X633L/B7)

not 12V

– Relay on AD28 failed to drop

F95 Airdetector System error.

Fresenius Medical Care 4008 5/03.09 (TM) 1-21

● Display test

Test description:

Check of all displays and indicators on the monitor front
– Display test
– Status LED
– Alarm LED
– Seven-segment display, all dark
– Seven-segment display, all 8888
– Bar graph
– CPU1/CPU2 alarm tone

This display test must be monitored by the user!

Illustration:

X632/ B27

X631/ A20

LP 632

CPU 2

LP 631

CPU 1

LP 635

(4008 E)

LP 924

(4008 H)

X632/ B28

X631/ A21

Display

board

X632/C29

LP 649

(4008 B)

LP 922

(4008 S)

LP 630

Mother

board

CPU2_AL

LP 633

Input

board board

DATA BUS

Test Display

8888

8888

8888

8888

X634R/A16

LP 634

Output

+LS X634L/A13

-LS X634L/B13

Testgenerierung/Generation of Test

Rueckmeldung/Acknowledgement

1-22 Fresenius Medical Care 4008 5/03.09 (TM)