Fresenius Medical Care 2008K Troubleshooting Manual
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Fresenius Medical Care 2008K Troubleshooting Manual

Hemodialysis system
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FRESENIUS 2008K
HEMODIALYSIS SYSTEM
TROUBLESHOOTING GUIDE
FOR TRAINING PURPOSES ONLY
Part Number 507298 Rev B (Draft 1)
2002 - 2009 Fresenius Medical Care North America

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Summary of Contents for Fresenius Medical Care 2008K

  • Page 1 FRESENIUS 2008K HEMODIALYSIS SYSTEM TROUBLESHOOTING GUIDE FOR TRAINING PURPOSES ONLY Part Number 507298 Rev B (Draft 1) 2002 - 2009 Fresenius Medical Care North America...

  • Page 3: Table Of Contents

    SECTION 17 - CHECKING THE SENSOR BOARD CABLE................228 SECTION 18A - AUTOMATED VALVE LEAK TESTS.................230 SECTION 18B - MANUAL BALANCING CHAMBER VALVE LEAK TESTS..........236 Continued On Next Page Fresenius 2008K Troubleshooting Guide Page 1 P/N 507298 Rev. B (Draft 1)
  • Page 4 SECTION 26 – “ACT BLOOD PUMP FAILED” MESSAGE................258 APPENDIX A – TARGET DEAERATION PRESSURES PER GEOGRAPHICAL AREA.......260 APPENDIX B – CALIBRATE IF REPLACED....................261 APPENDIX C – BLOOD PUMP ERROR CODES..................262 Fresenius 2008K Troubleshooting Guide Page 2 P/N 507298 Rev. B (Draft 1)

  • Page 5: Using The Troubleshooting Guide

    Filter Plus: Mounted externally on the rear panel of the machine ® 2. Old Style DiaSafe Filter: Mounted inside, on the floor of the hydraulic compartment Continued on next page Fresenius 2008K Troubleshooting Guide Page 3 P/N 507298 Rev. B (Draft 1)
  • Page 6 The connector caps are numerically labeled to match the distribution board position number. When replacing a component use a Sharpie to appropriately label its cap. Continued on next page Fresenius 2008K Troubleshooting Guide Page 4 P/N 507298 Rev. B (Draft 1)
  • Page 7 THE 8-PIN HEATER CONNECTOR PRESENTS AN ELECTROCUTION HAZARD. ALWAYS TURN THE POWER OFF AND/OR UNPLUG THE MACHINE BEFORE TOUCHING IT! Figure 3 – Distribution Board End of Using the Troubleshooting Guide Fresenius 2008K Troubleshooting Guide Page 5 P/N 507298 Rev. B (Draft 1)

  • Page 8: The (Hydraulic) 'Order Of Troubleshooting

    Assure that all five pin female connectors are plugged into their correct positions and aligned properly Check the eight-pin heater connector for brown or black discoloration Continued on next page Fresenius 2008K Troubleshooting Guide Page 6 P/N 507298 Rev. B (Draft 1)
  • Page 9 Treatment Options. Set ‘Forced Test’ to “No”. Press the ‘CONFIRM’ key (the “x” turns blue). Post a note as a reminder that Forced Test is off! End of Initial Checks Procedures Fresenius 2008K Troubleshooting Guide Page 7 P/N 507298 Rev. B (Draft 1)
  • Page 10 ALSO be installed otherwise a “Cond Ref” or “Cond Offset” error occurs. If a new style Power Logic Board is placed into a machine equipped with the old style Power Logic Board the Convertor board MUST be removed! Fresenius 2008K Troubleshooting Guide Page 8 P/N 507298 Rev. B (Draft 1)
  • Page 11 3.29 or greater If a new Actuator / Test Board is placed into the machine VOLTAGE DETECTOR CALIBRATION must be performed otherwise 5 or 12 volt alarms may occur Fresenius 2008K Troubleshooting Guide Page 9 P/N 507298 Rev. B (Draft 1)

  • Page 12: Final Checks

    ASSURE there is no flow through the external flow indicator (i.e. ‘bypass function’). 9. Perform Acid Clean and Bleach or Heat Disinfection per unit policy. End of Final Checks Procedures Fresenius 2008K Troubleshooting Guide Page 10 P/N 507298 Rev. B (Draft 1)

  • Page 13: Test Equipment

    TP 80 probes include a protective plastic cap to prevent shorting pins together when measuring voltages in tight areas. Figure 5 - Fluke Meter Accessories / Mag Probe Fresenius 2008K Troubleshooting Guide Page 11 P/N 507298 Rev. B (Draft 1)

  • Page 14: Operating Modes

    Hardware Options. Select “Yes” for T and C and press the ‘CONFIRM’ key (the ‘x’ turns blue). Turn the machine off, back on then enter whatever program is desired. End of Operating Modes Fresenius 2008K Troubleshooting Guide Page 12 P/N 507298 Rev. B (Draft 1)
  • Page 15 Figure 6 – Machine Rear View Fresenius 2008K Troubleshooting Guide Page 13 P/N 507298 Rev. B (Draft 1)

  • Page 16: Section 1 - Flow Errors In Dialysis Program

    NOTE B, page 8). If (and ONLY if) the problem still exists (i.e. bad or unstable +12 or +5 volts) after board replacement proceed to page Error! Bookmark not defined., SECTION 24 – TROUBLESHOOTING POWER DISTRIBUTION Fresenius 2008K Troubleshooting Guide Page 14 P/N 507298 Rev. B (Draft 1)
  • Page 17 BOTH motors from the distribution board to the motors. If (and ONLY if) both motors are connected properly replace the actuator board. The “Select Program” screen is required! Repeat procedure number F- 1.0.3 (page 15). Fresenius 2008K Troubleshooting Guide Page 15 P/N 507298 Rev. B (Draft 1)
  • Page 18 IMPORTANT! b) Leaving the “AIR-SEN” position EMPTY, ALLOW up to 30 seconds. FILACT response is not instantaneous! c) From debug screen 1, does FILACT = 1? Fresenius 2008K Troubleshooting Guide Page 16 P/N 507298 Rev. B (Draft 1)
  • Page 19 “Adjusting TMP” message to expire. If a TMP alarm returns repeat the RESET sequence up to twice more then see procedure number F- 2.0.3 (page 18). See procedure number F- 2.0.3 (page 18). Fresenius 2008K Troubleshooting Guide Page 17 P/N 507298 Rev. B (Draft 1)
  • Page 20 NOT visible see procedure number F- 15.0.0 (page 53). c) Does loading pressure MAXIMUM remain low? Fresenius 2008K Troubleshooting Guide Page 18 P/N 507298 Rev. B (Draft 1)
  • Page 21 (idle flow option). If (and ONLY if) flow rate has changed repeat procedure number F- 2.0.8 (page 19). b) There is a problem with the ‘In Bypass’ circuit. See procedure number F- 5.0.0 (page 25). Fresenius 2008K Troubleshooting Guide Page 19 P/N 507298 Rev. B (Draft 1)
  • Page 22 Turn Dialysate flow OFF (Dialysate Flow on/off LED blinks). c) Remove the red connector and hang it over the dialyzer holder. IMPORTANT! Close the shunt door. Ignore “Emptying” related messages. Fresenius 2008K Troubleshooting Guide Page 20 P/N 507298 Rev. B (Draft 1)
  • Page 23 If (and ONLY if) the Dialysate flow on/off LED is blinking repeat procedure number F- 3.4.0 (page 21) from part e. c) See procedure number F- 3.5.0 (page 22). Fresenius 2008K Troubleshooting Guide Page 21 P/N 507298 Rev. B (Draft 1)
  • Page 24 “AIR-SEN”. c) Allow 30 seconds. Call debug screen 1 and assure FILACT = 0 constant indicating the air sensor is plugged in correctly. Continued on next page! Fresenius 2008K Troubleshooting Guide Page 22 P/N 507298 Rev. B (Draft 1)
  • Page 25 Turn the machine off then back on. b) Return to Dialysis program (remember to press the ‘CONFIRM’ key). c) ASSURE Dialysate flow in ON (Dialysate Flow on/off LED off). Fresenius 2008K Troubleshooting Guide Page 23 P/N 507298 Rev. B (Draft 1)
  • Page 26 Two possibilities: 1) Bad actuator board; 2) Bad function board. NOTE which valve(s) is exhibiting bad resistance then see procedure number F- 4.4.0 (page 25). Figure 8 – Checking Solenoid Resistances (V43, V24) Fresenius 2008K Troubleshooting Guide Page 24 P/N 507298 Rev. B (Draft 1)
  • Page 27 Wiring harness tie wraps may have to be removed! e) If (and ONLY if) a wiring error is NOT located see procedure number F- 6.0.0 (page 26). Fresenius 2008K Troubleshooting Guide Page 25 P/N 507298 Rev. B (Draft 1)
  • Page 28 Observe drain flow for one minute. It will closely (if not exactly) match one of four scenarios. IMPORTANT! CAREFULLY consider ALL FOUR scenarios (next page) and respond accordingly: Fresenius 2008K Troubleshooting Guide Page 26 P/N 507298 Rev. B (Draft 1)
  • Page 29 See Figure D. If (and ONLY if) OBSERVED drain flow = Continuous slow flow. It NEVER, EVER stops. Individual ‘pulses’ CAN NEVER be distinguished: See procedure number F- 6.2.0 (page 29). Figure D Fresenius 2008K Troubleshooting Guide Page 27 P/N 507298 Rev. B (Draft 1)
  • Page 30 2) Pulse – Stop – Pulse – Dribble – etc: Call the Home screen. Is Conductivity greater than 16.5 See procedure number F- 7.0.0 (page 32). See procedure number F- 6.5.0 (page 31). Fresenius 2008K Troubleshooting Guide Page 28 P/N 507298 Rev. B (Draft 1)
  • Page 31 3. There is drain flow but it NEVER stops AND Conductivity is NOT greater than 16.0 mS: See procedure number F- 6.5.0 (page 31). See procedure number F- 15.0.0 (page 53). Fresenius 2008K Troubleshooting Guide Page 29 P/N 507298 Rev. B (Draft 1)
  • Page 32 Reattach valve #30’s tubing and return the dialyzer lines to the shunt b) See procedure number F- 7.0.0 (page 32). Figure 11 – Valve #30 Location (with Aliquot Option) Fresenius 2008K Troubleshooting Guide Page 30 P/N 507298 Rev. B (Draft 1)
  • Page 33 Watch the (green or red) ‘actual’ TMP bar. TMP is STABLE if (and ONLY if) it REMAINS between the 0 and 520 limits AND varies less than +/- 40 mmHg in two minutes. Proceed accordingly (three scenarios): Fresenius 2008K Troubleshooting Guide Page 31...
  • Page 34 If equipped with Test Valve #91, assure the knob is pointing to ‘DIALYZE’ (see Figure, right) otherwise flow is blocked at the valve. Proceed to F- 7.0.2 (page 33). Fresenius 2008K Troubleshooting Guide Page 32 P/N 507298 Rev. B (Draft 1)
  • Page 35 Do NOT unplug valve #37 until instructed otherwise! d) Four possible scenarios based on PART 1 AND PART 2 results. Respond according to Table 2 (page 34): Fresenius 2008K Troubleshooting Guide Page 33 P/N 507298 Rev. B (Draft 1)
  • Page 36 Valve #31 and/or valve #35 not opening! Automated Valve Leak Tests will NOT help! NOTE that BOTH VALVES #31 AND #35 will be checked and proceed to page 78, TROUBLESHOOTING VALVES. Fresenius 2008K Troubleshooting Guide Page 34 P/N 507298 Rev. B (Draft 1)
  • Page 37 Remove the clamp and measure flow from the tubing for 30 seconds. 400 ml or greater? See procedure number F- 7.0.6 (page 36), See procedure number F- 7.0.9 (page 37). Figure 16 – Valve #26 Location Fresenius 2008K Troubleshooting Guide Page 35 P/N 507298 Rev. B (Draft 1)
  • Page 38 (page 36), touch valve #25’s (black) solenoid. Is it warm (i.e. energized)? The actuator board is okay. Replace valve #25. NOTE that VALVES #25 (ONLY) will be checked and proceed to page 78, TROUBLESHOOTING VALVES. Fresenius 2008K Troubleshooting Guide Page 36 P/N 507298 Rev. B (Draft 1)
  • Page 39 Remove the quick connector and measure flow from it for 30 seconds. Greater than 400 ml? ® Replace the DiaSafe Filter. Test valve #91 or its tubing is restricted. Fresenius 2008K Troubleshooting Guide Page 37 P/N 507298 Rev. B (Draft 1)
  • Page 40 30 seconds. If no flow, connector placement! If there is flow, two measurements are recommended! b) RECORD PART 3 results then perform PART 4 EVEN IF there no flow. Fresenius 2008K Troubleshooting Guide Page 38 P/N 507298 Rev. B (Draft 1)
  • Page 41 CAREFULLY return ALL valves to their distribution board positions and repeat procedure number F- 7.3.2 (page 38). If all valves ARE plugged in correctly (except for valves #38 and #31) continue to part b. Fresenius 2008K Troubleshooting Guide Page 39 P/N 507298 Rev. B (Draft 1)
  • Page 42 NOZZLE and the WHITE tubing. e) Place the machine into Rinse Program. Assure no leaks at the gauge. Assure the flow AND deaeration pumps are running (i.e. they are plugged in correctly). Fresenius 2008K Troubleshooting Guide Page 40 P/N 507298 Rev. B (Draft 1)
  • Page 43 Valve #32 and/or valve #36 not opening! Automated Valve Leak Tests will NOT help! NOTE that BOTH VALVES #32 AND #36 will be checked and proceed to page 78, TROUBLESHOOTING VALVES. Figure 20 – Balancing Chamber Valves Fresenius 2008K Troubleshooting Guide Page 41 P/N 507298 Rev. B (Draft 1)
  • Page 44 NOTE the FLOW MOTOR ONLY will be checked and proceed to page 60, TROUBLESHOOTING MOTORS. b) Plug the concentrate connectors into their respective rinse ports to call the “Select Concentrate” screen. Fresenius 2008K Troubleshooting Guide Page 42 P/N 507298 Rev. B (Draft 1)
  • Page 45 Table L’s (page 43) maximum? Two possibilities: 1) Bad flow pump head (#21); 2) Bad flow pump motor (possibly bad brushes). See procedure number F- 9.0.2 (page 44). Fresenius 2008K Troubleshooting Guide Page 43 P/N 507298 Rev. B (Draft 1)
  • Page 46 The cable can be checked. NOTE that three (3) CFS TRANSDUCER connections will be checked and proceed to page 228, SECTION 17 - CHECKING THE SENSOR BOARD CABLE. Fresenius 2008K Troubleshooting Guide Page 44 P/N 507298 Rev. B (Draft 1)
  • Page 47 If a diaphragm leak is not located, place the machine into Dialysis program. If BC Switch (screen 6) = 897 (constant) AND ACFS (screen 10) remains between 3 and 8 two possibilities: 1) Bad CFS transducer #10 (see Figure 21, page 43): 2 Bad sensor board. Fresenius 2008K Troubleshooting Guide Page 45 P/N 507298 Rev. B (Draft 1)
  • Page 48 Remove the red dialyzer connector and hang it over the dialyzer holder. IMPORTANT! Close the shunt door. Ignore “Emptying” related messages. d) Call debug screen 4. Is PDIA (left column) remaining between 4.0 and 6.0? Fresenius 2008K Troubleshooting Guide Page 46 P/N 507298 Rev. B (Draft 1)
  • Page 49 Return the dialyzer connectors to the shunt and close the door. c) Connect to concentrate and place the machine into Dialysis program (remember to press the ‘CONFIRM’ key). d) See procedure number F- 11.0.5 (page 48). Fresenius 2008K Troubleshooting Guide Page 47 P/N 507298 Rev. B (Draft 1)
  • Page 50 With the Bypass LED ON CONSTANT is the flow indicator’s ‘bob’ rising, at least ¼ way up, and falling? See procedure number F- 14.0.9 (page 51). See procedure number F- 14.0.10 (page 52). Fresenius 2008K Troubleshooting Guide Page 48 P/N 507298 Rev. B (Draft 1)
  • Page 51 Return the red dialyzer connector to the shunt but do NOT shut the door so that Rinse program remains uninterrupted. b) See procedure number F- 14.0.6 (page 50). Fresenius 2008K Troubleshooting Guide Page 49 P/N 507298 Rev. B (Draft 1)
  • Page 52 Remove the red concentrate connector from its rinse port to interrupt Rinse. b) Reattach valve #24’s tubing then see procedure number F- 14.0.8 (page 51). See procedure number F- 14.0.7 (page 51). Fresenius 2008K Troubleshooting Guide Page 50 P/N 507298 Rev. B (Draft 1)
  • Page 53 If okay, return valve #26 to distribution board position labeled “V26” or “P26”. Continue to part c. IMPORTANT! Open the shunt door (Bypass LED on). Fresenius 2008K Troubleshooting Guide Page 51 P/N 507298 Rev. B (Draft 1)
  • Page 54 Less than 400 ml: a) CAREFULLY return valve #30, #34 and #24 to their respective distribution board positions. ® b) Two possibilities: 1) Restricted DiaSafe filter (if equipped); 2) Restricted valve # 24 (see Figure 25, page 51). Fresenius 2008K Troubleshooting Guide Page 52 P/N 507298 Rev. B (Draft 1)
  • Page 55 See procedure number F- 15.0.1 (page 54). NOTE the DEAERATION MOTOR ONLY will be checked and proceed to page 60, TROUBLESHOOTING MOTORS Figure 26 – DEAERATION Motor / Pump Fresenius 2008K Troubleshooting Guide Page 53 P/N 507298 Rev. B (Draft 1)
  • Page 56 Old Style Hydro Block: See procedure number F- 15.0.3 (page 55). New Style Hydro Chamber: See procedure number F- 15.0.4 (page 55). Figure 27 – Hydro Block / Hydro Chamber Fresenius 2008K Troubleshooting Guide Page 54 P/N 507298 Rev. B (Draft 1)
  • Page 57 Assure the ‘Drive Magnet’ rotates the motor shaft. It may have come uncoupled. b) Two possibilities: 1) Bad pump; 2) Bad motor (or brushes). The motor is bad (brushes WON’T help). Fresenius 2008K Troubleshooting Guide Page 55 P/N 507298 Rev. B (Draft 1)
  • Page 58 Reinstall the restrictor and see procedure number F- 16.0.5 (page 57). Recurring debris may indicate: 1) Inadequate acid clean cycles (causing excessive bicarbonate precipitate); 2) Inadequately filtered incoming water. Fresenius 2008K Troubleshooting Guide Page 56 P/N 507298 Rev. B (Draft 1)
  • Page 59 * The sensor cable can be checked for continuity. NOTE that you are checking one (1) FLOAT connection and see SECTION 17 - CHECKING SENSOR BOARD CABLE (page 228). Fresenius 2008K Troubleshooting Guide Page 57 P/N 507298 Rev. B (Draft 1)
  • Page 60 Watch loading pressure for three minutes. Does it consistently fluctuate between its maximum and to LOWER than its minimum per Table 1 (page 18)? Acid Clean the machine. See procedure number F- 20.0.0 (page 59). Fresenius 2008K Troubleshooting Guide Page 58 P/N 507298 Rev. B (Draft 1)
  • Page 61 Block: 1) Inadequate acid clean cycles (causing excessive bicarbonate precipitate); 2) Inadequately filtered incoming water. Figure 28 – Float Switch #5 and Chamber E Rod (in Old Style Hydro block ONLY) Fresenius 2008K Troubleshooting Guide Page 59 P/N 507298 Rev. B (Draft 1)
  • Page 62 Place the machine into Rinse Program. Is the NOTED motor now rotating counterclockwise? Allow Rinse for three minutes to eliminate an air lock. Return to procedure number MOTORS- 1.0.0 (page 60). Fresenius 2008K Troubleshooting Guide Page 60 P/N 507298 Rev. B (Draft 1)
  • Page 63 A problem is not indicated however, the motor may be stalling intermittently due to an intermittent bad motor or brushes. Replace the brushes! Replace the motor (brushes WON’T help). Fresenius 2008K Troubleshooting Guide Page 61 P/N 507298 Rev. B (Draft 1)
  • Page 64 IMPORTANT! The meter leads MUST make good contact with BOTH terminals! An error here may cause unnecessary and time consuming work! Table 4 (page 63), perform the given Response based on measured voltage. Fresenius 2008K Troubleshooting Guide Page 62 P/N 507298 Rev. B (Draft 1)
  • Page 65 The cable can be checked for continuity. NOTE which motor (FLOW or DEAERATION) will be checked and proceed to page 225, SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE. Fresenius 2008K Troubleshooting Guide Page 63 P/N 507298 Rev. B (Draft 1)

  • Page 66: Section 2 - "No Water" Message

    20 psi. If not, calibrate regulator #61 (see Figure 30, page 66). If unsuccessful, a bad pressure regulator #61 may be indicated. h) See procedure number NW- 5.0.0 (page 68). Fresenius 2008K Troubleshooting Guide Page 64 P/N 507298 Rev. B (Draft 1)
  • Page 67 Confirm that VERR is increasing again (and NOT = 255, its maximum). b) Valve #41 is causing a Valve Error. NOTE the machine is in DIALYSIS PROGRAM then proceed to page 81, TROUBLESHOOTING VALVE ERRORS Fresenius 2008K Troubleshooting Guide Page 65 P/N 507298 Rev. B (Draft 1)
  • Page 68 (page 67). Three possibilities: 1) Restricted inlet water filter (if present, see Figure 6, page 13); 2) Restricted incoming water tubing; 3) Low incoming water flow/pressure (from the RO). Fresenius 2008K Troubleshooting Guide Page 66 P/N 507298 Rev. B (Draft 1)
  • Page 69 ! Turn the water on. Valve #41 should be open and allowing water into the machine. After no more than 45 seconds is there overflow from the vent tubing? See procedure number NW- 5.0.0 (page 68). See procedure number NW- 4.0.1 (page 68). Fresenius 2008K Troubleshooting Guide Page 67 P/N 507298 Rev. B (Draft 1)
  • Page 70 (i.e. melting). If (and ONLY if) damage is located it will be necessary to replace the hydroblock/hydrochamber. Fresenius 2008K Troubleshooting Guide Page 68 P/N 507298 Rev. B (Draft 1)
  • Page 71 Does the “No Water” message reappear? Return to procedure number NW- 1.0.0 (page 64), step g. Valve #24 and/or #43 were plugged in incorrectly causing the “No Water” message. Fresenius 2008K Troubleshooting Guide Page 69 P/N 507298 Rev. B (Draft 1)

  • Page 72: Section 3 - Flow Errors In Cleaning / Disinfection Programs

    CLEAN- 1.0.2 CHECK DEAERATION MOTOR Referring to the Figure (right), is the Deaeration motor shaft rotating? See procedure number CLEAN- 1.0.3 (page 71). See procedure number CLEAN- 2.0.0 (page 72). Page 70 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 73 If the restrictor does not tighten snug it may be stripped and this requires replacing the hydro block. IMPORTANT! Unclamp the vent tubing. See procedure number CLEAN- 2.0.0 (page 72). Figure 32 - Old Hydro block / New Hydro chamber Fresenius 2008K Troubleshooting Guide Page 71 P/N 507298 Rev. B (Draft 1)
  • Page 74 Turn the machine off. If (and ONLY if) hydro block/hydro chamber heat damage was located above replace it now then place the machine in Heat Disinfect. b) See procedure number CLEAN- 2.0.5 (page 73). Fresenius 2008K Troubleshooting Guide Page 72 P/N 507298 Rev. B (Draft 1)
  • Page 75 Turn the machine off then back on (to reset VERR). b) Return the concentrate connectors to concentrate and place the machine into Dialysis program (remember to press the ‘CONFIRM’ key). Fresenius 2008K Troubleshooting Guide Page 73 P/N 507298 Rev. B (Draft 1)
  • Page 76 #29’s nozzle. b) Attach the syringe tubing to the empty nozzle. If the valve is open you should be able EASILY push through it with no resistance (three scenarios): Fresenius 2008K Troubleshooting Guide Page 74 P/N 507298 Rev. B (Draft 1)
  • Page 77 3) Bad actuator cable; 4) Bad distribution board. 3) Can EASILY push through: Reattach #29’s tubing, remove the clamp then see procedure number CLEAN- 5.0.0 (page 76). Fresenius 2008K Troubleshooting Guide Page 75 P/N 507298 Rev. B (Draft 1)
  • Page 78 TMP alarm occurs attempt the RESET sequence up to twice more then continue. g) Does a TMP alarm continue to occur? Proceed to page 168, PROBLEMS. The machine remains free of TMP alarms. See procedure number CLEAN- 5.0.2 (page 77). Fresenius 2008K Troubleshooting Guide Page 76 P/N 507298 Rev. B (Draft 1)
  • Page 79 If the problem is occurring in a program other than Heat Disinfect there may be an intermittent loss of loading pressure (“Flow Inlet Error” message), valve #43 sticking closed intermittent, or an intermittent hydraulic restriction. Fresenius 2008K Troubleshooting Guide Page 77 P/N 507298 Rev. B (Draft 1)
  • Page 80 Measure solenoid resistance, inside the female connector, between the terminals, where the blue wires are soldered. Between 40 and 100 See procedure number TSV- 3.0.0 (page 80). See procedure number TSV- 2.0.0 (page 79). Page 78 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 81 Referring to the Figure (right), measure resistance ( ) between the metal solenoid terminals. Between 40 and 100 The two-wire (blue) valve wiring harness is bad. Replace the valve. Fresenius 2008K Troubleshooting Guide Page 79 P/N 507298 Rev. B (Draft 1)
  • Page 82 The cable can be checked for continuity. Proceed to page 225, SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE Figure 36 – Actuator Board (Old Style, New Style) Fresenius 2008K Troubleshooting Guide Page 80 P/N 507298 Rev. B (Draft 1)
  • Page 83 NOTE that valve #25 will be checked then see procedure number VE- 2.0.0 (page 84). NOTE that valve #30 AND valve #26 will be checked then see procedure number VE- 2.0.0 (page 84). Fresenius 2008K Troubleshooting Guide Page 81 P/N 507298 Rev. B (Draft 1)
  • Page 84 Watch VERR for one minute. Is it increasing at one unit per second? NOTE that valve #43 (ONLY) will be checked then see procedure number VE- 2.0.0 (page Return to page 17, procedure number 2.0.0. Fresenius 2008K Troubleshooting Guide Page 82 P/N 507298 Rev. B (Draft 1)
  • Page 85 NOTE that valves #31 AND #34 will be checked then see procedure number VE- 2.0.0 (page 84). NOTE that valves #36 AND #37 will be checked then see procedure number VE- 2.0.0 (page 84). Fresenius 2008K Troubleshooting Guide Page 83 P/N 507298 Rev. B (Draft 1)
  • Page 86 AND units display indicating between 40 and 100 See procedure number VE- 2.0.1 (page 85). The valve’s solenoid or its blue wiring harness is bad. Replace BOTH! Fresenius 2008K Troubleshooting Guide Page 84 P/N 507298 Rev. B (Draft 1)
  • Page 87 Assure the connector(s) plug in smoothly otherwise the distribution board pins may be bent or corroded. d) As NOTED previously, is the Valve Error occurring in Rinse or Heat Disinfect or Dialysis program? Fresenius 2008K Troubleshooting Guide Page 85 P/N 507298 Rev. B (Draft 1)
  • Page 88 There is NO NEED to check all pins! ONLY the NOTED valves per Table 5 (page 87). Figure 41 – Electronic Card Cage Fresenius 2008K Troubleshooting Guide Page 86 P/N 507298 Rev. B (Draft 1)
  • Page 89 Top row, 7 pins from the front of Less than 39 : Bad actuator board. the machine Greater than 101 : Two possibilities: 1) Bad actuator cable; 2) Bad distribution board Fresenius 2008K Troubleshooting Guide Page 87 P/N 507298 Rev. B (Draft 1)
  • Page 90 Less than 39 : Bad actuator board. front of the Greater than 101 : Two possibilities: 1) Bad actuator cable; machine 2) Bad distribution board Fresenius 2008K Troubleshooting Guide Page 88 P/N 507298 Rev. B (Draft 1)
  • Page 91 Top row, 5 pins from the front of Less than 39 : Bad actuator board. machine Greater than 101 : Two possibilities: 1) Bad actuator cable; 2) Bad distribution board Fresenius 2008K Troubleshooting Guide Page 89 P/N 507298 Rev. B (Draft 1)
  • Page 92 10 pins from Less than 39 : Bad actuator board. the front of the machine Greater than 101 : Two possibilities: 1) Bad actuator cable; 2) Bad distribution board Fresenius 2008K Troubleshooting Guide Page 90 P/N 507298 Rev. B (Draft 1)
  • Page 93 Less than 39 : Bad actuator board. front of the machine Greater than 101 : Two possibilities: 1) Bad actuator cable; 2) Bad distribution board Fresenius 2008K Troubleshooting Guide Page 91 P/N 507298 Rev. B (Draft 1)

  • Page 94: Section 4 - Temperature Problems

    Connect to concentrate and place the machine into Dialysis Program (remember to press the ‘CONFIRM’ key). IMPORTANT! Allow five minutes then see procedure number T- 1.0.0 (page 93). Page 92 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 95 Set Temperature to 37° C and press the ‘Confirm’ key. This establishes the alarm limits at 39 and 35° C. b) Allow five minutes. If (and ONLY if) the Temperature problem is still present see procedure number T- 1.0.4 (page 94) Fresenius 2008K Troubleshooting Guide Page 93 P/N 507298 Rev. B (Draft 1)
  • Page 96 NOTE: If Temperature is or was ‘bouncing wildly’ up and down, within 0.5 seconds, but does NEVER exceeds 41° (in Dialysis Program), 91° (in Heat Disinfect) this may indicate a torn balancing chamber diaphragm. Fresenius 2008K Troubleshooting Guide Page 94 P/N 507298 Rev. B (Draft 1)
  • Page 97 The BTM may be bad. Check its dip switch settings per its Operator’s manual. Heat Disinfect : Return to Heat Disinfect Program and allow appropriate time (up to 30 minutes) for symptoms to appear. Is the problem still present? Fresenius 2008K Troubleshooting Guide Page 95 P/N 507298 Rev. B (Draft 1)
  • Page 98 “MON-NTC”! b) Turn the HEATER Switch OFF (rocker switch pressed in towards “0” or “OFF”). c) Leaving the resistor plug installed see procedure number T- 5.0.0 (page 118). Fresenius 2008K Troubleshooting Guide Page 96 P/N 507298 Rev. B (Draft 1)
  • Page 99 CAREFULLY return Conductivity cell #7 and NTC #3 to their distribution board positions (respectively labeled “COND” and “MON-NTC”). b) Proceed to page 14, SECTION 1 - FLOW ERRORS IN DIALYSIS PROGRAM Fresenius 2008K Troubleshooting Guide Page 97 P/N 507298 Rev. B (Draft 1)
  • Page 100 From the Home screen, is the machine’s Temperature display greater than 33° C? See procedure number T- 1.1.9 (page 99). Replace NTC #3 (see Figure 42, page 94) then see procedure number T- 7.0.0 (page 121). Fresenius 2008K Troubleshooting Guide Page 98 P/N 507298 Rev. B (Draft 1)
  • Page 101 Activate the screen’s RINSE button. If all three switches are held Rinse program starts. Release the switches but do NOT shut the door. The “Cover is Open” message presents but Rinse program continues. Fresenius 2008K Troubleshooting Guide Page 99 P/N 507298 Rev. B (Draft 1)
  • Page 102 (6.808 K ) resistor plug is placed properly at distribution board position “MON-NTC”. If not, repeat procedure number T- 1.3.1 (page 100). b) See procedure number T- 1.3.2 (page 101). Fresenius 2008K Troubleshooting Guide Page 100 P/N 507298 Rev. B (Draft 1)
  • Page 103 Be patient to avoid error! Does TPRE decrease to 3900 or less? See procedure number T- 1.3.4 (page 102). Replace NTC #3 (see Figure 42, page 94) then proceed to T- 7.0.0 (page 121). Fresenius 2008K Troubleshooting Guide Page 101 P/N 507298 Rev. B (Draft 1)
  • Page 104 ALL THREE switches. e) Activate the screen’s HEAT DISINFECT button. If all switches are held Heat Disinfect Program starts. Fresenius 2008K Troubleshooting Guide Page 102 P/N 507298 Rev. B (Draft 1)
  • Page 105 From the Home screen, watch Temperature IMPORTANT for up to five minutes. Does it increase to 30° C or greater? See procedure number T- 7.0.0 (page 121). Replace NTC #3 (see Figure 42, page 94) then see procedure number T- 7.0.0 (page 121). Fresenius 2008K Troubleshooting Guide Page 103 P/N 507298 Rev. B (Draft 1)
  • Page 106 2.0 or lower, if ALL three pins Top row, first pin from 9.0 or greater, see procedure check okay see procedure number Rear of machine number T- 2.3.0 (page 106) T- 2.4.0 (page 108) Fresenius 2008K Troubleshooting Guide Page 104 P/N 507298 Rev. B (Draft 1)
  • Page 107 37° C? The previous sensor board is bad. Perform all calibrations per procedure. Perform INITIAL CHECKS (page 6). The distribution board may be bad. Fresenius 2008K Troubleshooting Guide Page 105 P/N 507298 Rev. B (Draft 1)
  • Page 108 * NOTE: The meter’s diode check function will not work because the diode is ‘in circuit’ Is the meter’s numeric AND units display indicating a resistance between 500 and 1500 (or between 0.50 K and 1.5 K )? Fresenius 2008K Troubleshooting Guide Page 106 P/N 507298 Rev. B (Draft 1)
  • Page 109 Remove the power logic board from the card cage and clip a meter lead onto motherboard pin C10 (fifth pin from the front of the machine). Reinstall the board keeping the meter lead vertical. ASSURE the meter lead is not contacting adjacent pins! Fresenius 2008K Troubleshooting Guide Page 107 P/N 507298 Rev. B (Draft 1)
  • Page 110 ASSURE it is plugged in securely at both ends. d) Touch the meter leads together and subtract the meter’s resistance ( ) reading from subsequent readings. Fresenius 2008K Troubleshooting Guide Page 108 P/N 507298 Rev. B (Draft 1)
  • Page 111 Touch the meter leads together and subtract the meter’s resistance ( ) reading from ALL subsequent readings. e) Referring to Figure 47 (page 109), measure resistance BETWEEN (two measurements, pin 6 and pin 7): Fresenius 2008K Troubleshooting Guide Page 109 P/N 507298 Rev. B (Draft 1)
  • Page 112 Two measurements: 1. Between ST 7 AND ST 13 2. Between ST 4 AND ST5 Is the meter’s numeric AND units display, for both measurements, indicating less than 2 Fresenius 2008K Troubleshooting Guide Page 110 P/N 507298 Rev. B (Draft 1)
  • Page 113 82 Yes See procedure number T- 3.0.3 (page 112). 80°C No a) ASSURE the plug (1.255 K ) is placed properly. If not, repeat procedure number T- 3.0.2. Fresenius 2008K Troubleshooting Guide Page 111 P/N 507298 Rev. B (Draft 1)
  • Page 114 Unclamp valve #29. Two possibilities: 1) Bad actuator board; 2) Bad valve #30 (see Figure A, page 79). Unclamp valve #29 then see procedure number T- 3.0.4 (page 113). Fresenius 2008K Troubleshooting Guide Page 112 P/N 507298 Rev. B (Draft 1)
  • Page 115 NEO-1 Display Actual Temperature 67.0° C 76 +/- 4° C 68.5° C 80 +/- 4° C 70.0° C 84 +/- 4° C 71.5° C 88 +/- 4° C Fresenius 2008K Troubleshooting Guide Page 113 P/N 507298 Rev. B (Draft 1)
  • Page 116 C plug is placed correctly before continuing! If not repeat T- 4.0.0 (page 114). b) See procedure number T- 4.7.0 (page 117). Figure 49 – Sensor Board / Pin C1 Fresenius 2008K Troubleshooting Guide Page 114 P/N 507298 Rev. B (Draft 1)
  • Page 117 Referring to Figure (right), remove the two front screws and lay the power supply’s panel down to access to the rear (solder) side of the board. Fresenius 2008K Troubleshooting Guide Page 115 P/N 507298 Rev. B (Draft 1)
  • Page 118 The Temperature calibration is WAY out. Set the [TEMP DAC] window to 50 less than ’ what was noted above. Press the ‘CONFIRM key twice to save the calibration then see procedure number T- 7.0.0 (page 121). Fresenius 2008K Troubleshooting Guide Page 116 P/N 507298 Rev. B (Draft 1)
  • Page 119 NOTE that one (1) NTC #2 connection will be checked and proceed to page 228, SECTION 17- CHECKING THE SENSOR BOARD CABLE. If the sensor cable checks good the distribution board may be bad. Figure 52 – NTC #2 Checks Fresenius 2008K Troubleshooting Guide Page 117 P/N 507298 Rev. B (Draft 1)
  • Page 120 NOTE that NTC #3’s connection will be checked and proceed to page 228, SECTION 17 - CHECKING THE SENSOR BOARD CABLE. If the sensor cable checks okay the distribution board may be bad. Figure 53 – NTC #3 Checks Fresenius 2008K Troubleshooting Guide Page 118 P/N 507298 Rev. B (Draft 1)
  • Page 121 Turn Dialysate flow ON (Dialysate Flow on/off LED off). Referring to Appendix A (page 260), is Deaeration pressure okay? See procedure number T- 6.2.0 (page 120). See procedure number T- 6.1.1 (page 120). Fresenius 2008K Troubleshooting Guide Page 119 P/N 507298 Rev. B (Draft 1)
  • Page 122 When PHTACT = 0 repeat the test by holding numeric keypad #1 until PHTACT = 1. When PHTACT = 0, from screen 1, check PHT0 and PHT1. Are both less than 25? Fresenius 2008K Troubleshooting Guide Page 120 P/N 507298 Rev. B (Draft 1)
  • Page 123 2. ASSURE that the ‘CONFIRM’ key was pressed before placing the next resistor plug. b) Did the NOTED problem(s) reoccur when repeating the calibration? See procedure number T- 7.1.1 (page 125). See procedure number T- 7.0.2 (page 122). Fresenius 2008K Troubleshooting Guide Page 121 P/N 507298 Rev. B (Draft 1)
  • Page 124 T- 7.0.4 (page 123). 3. [Monitor Reference] NEVER exceeds 41° C AND the external flow indicator NEVER stops moving up and down: See procedure number T- 7.0.5 (page 123). Fresenius 2008K Troubleshooting Guide Page 122 P/N 507298 Rev. B (Draft 1)
  • Page 125 (right), measure AC voltage ( ), at the distribution board’s heater connector, between the: Old style heaters: BROWN and BLUE wires; New style heaters: BLACK and WHITE wires. Fresenius 2008K Troubleshooting Guide Page 123 P/N 507298 Rev. B (Draft 1)
  • Page 126 Is it remaining stable (i.e. does not vary more than +/- ° C)? See procedure number T- 7.0.9 (page 125). Replace NTC #3 (see Figure 42, page 94) then return to procedure number T- 7.0.2 (page 122). Fresenius 2008K Troubleshooting Guide Page 124 P/N 507298 Rev. B (Draft 1)
  • Page 127 Turn the Heater switch ON and place the machine into Dialysis program (remember to press the ‘CONFIRM’ key). c) Return to procedure number T- 7.0.2 (page 122) however if the procedures return here see procedure number T- 7.3.0 (page 126). Fresenius 2008K Troubleshooting Guide Page 125 P/N 507298 Rev. B (Draft 1)
  • Page 128 C as measured with an accurate industrial grade thermometer. k) Referring to the Figure (right),drop NTC 2’s probe end into the cup and allow 30 seconds for stabilization. Fresenius 2008K Troubleshooting Guide Page 126 P/N 507298 Rev. B (Draft 1)
  • Page 129 37.7 5.724 K 5.849 K 5.974 K 37.8 5.700 K 5.825 K 5.950 K 37.9 5.676 K 5.801 K 5.926 K 38.0 5.652 K 5.777 K 5.902 K Fresenius 2008K Troubleshooting Guide Page 127 P/N 507298 Rev. B (Draft 1)

  • Page 130: Section 5 - Conductivity / On Line Clearance Problems

    Table 21 (page 129), loading pressure MUST be NEVER fluctuating to its maximum AND dropping below the minimum. CAREFULLY watch BOTH levels for 90 seconds. Is loading pressure ‘okay’? Fresenius 2008K Troubleshooting Guide Page 128 P/N 507298 Rev. B (Draft 1)
  • Page 131 Acetate is selected! NOTE this and see procedure number CO- 1.0.3 (page 130). Bicarbonate is selected. NOTE this and see procedure number CO- 1.0.5 (page 130). Figure 55 – CONFIRM Concentrate Screen Fresenius 2008K Troubleshooting Guide Page 129 P/N 507298 Rev. B (Draft 1)
  • Page 132 (if using bicarbonate) bicarbonate inlet tubing? See procedure number CO- 4.0.0 (page 139). See procedure number CO- 1.0.7 (page 131). Fresenius 2008K Troubleshooting Guide Page 130 P/N 507298 Rev. B (Draft 1)
  • Page 133 BC Switch: 300 ml/min 540 and 660 (5.40 and 6.60 seconds) 500 ml/min 324 and 396 (3.24 and 3.96 seconds) 800 ml/min 203 and 248 (2.03 and 2.48 seconds) Fresenius 2008K Troubleshooting Guide Page 131 P/N 507298 Rev. B (Draft 1)
  • Page 134 (page 133). a) Perform appropriate selections/settings. b) Press the ‘CONFIRM’ key. c) Allow eight minutes. If Conductivity is still a problem see procedure number CO- 1.0.11 (page 133). Fresenius 2008K Troubleshooting Guide Page 132 P/N 507298 Rev. B (Draft 1)
  • Page 135 (page 134), the acid (Conc-P) and bicarbonate (Bic-P) pump distribution board connectors are reversed. a) Return the bicarbonate connector to concentrate. b) IMPORTANT! Allow three minutes. c) See procedure number CO- 1.0.13 (page 134). Fresenius 2008K Troubleshooting Guide Page 133 P/N 507298 Rev. B (Draft 1)
  • Page 136 Using a flashlight, check inside, above and below the vacant SENSORS connector for ‘white’ corrosion and damaged male pins that may cause false signals from the distribution board. Fresenius 2008K Troubleshooting Guide Page 134 P/N 507298 Rev. B (Draft 1)
  • Page 137 Call debug screen 5. Is AFREQ less than 1000? Three possibilities: 1) Bad actuator board; 2) Bad function board; 3) Bad motherboard. See procedure number CO- 2.0.3 (page 136). Fresenius 2008K Troubleshooting Guide Page 135 P/N 507298 Rev. B (Draft 1)
  • Page 138 Call debug screen 1. If NPHT is less than 600 press and hold the “1” numeric keypad until NPHT is greater than 600. Ignore an “On Line PHT Failed” message if it occurs for now. Fresenius 2008K Troubleshooting Guide Page 136...
  • Page 139 If removed from a previous procedure, CAREFULLY return conductivity cell #7 to distribution board position labeled “COND” (6 position from the left). b) From the Home screen, proceed according to the machine’s Conductivity display (three scenarios): Fresenius 2008K Troubleshooting Guide Page 137 P/N 507298 Rev. B (Draft 1)
  • Page 140 600. Ignore an “On Line PHT Failed” message if it occurs. Allow one minute then continue to part b. b) Call debug screen 5. Watch CPRE for one minute noting the highest and lowest values. Proceed accordingly (two scenarios): Fresenius 2008K Troubleshooting Guide Page 138 P/N 507298 Rev. B (Draft 1)
  • Page 141 SECTION 6 - CONCENTRATE PUMP ERRORS. c) Connect to concentrate and return to Dialysis program (remember to press the ‘CONFIRM’ key). d) Is AIR FREE concentrate drawn steadily in one direction now? Fresenius 2008K Troubleshooting Guide Page 139 P/N 507298 Rev. B (Draft 1)
  • Page 142 They are more likely are inside! b) Are the (white insert) check valve(s) installed? See procedure number CO- 4.6.0 (page 141). See procedure number CO- 4.7.0 (page 141). Fresenius 2008K Troubleshooting Guide Page 140 P/N 507298 Rev. B (Draft 1)
  • Page 143 6. If a problem is not found, three possibilities: 1) Bad 6 psi check valve (if equipped, see Figure page 141); 2) Bad pump); 3) Bad actuator board. Fresenius 2008K Troubleshooting Guide Page 141 P/N 507298 Rev. B (Draft 1)
  • Page 144 Call debug screen 6 and CAREFULLY watch BC Switch for one minute. Referring to Table X (page 143) is it remaining between the indicated times for the NOTED selected flow rate? Fresenius 2008K Troubleshooting Guide Page 142 P/N 507298 Rev. B (Draft 1)
  • Page 145 When PHTACT = 0 (test complete), once again, press and hold the numeric key pad #1 key until PHTACT = 1. When PHTACT = 0 note PHT0 and PHT1. d) Proceed according to Table V (page 144). Fresenius 2008K Troubleshooting Guide Page 143 P/N 507298 Rev. B (Draft 1)
  • Page 146 30 seconds. d) Clamp the vent tubing. This pressurizes the Block/Chamber to approximately 20 psi (per incoming water regulator #61). Fresenius 2008K Troubleshooting Guide Page 144 P/N 507298 Rev. B (Draft 1)
  • Page 147 Select the [Conductivity] data box (it turns bright yellow) and enter the external meter’s reading. h) Press the ‘CONFIRM’ key (the screen changes) then see procedure number CO- 6.0.2 (page 146). Fresenius 2008K Troubleshooting Guide Page 145 P/N 507298 Rev. B (Draft 1)
  • Page 148 New style power logic board: Measure directly from the empty TEST connector at pin 5 (five pins from the left) then see part d. Fresenius 2008K Troubleshooting Guide Page 146 P/N 507298 Rev. B (Draft 1)
  • Page 149 Between -11 and -13 volts DC AND stable (does not vary greater than 0.1)? See procedure number CO- 7.0.3 (page 148). Proceed to page 167, procedure number CR- 1.0.3. Fresenius 2008K Troubleshooting Guide Page 147 P/N 507298 Rev. B (Draft 1)
  • Page 150 Swap the following components, one at a time, with known good, attempting Cond Cells calibration in between: 1) Actuator board; 2) Sensor board; 3) Function board; 4) Distribution board. Fresenius 2008K Troubleshooting Guide Page 148 P/N 507298 Rev. B (Draft 1)
  • Page 151 (page 150), tightly clamp the input tubing at valve #29. b) Allow up to 15 minutes. Does conductivity return to a normal? See procedure number CO- 8.0.5 (page 150). See procedure number CO- 8.0.6 (page 150). Fresenius 2008K Troubleshooting Guide Page 149 P/N 507298 Rev. B (Draft 1)
  • Page 152 CO- 4.1.0 (page 139). e) From debug screen 1, does the acid pump draw between AMIN and AMAX AND the bicarbonate pump between BMIN and BMAX? Fresenius 2008K Troubleshooting Guide Page 150 P/N 507298 Rev. B (Draft 1)
  • Page 153 Replace heat exchanger’s plate (P/N 650775). a) Return the tubing to the heat exchanger. b) Turn Dialysate Flow ON (Dialysate Flow on/off LED off). c) See procedure number CO- 5.0.0 (page 142). Fresenius 2008K Troubleshooting Guide Page 151 P/N 507298 Rev. B (Draft 1)
  • Page 154 (page 153). No (to one OR both): NOTE a problem with either or both the Post Dialyzer TEMP or COND sensor then see procedure number 10.2.0 (page 154). Fresenius 2008K Troubleshooting Guide Page 152 P/N 507298 Rev. B (Draft 1)
  • Page 155 Return Conductivity cell #13 to distribution board position x13 (“COND-POS”). c) Return the Post-Dialyzer Temperature sensor #44 to position #44 (“NTC-POST”). d) Proceed to page 145, procedure number 6.0.0. Fresenius 2008K Troubleshooting Guide Page 153 P/N 507298 Rev. B (Draft 1)
  • Page 156 Assure flow through the external flow indicator. From debug screen 0, if the Post Dialyzer data box is NOT greater than 34° C replace NTC #44 (see page 154). Fresenius 2008K Troubleshooting Guide Page 154 P/N 507298 Rev. B (Draft 1)
  • Page 157 AND matched exactly pin for pin to the TEST connector. If a +12 volt problem still exists after replacement proceed to page Error! Bookmark not defined., SECTION 24 – TROUBLESHOOTING POWER DISTRIBUTION. Fresenius 2008K Troubleshooting Guide Page 155 P/N 507298 Rev. B (Draft 1)
  • Page 158 600. Ignore an “On Line PHT Failed” message if it occurs. e) IMPORTANT! ALLOW two minutes for stabilization before continuing. Call debug screen 5 (see below): Fresenius 2008K Troubleshooting Guide Page 156 P/N 507298 Rev. B (Draft 1)
  • Page 159 Allow five minutes for stabilization and perform the Manual OLC test. d) Allow the Manual OLC test to complete (between 8 and 16 minutes). e) See procedure number CO- 10.7.0 (page 158). Fresenius 2008K Troubleshooting Guide Page 157 P/N 507298 Rev. B (Draft 1)
  • Page 160 NOTE: Some of this data is no longer available after the machine has been turned off. 8. Call debug screen 5 then refer to Table B (page 160). Fresenius 2008K Troubleshooting Guide Page 158 P/N 507298 Rev. B (Draft 1)
  • Page 161 After achieving 15.5 mS Conductivity ramps down to 13.5 mS unless the base conductivity is less than 13.5. In this event it ramps down to the base conductivity. Fresenius 2008K Troubleshooting Guide Page 159 P/N 507298 Rev. B (Draft 1)
  • Page 162 OLC test performed previously CPOS Stable Post-dialyzer conductivity Not applicable unless OLC (on Line or Manual) were not when stable during OLC test performed previously Fresenius 2008K Troubleshooting Guide Page 160 P/N 507298 Rev. B (Draft 1)

  • Page 163: Section 6 - Concentrate Pump Errors

    Place the machine into Dialysis program (remember to press the ‘CONFIRM’ key). Wait one minute then call debug screen 0. Ignore the BIC symbol! Is the CONC symbol pink (solid or blinking) or white? Fresenius 2008K Troubleshooting Guide Page 161 P/N 507298 Rev. B (Draft 1)
  • Page 164 White The bicarbonate pump may be bad. a) IMPORTANT! Turn the machine off to prevent damage and CAREFULLY return the acid pump to distribution board position P16, “CONC-P”. Fresenius 2008K Troubleshooting Guide Page 162 P/N 507298 Rev. B (Draft 1)
  • Page 165 Place the machine into Dialysis program (remember to press the ‘CONFIRM’ key). c) Allow one minute then call debug screen 0. Is the pump’s symbol remaining white? Fresenius 2008K Troubleshooting Guide Page 163 P/N 507298 Rev. B (Draft 1)
  • Page 166 5.0.1, step a, for the bicarbonate pump (“P17”). Four possibilities (see Figure 4A, page 8): 1) Bad actuator cable; 2) Bad sensor cable; 3) Bad distribution board; 4) Bad mother board Fresenius 2008K Troubleshooting Guide Page 164 P/N 507298 Rev. B (Draft 1)

  • Page 167: Section 7 - Cond Ref Failure Or Cond Offset Failure

    NOTE B, page 8). If (and ONLY if) the problem still exists (bad +12 volts) after board replacement proceed to page Error! Bookmark not defined., SECTION 24 – TROUBLESHOOTING POWER DISTRIBUTION Fresenius 2008K Troubleshooting Guide Page 165 P/N 507298 Rev. B (Draft 1)
  • Page 168 Between -11 and -13 volts DC AND stable (i.e. does not vary more than +/- See procedure number CR- 1.0.4 (page 167). See procedure number CR- 1.0.3 (page 167). Fresenius 2008K Troubleshooting Guide Page 166 P/N 507298 Rev. B (Draft 1)
  • Page 169 Swap the following components, one at a time, with known good attempting Conductivity Cells calibration in between (see Figure 4A, page 8): 1) Sensor board; 2) Function board EEPROM (IC2); 3) Function board. Fresenius 2008K Troubleshooting Guide Page 167 P/N 507298 Rev. B (Draft 1)

  • Page 170: Section 8 - Filling Program Problems

    Call debug screen 4. Is 5 V (left column) between 4.7 and 5.3 volts AND stable? See procedure number FIL- 1.0.5 (page 169). See procedure number FIL- 1.0.4 (page 169). Fresenius 2008K Troubleshooting Guide Page 168 P/N 507298 Rev. B (Draft 1)
  • Page 171 IMPORTANT! Close the shunt door! c) From the Home screen, set Dialysate to 500 ml/min (NOT “a500”) and press the ‘CONFIRM’ key. IMPORTANT! Do NOT reset alarms! Fresenius 2008K Troubleshooting Guide Page 169 P/N 507298 Rev. B (Draft 1)
  • Page 172 ‘post-dialyzer’ conductivity and temperature sensors are installed. Is the machine OLC equipped? See procedure number FIL- 3.0.1 (page 171). See procedure number FIL- 3.0.3 (page 171). Figure 65 – OLC Components Fresenius 2008K Troubleshooting Guide Page 170 P/N 507298 Rev. B (Draft 1)
  • Page 173 This simulates ‘no air in chamber #69’. Leave them connected together until instructed otherwise! IMPORTANT! Allow 30 seconds. FILACT response is NOT instantaneous. Fresenius 2008K Troubleshooting Guide Page 171 P/N 507298 Rev. B (Draft 1)
  • Page 174 Allow four minutes to allow valve #43’s solenoid to become warm (if energized). d) Referring to Figure 66 (page 171), and after four minutes, touch valve 43’s (black) solenoid. Is it warm (i.e. energized)? Fresenius 2008K Troubleshooting Guide Page 172 P/N 507298 Rev. B (Draft 1)
  • Page 175 ASSURE the resistor plug is placed correctly (at distribution board “AIR-SEN”) before continuing! If not, repeat procedure number FIL- 3.2.0 (page 173). b) See procedure number FIL- 4.0.0 (page 174). Fresenius 2008K Troubleshooting Guide Page 173 P/N 507298 Rev. B (Draft 1)
  • Page 176 Clear all blood alarms and turn the blood pump on to greater than 200 ml/min. g) Set UF GOAL to 3000 ml/Hr. Set UF RATE to 700 ml/hr and press the ‘CONFIRM’ key. Fresenius 2008K Troubleshooting Guide Page 174 P/N 507298 Rev. B (Draft 1)
  • Page 177 Spent Side Balancing Chamber Valves #32, #34, #36, #38 through #38 then see SECTION 18A – AUTOMATED VALVE LEAK TESTS (page 230). Fresenius 2008K Troubleshooting Guide Page 175 P/N 507298 Rev. B (Draft 1)
  • Page 178 SECTION 18A – AUTOMATED VALVE LEAK TESTS (page 230). If the above procedures have been performed correctly AND FILACT remains = 1 the air sensor probes (inside air removal chamber #69) may be bad. Fresenius 2008K Troubleshooting Guide Page 176 P/N 507298 Rev. B (Draft 1)

  • Page 179: Section 9 - Tmp Problems

    Connect to concentrate and return to Dialysis program (remember to press the ‘CONFIRM’ key). d) From the Home screen, set Dialysate flow to 800 ml/min and press the ‘CONFIRM’ key. Fresenius 2008K Troubleshooting Guide Page 177 P/N 507298 Rev. B (Draft 1)
  • Page 180 (NOT “a500”). IMPORTANT! If flow rate is or was changed allow three minutes for stabilization. If Flow is manually changed press the “CONFIRM’ key! IMPORTANT! Unless instructed, do NOT reset alarms! Fresenius 2008K Troubleshooting Guide Page 178 P/N 507298 Rev. B (Draft 1)
  • Page 181 , IMPORTANT! b) With “AIR-SEN” empty ALLOW 30 seconds BEFORE continuing! FILACT response in not instantaneous! c) From debug screen 1, does FILACT = 1? Fresenius 2008K Troubleshooting Guide Page 179 P/N 507298 Rev. B (Draft 1)
  • Page 182 3. TMP is STABLE AND the ‘actual’ TMP bar is REMAINING between the 520 and 0 Limits: Is the ‘actual’ TMP bar green? See procedure number TMP- 1.3.0 (page 182). See procedure number TMP- 1.0.11 (page 181). Fresenius 2008K Troubleshooting Guide Page 180 P/N 507298 Rev. B (Draft 1)
  • Page 183 68) for an external water leak. If a leak is located this is probably the problem! c) See procedure number TMP- 1.0.17 (page 182). Figure 68 – UF Sample / Check Valves Fresenius 2008K Troubleshooting Guide Page 181 P/N 507298 Rev. B (Draft 1)
  • Page 184 HOLD it (+/- 20 mmHg per minute) on the external meter? See procedure number TMP- 1.4.2 (page 183). Negative pressure leak! Remove the tubing from the P port then see procedure number TMP- 1.4.3 (page 183). Fresenius 2008K Troubleshooting Guide Page 182 P/N 507298 Rev. B (Draft 1)
  • Page 185 Check the four way assembly connections for a leak. If SURE that the assembly is NOT leaking see procedure number TMP- 8.1.0 (page 189). Figure 69 – Clamping Valve #43 Fresenius 2008K Troubleshooting Guide Page 183 P/N 507298 Rev. B (Draft 1)
  • Page 186 (#9) body for signs of (rust colored) external leakage. Replace the transducer if leakage is located as this may be the problem! c) See procedure number TMP- 2.2.0 (page 184). Fresenius 2008K Troubleshooting Guide Page 184 P/N 507298 Rev. B (Draft 1)
  • Page 187 To avoid time consuming error, using the screen’s clock (upper right), allow up to five minutes (PDIA response is NOT instantaneous). Does PDIA increase to 9 or greater? Fresenius 2008K Troubleshooting Guide Page 185 P/N 507298 Rev. B (Draft 1)
  • Page 188 Turn Dialysate flow ON (Dialysate Flow on/off LED off) and allow Conductivity and Temperature to stabilize. c) RESET all blood alarms and select the screen’s Test & Options button. If the ‘Pressure Test’ button is: Fresenius 2008K Troubleshooting Guide Page 186 P/N 507298 Rev. B (Draft 1)
  • Page 189 HOLD) +/- 20 mmHg per minute) see procedure number TMP- 1.4.3 (page 183). c) The screen’s [Dial Pressure Reference] data box should read approximately 140. d) Press the “CONFIRM’ key. Does the message “Operator Error” occur? Fresenius 2008K Troubleshooting Guide Page 187 P/N 507298 Rev. B (Draft 1)
  • Page 190 LED off). d) Referring to Appendix A (page 260), is Deaeration pressure okay? See procedure number TMP- 8.1.0 (page 189). See procedure number TMP- 8.2.0 (page 189). Fresenius 2008K Troubleshooting Guide Page 188 P/N 507298 Rev. B (Draft 1)
  • Page 191 Return to Dialysis program (remember to press the ‘CONFIRM’ key). If the TMP problem continues return to procedure number TMP- 1.0.6 (page 178). Proceed to page 211, SECTION 13 - DEAERATION PROBLEMS. Fresenius 2008K Troubleshooting Guide Page 189 P/N 507298 Rev. B (Draft 1)

  • Page 192: Fail Get Neg Tmp

    0.2 mS) proceed to page 128, SECTION 5 – CONDUCTIVITY PROBLEMS. 3) If (and ONLY if) Temperature and Conductivity are okay see procedure number PHT- 1.0.1 (page 191). Fresenius 2008K Troubleshooting Guide Page 190 P/N 507298 Rev. B (Draft 1)
  • Page 193 (if equipped) and its ‘Test’ valve for an external water leak. If ® (and ONLY if) the DiaSafe filter is leaking replace it. If (and ONLY if) the ‘Test’ valve is leaking see procedure number PHT- 10.0.0 (page 200). Fresenius 2008K Troubleshooting Guide Page 191 P/N 507298 Rev. B (Draft 1)
  • Page 194 Fluid Sample port may be the problem! If (and ONLY if) no leaks from the Connector or port see part b. b) See procedure number PHT- 1.0.5 (page 193). Figure 72 – UF Fluid Sample / Check Valves Fresenius 2008K Troubleshooting Guide Page 192 P/N 507298 Rev. B (Draft 1)
  • Page 195 ( ) to BETWEEN the 0 and 520 scale reaching 220 mmHg or greater? See procedure number PHT- 4.0.0 (page 194). See procedure number PHT- 2.2.0 (page 194). Fresenius 2008K Troubleshooting Guide Page 193 P/N 507298 Rev. B (Draft 1)
  • Page 196 Has the “On Line PHT Failed” message occurred more than once during a patient treatment? See procedure number PHT- 4.4.0 (page 195). See procedure number PHT- 9.0.0 (page 200). Fresenius 2008K Troubleshooting Guide Page 194 P/N 507298 Rev. B (Draft 1)
  • Page 197 Clamp the syringe tubing to hold pressure then see procedure number PHT- 5.2.0 (page 196). Remove the tubing from the P port and see procedure number PHT- 5.3.0 (page 196). Fresenius 2008K Troubleshooting Guide Page 195 P/N 507298 Rev. B (Draft 1)
  • Page 198 Referring to Figure 69 (page 183), touch valve #43’s (black) solenoid. Is it warm? Replace the actuator board (see Figure 4A, page 8). Replace valve #43 (leaking). Fresenius 2008K Troubleshooting Guide Page 196 P/N 507298 Rev. B (Draft 1)
  • Page 199 Two checks: 1) Check the four way assembly for a leak; 2) If SURE the four way assembly is NOT leaking proceed see procedure number PHT- 8.1.0 (page 199). Figure 73 Isolation Area B (excludes dialysate lines) Fresenius 2008K Troubleshooting Guide Page 197 P/N 507298 Rev. B (Draft 1)
  • Page 200 2) BOTH Pressure Tests (Negative and Positive) PASS: Repeat the Pressure Tests. If they pass again calibrating deaeration fixed the problem. If (and ONLY if) either fail see procedure number PHT- 8.0.0 (page 199). Fresenius 2008K Troubleshooting Guide Page 198 P/N 507298 Rev. B (Draft 1)
  • Page 201 1) IOS; 2) Balancing Chamber Valves #31 through #38. SECTION 18A – AUTOMATED VALVE LEAK TESTS (page 230). e) After repairs and the Pressure Tests pass perform also procedure number PHT- 9.0.0, INTEGRITY CHECK (page 200). Fresenius 2008K Troubleshooting Guide Page 199 P/N 507298 Rev. B (Draft 1)
  • Page 202 Valve #28 (with DiaSafe Plus Filter): See procedure number PHT- 10.2.0 (page 201). ® Valve #91 (with old style DiaSafe filter): Replace valve #91. ® Figure 301 – DiaSafe Options Fresenius 2008K Troubleshooting Guide Page 200 P/N 507298 Rev. B (Draft 1)
  • Page 203 Valves #43, #24, #25 leaking internally Balancing chamber valve (#31 through #38) leaking internally Deaeration pressure too high or too low Dialysate Pressure (or Transmembrane Pressure (TMP) out of calibration specifications) Fresenius 2008K Troubleshooting Guide Page 201 P/N 507298 Rev. B (Draft 1)

  • Page 204: Section 11 - Induced Air Leak Tests

    (#73). This is Location #1 (L1) referring to the abbreviated flow diagram (Figure 74). Are large air bubbles seen at L1? See procedure number AIR- 1.0.2 (page 203). See procedure number AIR- 1.0.3 (page 205). Page 202 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 205 75, p Filter Plus) Before Conductivity Cell #7 / NTC #3 Conductivity Cell #7 or NTC #3 See procedure age 204) (Figure 75, p number AIR 1.0.5 (page 206) Fresenius 2008K Troubleshooting Guide Page 203 P/N 507298 Rev. B (Draft 1)
  • Page 206 Section 11 – Induced Air Leak Tests Figure 75 – Hydraulics (External & Rear Views) Figure 76 – Hydraulics (Top View) Fresenius 2008K Troubleshooting Guide Page 204 P/N 507298 Rev. B (Draft 1)
  • Page 207 204) (Figure Dialysate Pressure Transducer #9 Output Valve #25 (Figure page 204) Input Valve #25 (Figure Valve #25 See procedure number page 204) (page 203). AIR- 1.0.2 Fresenius 2008K Troubleshooting Guide Page 205 P/N 507298 Rev. B (Draft 1)
  • Page 208 If using jugs, check the concentrate wand(s). See Figure right. c) Check the connector(s) for cracks. See procedure number AIR- 1.0.7 (page 207). Figure 79 – Concentrate Inlet Systems Fresenius 2008K Troubleshooting Guide Page 206 P/N 507298 Rev. B (Draft 1)
  • Page 209 Proceed to page 214, procedure number DAIR- 7.0.0. a) Return the float connector to distribution board position “FLOAT-SW” and unclamp the vent tubing. b) Return to AIR 1.0.1 (page 202). Fresenius 2008K Troubleshooting Guide Page 207 P/N 507298 Rev. B (Draft 1)

  • Page 210: Section 12 - Induced Positive Pressure Tests

    If no leaks are located see step 6. Figure 80 – Internal Dialysate Circuit Leak Checks Figure 81 – External Dialysate Circuit Leak Tests Page 208 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 211 9. Connect to concentrate and return to Dialysis program (remember to press the ‘CONFIRM’ key). 10. If referred to INDUCED POSITIVE PRESSURE TESTS return to the procedure that brought you here. Fresenius 2008K Troubleshooting Guide Page 209 P/N 507298 Rev. B (Draft 1)
  • Page 212 Referring to the Figure (right), unplug valve #28 from the distribution board. Does the valve continue to leak? Yes Replace valve #28 (leaking). Replace the actuator board (see Figure page 8). Fresenius 2008K Troubleshooting Guide Page 210 P/N 507298 Rev. B (Draft 1)

  • Page 213: Section 13 - Deaeration Problems

    Check the hydraulic drawer and the DiaSafe filter (if equipped). Is a LARGE external water leak located? Proceed to page 248, SECTION 21- LARGE HYDRAULIC LEAKS. See procedure number DAIR- 1.0.3 (page 212). Page 211 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 214 If it won’t tighten, the threads may be stripped and this requires replacing the hydro block. e) See procedure number DAIR- 3.0.0 (page 213). Figure 84 – Hydro Block/Hydro Chamber Fresenius 2008K Troubleshooting Guide Page 212 P/N 507298 Rev. B (Draft 1)
  • Page 215 Referring to the Figure (right), unplug valve 39 from distribution board position V39, “DEAR-V” (2 connector from the right). b) Does deaeration pressure remain at target? Replace the actuator board. Replace valve #39 (leaking). Fresenius 2008K Troubleshooting Guide Page 213 P/N 507298 Rev. B (Draft 1)
  • Page 216 1) Bad Hydro Block seal, P/N 565642 (Type 1 block) or P/N 676270 (Type 2 block); 2) Attempt installing the Hydro Block ‘brace’ (P/N M31138); 3) Bad Hydro Block NEW STYLE HYDRO CHAMBER: Replace the chamber. Fresenius 2008K Troubleshooting Guide Page 214 P/N 507298 Rev. B (Draft 1)

  • Page 217: Section 14 - Uf Pump Problems

    Are there strong individual ‘pulses’ through the Fluid Sample Connector? See procedure number UF- 2.0.0 (page 216). See procedure number UF- 3.0.0 (page 216). Figure 86 – UF Fluid Sample / Check Valve #64 Page 215 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 218 UF- 3.0.2 (page 217). New Style: The ‘heavy’ spring is encased and cannot be seen. See procedure number 3.0.3. (page 217). Figure 87 – UF Pump’s Heavy Spring Fresenius 2008K Troubleshooting Guide Page 216 P/N 507298 Rev. B (Draft 1)
  • Page 219 Attempt UF PUMP Calibration per Procedure. If the pump will not calibrate possibly the number of factory installed ‘shim washers’ are incorrect or the UF pump is bad. Figure 88 – UF Pump Exploded Fresenius 2008K Troubleshooting Guide Page 217 P/N 507298 Rev. B (Draft 1)
  • Page 220 * The cable can be checked for continuity. NOTE that four (4) UF PUMP connections will be checked and proceed to page 225, SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE. Fresenius 2008K Troubleshooting Guide Page 218 P/N 507298 Rev. B (Draft 1)

  • Page 221: Section 15 - Blood Leak Problems

    Ignore temporary Flow Errors during reset! If a TMP alarm occurs repeat the RESET sequence once more then continue. c) Watch for 45 seconds. Does the ‘actual’ TMP bar remain green? Page 219 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 222 Sensor #8. Is air seen? See procedure number BL- 3.0.0 (page 221). See procedure number BL- 6.0.0 (page 224). Figure 89 – Hydraulics (Top View) / Blood Leak Sensor Fresenius 2008K Troubleshooting Guide Page 220 P/N 507298 Rev. B (Draft 1)
  • Page 223 Perform SECTION 11 - INDUCED AIR LEAK TESTS (page 202). IMPORTANT! Do NOT troubleshoot Blood Leak Problems if leaks are present! Fresenius 2008K Troubleshooting Guide Page 221 P/N 507298 Rev. B (Draft 1)
  • Page 224 Allow eight minutes for stabilization then see procedure number BL- 5.0.0 (page 223). Three possibilities: 1) Bad sensor cable; 2) Bad sensor board (see Figure 4A, page 8); 3) Bad distribution board. Fresenius 2008K Troubleshooting Guide Page 222 P/N 507298 Rev. B (Draft 1)
  • Page 225 Between 4.0 and 6.0 volts DC: Does debug screen 4, DIMN = pin 7 +/- 0.3? Yes See procedure number BL- 6.0.0 (page 224). Bad sensor board (see page 8). Fresenius 2008K Troubleshooting Guide Page 223 P/N 507298 Rev. B (Draft 1)
  • Page 226 Figure 89, page 220); 4) Sensor cable; 5) Sensor board; 6) Function board; 7) Distribution board. NOTE: See Figure 4A (page 8) to locate all listed circuit boards. Fresenius 2008K Troubleshooting Guide Page 224 P/N 507298 Rev. B (Draft 1)

  • Page 227: Section 16 - Checking The Actuator Board Cable

    Odd numbered in the bottom row, even numbered in the top. NOTE the reference to the ‘rear of the machine’ to locate the appropriate pin per Table 26 Table Figure 92 – Electronic Card Cage (Actuator Board) Page 225 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 228 UF PUMP (3 of 4) Bottom row, 13 pins from the rear of machine UF PUMP (4 of 4) Top row, 13 pins from the rear of machine Fresenius 2008K Troubleshooting Guide Page 226 P/N 507298 Rev. B (Draft 1)
  • Page 229 Top row, 5 pins from the front of the machine Bottom row, 4 pins from the front of the machine Top row, 4 pins from the front machine Top row, 3 pins from the front of machine Fresenius 2008K Troubleshooting Guide Page 227 P/N 507298 Rev. B (Draft 1)

  • Page 230: Section 17 - Checking The Sensor Board Cable

    NOTE the reference to the ‘rear of the machine’ to locate the appropriate pin number per Table Figure 94 – Electronic Card Cage (Sensor Board) Page 228 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 231 DIALYSATE TRANSDUCER (2 of 3) Top row, 5 pins from the rear of machine DIALYSATE TRANSDUCER (3 of 3) Bottom row, 6 pins from the rear of machine Fresenius 2008K Troubleshooting Guide Page 229 P/N 507298 Rev. B (Draft 1)

  • Page 232: Section 18A - Automated Valve Leak Tests

    AUTOTEST- 3.0.0 (page 233). NOTE 4. IOS passed and other valves (besides valve #43 and #29) have failed: the leaking valve then see procedure number AUTOTEST- 5.0.0 (page 234). Page 230 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 233 Figure (right), is the PDial window within +/- 25 of the external meter reading? Return to A. INITIALIZING AUTOMATED LEAK TESTS (page 230). Proceed to page 187, procedure number TMP- 6.0.0. Fresenius 2008K Troubleshooting Guide Page 231 P/N 507298 Rev. B (Draft 1)
  • Page 234 Fails: NOTE that valve #43 is the leaking valve then see procedure number AUTOTEST- 5.0.0 (page 234) Passes: If other Leak tests are desired return to B. PERFORM LEAK TESTS (page 230). Figure 95 – Valve #43 Fresenius 2008K Troubleshooting Guide Page 232 P/N 507298 Rev. B (Draft 1)
  • Page 235 1) Valve #29’s clear input tubing. 2) Both sides of the heat exchanger’s ‘to drain’ (CLEAR) tubing. c) Repeat the Leak Test twice on Valve #29. Does it pass both times? Fresenius 2008K Troubleshooting Guide Page 233 P/N 507298 Rev. B (Draft 1)
  • Page 236 Turn the power off and swap in a known good actuator board (see Figure 4A, page 8). c) If the NOTED leaking valve was (two scenarios): Fresenius 2008K Troubleshooting Guide Page 234 P/N 507298 Rev. B (Draft 1)
  • Page 237 Valve #43 Valve #31 Valve #32 Valve #33 Valve #34 Valve #35 Valve #36 Valve #37 Valve #38 Valve #26 Valve #29 Valve #24 ----------- Valve #25 ----------- Fresenius 2008K Troubleshooting Guide Page 235 P/N 507298 Rev. B (Draft 1)

  • Page 238: Section 18B - Manual Balancing Chamber Valve Leak Tests

    Replace any valve that is seen leaking (either valve #33 or valve #34). Unplug valve #38 and leave it. None of the top side balancing chamber valves are leaking. Continue with BOTTOM SIDE LEAK PROCEDURE (page 237). Page 236 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 239 A balancing chamber valve leak is not obvious using this test. Turn the machine off and CAREFULLY plug all valves back into the distribution board. Place the machine into Dialysis Program and perform automated Alarm/Pressure tests. Fresenius 2008K Troubleshooting Guide Page 237 P/N 507298 Rev. B (Draft 1)

  • Page 240: Section 19 - Testing For A Leaking Balancing Chamber Diaphragm

    Call debug screen 0 and allow valve #43’s adjacent dot to turn blue (see Figure right). IMPORTANT! When it turns white again begin watching the gauge for one minute. Does it consistently reach its maximum pressure per Table Page 238 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 241 A torn balancing chamber diaphragm is indicated. Remove the clamp from valve #29 then replace both balancing chamber diaphragms. See procedure number BC LEAK- 4.0.0 (page 241). Fresenius 2008K Troubleshooting Guide Page 239 P/N 507298 Rev. B (Draft 1)
  • Page 242 A torn balancing chamber diaphragm IS indicated. Remove the clamp from valve #29 then replace both balancing chamber diaphragms. A torn balancing chamber is NOT indicated. See BC LEAK- 4.0.0 (page 241). Fresenius 2008K Troubleshooting Guide Page 240 P/N 507298 Rev. B (Draft 1)
  • Page 243 1) IOS; 2) Balancing Chamber Valves #31 through #38. See SECTION 18A – AUTOMATED VALVE LEAK TESTS (page 230). b) If a valve leak is NOT located proceed to page 33, procedure number 7.0.2. Fresenius 2008K Troubleshooting Guide Page 241 P/N 507298 Rev. B (Draft 1)

  • Page 244: Section 20 - Troubleshooting Overflow From The Vent Tube

    Watch for one minute. Ignore a water crown that may appear. Is water is continually dripping from the open heat exchanger nozzle? Replace the heat exchanger’s plate (P/N 650775). Reattach the tubing to the heat exchanger then see procedure number OVER- 3.0.0 (page 243). Page 242 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 245 OVER- 3.0.1 (page 244). a) Leaving the gauge installed, if pressure remains less than 10 psi ASSURE the water is b) See procedure number OVER- 3.0.1 (page 244). Fresenius 2008K Troubleshooting Guide Page 243 P/N 507298 Rev. B (Draft 1)
  • Page 246 “V27, IN-V”. Watch for one minute. Does the dripping continue? Replace valve #41 (leaking). Leaving the tubing disconnected, see procedure number OVER- 4.0.2 (page 245). Fresenius 2008K Troubleshooting Guide Page 244 P/N 507298 Rev. B (Draft 1)
  • Page 247 Reinstall the heater. d) All systems that cause vent tubing overflow are initially checking okay. If overflow continues, float switch #5 may be bad (see Figure 28, page 59). Fresenius 2008K Troubleshooting Guide Page 245 P/N 507298 Rev. B (Draft 1)
  • Page 248 MOTORS- 2.0.0 (page 60). NOTE: If not counterclockwise! rotating it was plugged in incorrectly! It should rotate 3) See procedure number OVER- 5.0.2 (page 245). Fresenius 2008K Troubleshooting Guide Page 246 P/N 507298 Rev. B (Draft 1)
  • Page 249 Reinstall the heater. d) If massive overflow continues, three possibilities: 1) Bad float switch (see Figure 28, page 59); 2) Bad actuator cable; 3) Bad distribution board. Fresenius 2008K Troubleshooting Guide Page 247 P/N 507298 Rev. B (Draft 1)

  • Page 250: Section 21 - Large Hydraulic Leaks

    Dry the leak site and allow 30 seconds. Does the leak remain active? See procedure number LEAKING- 2.0.0 (page 249). See procedure number LEAKING- 3.0.0 (page 250). Figure 104 – Distribution Board / Hydraulics (FRONT View) Motors Page 248 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 251 VALVE #30: 1) Check tubing connections and tie wrap or replace the tubing; 2) Possible bad o-ring seal on BC valves 3) The valve body may be leaking Fresenius 2008K Troubleshooting Guide Page 249 P/N 507298 Rev. B (Draft 1)
  • Page 252 Place the machine into Rinse program for 30 seconds. b) Return to Dialysis program (remember to press the ‘CONFIRM’ key). c) Allow three minute then call debug screen 0 and check Flow Error. Fresenius 2008K Troubleshooting Guide Page 250 P/N 507298 Rev. B (Draft 1)
  • Page 253 28, page 59); 2) Excessive o-ring lubrication at the restrictor o-rings; 3) O-ring debris (if the restrictor o-rings are/were broken). B) New Style Hydro chamber AND Old style Hydro Block: 1) Inadequate acid clean cycles (causing excessive bicarbonate precipitate); 2) Inadequately filtered incoming water. Fresenius 2008K Troubleshooting Guide Page 251 P/N 507298 Rev. B (Draft 1)

  • Page 254: Section 23 - Heat Relay Test Fail

    (page Error! Bookmark not defined.), assure the 24V POWER harness is plugged securely into the motherboard. Turn the machine on and allow the “Select Program” screen to appear. Page 252 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 255 Heater Relay alarm reoccur? Replace the function board (see Figure 4A, page 8). The previous power logic board is good. Problem solved! The previous power logic board is bad (IC19). Fresenius 2008K Troubleshooting Guide Page 253 P/N 507298 Rev. B (Draft 1)
  • Page 256 Two possibilities: 1) Bad power logic board AND power control board (diode 17); 2) Bad function board. Problem solved. The previous power logic board was bad (transistor T5). Fresenius 2008K Troubleshooting Guide Page 254 P/N 507298 Rev. B (Draft 1)

  • Page 257: Section 25 - Dialyzer Valve 1 Fail Message

    (page 256). Act Byp Valve Fail 1: See procedure number DIALYZE VALVE FAIL- 2.0.0 (page 256). Dialyze Valve #2 Fail: See procedure number DIALYZE VALVE FAIL- 3.0.0 (page 256). Page 255 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 258 Place the machine into Dialysis program. Does the error reoccur? See procedure number DIALYZE VALVE FAIL- 4.0.1 (page 257). The previous actuator board is okay. Problem solved. The previous actuator board is bad. Fresenius 2008K Troubleshooting Guide Page 256 P/N 507298 Rev. B (Draft 1)
  • Page 259 1 and 5 (top and bottom), Between 40 and 100 ? Replace the actuator cable (see Figure 4A, page 8). Either the valve’s solenoid or its blue wiring harness is bad. Fresenius 2008K Troubleshooting Guide Page 257 P/N 507298 Rev. B (Draft 1)

  • Page 260: Section 26 - "Act Blood Pump Failed" Message

    Three possibilities: 1) Bad Arterial Pump Ribbon cable; 2) Bad Arterial Blood Pump Module; 3) Bad Mother Board See procedure number ABPF- 1.0.1 (page 259). Page 258 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)
  • Page 261 20 and 29 volts DC at any time during the power up sequence before the Alarm occurs? Bad Power Cable X1 (see Figure 135, page 258). Bad Power Control Board. Fresenius 2008K Troubleshooting Guide Page 259 P/N 507298 Rev. B (Draft 1)

  • Page 262: Appendix A Target Deaeration Pressures Per Geographical Area

    4,221 Jackson, MS San Francisco, CA Jacksonville, FL Seattle, WA Kansas City, MO 1,014 Springfield, MO 1,268 Las Vegas, NV 2,020 Washington, DC Little Rock, AR Wilmington, DE Page 260 Fresenius 2008K Troubleshooting Guide P/N 507298 Rev. B (Draft 1)

  • Page 263: Appendix B Calibrate If Replaced

    APPENDIX B CALIBRATE IF REPLACED Fresenius 2008K Troubleshooting Guide Page 261 P/N 507298 Rev. B (Draft 1)

  • Page 264: Appendix C Blood Pump Error Codes

    APPENDIX C BLOOD PUMP ERROR CODES Fresenius 2008K Troubleshooting Guide Page 262 P/N 507298 Rev. B (Draft 1)
  • Page 265 APPENDIX C CONTINUED Fresenius 2008K Troubleshooting Guide Page 263 P/N 507298 Rev. B (Draft 1)

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