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Fresenius Medical Care 2008K2 Troubleshooting Manual

Hemodialysis system

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2008K/K

2

HEMODIALYSIS

SYSTEM

Troubleshooting

GUIDE

Part Number 507298 Rev. H

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Troubleshooting

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Recirc flow error 1 when temp reaches 70 degrees C or flow inlet error if select rinse to exit heat disinfect…

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Summary of Contents for Fresenius Medical Care 2008K2

Page 1 2008K/K HEMODIALYSIS SYSTEM TROUBLESHOOTING GUIDE Part Number 507298 Rev. H...
Page 2 FRESENIUS MEDICAL CARE NORTH AMERICA 800-227-2572 Fresenius Medical Care North America 920 Winter St. Waltham, MA 02451 Manufactured by: Fresenius USA, Inc. 4040 Nelson Avenue Concord, CA 94520 REGIONAL EQUIPMENT SPECIALIST: __________________________________...
Page 3: Troubleshooting
Fresenius Medical Care North America 920 Winter St. Waltham, MA 02451 Manufactured by: Fresenius USA, Inc. 4040 Nelson Avenue Concord, CA 94520 http://www.fmcna.com Copyright  2002, 2010, 2012, 2014, 2015 & 2017 Fresenius Medical Care North America, All Rights Reserved...
Page 4 This document contains proprietary information of Fresenius USA, Inc. d/b/a Fresenius Medical Care North America and its affiliates (“Fresenius Medical Care”). The contents of this document may not be disclosed to third parties, copied, or duplicated in any form, in whole or in part, without the prior written permission of Fresenius Medical Care.
Page 5: Table Of Contents
TABLE OF CONTENTS Page # USING THE TROUBLESHOOTING GUIDE ....................3 THE (HYDRAULIC) 'ORDER' OF TROUBLESHOOTING ................5 INITIAL CHECKS ............................6 FINAL CHECKS BEFORE RETURNING THE MACHINE TO CLINICAL SERVICE ....... 12 TEST EQUIPMENT ........................... 13 VOLTAGE DETECTOR CALIBRATION ....................14 OPERATING MODES ..........................
Page 6: Table Of Contents
TABLE OF CONTENTS (CONTINUED) Page # SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE ............. 521 SECTION 17 - CHECKING THE SENSOR BOARD CABLE ..............524 SECTION 18A - DIAGNOSTIC VALVE LEAK TESTS ................527 SECTION 18B - MANUAL BALANCING CHAMBER VALVE LEAK TESTS .......... 533 SECTION 19 - TESTING FOR LEAKING BALANCING CHAMBER DIAPHRAGM .......
Page 7: Using The Troubleshooting Guide
USING THE TROUBLESHOOTING GUIDE A. ALWAYS turn the machine OFF before replacing a circuit board or unplugging ribbon cables. B. Observe Electrostatic Discharge (ESD) Precautions when working inside the card cage! C. It is assumed the troubleshooter is certified and has working knowledge of the machine. D.
Page 8  The 5-pin female connectors can be unplugged and returned with the power on without causing damage  CAUTION! The green 8-pin Heater Connector (Figure right) is connected to 120 Volts AC! Figure 1 – Distribution Board ) and in some cases resistance (Ω) connect the M.
Page 9: The (Hydraulic) 'Order' Of Troubleshooting
THE (HYDRAULIC) 'ORDER' OF TROUBLESHOOTING Understanding the ‘Order of Troubleshooting’ will lead to the root cause of a problem and NOT its effects. 1. Hydraulic Leaks 2. No Water 3. Flow Errors 4. Temperature 5. Conductivity 6. Filling Programs 7. TMP (Transmembrane Pressure) 8.
Page 10: Initial Checks
INITIAL CHECKS To prevent shock, turn the machine OFF! Figure below, remove the DISTRIBUTION BOARD cover: ENSURE the Sensors and Actuator cables are plugged in securely AND are not damaged. Figure right, ENSURE position “X4-PH-PR” is VACANT! Using a flashlight, check the distribution board. If corrosion is located replace it! Figure right, ENSURE the black Power Ground (PGND) wire is plugged in securely and shows no signs of burning...
Page 11 To avoid pulling cables loose, gently open the CARD CAGE: Figure right, at the rear of the card cage, ENSURE the 24V POWER harness is plugged in PROPERLY with the orange wire to the left! Figure below, trace the cable from the Blood Pressure Module to ENSURE it is NOT reverse connected with another module! ENSURE no damaged module cables! Referring to...
Page 12 Are you troubleshooting a voltage problem (example “24V Low”) OR Acid and / or Bicarb Pump “EOS” or ‘pink pump symbol’ problem? Continue to step #7. A problem located, and repaired, during INITIAL CHECKS may have solved the problem you were troubleshooting! If not return to the procedure that brought you to INITIAL CHECKS! Unmount and slide the Power Supply ¼...
Page 13 Figure 4A – Card Cage SEE NOTE A ( page 9) 1 – Test Connector (9 pins) on motherboard; 2 – Power Logic Board ; 3 – Actuator-Test SEE NOTE B ( page 11) SEE NOTE B ( page 11) Board ;...
Page 14 Figure 4B – Old / New Style Power Logic Board P/N 190099 P/N 190214 P/N 190246 2008K/K2 Troubleshooting Guide Page 10 P/N 507298 Rev. H...
Page 15 NOTE B Per the Figure below, machines produced prior to 2007 machines were equipped with separate Actuator and Test board. Machines produced in 2007 and after are equipped with an Actuator-Test board which is a single board: • The K/K2 Troubleshooting Guide, REV H, assumes all machines are equipped with the new style Actuator-Test board i.e.
Page 16: Final Checks Before Returning The Machine To Clinical Service
FINAL CHECKS BEFORE RETURNING THE MACHINE TO CLINICAL SERVICE 1) Remove all test equipment from the distribution board and ENSURE all connectors and cables are plugged in properly. 2) Reinstall the distribution board cover. 3) Clean spills from inside the hydraulic drawer and floor. This is helpful to locate leaks in the future. 4) Figure right, ENSURE the ‘To Float’...
Page 17: Test Equipment
TEST EQUIPMENT • ® CALIBRATED annually digital Multimeter (Fluke recommended!) • Test Gauge Kit (P/N 150034) • Resistor Test Plugs: Four-Resistor Set (P/N 190060); Two-Resistor Set (P/N 190168). • One (1) 1000 ml Graduated Cylinder; One (1) 100 ml Graduated Cylinder; One (1) 60 ml syringe •...
Page 18: Voltage Detector Calibration
VOLTAGE DETECTOR CALIBRATION A) Turn the machine OFF. B) To prevent pulling cables loose, GENTLY open the card cage! C) Behind the card cage, ENSURE the 24V POWER cable is securely plugged in! D) Enter Service Mode → Calibrate Monitor → Voltage Detection. Set your CALIBRATED volt meter to volts DC.
Page 19 page 618, “Operator Error” occurs! Proceed to procedure number H.1.2. “Operator Error” DID NOT occur! See part N. N) If done correctly, the screen says “4. Verify that 5V EST is between 4.8 to 5.2….”. screen’s O) Based on the [5V EST] AND [12V EST] windows, TWO (2) CHECKS: Check #1: Is [5V EST] between 4.8 and 5.2?
Page 20: Operating Modes
OPERATING MODES How to Enter Service Mode: a) Turn the machine OFF. b) Turn the machine on. When the “Press CONFIRM for Service Mode” appears on the screen press ‘CONFIRM. The screen says “Machine In Service Mode”. How to Enter T and C (Test and Calibration) Mode: Swapping in a Sensor and / or a Functional Board for troubleshooting purposes may cause a “COND OFFSET FAILURE”...
Page 21 How to Enter Dialysis Program: a) Turn the machine on and allow the “Select Program” screen (1) to appear. b) Select the screen’s ‘Dialysis’ button to call the Dialysate (“Select Concentrate”) screen (2). c) Select the screen’s ‘Conc’ button. A list of up to 10 ACID concentrates appears. d) Using the arrow keypads, select the ACID that is connected to the machine.
Page 22 h) The "CONFIRM Concentrate” screen can be called at any time by selecting the screen’s lower [Dialysate] tab or the Home screen’s [Conductivity] window. Auto Flow Selecting Dialysate Flow rates more than 800 ml/min enables auto flow (1.5x or 2x). At these settings Dialysate Flow rate will automatically adjust itself, in 100 ml/min increments, depending on blood pump rate.
Page 23 Figure 6 – Machine Rear View Valve #65 spring ® with DiaSafe P/N 642585 Valve #65 spring ® if no DiaSafe P/N 640330 2008K/K2 Troubleshooting Guide Page 19 P/N 507298 Rev. H...
Page 24: Section 1 – Flow Errors In Dialysis Program
SECTION 1 – FLOW ERRORS IN DIALYSIS PROGRAM A) Figure right, TWO (2) checks: CHECK #1: ENSURE the ‘To drain’ tubing is NOT restricted AND (if used) the ‘quick connector’ is attached PROPERLY to the station! CHECK #2: ENSURE the Vent Tubing is NOT restricted! NOTE: Vent ‘slow dripping’...
Page 25 F- 1.0.1 NO WATER NEVER APPEARS / INITIAL LOADING PRESSURE CHECK a) ENSURING the Loading Pressure gauge (yellow connector) reads 0 psi before inserting it, SLAM* it into the red Acetate/Acid rinse port. *OR ELSE pressure will not be read correctly! b) Loading Pressure MAY OR MAY NOT be cycling but is it PEAKING to MORE than 15 psi? More than 15 psi! Leaving the gauge installed, see procedure number F- 1.0.2...
Page 26 1) IF says “Air” always: See procedure number F- 1.0.2.11 (page 22). 2) IF says “No Air” OR toggles between “Air” and “No Air”: See parts a AND b below: a) Inside the distribution board, ENSURE the Air Sensor’s female connector is UNPLUGGED position from FROM THE LEFT!
Page 27 b) Figure right, TWO (2) checks: Check #1: At the top of the distribution board, ENSURE the Sensor Cable is plugged in SECURELY! Check #2: ENSURE a resistor plug has NOT been prematurely plugged into the position from the left! c) Turn the machine ON and return to Dialysis Program (“Select Program”...
Page 28 F- 1.0.4 FILACT = 1 OR CHAMBER #69 SAYS “AIR” FIGURE BELOW FOUR-RESISTOR SET , place one of the plugs, from the , into the Air Sensor’s distribution board position i.e. position* from the LEFT. NOTE: If CBE modified the resistor plugs into the CBE board pin for pin! b) Based on Chamber #69’s text box now.
Page 29 Chamber #69 says “Air’ continued: four-resistor d) Use a different plug from the set! If (and ONLY if) the text box now says “No Air” always see procedure number F- 1.0.5 (page 26). If it EVER says “Air” continue to part e. e) The text box continues to say “Air”...
Page 30 F- 1.0.5 RESET MACHINE / DEFEAT IDLE FLOW Turn the machine OFF! Open the shunt door and leave it OPEN till instructed! c) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! d) From the Home screen, select the [Dialysate Flow] window. e) Set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’.
Page 31 F- 1.0.6 ISOLATE LOADING PRESSURE WITH FILACT = 0 SLAM the Loading Pressure gauge (yellow connector) into the Acetate/Acid rinse port! B) Pressure may or may not cycle. TWO (2) possible scenarios: IF cycling, possibly every nine (9) seconds: Loading pressure is ‘OKAY’ if it cycles to a PEAK of somewhere between 23 and 27 AND a low of NEVER LESS than 11 psi.
Page 32 Scenario #2 continued, between 23 and 25 psi CAN BE acheived: a) Figure right, if threads ARE visible under Valve #65’s nut see part b. If no threads are visible either the wrong spring is installed (see Figure 6 (page 19)) OR Valve #65 is bad.
Page 33 F- 1.0.9 SCENARIO #1 / LOADING PRESSURE MORE THAN 29 PSI Referring to the Figure below, adjust Loading Pressure Valve #65’s nut counterclockwise but no more than a few turns. Can you adjust PEAK pressure to between 23 and 25 psi (Yes or No)? Between 23 and 25 psi! Call debug screen 0.
Page 34 F- 2.0.0 ISOLATE VALVE ERROR / BALANCING CHAMBER VALVES CYLING a) Call debug screen 1 to ENSURE FILACT REMAINS = 0! b) Call debug screen 0. c) Figure right, watch the Balancing Chamber valve thirty (30) seconds ‘dots’ for or until if they CYCLE between white and blue.
Page 35 ! EMPTY = 1: See procedure number F- 2.3.0 (page 31). ! EMPTY = 0: Either the arterial (red) dialyzer line is NOT connected to the shunt properly OR a, b FOUR (4) possible bad components: 1) Actuator-Test Board OR; 2) Functional Board 3) Arterial dialyzer line shunt door switch OR;...
Page 36 F- 2.5.0 BC VALVES CYCLING OR FLWP NOT REMAINING = 255 a) The shunt door MUST remain open till instructed! b) TWO (2) checks for an intermittent bad motor or Actuator Board: CHECK #1: a) Using the handle end* of a screwdriver, push on BOTH the FLOW AND DEAERATION MOTOR shafts, release, then push again.
Page 37 F- 2.6.0 MOTORS OKAY / ISOLATE ‘OPTIONAL’ DIALYSATE SAMPLER a) Press the ‘Escape’ key. b) At the bottom of the screen, select the Test & Options tab. DO NOT start the tests! c) Per the Figure below, does the OPTIONAL [Dialysate Sampler] button appear? The [Dialysate Sampler] button should NOT appear! Refer to the NOTE below! No The [Dialysate Sampler] does NOT appear! See procedure number F- 2.7.0...
Page 38 F- 2.8.0 ISOLATE FLOW ERROR a) Call debug screen 0 to see Flow Error. If EVER = 1, even if just once, a Flow Error is present! b) WITHOUT LOOKING AWAY, watch for two (2) minutes OR until Flow Error EVER = 1. TWO (2) possible scenarios: IF (and ONLY if) Flow Error EVER = 1 even if just once: A problem is indicated in the ‘bypass page 47...
Page 39 a) Momentarily plug JUST the acid (red) connector into its rinse port to call “Select Program”! b) RETURN the acid connector to concentrate! DO NOT TILL INSTRUCTED c) Select the ‘Dialysis’ button but press ’CONFIRM’ d) Call debug screen 0. If parts a through c were performed correctly the TOP balancing chamber valves ‘dots’, #31 through #34, are REMAINING BLUE! e) Remove the red DIALYZER connector from the shunt door and HOLD IT UP as seen in the Figure right!
Page 40 F- 2.9.2 ISOLATE TEMPERATURE AND CONDUCTIVITY ENSURE NO ACTIVE LEAKS BEFORE CONTINUING! b) Call the Home screen. Is [Temperature] REMAINING between 35.5 and 38.5 °C AND Conductivity REMAINING between 13.0 and 14.5 mS? TWO (2) possible scenarios: IF (and ONLY if) Temperature AND / OR Conductivity is remaining in range: Proceed page 39 , procedure number F- 2.0.15.
Page 41 F- 2.0.10 VALVE #24’S ‘DOT’ IS BLUE a) Call the Home screen to ENSURE [Dialysate Flow] has REMAINED set to 800 ml/min!! b) Does a leak develop? Refer to Table 2 below: Table 1 Does a leak develop? Your Response: See parts a THROUGH c below: a) Turn the machine OFF! Yes (a leak...
Page 42 F- 2.0.12 VALVE #24’S ‘DOT’ IS WHITE / IN BYPASS Call the Home screen. Is the [Temperature] window (Figure right) RED? [Temperature] window is red! See procedure number F- 2.0.13 (page 38). [Temperature] window is pale yellow/white! See parts a AND b below: a) Return to the Home screen.
Page 43 F- 2.0.15 [TEMPERATURE] NOT 35.0 - 39.0 °C AND / OR [CONDUCTIVITY] NOT 13.0 - 14.5 mS a) Call the Home screen. b) Select the [Temperature] window to ENSURE “Temp Setting” is 37.0° C. c) Press ‘CONFIRM’. d) With the shunt door REMAINING open, call debug screen 0. e) WITHOUT LOOKING AWAY, watch Flow Error for one (1) minute.
Page 44 F- 3.0.0 ISOLATE VALVE #43 (FILLING PROGRAM) DRAIN FLOW A) WITHOUT returning the Air Sensor’s connector yet, remove the resistor plug from the distribution board. B) ENSURE debug screen 0’s Chamber #69 says “Air”. C) Obtain a 1000 ml graduated cylinder! D) Figure right, ENSURE a “Dial Valve Failure”...
Page 45 F- 3.1.1 FLOW LESS THAN 600 / ISOLATE ACTUATOR-TEST BOARD / VALVE #43 a) ENSURE FILACT REMAINS = 1! Figure below , using a flashlight, check through Valve #43’s OUTPUT tubing for bio-growth restrictions. If a restriction is located this may be the problem! Figure 8 –...
Page 46 F- 3.2.0 SIX HUNDRED (600) ML OR MORE IN FILLING PROGRAM a) Return the Air Sensor’s female connector to distribution board position from the left. If the Air Sensor is b) Call debug screen 0. plugged in properly, Chamber #69’s box says “No Air”.
Page 47 F- 3.3.0 GOOD FLOW PUMP PRESSURE a) Return the connectors to acid and bicarbonate. b) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! c) From the Home screen, set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’! d) Allow [Conductivity] to increase to more than 13.0 mS! e) TWO (2) possible TMP window scenarios below: IF (and ONLY if) the TMP window is NOT red: See procedure number F- 3.6.0...
Page 48 Procedure number F- 3.6.0 continued from previous page: IF (and ONLY if) REMAINS ALWAYS = 897 or more: Return to (ABOVE) procedure page 30 number F- 2.0.0 2) IF (and ONLY if) NEVER 897 or more: The Flow Error is not occurring now. Replacing ®...
Page 49 F- 3.8.1 TROUBLESHOOTING INTERMITTENT FLOW ERRORS The following step-by-step procedures may locate an extremely intermittent Flow Error: Figure right, check the (blue) CFS transducer #10 AND Dialysate Pressure #9 transducers for signs of a small external leak. If leakage is located replace the transducer.
Page 50 Call debug screen 0. Watch Flow Error for five (5) minutes. If it EVER = 1 along with a “TMP is High” alarm and/or “Filling Program” AND Loading Pressure remains ‘OKAY’ may indicate a: 1) ® Restricted DiaSafe filter OR: 2) Restricted Valve #26. If Flow Error is ALWAYS = 0 continue to step #11.
Page 51 F- 5.0.0 FLOW ERROR ‘1’ OR QDL NOT BETWEEN 720 AND 880 OR BC SWITCH > 400 IMPORTANT! CLOSE THE SHUNT DOOR! b) The following is ESPECIALLY IMPORTANT if the machine was worked on by someone who may have connected the BALANCING CHAMBER VALVES (#31 through #38) incorrectly between the distribution board and their solenoid terminals (Figure right)! c) TWO (2) possible scenarios 1) or 2) below:...
Page 52 F- 5.1.0 BALANCING CHAMBER VALVES WIRED CORRECTLY a) Call debug screen 6. b) Watch BC Switch (middle column) for thirty (30) FULL seconds. Does it REMAIN ALWAYS = 897? BC Switch ALWAYS = 897! See procedure number F- 5.1.1 (page 48). page 49 BC Switch is NOT always = 897! Proceed to , procedure number...
Page 53 F- 5.2.0 PREPARE TO ISOLATE VALVE #24 / VALVE #26 IMPORTANT! ENSURE the shunt door is CLOSED! b) ENSURE Dialysate Flow is ON (Flow on/off lamp NOT blinking)! c) Call the Home screen and ENSURE [Dialysate Flow] is set to 800 ml/min! d) Figure right, is the [Conductivity] AND / OR the [Temperature] window REMAINING ALWAYS RED? REMAINING ALWAYS RED! See procedure number...
Page 54 F- 6.0.0 DRAIN STREAM CHECKS a) Figure right, if a ‘Quick Connector’ is present at the end of the ‘to drain’ tubing an ADAPTOR is required! UP at b) Figure below, point the drain tube OPENING 45° , at a level no higher than two (2) feet above the IF POINTED DOWN GRAVITY FLOW floor! RESULTS IN ERROR!
Page 55 Scenario #3: Referring to Figure C, for a ONE MINUTE PERIOD if EVER a continuous weak stream that LASTS for five (5) seconds or longer: page ENSURING the drain tube OPENING was pointed up, proceed to , procedure number 6.2.0. Figure C Scenario #4: IF No Flow EVER: If (and ONLY if) the Dialysate Flow on/off lamp is blinking...
Page 56 F- 6.1.1 PDIA NOT BETWEEEN 1.0 AND 8.5 OR UNSTABLE a) Momentarily plug the RED (acid) concentrate connector into its rinse port to call “Select Program”. b) Return the RED connector to acid concentrate! DO NOT c) Select the ‘Dialysis’ button but press ‘CONFIRM’! d) Remove the red DIALYZER connector from the shunt door and HOLD IT as seen in the Figure right!
Page 57 F- 6.1.2 PDIA AND ADIA STABLE BETWEEN 2.0 AND 7.5 Turn the machine OFF! ® B) Preferably from another machine, that is not having Flow Errors, swap in a DiaSafe filter! C) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘Enter’)! OPEN the shunt door till instructed OTHERWISE! E) Allow five (5) minutes OR until NO AIR bubbles are seen flowing through the DiaSafe housing tubing.
Page 58 F- 6.1.4 PDIA STABLE BETWEEN 1.0 AND 8.5 a) From the Home screen, ENSURE [Dialysate Flow] is set to 800 ml/min. b) [Conductivity] MUST BE more than 11.0 mS indicating the Acid Pump is drawing! c) Is [Conductivity] more than 14.6 mS? page 62 [Conductivity] more than 14.6 mS! Proceed to , procedure number F- 7.0.0.
Page 59 E) WITHOUT LOOKING AWAY, ENSURING a “No Water” banner NEVER appears, watch BC Switch for up to five (5) minutes OR until if it EVER is more than 400 OR less than 203. FOUR (4) possible scenarios 1) or 2) or 3) or 4): page 89 IF (and ONLY if) BC Switch is CONSTANTLY 897 or more: Proceed to procedure number...
Page 60 F- 6.1.6 ISOLATE DIALYSATE PRESSURE (PDIAL) Call debug screen 4 to again watch PDIA for TWO (2) FULL minutes. TWO (2) possible scenarios: page IF (and ONLY if) PDIA increases to more than 8.0 OR drops to less than 2.0: Return to procedure number 6.1.1.
Page 61 F- 6.1.8 VERIFY FLOW RATE (BC SWITCH) Do NOT reset alarms! b) Call debug screen 6. WITHOUT LOOKING AWAY, watch BC Switch (middle column) for two (2) minutes OR until it EVER = 897 or more. FOUR (4) possible scenarios 1) or 2) or 3) or 4) below: IF (and ONLY if) BC Switch REMAINS ALWAYS = 897: ENSURING a “No Water”...
Page 62 F- 6.2.0 TROUBLESHOOT ‘CONTINUOUS’ DRAIN FLOW Drain flow NEVER stops! From the Home screen, is [Conductivity] more than 15.0 mS? [Conductivity] more than 15.0! ENSURING Loading Pressure (Rinse port gauge) is PEAKING to between 23 and 27 psi, see procedure number F- 6.3.0 (page 59).
Page 63 F- 6.3.0 RESTRICTED DRAIN FLOW / ISOLATE ‘DRAIN’ VALVE #30 / ACTUATOR-TEST BOARD Per the Figure below, touch valve #30’s (black) solenoid. Is it HOT? Solenoid is hot! See procedure number F- 6.3.1 (page 59). ONLY page 192 Solenoid is NOT hot! NOTE VALVE #30 will be checked and proceed to TROUBLESHOOTING A VALVE.
Page 64 IF (and ONLY if) the plunger moves with NO resistance: Valve #30 is open! See procedure number F- 6.4.0 (page 60). 2) IF the plunger OFFERS RESISTANCE: Valve #30 is restricted! TWO (2) possible bad components: 1) Bad Valve #30 OR; 2) Bad Actuator-Test Board. To LOCATE the board refer to Figure 4A (page 9).
Page 65 F- 6.5.0 TMP ALARM? a) From the Home screen, set [Dialysate Flow] to 500 ml/min and press CONFIRM! b) Allow thirty (30) seconds THEN TWO (2) possible TMP window scenarios: IF the TMP window is NOT red: See procedure number F- 6.5.2 (page 61).
Page 66 F- 7.0.0 ISOLATE POSSIBLE RESTRICTIONS a) ENSURE Dialysate Flow is ON (Dialysate Flow on/off lamp NOT blinking)! b) Recheck Loading Pressure (Rinse port gauge). It may not cycle but MUST reach a PEAK between 23 and 27 psi? Between 23 and 27 psi! See procedure number F- 7.0.1 (page 62).
Page 67 F- 7.0.2 LOADING PRESSURE ‘OKAY’ (2) To prevent damage, turn the machine OFF! B) To avoid pulling cables loose, GENTLY open the card cage. C) Per the Figure below, THREE (3) checks: CHECK #1 CAREFULLY check the ENTIRE LENGTH of the Actuator Cable for damage! CHECK #2 ENSURE the Actuator Cable is plugged in securely at both ends! CHECK #3 ENSURE the valves are plugged into their CORRECT distribution board positions! D) Was a problem located during the above three (3) checks?
Page 68 F- 7.0.3 ISOLATE ACTUATOR-TEST BOARD To prevent damage, turn the machine OFF! b) Swap in a known good* Actuator-Test Board**. * Known good = has been tested in another machine that is NEVER issuing Flow Errors! If a known good Actuator-Test board is NOT used here AND the problem is a bad board you may perform unnecessary, and time consuming, component replacement! ** To LOCATE the Actuator-Test board refer to the Figure (previous page).
Page 69 F- 7.0.4 FLOW ERROR = 1 / ISOLATE ‘FRESH SIDE’ FLOW PATHS Plug the acid connector into its rinse port to call the “Select Program” screen but DO NOT press any keys! b) Balancing Chamber valve connectors will be switched to test ‘fresh side’ flow paths. Flow is measured into a 1000 ml GRADUATED cylinder for one (1) minute.
Page 70 FRESH SIDE THEORY: Per the Figure below, when ‘Select Program” is up, the top Balancing Chamber (BC) valves (V31 – V34) are supposed to be open, the bottom BC valves (V35 – V38) are closed. V30, V26 and V25 are open. Deaeration Pump #20 is running and can draw from hydrochamber C and D. PART 1 THEORY: Plugging V35 into V30’s distribution board position should open V35.
Page 71 F- 7.3.33 PART 1 BAD FLOW / PART 2 MORE THAN 800 ML / RESTRICTED VALVES #31 OR #35 Balancing Chamber Valve #35 and/or Valve #31 is not opening. Also, the Actuator Cable or distribution board may be bad. These procedures isolate between these components: A) Turn the machine OFF! B) Return #37 to its PROPER distribution board position.
Page 72 DO NOT E) Turn the machine on but press any other keys. F) With “Select Program” up, measure flow, from the RED connector, for one (1) minute. More than 800 ml collected? More than 800 ml collected! Problem located! The previous Valve #31 is bad. Less than 800 ml collected! See parts a AND b below: a) Return all valves to their PROPER distribution board positions.
Page 73 F- 7.4.44 PART 1 MORE THAN 800 ML / PART 2 BAD FLOW / RESTRICTED VALVE #37 OR #33 Balancing Chamber Valve #37 and/or Valve #33 is not opening. Also, the Actuator Cable or distribution board may be bad. These procedures isolate between these components: A) Turn the machine OFF! Per the Figure below Valve #37...
Page 74 DO NOT E) Turn the machine but press any other keys! F) With “Select Program” up, measure flow, from the RED connector, for one (1) minute. More than 800 ml collected? More than 800 ml collected! Problem solved! The previous Valve #33 is bad. Less than 800 ml collected! See parts a and b below: a) Return all valves to their PROPER distribution board positions.
Page 75 F- 7.0.5 ISOLATE VALVE #26 / VALVE #25 ACTUATOR-TEST BOARD CONTROL ENSURE “Select Program” REMAINS up! b) EXCEPT for valve #37 and valve #30, ENSURE ALL OTHER valves are plugged into their PROPER distribution board positions! c) TWO (2) ‘touch’ checks on valve #26 AND #25’s (black) solenoids: Figure 15 TOUCH CHECK #1: Per below touch Valve #26’s solenoid.
Page 76 Figure 16 – Valve #25 F- 7.0.6 ISOLATE VALVE #26 INPUT FLOW Figure 15 (previous page) VALVE #26’s a) Per , clamp INPUT tubing. b) Remove the tubing and route it into the cylinder. c) Remove the clamp and measure flow, from the tubing, for one (1) minute. 800 ml or more collected? 800 ml or more! A) Clamp and reattach the tubing;...
Page 77 F- 7.0.8 800 ML OR MORE FROM FLOW PUMP’S INPUT TUBING IMPORTANT! Reattach the Flow Pump’s tubing! IMPORTANT! Remove the clamp from valve #26! c) Figure below, open Dialysate Line Filter #73’s housing and measure flow from the tubing segment shown for one (1) minute.
Page 78 F- 7.0.9 ISOLATE FLOW FROM THE BALANCING CHAMBERS a) Figure below, clamp and remove the bottom tubing at Pre-Cell #7 b) Direct the tubing into the cylinder. IMPORTANT! Remove the clamps from Pre-Cell #7 AND valve #26! d) Measure flow, from the tubing for one (1) minute. 800 ml or more collected? 800 or more! A) Clamp and reattach the tubing;...
Page 79 F- 7.3.1 ISOLATE FLOW PUMP ORIENTATION Return valves #30 AND #37 to their proper distribution board positions. b) “Select Program” MUST REMAIN up! c) A bucket, filled with at least ten (10) liters (3.0 gallons) tap or RO water, is REQUIRED! d) Remove the RED DIALYZER connector from the shunt door and place it into the filled bucket on the floor.
Page 80 F- 7.3.2 ISOLATE ‘SPENT SIDE’ FLOW PATHS a) Valve connectors will be switched to test ‘spent side’ flow paths to drain. A second bucket and the 1000 ml cylinder is required! b) Figure right, at the rear of the machine, remove the tubing from the Drain (BOTTOM!) nozzle.
Page 81 SPENT SIDE THEORY: Per the Figure below, when “Select Program” is up the top balancing chamber (BC) valves (V31 – V34) are supposed to be open, the bottom BC valves (V35 – V38) are closed. Flow Pump #21 is off which is why it must be plugged into the Deaeration Pump’s distribution board position. Also, the red dialyzer line is placed into a bucket of water to provide the Flow Pump with a source of water.
Page 82 F- 7.4.0 VERIFY DRAIN FLOW The “Select Program” screen remains up till instructed otherwise! b) Was there ANY drain flow at all? page 79 There was some flow! Proceed to , procedure number F- 7.4.3 There was no flow at all! See procedure number F- 7.4.2 (page 78).
Page 83 F- 7.4.3 ISOLATE ACTUATOR-TEST BOARD Per the Figure below, touch valve #30’s (black) solenoid. Is it HOT? Valve #30’s solenoid is hot! See procedure number F- 7.4.4 (page 79). Valve #30’s solenoid is NOT hot! See parts a THROUGH c below: a) Return valve #38 AND #31 to their distribution board positions.
Page 84 F- 7.4.5 RE-CHECK ‘FRESH SIDE’ PATH a) Reattach valve #30’s tubing AND the tubing to the rear drain port. IMPORTANT! Return valve’s #38 AND #31 to their PROPER distribution board positions. c) The “Select Program” remains up! d) Figure right, return Deaeration Pump #20 AND Flow Pump #21 to their distribution board positions.
Page 85 F- 7.4.6 ISOLATE FLOW PUMP INPUT a) ENSURE “Select Program” remains up! Return the dialyzer connector to the shunt door! Return valve #35 to valve #30’s distribution board position! d) Figure right, remove the Flow Pump’s clear INPUT tubing and measure from it for one (1) minute. 800 ml or more collected? 800 ml OR more! See procedure number F- 7.4.6.1...
Page 86 F- 7.5.0 ISOLATE FLOW PUMP #21 a) This procedure uses a psi pressure gauge. ENSURE it reads 0 psi before installing it! b) Figure right, tee the gauge between the Flow Pump's OUTPUT NOZZLE and its WHITE tubing. Tie wrap both sides of the gauge tubing to prevent leaks and false readings! Place the machine into RINSE! e) Watch for one (1) minute to ENSURE a “No Water”...
Page 87 BC Switch goes to 897 or more, even if only once! Read before performing! Return to page 26 , procedure number F- 1.0.5 but, if you return here, because of no drain flow, THREE (3) possible bad components (see COMPONENT LIST below): COMPONENT LIST: 1) Actuator-Test Board OR;...
Page 88 F- 7.6.10 PART 3 BAD FLOW / PART 4 MORE THAN 800 / RESTRICTED VALVES #36 AND/OR #32 Balancing Chamber Valve #36 and/or Valve #32 is not opening. Also, the Actuator Cable or the distribution board may be bad. These procedures isolate between these components: A) Turn the machine OFF! B) Return valves #31 AND #38 to their PROPER distribution board positions.
Page 89 D) Plug the new Valve #32’s connector into Valve #33’s distribution board position, “V33”. ENSURE the bucket with the RED dialyzer connector submersed is full! DO NOT F) Turn the machine on but press any other keys! G) With “Select Program” up, measure drain flow for one (1) minute. More than 800 ml every minute? More than 800 ml! Problem located! The previous Valve #32 is bad! Less than 800 ml! See parts a AND b below: a) Return all valves to their PROPER distribution board positions.
Page 90 F- 7.7.20 PART 3 GOOD FLOW / PART 4 LESS THAN 800 ML / RESTRICTED VALVES #38 AND #34 Balancing Chamber Valve #38 and/or Valve #34 is not opening. Also, the Actuator Cable or the distribution board may be bad. These procedures isolate between these components: a) Turn the machine OFF! b) The Flow Pump remains plugged into the Deaeration Pump’s distribution board position! Per the Figure below,...
Page 91 F- 7.7.22 LESS THAN 800 ML COLLECTED / ISOLATE VALVE #34 A) Turn the machine OFF! B) Return Valves #38 AND #31 to their PROPER distribution board positions. Per the Figure previous page Valve #34 , replace with a known good! D) Plug the new valve #34’s connector into valve #33’s distribution board position, “V33”.
Page 92 F- 7.8.0 PARTS 3 AND 4 YIELDED 800 ML OR MORE / RETURN SYSTEMS All secondary side components are checking good HOWEVER, the problem may be intermittent. a) Turn the machine OFF! b) Reattach the drain tubing. ENSURING it is properly attached to the station! c) Return Valves #31 AND #38 to their distribution board positions.
Page 93 F- 8.0.0 BC SWITCH = 897 a) Turn Dialysate Flow OFF (Flow on/off lamp blinks)! b) Call debug screen 0. If Flow is OFF all eight (8) Balancing Chamber valve ‘dots’ REMAIN white (Figure right)! c) Call debug screen 4 to see PDIA (lower left column). TWO (2) possible scenarios: IF (and ONLY if) PDIA is between 2.0 and 7.5: See procedure number...
Page 94 F- 8.2.0 ANALYZE ACFS a) Call debug screen 0. Figure right, look at ACFS (Figure right) THEN locate its value in COLUMN 1 of the Table below. b) Call debug screen 10. c) Look at ACFS (right column, bottom) THEN locate its value in COLUMN 2 of the Table below next to screen 0’s ACFS value seen in part a.
Page 95 F- 8.3.0 BOTH ACFS VALUES ARE GOOD a) Turn Dialysate Flow ON (Flow on/off lamp NOT blinking). b) From the home screen, select the [Dialysate Flow] window. c) Set [Dialysate Flow] to to 800 ml/min and press ‘CONFIRM’. d) Allow one (1) minute BEFORE continuing to part e. e) Call debug screen 10 to watch ACFS for one (1) minute.
Page 96 F- 9.0.0 ACFS BETWEEN 3.1 AND 8.0 / ISOLATE FLOW PUMP a) Return BOTH concentrate connectors to their rinse ports! ENSURE b) This procedure requires a psi gauge. it reads 0 psi before installing it! c) Per Figure 21 below, tee the gauge into the Flow Pump’s WHITE (output) tubing. Tie wrap both sides of the gauge tubing to prevent leaks and false readings! Place the machine in RINSE! ENSURING a “No Water”...
Page 97 F- 9.0.23 LOW FLOW PUMP PRESSURE / ISOLATE VALVE #43 Figure 22 (below) a) Still in RINSE, , DOUBLE CLAMP Valve #43’s OUTPUT tubing! NOTE: Valve #43’s output tubing extends towards the front of the machine! Figure 22 - Isolate Valve #43 b) Does gauge pressure NOW CYCLE to more than 35 psi about every three (3) seconds (Yes or No)? More than 35 psi! This may indicate Valve #43 is sticking open.
Page 98 F- 9.0.24 ISOLATE FLOW PUMP INPUT FLOW a) Obtain a 1000 ml (or larger) graduated cylinder! Service Mode’s Flow Pressure is used to isolate the Flow Pump’s input circuit! DO NOT follow the screen instructions! Perform no adjustments until instructed! c) Enter Service Mode →...
Page 99 F- 9.0.26 BAD FLOW PUMP PRESSURE a) Return to Calibrate Hydraulics → Flow Pressure. b) Press ‘CONFIRM’ THEN ENSURE the FLOW MOTOR shaft is rotating! Per the Figure below , above the Deair Pump, locate Valve #78. WARNING! To avoid error DO NOT use a plastic clamp in part e! Use METAL NEEDLE NOSE PLIERS instead! using PLIERS e) While watching the gauge,...
Page 100 F- 9.0.27 40 PSI OR MORE / ISOLATE VALVE #78 Turn the machine OFF! b) Replace Valve #78* with a known good! *To LOCATE Valve #78 refer to the Figure previous page. c) Enter Service Mode → Calibrate Hydraulics → Flow Pressure. d) Press ‘CONFIRM’...
Page 101 F- 9.0.4 INPUT FLOW PUMP FLOW LESS THAN 800 ML / ISOLATE V26 INPUT FLOW Remove the clamps from Valve #43! b) Obtain an empty bucket. Figure below , remove Valve #26’s INPUT tubing and direct it into the bucket! d) Return to Calibrate Hydraulics →...
Page 102 F- 9.0.41 LESS THAN 800 ML TO VALVE #26 ® a) ENSURE no restrictions or leaks between the DiaSafe filter and the Balancing Chambers. ® b) ENSURE no restrictions between the DiaSafe filter and Valve #26. Figure below , at the rear of the DiaSafe ®...
Page 103 F- 9.0.42 MORE THAN 800 ML INPUT FLOW TO VALVE #26 / ISOLATE VALVE #24 a) Return to Calibrate Hydraulics → Flow Pressure. b) Press ‘CONFIRM’ then ENSURE the Flow Motor is rotating! c) Remove the BLUE dialyzer connector from the shunt door. d) Measure flow from the dialyzer connector for one (1) minute! e) Press ‘CONFIRM’...
Page 104 ONLY More than 800 ml! A) Reconnect Valve #24’s tubing; B) NOTE VALVE #24 page 192 will be checked and proceed to TROUBLESHOOTING A VALVE. ® No TWO (2) possibilities: 1) Bad (restricted) DiaSafe filter OR 2) Tubing restriction between the balancing chambers and Valve #24. F- 9.0.43 GOOD FLOW FROM VALVE #24 A restriction is indicated in the ‘from (red) Dialyzer line’.
Page 105 F- 9.0.5 GOOD FLOW PUMP PRESSURE / ISOLATE CFS CIRCUIT a) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! b) From the Home screen, set [Dialysate Flow] to 500 ml/min and press ‘CONFIRM’. c) Figure below, insert one of the resistor plugs, from the FOUR-RESISTOR SET, into CFS #10’s distribution board position, “x10, CFS”.
Page 106 F- 9.0.6 ACFS = 0 a) Return CFS #10’s connector to distribution board position “x10, CFS”. If returned properly ACFS = between 3.0 and 8.1. 500 ml/min b) From the Home screen, ENSURE [Dialysate Flow] is set to c) Is the TMP window RED? Red TMP window! RESET SEQUENCE: A) Press and release the ‘Reset’...
Page 107 F- 10.0.0 BAD ACFS SIGNAL a) Figure right, ENSURE the CFS #10 Pressure Transducer’s connector is plugged PROPERLY into the distribution board. b) See procedure number F- 10.1.0 (page 103). F- 10.1.0 CFS PLUGGED IN PROPERLY PDIA a) Call debug screen 10. If all procedures were performed correctly (middle column) = between 3.5 and 6.5.
Page 108 F- 11.0.0 ACFS = BETWEEN 0 AND 3.0 a) Turn Dialysate Flow OFF (Flow on/off lamp blinks)! b) Press and release the ‘Reset’ key then immediately press and hold it for three (3) seconds. Allow thirty (30) seconds. If a TMP occurs attempt RESET up to FIVE (5) times BEFORE continuing to part c. c) Call debug screen 10.
Page 109 PDial = 0 +/- 50! A) Return the dialyzer connectors to the shunt and close the door! B) See procedure number F- 11.0.5 (page 105). IMPORTANT! PDial is NOT = 0 +/- 50! A) Turn Dialysate flow ON (Flow on/off lamp NOT page 107, blinking);...
Page 110 F- 11.0.7 CHECK FOR SECONDARY SIDE RESTRICTION a) Obtain a 1000 ml graduated cylinder. b) Plug the red concentrate connector into its rinse port. c) Turn the machine on but DO NOT press any keys! “Select Program” remains up till instructed otherwise! d) Remove the red dialyzer connector from the shunt door and place it into a 1000 ml graduated cylinder.
Page 111 F- 12.0.0 CALIBRATE/TROUBLESHOOT DIALYSATE PRESSURE This is NOT a routine calibration! Follow the instructions exactly to avoid error! Open the shunt door! b) Enter Service Mode → Calibrate Sensors → Dialysate Pressure. The screen says “1. Connect a pressure gauge in line…”. c) Figure right, connect the Four-Way Assembly (P/N 150034) to the dialyzer connectors.
Page 112 F- 12.2.0 NEGATIVE 250 MMHG WAS ACHIEVED / PRESSURE TEST Does meter pressure HOLD, +/- 15 mmHg, for one (1) minute? Pressure holds! See procedure number F- 12.2.2 (page 108). page 109, Pressure DOES NOT hold! Proceed to procedure number 12.3.0.
Page 113 F- 12.3.0 EITHER -250 MMHG COULD NOT BE ACHIEVED OR IT DID NO HOLD / ISOLATE FOUR-WAY Figure right , clamp BOTH Four-Way dialyzer tubing segments. b) Can you achieve -250 mmHg and HOLD it (+/- 15 mmHg) for one (1) minute now? -250 can be achieved AND it held! See procedure number F- 12.3.2...
Page 114 F- 12.4.0 “OPERATOR ERROR” OCCURED / TROUBLESHOOT DIALYSATE PRESSURE a) ENSURE the transducer protector, at the external meter, is not WET or consider replacing it! b) Return the Dialysate lines to the shunt and close the door. c) Turn the machine OFF! d) Turn the machine on and return to Dialysis Program (“Select Program”...
Page 115 F- 13.0.0 ‘BOB’ IS MOVING WHEN IT’S NOT SUPPOSED TO The Temperature AND / OR the Conductivity window is REMAINING RED BUT the external flow indicator’s bob is moving! a) Per the Figure BELOW, trace the wires from Valve #24’s AND #26’s distribution board connectors, to ENSURE Valve #24 and #26 in the hydraulics to they are wired to the CORRECT valve!
Page 116 F- 14.0.0 ISOLATE 'OUT OF BYPASS' CIRCUIT a) Turn the machine OFF! b) Figure right, ENSURE the flow indicator’s INNER Tapered Tube AND its ‘bob’ is orientated narrow to wide from the bottom up. c) See procedure number F- 14.0.2 (page 112).
Page 117 LESS THAN 800 ml collected continued: ® a) ENSURE no tubing restrictions at the DiaSafe filter. b) Figure below, open Dialysate Filter #73’s housing and ENSURE the filter inside is clean! c) Per the Figure below, touch Valve #25’s black solenoid. Is it warm? The solenoid is warm! TWO (2) possible bad components: 1) Bad Actuator-Test Board OR;...
Page 118 F- 14.0.6 BAD FLOW FROM VALVE #24 / ISOLATE VALVE #26 Per the Figure below , clamp Valve #26’s INPUT tubing! Figure 24 – Valve #26 b) Return to Calibrate Hydraulics → Flow Pressure. c) Press ‘CONFIRM’ THEN ENSURE the Flow Motor is rotating! d) Measure again from the blue dialyzer connector for one (1) minute.
Page 119 F- 14.0.8 VALVE #26 OKAY Remove the clamp from Valve #26! b) Obtain a bucket! Per the Figure below , remove the tubing from Valve #24’s INPUT and direct into the bucket Figure 25 – Valve #24 d) From Calibrate Hydraulics → Flow Pressure. e) Press ‘CONFIRM’...
Page 120 F- 15.0.0 LOADING PRESSURE LOW / ISOLATE DEAERATION MOTOR RATE (DEAP) A) Turn the Heater Switch OFF for now! B) Call debug screen 1 to see DEAP (upper right). TWO (2) possible scenarios: IF (and ONLY if) DEAP = 75 OR LESS! See procedure number F- 15.2.0 (page 117).
Page 121 F- 15.2.0 DEAP LESS THAN OR = 75 / ISOLATE DEAERATION MOTOR Per the Figure below, is the DEAERATION MOTOR shaft rotating COUNTERCLOCKWISE (CCW)? Rotating CCW! See procedure number F- 15.2.1 (page 117). ONLY No NOT rotating CCW! NOTE the DEAERATION MOTOR will be checked then proceed to page 130 TROUBLESHOOTING MOTORS.
Page 122 F- 15.2.2 MOTOR CONTINUES TO ROTATE Recheck Loading Pressure (Rinse Port gauge). TWO (2) possible scenarios below: IF (and ONLY if) REMAINING LESS THAN 15 psi: See procedure number F- 15.2.3 (page 119). IF peaking to at least 15 psi: NOTING how many turns, turn Loading Pressure Valve #65’s nut (Figure right) CLOCKWISE (inward) until if pressure reaches a PEAK of between 23 and...
Page 123 F- 15.2.3 LOW LOADING PRESSURE / ISOLATE POSSIBLE AIR LOCK Obtain a 1000 ml graduated cylinder AND a bucket! b) Figure right, unplug the DERATION PUMP’s, connector from distribution board position “P20-Degas- P”! clear tubing c) Figure right, remove the from the Keep the Deaeration Pump’s INPUT nozzle.
Page 124 F- 15.5.0 ISOLATE BETWEEN THE DEAERATON PUMP AND VALVE #65 WARNING! Using a plastic clamp in part b will cause error! Use METAL NEEDLE NOSE PLIERS instead! Figure 27 below , using NEEDLE NOSE PLIERS, AND WHILE WATCHING THE GAUGE, tightly clamp then QUICKLY release the white tubing at the TOP of Loading Pressure Valve #65! c) When clamped, does pressure PEAK to 35 psi OR more? Peaks to 35 psi or more! The Deaeration Pump is okay! TWO (2) possible bad...
Page 125 F- 15.5.2 ISOLATE ‘BINDING’ DEAERATION MOTOR a) Turn the machine OFF! b) Per the Figure right, remove the pump head from the deaeration motor to expose the ‘Drive Magnet’. c) Manually spin the ‘Drive Magnet’. Does it rotate freely (Yes or No)? Rotates freely! See parts a AND b below! a) Ensure the ‘Drive Magnet’...
Page 126 F- 16.0.0 LESS THAN 150 ML COLLECTED / ISOLATE RESTRICTOR #48 This procedure attempts to clear an air lock. First Restrictor #48 is checked to see if it is plugged. 60 ml syringe a) Figure right, a *, with its plunger pushed ALL THE WAY IN is required! Using a smaller syringe may cause error! b) Attach the syringe, to the DEAERATION PUMP’s clear (INPUT) tubing removed earlier.
Page 127 F- 16.0.7 LESS THAN 130 ML PER MINUTE COLLECTED / ISOLATE INCOMING WATER 274 Ω a) Figure right, place the resistor plug, from the TWO-RESISTOR SET , into the float’s distribution board position, “X5, FLOAT-SW”. b) Allow forty (40) seconds or until flow from the Vent Tubing occurs indicating hydrochambers A through C are full! c) MEASURE flow from the Vent Tubing for ONE (1) minute.
Page 128 F- 16.0.9 MORE THAN 130 ML EVERY MINUTE / ISOLATE FLOAT SWITCH #5 a) This procedure requires up to five (5) minutes to prevent labor-intensive error! five (5) minutes b) Direct the tubing into the bucket for up to . Flow will either: 1) Continue at more than 130 ml every minute OR 2) Stop.
Page 129 F- 16.2.0 FLOW DOES NOT STOP Reattach the Deaeration Pump’s input tubing! b) FIGURE right, return the Deaeration Pump’s connector to position “P20, Degas-P”. ENSURE the Deaeration Motor is running! d) Can you adjust Valve #65’s nut (Figure right) clockwise (tighter) until PEAK Loading Pressure is between 23 and 25 psi? Between 23 and 25 psi! See procedure number...
Page 130 F- 18.0.0 LOADING PRESSURE CYCLES BELOW 11 psi a) The following procedure is ESPECIALLY IMPORTANT if the machine was worked on by someone who may have connected the BALANCING CHAMBER VALVES (#31 through #38) incorrectly between the distribution board and their solenoid terminals (Figure right). b) TWO (2) possible scenarios: IF (and ONLY if) SURE the machine was NOT worked on previously for this Flow problem: See procedure number...
Page 131 F- 18.1.0 ISOLATE LOADING PRESSURE VALVE #65 a) Ignoring the MINIMUM pressure for now, if Loading Pressure is NOT achieving a PEAK of somewhere between 23 and 25 psi, adjust Loading Pressure Valve #65’s nut (Figure below) until it does. b) Figure right, if threads are visible under Valve #65’s nut see part c.
Page 132 IF (and ONLY if) PDIA AND ADIA REMAIN between 2.0 and 8.0: See procedure number F- 19.0.0 (page 128). IF PDIA OR ADIA does DOES NOT REMAIN between 2.0 and 8.0: See parts A THROUGH C below: A) A procedure in a different Section is performed next. NOTE this page and procedure number (F- 18.2.0) because you may be prompted to return here.
Page 133 Peak between 23 and 27 psi! Call debug screen 0 to watch Flow Error for three (3) minutes. If it remains = 0 perform an ACID CLEAN. If (and ONLY if) the Loading Pressure problem reoccurs in the near future FIVE (intermittent) possible bad components (see Component List below).
Page 134 TROUBLESHOOTING MOTORS MOTORS- 1.0.0 MOTOR TROUBLESHOOTING A) The procedure that directed you here asked you to NOTE which motor (Deaeration OR Flow) to be CHECK ONLY this motor! checked. B) Per the Figure below, the motor shaft is THREE (3) possible scenarios 1) or 2) or 3) below: page 133 IF (and ONLY if) NOT rotating at ALL: Proceed to , procedure number...
Page 135 MOTORS- 3.0.0 MOTOR ROTATING COUNTERCLOCKWISE (CCW) NOTED a) To ENSURE a proper connection, per the Figure below, trace the wires from the motor to the Distribution Board. Deaeration Pump → Distribution Board position “P20”; Flow Pump → distribution board position “P21”. b) To ENSURE the pump head is oriented correctly, per the Figure 29 below, the ‘ID Decal’, MUST be...
Page 136 MOTORS- 3.1.0 ISOLATE A POTENTIAL ‘BINDING’ MOTOR a) Return the lines to the shunt! IMPORTANT! To prevent damage turn the machine OFF! c) Figure right, remove the pump head from the NOTED motor to expose the ‘Drive Magnet’. d) Manually spin the ‘Drive Magnet’! Does it rotate freely i.e. is NOT binding? Rotates freely! A) Ensure rotating the drive magnet causes the motor shaft to rotate;...
Page 137 MOTORS- 4.0.0 MOTOR NOT ROTATING NOTED Hit the motor HARD with a screwdriver handle. Does it start rotating? page 138 Motor rotating! Proceed to , procedure number MOTORS- 5.0.0. No Motor does NOT start rotating! Perform parts a THROUGH e below: To prevent damage TURN THE MACHINE OFF! b) Figure below, remove the distribution board cover.
Page 138 MOTORS- 4.1.0 MOTOR ROTATING? NOTED Is the motor rotating now (Yes or No)? Motor is rotating! If (and ONLY if) a bad connection was corrected above AND if a Flow Error occurs see the Table of Contents for whatever Program the machine is in! If a bad connection page 138 was NOT located above proceed to , procedure number...
Page 139 MOTORS- 4.5.0 ! EMPTY = 1 / ISOLATE MOTOR BRUSH CONNECTION a) UNPLUG the NOTED motor from the distribution board! b) Using a flashlight, check inside the motor’s distribution board position for ‘white’ corrosion or damaged male pins. Damage indicates the distribution board may need to be replaced! c) Figure right, remove the plastic cap from the female distribution connector.
Page 140 MOTORS- 4.6.0 ISOLATE MOTOR VOLTAGE a) Figure right, avoiding the VACANT positions on the left without the and right, return the motor connector, , to its distribution board position. b) ENSURE the connector is aligned properly! DC voltage (V c) Set your CALIBRATED volt meter to d) Measure, inside the distribution board, between the terminals where the wires are soldered.
Page 141 MOTORS- 4.7.0 BAD MOTOR VOLTAGE MEASUREMENT / ISOLATE A ‘BINDING’ MOTOR IMPORTANT! Turn the machine OFF! b) Figure right, remove the pump head from the NOTED motor to expose the ‘Drive Magnet’. c) Manually spin the ‘Drive Magnet’. Does it rotate freely i.e. is NOT ‘binding’? Rotates freely! See procedure number...
Page 142 MOTORS- 5.0.0 ISOLATE INTERMITTENT MOTOR IMPORTANT! Turn the machine OFF! b) Figure right, remove the pump head from the motor to expose the ‘Drive Magnet’. c) Manually spin the ‘Drive Magnet’. Does it rotate freely i.e. is NOT ‘binding’ (Yes or No)? Rotates freely! ge 138).
Page 143 PRESSURE TEST HYDROCHAMBER This procedure pressurizes the Hydrochamber to locate a potential leak. Two (2) clamps are required: a) Return the red (acid) connector to its Rinse Port. DO NOT place the machine into a program! The “Select Program” banner MUST remain up! c) Figure right, locate the tubing segment that attaches to the port at the top of the Float.
Page 144 BLOCK LEAK- 2.0.0 HYDROCHAMBER LEAK LOCATED a) Return the float’s connector to distribution board position “FLOAT-SW”. IMPORTANT! Unclamp the Vent Tubing. Per the Figure below , based on where a leak was seen, THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) a tubing leak: Repair (tie wrap, if possible) and retest for a leak.
Page 145: Section 2 – "No Water" Alarm
SECTION 2 – “NO WATER” ALARM A) ENSURE the water is on! If attached to a PORTABLE RO ENSURE it is on, alarm free AND NOT in product divert! B) ENSURE the incoming water line, between the 2008K/K and the RO, is connected PROPERLY! C) Call debug screen 0.
Page 146 IF (and ONLY if) NOT attached to a PORTABLE RO: See procedure number NW- 1.0.1 (page 142). IF attached to a PORTABLE RO: See parts a THROUGH g below: a) If multiple machines are attached to the same RO the RO may not support this! At the OTHER machines turn [Dialysate Flow] “OFF”...
Page 147 NW- 1.0.2 “NO WATER” CHECKS a) ENSURE no leaks, ESPECIALLY from Heat Exchanger #77 (Figure right). b) Call debug screen 0. c) WITHOUT LOOKING AWAY, watch Valve #41’s ‘dot’ (Figure right) for ninety (90) seconds. TWO (2) possible scenarios: IF (and ONLY if) Valve #41’s ‘dot’ remains white OR cycles between white and blue: See procedure number NW- 1.0.3...
Page 148 NW- 1.0.5 “NO WATER” IN HEAT DISINFECT / ISOLATE RINSE PROGRAM a) Press ‘Escape’ TWICE then ‘CONFIRM’ TWICE to call the “Select Program” screen! Place the machine into RINSE (NOT HEAT DISINFECT)! c) Allow one (1) minute BEFORE continuing! d) WITHOUT LOOKING AWAY, watch for four (4) minutes OR until if a “No Water” alarm EVER reoccurs? page 146 “No Water”...
Page 149 NW- 1.0.8 IN HEAT DISINFFECT “NO WATER” REOCCURS a) Call debug screen 4. If debug does not appear press ‘Escape’ then call screen 4. b) When Valve #43 is closed*, PDIA (left column) NORMALLY cycles between 0.0 and to more than 0.1. When Valve #43 opens it stays more than 1.0 but NORMALLY for no more than sixteen (16) seconds.
Page 150 NW- 1.0.10 “NO WATER” ALARM REOCCURS a) Leaving the machine on, turn the WATER OFF! b) A psi pressure gauge is required. ENSURE it reads 0 psi before installing it! c) Figure below, tee the gauge into Inlet Pressure Regulator #61. d) Tie wrap both sides of the gauge tubing to prevent leaks and false readings! TURN THE WATER ON! See procedure number...
Page 151 IF (and ONLY if) ALWAYS LESS THAN 18 psi: See procedure number NW- 1.0.14 (page 147). IF the PEAK cycles to or remains MORE THAN 18 psi: THREE (3) possible scenarios below: Scenario #1: IF (and ONLY if) the MINIMUM EVER falls lower than 8 psi: This indicates a problem with RO Product flow or pressure! Scenario #2: IF (and ONLY if) the MINIMUM remains more than 8 psi AND a “No Water”...
Page 152 NW- 2.0.0 VALVE #41’S ‘DOT ALWAYS BLUE = CONSTANT “NO WATER” ALARM a) Figure below, ENSURE Valve #41’s connector is plugged PROPERLY into distribution board position “V27, IN-V”. b) Call debug screen 0 to watch Valve #41’s ’dot’ for one (1) FULL minute. TWO (2) possible scenarios: IF (and ONLY if) Valve #41’s ‘dot’...
Page 153 NW- 2.0.1 VALVE ERROR = 0 / ISOLATE INLET WATER PRESSURE a) Leaving the machine in a program, TURN THE WATER OFF! b) A psi pressure gauge is required. ENSURE it reads 0 psi before installing it! c) Per the Figure below, tee the gauge into Inlet Pressure Regulator #61. TURN THE WATER ON! WARNING! Using a plastic clamp here will cause error! Using METAL PLIERS, tightly...
Page 154 e) Directing the tubing into cylinder, TURN THE WATER ON and measure for one (1) minute. TWO (2) possible scenarios: IF (and ONLY if) 1000 ml or more collected: See procedure number NW- 2.0.3 (page 150). 2) IF less than 1000 ml: This is the problem! TWO (2) checks: Check #1: Figure right, if the (optional) incoming water filter is present ENSURE it is clean! Check #2: ENSURE RO Product output is consistently more...
Page 155 NW- 3.0.0 ISOLATE FLOAT (#5) SIGNAL IMPORTANT! TURN THE WATER OFF! 274 Ω b) Figure right, place the resistor plug, from TWO-RESISTOR SET , into the float’s distribution board position, “FLOAT-SW”. This simulates a ‘closed’ float switch! c) Call debug screen 0. WITHOUT LOOKING AWAY, watch VALVE #41’s dot’...
Page 156 NW- 4.0.0 ISOLATE INCOMING WATER VALVE #41 a) Place a 1000 ml graduated cylinder under the Vent tubing it to capture overflow. IMPORTANT! TURN THE WATER ON! c) Valve #41 should be open. After no more than thirty (30) seconds more than 800 ml per minute measured from the Vent tubing? 800 ml or more! See procedure number NW- 5.0.0...
Page 157 NW- 5.0.0 CHECK FLOAT AND VALVE #41 IMPORTANT! TURN THE WATER OFF! b) Obtain a 1000 ml graduated cylinder. c) Per the Figure below, locate the clear tubing (from Valve #41) that enters the ‘Air Gap Tower’ vertically at the top of the Hydrochamber. Figure 31 –...
Page 158 NW- 5.1.0 CHECK WATER SYSTEMS a) Turn the water OFF and reattach the tubing. b) Figure right, a previous procedure may have placed the Ω resistor plug in the Float’s distribution board position “X5- FLOAT-SW”. If so, return the Float’s connector. c) Turn the machine OFF! d) ENSURE the vent tubing is NOT kinked anywhere! If the short segment going back to the Float is not routed over the...
Page 159: Section 3 - Flow Errors In A Cleaning / Disinfection Program
SECTION 3 - FLOW ERRORS IN A CLEANING / DISINFECTION PROGRAM NOTE: If you placed the machine in RINSE because a Flow Error was occurring in Dialysis Program return page 20 to Dialysis Program and proceed to SECTION 1 - FLOW ERRORS IN DIALYSIS PROGRAM These procedures troubleshoot Flow Errors that occur in Heat Disinfect, Rinse, etc.
Page 160 ENSURE the ‘to drain’ tubing is not kinked AND (if used) the ‘Quick connector’ is attached PROPERLY to the station. till INSTRUCTED OTHERWISE d) Figure right, direct the Fluid Sample Connector into a bucket on the floor! e) Below the machine will be returned to a Cleaning Program.
Page 161 CLEAN- 1.0.5 ISOLATE VERR NOTE: page From here forward, if (and ONLY if) a leak develops, address it first by proceeding to SECTION 21- HYDRAULIC LEAKS a) Figure right, ENSURE a “No Water” alarm NEVER occurs! From here forward, if (and ONLY if) a “No Water” alarm EVER occurs address it first! b) Call debug screen 1 (Figure right).
Page 162 CLEAN- 1.2.0 NO LEAKS / VENT RESTRICTION? NOTE: Flow Errors may cause some Vent Tubing overflow. This is normal and can be ignored. INCLUDING a) Per the Figure below, check for Vent Tubing kinks, the short segment going back to the float! b) If a kink was located and eliminated allow three (3) minutes to see if this fixes the flow error.
Page 163 CLEAN- 1.2.1 PREPARE TO ISOLATE LOADING PRESSURE Figure right , remove the ACID (RED) connector from the acid inlet tubing AND attach the Loading Pressure gauge tubing to ENSURE the gauge reads 0 psi before inserting it in the Rinse Port! c) Place the Acid Inlet tubing into water.
Page 164 CLEAN- 1.2.3 ISOLATE LOADING PRESSURE (3) Loading Pressure may or may not be cycling. TWO (2) possible scenarios below: IF NOT cycling: Pressure is ‘OKAY’ if it REMAINS between 22 and 27 psi. See part B! IF cycling: It may cycle to but SHOULD NOT remain less than 15 psi. It is ‘OKAY’ if it EVER cycles to a PEAK of somewhere between 22 and 27 psi.
Page 165 CLEAN- 1.2.33 LOADING PRESSURE REMAINS LOW Place the machine into RINSE (NOT HEAT DISINFECT)! b) Call debug screen 0 (Figure below). If debug does not appear press ‘Escape’ then call screen 0. c) Locate DEAP. TWO (2) possible scenarios: IF (and ONLY if) DEAP = 75 OR less: See procedure number CLEAN- 1.2.4 (page 162).
Page 166 CLEAN- 1.2.4 DEAP = 75 OR LESS / ISOLATE DEAERATION MOTOR If (and ONLY if) the problem was occurring in Heat Disinfect return to it. If not stay in RINSE! b) Figure right, is the Deaeration Motor shaft rotating COUNTERCLOCKWISE (CCW)? Yes Rotating CCW! See procedure number CLEAN- 1.2.5...
Page 167 CLEAN- 1.2.6 MOTOR CONTINUES TO ROTATE Recheck Loading Pressure (gauge in Rinse port). THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) ALWAYS less than 15 psi: Leaving the machine in the Cleaning Program, see procedure number CLEAN- 1.5.0 (page 163).
Page 168 CLEAN- 1.5.1 ISOLATE POSSIBLE AIR LOCKk CAUTION! Fluid and tubing may be HOT! b) Figure right, remove the CLEAR TUBING from the Deaeration Pump’s Input Nozzle. To encourage gravity flow, keep the tubing at the level of the pump head!. c) The tubing is from hydrochamber D.
Page 169 CLEAN- 1.6.0 MORE THAN 300 ML Return the tubing to the DEAERATION pump. b) Figure right, return the Deaeration Pump to distribution board position, “P20”! ENSURE the DEAERATION MOTOR is running! c) Turn Valve #65’s nut (Figure right) clockwise (tighter) attempting to achieve a PEAK Loading Pressure of between 22 and 25 psi? Between 22 and 25 psi! Proceed to page 171...
Page 170 CLEAN- 2.0.0 LESS THAN 300 ML PER MINUTE COLLECTED / ISOLATE RESTRICTOR #48 This procedure attempts to clear a DEAERATION PUMP air lock. First Restrictor #48 is checked to see if it is plugged: a) Turn the machine off then back on. b) Allow the “Select Program”...
Page 171 CLEAN- 2.0.2 MORE THAN 130 ML Direct the tubing into a bucket for up to FIVE (5) FULL minutes. Flow will either: 1) Continue at more than 130 ml per minute OR 2) Stop. TWO (2) possible scenarios: IF (and ONLY if) flow continues at 130 ml per minute: See procedure number CLEAN- 2.0.3 (page 167).
Page 172 Yes More than 200 ml! Valve #39 is okay! See procedure number CLEAN- 2.0.4 (page 168). No Less than 200 ml! Valve #39 may be bad! See parts a AND b below: a) ENSURE Valve #39 is plugged properly into distribution board position V39! b) Swap in the following components (see Component List below) one at a time, with known good, then repeat (ABOVE) procedure number CLEAN- 2.0.3 (page 167).
Page 173 CLEAN- 2.1.0 ISOLATE INCOMING WATER FLOW 274 Ω a) Figure right, place the plug, from the TWO-RESISTOR SET , into the float’s distribution board position, “X5, FLOAT-SW”. b) Allow forty (40) seconds OR until flow from the Vent Tubing occurs indicating hydrochambers A through C are full! c) MEASURE from the Vent Tubing, for ONE (1) MINUTE.
Page 174 CLEAN- 2.1.2 ISOLATE FLOAT SWITCH #5 a) This procedure requires up to four (4) minutes to prevent labor-intensive error. b) Direct the tubing into the bucket for up to four (4) minutes. Flow will either: 1) Continue at more than 130 ml per minute OR 2) Stop.
Page 175 CLEAN- 2.4.0 LOADING PRESSURE WITHIN RANGE IMPORTANT! Turn the Heater Breaker Switch ON! b) Figure right, several threads should be visible under Valve #65’s nut. If threads ARE VISIBLE continue to part c. If no threads are visible either the wrong spring is installed under Valve #65’s nut* OR Valve #65 is bad! * Refer to Figure 6...
Page 176 CLEAN- 3.0.0 LOADING PRESSURE OKAY / ISOLATE MOTORS If the “Interrupted” banner is on the screen return to Heat Disinfect OR Rinse! b) THREE (3) checks on the Flow AND Deaeration motors (Figure below): Check #1: Is the FLOW MOTOR shaft rotating in the same direction as the Deaeration Motor i.e. counterclockwise (CCW)? Flow Motor rotating CCW! See CHECK #2.
Page 177 CLEAN- 3.2.0 MOTORS OKAY / ISOLATE FLOW PUMP PRESSURE (1) a) ENSURE the “Select Program” banner is up! b) A psi pressure gauge is required next. ENSURE it reads 0 before installing it! c) Per the Figure below, tee the gauge into the OUTPUT (white tubing) side of the Flow Pump. Fluid and tubing may be hot but won’t scald you! Tie wrap both sides of the gauge tubing to prevent leaks and false readings! If (and ONLY if) the Flow Error was occurring in Heat Disinfect return to it.
Page 178 page 175 Between 34 and 36 psi! Proceed to , procedure number CLEAN- 4.0.0. No Remains less than 34 psi! ENSURING Heat Disinfect OR Rinse is running AND no leaks, see parts a THROUGH c below: a) Watch for one (1) minute to ENSURE a “No Water” alarm NEVER occurs! Valve #78 b) Referring to Figure 32...
Page 179 CLEAN- 4.0.0 GOOD FLOW PUMP PRESSURE / ISOLATE THE CLEANING PROGRAM ENSURE a) Leave the gauge installed its tubing is NOT kinked (restricting flow)! Open the shunt door and LEAVE IT OPEN until instructed!! c) Leaving the machine in whatever Program it is CURRENTLY in: 1) Rinse? OR 2) Heat Disinfect? page 184 IF (and ONLY if) in RINSE: Proceed to , procedure number CLEAN- 5.0.0.
Page 180 CLEAN- 4.3.0 VALVE #29’S ‘DOT’ ALWAYS BLUE Call debug screen 1 (Figure right). Does VERR (lower right column) = 0? page VERR = 0! Proceed to , procedure number CLEAN- 4.3.2. No VERR = 1 OR more! See procedure number CLEAN- 4.3.1 (page 176).
Page 181 CLEAN- 4.3.2 VERR = 0 / VERIFY TOTAL FLOW Watching for fifteen (15) seconds, does the external flow indicator’s ‘bob’ EVER rise at least ¼ way up in the sight tube? page 180 ‘Bob’ moving! Proceed to , procedure number CLEAN- 4.6.0.
Page 182 More than 300 ml! Valve #24 is open! Without returning the connector to the shunt, see procedure number CLEAN- 4.4.2 (page 179). Less than 300 ml! ENSURING the “Interrupted” banner IS NOT up, see parts a THROUGH c below: DO NOT a) Return the dialyzer connector to the shunt but close the door! Per the Figure below...
Page 183 CLEAN- 4.4.2 MORE THAN 300 ML / VALVE #24 OPEN / ISOLATE VALVE #25 a) With the dialyzer connector out of the shunt ENSURE the external flow indicator’s ‘bob’ is rising at least ¼ way up in the sight tube! b) Return the connector to the shunt and close the door.
Page 184 CLEAN- 4.6.0 VERR = 0 / ISOLATE DIALYSATE PRESSURE SENSOR When Remaining Prerinse Time = 0:00, Valve #29 stays open and Valve #30 stays closed. The Actuator- Test Board watches for Dialysate Pressure Sensor #9 (debug screen 4’s PDIA and ADIA) transitions to sense flow.
Page 185 CLEAN- 4.6.1 BOTH PDIA AND ADIA ARE GOOD a) Return the dialyzer connector to the shunt and close the door! return to HEAT DISINFECT! b) Press ‘CONFIRM’ then c) To isolate between four (4) possible bad valves read part d’s two-part description BEFORE performing part e! d) Return to debug screen 4.
Page 186 CLEAN- 4.6.22 PDIA STAYING BETWEEN 1.0 AND 5.0 / ISOLATE VALVE #43 ‘STICKING OPEN’ a) PDIA is staying between 1.0 AND 5.0. This procedure (parts b and c) confirms a problem with Valve #43 or the Actuator-Test Board. Per the Figure below , double clamp the OUTPUT tubing at Valve #43.
Page 187 CLEAN- 4.6.33 ISOLATE VALVE #43 POSSIBLY STICKING CLOSED PDIA is NEVER 6.0 or AND NEVER 0.0 longer than seven (7) seconds! a) Call debug screen 0 (Figure right). b) Allow Valve #43’s ‘dot’ to turn blue then white again. c) As seen earlier, ENSURE the external Flow Indicator’s ‘bob’...
Page 188 CLEAN- 5.0.0 ISOLATE POSSIBLE VALVE ELECTRICAL PROBLEM Leaving the shunt door OPEN: a) Call debug screen 1 (Figure right). If debug does not appear press ‘Escape’ then call screen 0. b) Does VERR (lower right column) = 0? page VERR = 0! Proceed to , procedure number CLEAN- 5.2.0.
Page 189 CLEAN- 5.2.0 VERR = 0 / ISOLATE DIALYSATE SAMPLING OPTION a) Call debug screen 0 to locate Valve #29’s and Valve #30’s ‘dots’ (Figure right). NORMALLY when one turns white the other turns blue almost immediately. b) WITHOUT LOOKING AWAY, watch BOTH ‘dots’ for three (3) FULL minutes to see if they EVER BOTH turn white, at the SAME TIME, for LONGER THAN thirty (30) seconds! TWO (2) possible scenarios:...
Page 190 BOTH ‘dots’ turn white for more than thirty (30) seconds again! If ABSOLUTELY SURE the Dialysate Sampling Hardware Option has a blue ‘X’ in the No box the Functional Board may be bad. BOTH dots DO NOT turn white at the same time. See parts a and b below: If the flow error was originally occurring in Heat Disinfect return to it! If not leave the machine in RINSE.
Page 191 IF (and ONLY if) “Flow Recirc Error 1” DOES NOT occur: Whatever was causing the Flow Error is no longer occurring! Do NOT continue to troubleshoot a Flow Error. IF “Flow Recirc Error 1” occurs: See (ABOVE) procedure number CLEAN- 4.2.0 page 175 CLEAN- 6.0.0 ‘BOB’...
Page 192 Air moving ALL THE WAY through Valve #29! See procedure number CLEAN- 6.1.0 (page 188). No Air is NOT moving through Valve #29! See parts a AND b below: Remove the clamp from Valve #30! b) The Troubleshooting Guide cannot locate an immediate problem. Return to Dialysis Program and troubleshoot potential hydraulic problems from there! CLEAN- 6.1.0 ‘AIR’...
Page 193 CLEAN- 7.0.0 VALVE ERROR = 1 LONGER THAN TWO SECONDS To avoid damage turn the machine OFF! B) Figure below, remove the distribution board cover. C) FOUR (4) IMPORTANT checks!! CHECK #1 ENSURE the ACTUATOR CABLE is plugged in SECURELY! CHECK #2 Check the entire length of the ACTUATOR CABLE for damage! CHECK #3 ENSURE all Valves are plugged PROPERLY into their distribution board positions! CHECK #4 ENSURE the black PGND wire is plugged in and shows no signs of burning.
Page 194 CLEAN- 7.3.0 ISOLATE VALVE CIRCUITS four (4) Valves a) Figures below, you will check : 1) Valve #24; 2) Valve #38; 3) Valve #39; 4) Valve #43. b) THREE (3) checks on EACH Valve! Trace the blue wires from between the distribution board to their solenoid terminals: CHECK #1 ENSURE no ‘pinched’...
Page 195 CLEAN- 7.4.0 ISOLATE VALVE SOLENOIDS Set your CALIBRATED volt meter to RESISTANCE (Ω). Four (4) Valve solenoids will be checked. Perform parts c through h on: 1) Valve #24; 2) Valve #38; 3) Valve #39; 4) Valve #43. c) Unplug one of the four (your choice) from the distribution board. d) Using a flashlight, check inside its vacant distribution board position for corrosion or damage! e) Figure right, open the female connector cap.
Page 196 TROUBLESHOOTING A VALVE To avoid damage, turn the machine OFF! There is NO NEED to check all 17 valves! Check ONLY the valve as NOTED in the procedure that brought you here!! C) See procedure number TSV- 1.0.0 below: TSV- 1.0.0 CHECK DISTRIBUTION BOARD CONNECTIONS Per the Figure below...
Page 197 Figure 35 – Hydraulics Top View Figure 36 – Hydraulics Rear View 2008K/K2 Troubleshooting Guide Page 193 P/N 507298 Rev. H...
Page 198 TSV- 2.0.0 ISOLATE VALVE WIRES a) THREE (3) checks, WHILE tracing the NOTED valve’s wires from the distribution board to the solenoid terminals (Figure right): Check #1: ENSURE no pinched or bare wires! Check #2: ENSURE both wires terminate PROPERLY at the valve’s solenoid terminals! Check #3: ENSURE no corrosion at the solenoid terminals! b) If no problems were located, see procedure number...
Page 199 TROUBLESHOOTING VALVE ERRORS IN DIALYSIS PROGRAM If VERR = one (1) or more and / or is continuing to increase indicates a valve circuit resistance of less than 20 Ω and is used for troubleshooting. HOWEVER, if VERR reaches it maximum of 255 it becomes useless! A) From here forward, Figure right, if (and ONLY if) a “Dial Valve Failure”...
Page 200 A resistor plug IS NOT ALREADY in place continued: a) Unplug the female Air Sensor’s connector, connector cap position, from the LEFT! b) Call debug screen 0. Figure right, the text box above Chamber #69 MUST say “Air”! FOUR-RESISTOR SET c) Place one of the plugs, from the into the Air Sensor’s distribution board position! * If CBE modified the resistor plugs into the CBE board pin for pin.
Page 201 VE- 1.0.2 ISOLATE VERR a) Call debug screen 0. Figure 37 – Debug Screen 0 Figure above Balancing Chamber Valve , watch the ‘dots’, for one (1) minute. THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) ALL EIGHT are REMAINING white: See procedure number VE- 2.0.0 (page 197).
Page 202 IF (and ONLY if) ONLY Valves #30 AND #26 ‘dots’ are blue AND all others are white: See procedure number VE- 2.0.1 (page 198). page 205 ALL other scenarios: Proceed to , procedure number 7.0.0. VE- 2.0.1 ONLY VALVES #30 AND #26 ‘DOTS’ ARE BLUE Valve #26’s a) At the distribution board (Figure below), unplug connector.
Page 203 VE- 3.0.0 ALL BALANCING CHAMBER VALVES CYCLING BETWEEN WHITE AND BLUE a) Call debug screen 1. b) NOTE VERR’s value for future reference. If VERR EVER reaches 255 return to procedure number page 196 VE- 1.0.0 ) to reset it. c) Figure right, if (and ONLY if) a “Dial Valve Failure”...
Page 204 VE- 4.0.0 FOUR BALANCING CHAMBER VALVES REMAINING BLUE, FOUR REMAINING WHITE NOTE: One of the valve circuits whose ‘dots’ are blue is the problem. These procedure isolate between them: a) Turn Dialysate Flow off (lamp above the Flow on/off button blinks). b) Return to screen 0.
Page 205 VE- 5.0.0 VALVE ERROR AT BALANCING CHAMBER CYCLE 1 Valves #32, #33, #35, and #38 ‘dots’ REMAINING blue. One of these valve circuits is causing the problem and these procedures isolate between them! Valve #32’s a) At the distribution board (Figure below), unplug connector.
Page 206 The Balancing Chamber Valves begin to cycle between white and blue! Valve #35 OR its blue wire harness is bad. No Valves DO NOT cycle! See procedure number VE- 5.0.3 (page 202). VE- 5.0.3 VALVE #35 UNPLUGGED AND VALVES DO NOT CYCLE Valve #38’s a) At the distribution board (Figure above), unplug connector.
Page 207 VE- 6.0.0 VALVE ERROR AT BALANCING CHAMBER CYCLE 2 Valves #31, #34, #36, and #37 ‘dots’ REMAINING blue. One of these valve circuits is causing the problem and these procedures isolate between them. Valve #31’s a) At the distribution board (Figure below), unplug connector.
Page 208 The Balancing Chamber Valves cycle! Valve #36 OR its blue wire harness is bad. Valves DO NOT cycle! See procedure number VE- 6.0.3 (page 204). VE- 6.0.3 VALVE #36 UNPLUGGED AND VALVES DO NOT CYCLE Valve #37’s a) At the distribution board (Figure above), unplug connector.
Page 209 VE- 7.0.0 ISOLATE VERR One of a) From debug screen 0, RECORD the valve numbers of the valves whose ‘dots’ are BLUE! these valve circuits may be the problem! These procedures isolate between them. b) Call debug screen 1. NOTE VERR’s value for reference later. If VERR EVER reaches 255 return to page 196 procedure number VE- 1.0.0...
Page 210 TROUBLESHOOTING VALVE ERRORS IN CLEANING PROGRAMS To prevent damage, turn the machine OFF! Per the Figure below , at the distribution board, THREE (3) checks: Check #1: ENSURE the ACTUATOR CABLE is plugged in securely AND is not damaged! Check #2: ENSURE the black PGND is plugged in securely AND shows no sign of burning! Check #3: ENSURE all Valves are plugged PROPERLY into their distribution board positions Figure 41 –...
Page 211 VEC- 1.1.0 BOB NOT MOVING / ISOLATE VALVE # 24 a) Call debug screen 2 (Figure below). If debug does not appear press ‘Escape’ then call screen 2. b) Watch DIAVLO (lower left) for forty-five (45) seconds. BE CAREFUL, THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) DIAVLO cycles between 1 (for three seconds), and 0 (for one second): See procedure number...
Page 212 VEC- 1.2.0 ‘BOB’ NOT MOVING / DIAVLO CYCLING BETWEEN 1 AND 0 a) Press ‘Escape’ to return to the Cleaning Program’s Main screen! b) Leave the machine in whatever Program it is CURRENTLY in: 1) In Rinse? OR 2) In Heat Disinfect? IF (and ONLY if) in RINSE: See procedure number VEC- 1.3.0 (page 209).
Page 213 VEC- 1.3.0 ISOLATE DRAIN VALVE #30 DO NOT a) Turn the machine OFF then back on. Allow the “Select Program” screen to appear but press any keys till instructed! b) With “Select Program” up, Figure right, screw a 60 ml syringe, filled COMPLETELY with water, onto the Fluid Sample Port.
Page 214 INPUT b) Figure below, routing Valve #24’s tubing so that spillage into the hydraulics will NOT occur, remove it and measure flow from it for thirty (30) seconds. c) More than 300 ml every 30 seconds? ONLY More than 300 ml! A) Return Valve #24’s tubing; B) NOTE VALVE page 192 #24 will be checked and proceed to...
Page 215 VEC- 1.5.0 VALVE #24 OKAY / ISOLATE VALVE #25 a) With the shunt door open, the dialyzer connector NOT in the shunt AND still in Heat Disinfect OR Rinse, ENSURE the external flow indicator’s ‘bob’ is rising! DO NOT b) Return the dialyzer connector to the shunt but close the door! c) Watching for thirty (30) seconds, does the external flow indicator’s ‘bob’...
Page 216 VEC- 2.0.0 ‘BOB’ MOVING UP AND DOWN A) Turn the machine OFF! B) This procedure checks Valve #39 in RINSE. If it opens, as it should, deaeration pressure will be between 0 and -13 inHg. See parts a THROUGH e below: a) The deaeration gauge is here.
Page 217 VEC- 2.2.0 VALVE #39 IS OPEN A) Turn the machine OFF and remove the gauge! B) Turn the machine on and allow the “Select Program” screen to appear. What color is the ‘Dialysis’ button (Gray or Blue)? 1) IF GRAY: Place the machine in RINSE. Most Valve Errors will not stop Program timing for very long.
Page 218: Section 4 - Temperature Problems
SECTION 4 - TEMPERATURE PROBLEMS NOTE: Temperature does not change instantaneously. Observe all stated times to avoid error! A) Figure right, ENSURE the Heater Switch is in the “1” or “ON” position! B) External leaks, “No Water” and Flow Error alarms cause temperature problems.
Page 219 T- 1.0.0 IN DIALYSIS PROGRAM / TROUBLESHOOTING TEMPERATURE a) Select the [Temperature] window and set it to 37.0° C! Press ‘CONFIRM’. c) Call debug screen 1. TWO (2) checks: Check #1: 5V EST (right column): Between 4.7 and 5.3? Check #2: 12V EST (right column): Between 11.7 and 12.3? d) TWO (2) possible scenarios: IF (and ONLY if) BOTH are in range AND stable i.e.
Page 220 Place the machine in RINSE! c) In RINSE, is the external flow indicator’s ‘bob’ rising at least ¼ way up in the sight tube? ‘Bob’ moving! See procedure number T- 1.0.2 (page 216). In RINSE, ‘bob’ is NOT moving! See parts a THROUGH c below: a) Connect to acid and LIQUID bicarb.
Page 221 T- 1.0.3 ISOLATE HEATER To avoid shock “Select Program” REMAINS up till instructed! B) Figure below, remove the distribution board cover. C) Figure above, at the green eight-pin Heater Connector, THREE (3) checks: CHECK #1: From RIGHT-TO-LEFT, the BOTTOM four (4) wires MUST BE brown, blue, green/yellow OR black, white, green;...
Page 222 T- 1.0.4 HEATER GOOD / ISOLATE TEMPERATURE SENSORS (NTCs’) Figure BELOW, trace NTC #2 AND NTC #3’s cables from their distribution board connectors to the sensors. TWO (2) IMPORTANT checks: CHECK #1 ANY insulation damage indicates the sensor need to be replaced! CHECK #2 ENSURE the sensors are not reverse connected with another component! Figure 42 –...
Page 223 T- 1.0.6 OPTIONAL BLOOD TEMPERATURE MODULE (BTM) EQUIPPED? Per the Figure right, TWO (2) possible scenarios: IF NOT equipped with the optional Blood Temperature Module (BTM): See procedure number T- 1.0.7 (page 221). IF equipped with a Blood Temperature Module (BTM): See parts a THROUGH g below: a) Place the machine into Service Mode →...
Page 224 Scenario #1: IF (and ONLY if) the temperature problem REOCCURS: The BTM is not causing the problem. See parts a AND b below: a) To cool the machine quickly, place it into RINSE for fifteen (15) minutes! b) See procedure number T- 1.0.7 (page 221)! Scenario #2:...
Page 225 T- 1.0.7 TEMPERATURE PROBLEM A) Remove a ‘dummy chamber’ from the Level Detector module. B) Connect to known good acid* and LIQUID bicarbonate*! * Tested per clinic procedures! C) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM). D) From the Home screen, select the [Dialysate Flow] window. E) Set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’.
Page 226 T- 1.0.8 ISOLATE TEMPERATURE PROBLEM a) Watch [Temperature] for one (1) minute. If UNSTABLE i.e. changes more than 0.2° C watch for three (3) more minutes BEFORE continuing to part b. If STABLE i.e. does NOT change more than 0.2° C see part b.
Page 227 Between 64 and 76! ‘Sharply’ press ‘CONFIRM’ ONCE. If no Error banners* appear see STEP #2 (page 223). * If an “Operator Error” OR “Actuator Board Error” banner appears see procedure number T- 1.0.10 (page 223). NOT between 64 and 76! ENSURE the 34° C plug is placed properly at the position from the LEFT! If okay see procedure number T- 1.0.10...
Page 228 T- 1.0.122 TEMP SENSOR CALIBRATION SUCESSFUL / VERIFY TEMPERATURE ALARM a) Return NTC #3’s connector to the distribution board position from the left, “MON-NTC”. b) Turn the machine OFF. c) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! d) From the Home screen, select the [Dialysate Flow] window.
Page 229 T- 1.0.130 [TEMPERATURE] WINDOW IS PALE/YELLOW a) Figure right, at the distribution board, unplug the connector from the LEFT, “MON-NTC”! This is temp sensor NTC #3. b) Based on the [Temperature] window, TWO (2) possible scenarios: IF (and ONLY if) LESS THAN 30.0° C: See procedure number T- 1.0.131 (page 225).
Page 230 [Conductivity] window is white! See procedure number T- 1.0.133 (page 226). No [Conductivity] window is red! Allow up to three (3) minutes OR until if the [Conductivity] window turns white. TWO (2) possible scenarios below: IF the window turns white: See procedure number T- 1.0.133 (page 226).
Page 231 T- 1.0.142 [TEMPERATURE] LESS THAN 35.1° C / ISOLATE HEATER CONTROL Turn the Heater Switch OFF! Set your CALIBRATED volt meter to AC volts (~ V, V c) Allow NINETY (90) FULL SECONDS BEFORE continuing to part d! d) Figure right, TIGHTLY HOLD the meter leads BETWEEN the Heater Connector’s BROWN and BLUE wires.
Page 232 T- 1.0.146 MORE THAN 100.0 VOLTS AC / ISOLATE NTC #2 a) Using a flashlight, check inside NTC #2’s distribution board position, if corrosion or damage is located this may be the problem! Return NTC #2’s connector to the 1 distribution board position from the left, “CON-NTC”...
Page 233 T- 1.0.155 ISOLATE TEMPERATURE MONITOR 6.04 KΩ a) Figure right, plug the resistor TWO-RESISTOR plug, from the into distribution board position from the left, “MON-NTC”! b) Call debug screen 4. c) Watching TEMP (lower left) for one (1) minute, THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) between 4.0 and 6.0 AND STABLE i.e.
Page 234 T- 1.0.17 SIMULATE CONDUCTIVITY a) Figure right, leaving the 6.04 KΩ resistor in, plug the 274 Ω TWO-RESISTOR resistor plug, from the into the Cond Cell’s distribution board position, “X7, COND”. b) Watch the [Conductivity] window for one (1) minute. THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) BETWEEN 12.9 and 14.5 mS AND does NOT change more...
Page 235 IF (and ONLY if) the [Conductivity] window turns white: See procedure number T- 1.0.19 (page 231) page IF AFTER three (3) minutes the [Conductivity] window remains RED: Proceed to , procedure number 7.0.0. T- 1.0.19 VERIFY ‘OUT OF BYPASS’ Call debug screen 0. Figure right, is Valve #24’s ‘dot’ blue OR white? IF (and ONLY if) BLUE: See procedure number T- 1.0.191 (page...
Page 236 T- 1.0.20 FLOW THROUGH THE EXTERNAL INDICATOR a) Leaving Dialysate Flow on, install a Temperature meter (°C) IMPORTANT! Figure right, Flow into the dialysate lines. MUST be bottom to top! CLOSE THE SHUNT DOOR! c) ENSURING the flow indicator’s ‘bob’ is moving, see procedure number T- 1.0.21 (page 232).
Page 237 IF (and ONLY if) falls to less than 35.1 °C: See procedure number T- 1.0.22 (page 234). page 2) IF remains more than 35.1° BUT NEVER more than 38.8° C: Proceed to , procedure number 6.0.0. IF EVER more than 38.8° C even if only once: Perform parts a THROUGH d below: a) If a 6.04 KΩ...
Page 238 35.1° C T- 1.0.22 TEMPERATURE LESS THAN Set your CALIBRATED volt meter to AC volts (~ V, V b) Figure right, unplug the connector from the distribution board position from the left, “CON-NTC”. This is NTC #2. c) Figure right, measure at the distribution board’s Heater Connector, between the BROWN and BLUE wires.
Page 239 T- 1.0.255 ‘MEASURED’ TEMPERATURE REMAINS BETWEEN 35.1 AND 38.9° C a) Figure right, if a 274 Ω plug was previously placed at the Cond Cell’s distribution board position, “X7, COND”, remove it and RETURN the Cond Cell’s connector. b) If a 6.04 KΩ plug was previously placed at NTC #3’s position, “MON-NTC”, remove it then, avoiding the VACANT position on the right (“PH-PR”), RETURN NTC #3’s connector to the position from the left,...
Page 240 T- 1.0.28 METER VERSUS THE MACHINE’S [TEMPERATURE] DISPLAY IN RANGE Proceed according to why you ORIGINALLY started troubleshooting. THREE (3) possible scenarios 1) or 2) or 3) below: IF the problem was in a Heat Disinfect AND a “TEMP OVER 95 DEGREES” occurred: Proceed to page 246 , procedure number 1.5.0.
Page 241 Figure below, plug in the 10 pin ribbon cable to Functional Board’s P8 connector. Close the card cage! h) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! Allow the machine to run for several hours to see if a temperature problem reoccurs: IF a temperature problem DOES NOT reoccur: A temperature problem is not occurring at this time.
Page 242 T- 1.3.0 TEMPERATURE EXCEEDS 38.9°C This procedure isolates between uncontrollable temperature, unstable monitoring, or high incoming water temperature. BE CAREFUL! From the Home screen, set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’. b) Allow [Temperature] to increase to more than 38.9° C! TURN THE HEATER SWITCH OFF TILL INSTRUCTED! d) Watch [Temperature] for up to five (5) minutes until it either: 1) Starts falling OR 2) NEVER starts falling: 0.3°...
Page 243 TEMP LESS THAN 0.3! See procedure number T- 1.3.13 (page 239). TEMP is NOT less than 0.3! See parts a and b below: a) ENSURE NTC 3’s connector is unplugged from the distribution board position from the left, “MON-NTC”. If NOT, return to (ABOVE) procedure number T- 1.3.12 (page 238).
Page 244 T- 1.3.17 TEMP 6.0 OR LOWER / ISOLATE NTC# 3 CIRCUIT Call debug screen 5. WITHOUT LOOKING AWAY, watch TPRE (top, middle column) for one (1) minute noting its highest and lowest values. TWO (2) possible scenarios 1) or 2) below: IF (and ONLY if) TPRE changes more than +/- twenty (20)! TPRE is unstable: Leaving the 6.04 KΩ...
Page 245 T- 1.3.40 ISOLATE TEMPERATURE CONTROL (0.915 KΩ) 90° C a) Figure right, place the FOUR-RESISTOR plug, from the into the distribution board position from the left, “CON-NTC”. Set your CALIBRATED volt meter to AC voltage (~ V, V Turn the HEATER Switch ON! d) Figure right, measure at the distribution board’s Heater Connector, between the BLUE and BROWN wires.
Page 246 T- 1.3.70 RETURN SYSTEMS / TEMP COMP? IMPORTANT! Plug NTC #2’s connector into the distribution board position from the left, “CON-NTC”! IMPORTANT! Avoiding VACANT position #4, RETURN NTC #3’s connector to the distribution board position from the left, “MON-NTC”. c) Enter Service Mode → Options → Hardware Options. Does the “Yes”...
Page 247 T- 1.3.90 ISOLATE NTC #2 / TEMP CONTROL a) Return to Calibrate Sensors → Temp Control b) Press ‘CONFIRM’ to turn the [TEMP DAC] data box pale yellow / white. c) ENSURING the shunt door is CLOSED the external flow indicator’s ‘bob’ MUST be moving up and down! d) WITHOUT LOOKING AWAY, watch the external meter for seven (7) minutes OR until if it EVER exceeds 39°.0 C even if only once.
Page 248 T- 1.4.0 [TEMPERATURE] NOT LESS THAN 30º C / ISOLATE DEBUG TEMP With NTC #3 REMAINING unplugged, call debug screen 4. Is TEMP (lower left) less than 0.3? TEMP less than 0.3! See procedure number T- 1.4.1 (page 244). TEMP more than 0.3! Swap in the following components (see COMPONENT LIST 1 below) one at a time, with known good, and in between repeat procedure number T- 1.4.0 (page 244) until screen...
Page 249 Less than 30.0° C! See procedure number T- 1.4.3 (page 245). More than 30.0° C! Swap the following components (see COMPONENT LIST below) in one at a time, with known good, in between repeating (ABOVE) procedure number T- 1.4.2 (page 244) until Temperature remains less than 30.0°...
Page 250 T- 1.5.0 “TEMP OVER 95 DEGREES” ALARM OCCURRED A) Install the hydraulics into the cabinet but DO NOT screw the rear panels in yet! B) Place the machine into HEAT DISINFECT. C) Call debug screen 10. If debug doesn’t appear press ‘Esc’ then call screen 10. D) Figure right, 5V HI should NEVER = 5.3 or more;...
Page 251 T- 1.5.1 [REMAINING TIME] = 0:00 a) Place the machine in HEAT DISINFECT. b) Is the screen’s TOP [Remaining Prerinse Time] window = 0:00? [Remaining Prerinse Time] = 0:00! See procedure number T- 1.5.2 (page 247). a) Escape HEAT DISINFECT and place the machine in RINSE! b) Allow [Remaining Time] = 0:00 BEFORE continuing to part c! c) Return to HEAT DISINFECT! d) See procedure number...
Page 252 T- 1.5.3 SCREEN [TEMPERATURE] IS UNSTABLE a) Figure right, insert the 80° C (1.255 KΩ) plug, from the FOUR- RESISTOR SET, into the distribution board position from the LEFT, “MON-NTC”. b) If the plug is placed properly the screen’s [Temperature] window should read more than 75°...
Page 253 T- 1.5.3.10 METER STABILITY MAY OR MAY NOT BE MORE THAN TWO a) Incoming RO water temperature, less than 20.0° C, may cause unstable temperature. In any event, continue to part b. b) Return NTC #3’s connector to the distribution board position from the LEFT, “MON-NTC”! c) If NTC #3 is plugged in properly screen [Temperature] returns to 80°...
Page 254 T- 1.5.4 [TEMPERATURE] DOES NOT = 95° C BUT “TEMP OVER 95 DEGREES” REOCCURED A) Read this step before performing it! Temp Sensor Calibrate per the Calibration Procedures booklet but does “Operator Error” OR “Actuator Board Error” occur during the calibration? Temp Sensor An “Error”...
Page 255 T- 1.5.5 SCREEN [TEMPERATURE] = 95° C A) Turn the machine OFF! B) Figure right, insert the 80° C (1.255 KΩ) plug, from the FOUR- RESISTOR SET, into the distribution board position from the LEFT, “MON-NTC”. This simulates approximately 80° C. C) Return to HEAT DISINFECT with an external temperature meter attached as described previously! D) IMMEDIATELY call debug screen 10.
Page 256 E) Per the Calibration Booklet, perform TWO (2) calibrations: Cal 1) Temp Sensor AND Cal 2) Temp Control. After BOTH calibrations are complete continue to part F. page 247 F) Read before performing! Return to , procedure number T- 1.5.1 to see if the calibrations fixed the problem.
Page 257 T- 1.5.51 5V HI MORE THAN 5.3 AND / OR 24 V HI MORE THAN 28.0 A) Turn the machine OFF! B) Open the card cage and push down HARD on ALL circuit boards! C) Using compressed air, clean the motherboard’s surface of excessive dust. D) Using a flashlight, inspect the surface of the motherboard for corrosion or burning! page 14 E) BEFORE going to part F, note this page number, then proceed to...
Page 258 T- 1.5.52 SCREEN [TEMPERATURE] WINDOW UNSTABLE A) Turn the machine OFF! B) Return the dialyzer lines to the shunt and close the door! C) Leave the 80° resistor plug installed until the problem is solved. D) Read before perform! THREE (3) possible bad components (COMPONENT LIST below). A) With the machine off, one at a time, swap in each, with known good* THEN;...
Page 259 T- 1.5.53 [TEMPERATURE] IS STABLE WITHOUT LOOKING AWAY (to avoid damage), watch the external meter for up to twenty-five (25) minutes or until if it exceeds 95° C! TWO (2) possible scenarios: IF (and ONLY if) the meter exceeds 95° C: See procedure number T- 1.5.677 (page 256).
Page 260 T- 1.5.677 EXTERNAL METER EXCEEDS 95° C a) Return NTC #3’s connector to the distribution board position from the left, “MON-NTC”. NTC #2* b) Replace Temperature control sensor with a known good.THEN continue to part C. *To LOCATE NTC #2 refer to Figure 42 (page 218).
Page 261 T- 1.7.0 TEMPERATURE IS LOW / ISOLATE TEMPERATURE MONITOR CIRCUIT a) Return the concentrate connectors to their rinse ports Place the machine in HEAT DISINFECT! c) Being aware that flow does not stop, remove the dialyzer connectors from the shunt and connect them to DO NOT a Temperature (°...
Page 262 T- 1.7.5 TEMPERATURE IS LESS THAN 36.0° C / CHECK AC HEATER VOLTAGE Set your CALIBRATED volt meter to AC voltage (~ V, V b) High voltage possible! Figure right, measure at the distribution board’s Heater Connector, between the BROWN and BLUE wires. More than 100.0 volts AC? More than 100.0 volts AC! See procedure number T- 1.7.6...
Page 263 T- 1.7.72 TEMP = 4.0 OR MORE Turn the HEATER Switch OFF! Return NTC #2 to the 1 distribution board position from the left, “CON-NTC”! c) Temperature may continue to increase for a few minutes! Allow the external meter to fall below 35.0° C BEFORE continuing to procedure number T- 1.7.8 (page 259).
Page 264 T- 1.8.0 ISOLATE NTC #2 Turn the HEATER Switch OFF! b) Figure right, move NTC #2’s connector from the distribution board position from the left, “CON-NTC” to position from the left, “MON-NTC”, AVOIDING the VACANT position at the right, c) Call debug screen 4. Allow up to seven (7) minutes OR until if TEMP (lower left) falls to 2.5 OR less? TEMP = 2.5 OR less! NTC #2 appears to be okay.
Page 265 T- 1.8.2 VERIFY TEMERATURE CONTROL This is NOT a routine Temperature calibration. Follow the procedure exactly to avoid error! a) Install a Temperature meter (° C) in the dialysate lines and! Figure right, flow through the meter MUST be bottom to top! CLOSE THE SHUNT DOOR! c) From the Service menu select Calibrate Sensors →...
Page 266 T- 1.8.5 INCOMING WATER MORE THAN 20.0 ° C / TROUBLESHOOT LOW TEMPERATURE To avoid damage turn the machine OFF! b) Open the card cage and reseat the sensor, Power Logic and Functional Boards! c) See procedure number T- 1.8.6 (page 262).
Page 267 T- 2.0.0 HEATER VOLTAGE LESS THAN 10.0 VOLTS AC a) Remaining in Dialysis Program or Heat Disinfect, to prevent pulling cables loose, GENTLY open the card cage. Set your volt meter to DC voltage (V Connect the black lead to chassis ground (see Figure 2, page 4).
Page 268 Pin 6 is 9.0 volts OR MORE! See procedure number T- 2.0.1 (page 264). page 274, Pin 6 LESS THAN 9.0 volts (bad signal from the Power Logic Board)! Proceed to procedure number 2.2.0. T- 2.0.1 PIN 6 MORE THAN 9.0 VOLTS a) If in Heat Disinfect see part b.
Page 269 T- 2.0.2 T5 LESS THAN 20.0 VOLTS CAUTION! The next measurement will be from the Power Logic board’s twenty-pin X2 cable, at touching pins 7 and 9 together WILL Pin 9, next door, is connected to 24 volts DC and DAMAGE several boards! To prevent this, TWO (2) precautions: 1) Use the protected red meter lead!
Page 270 c) ENSURE [Temperature] is still less than 35.0° C. d) Figure right, measure BETWEEN the Heater Connector’s BROWN and BLUE wires. TWO (2) possible scenarios: IF MORE THAN 100.0 volts! The heater is on! See procedure number T- 2.0.4 (page 266). page 2) IF LESS than 100.0 volts AC! Proceed to , procedure number T- 2.6.0.
Page 271 T- 2.0.5 T5 BETWEEN 20.0 AND 28.0 VOLTS DC a) Call debug screen 0. If debug does not appear press ‘Escape’ then call screen 0. b) Watching for one (1) minute, if Flow Error EVER = 1 OR a “No Water” alarm EVER appears DO NOT troubleshoot temperature! CAUTION! pin 7.
Page 272 T- 2.0.6 PIN 7 LESS THAN 4.0 VOLTS a) Turn the machine OFF! IMPORTANT! Return NTC #2’s connector to the distribution board position from the left, “CON-NTC”. c) Swap in known good Actuator-Test board. To LOCATE the board refer to Figure 4A (page 9).
Page 273 T- 2.1.0 POWER LOGIC BOARD PIN 7 4.0 VOLTS OR MORE / ISOLATE DIODE 17 (D17) A bad diode 17 (D17) destroys Power Logic Boards. Its RESISTANCE (Ω) is checked here: CAUTION! Turn the machine OFF and unplug it! Electrocution hazard if NOT unplugged!! b) Per the Figure below, open the power supply to see the component side of the Power Control board.
Page 274 T- 2.1.4 DIODE 17 CHECKED GOOD OR POWER CONTROL BOARD WAS REPLACED IMPORTANT! Figure below, ENSURE all cables are PROPERLY connected to the Power Control board! NOTE: A good diode 17 does NOT necessarily mean the Power Control board is good b) If troubleshooting a DIALYSIS PROGRAM temperature problem return to it (“Select Program”...
Page 275 T- 2.1.6 T5 BETWEEN 2.0 AND 28.0 VOLTS . a) Call debug screen 0. If debug does not appear press ‘Escape’ then call screen 0. b) Watching for one (1) minute, if Flow Error EVER = 1 OR a “No Water” alarm EVER appears DO NOT troubleshoot temperature! CAUTION! pin 7...
Page 276 T- 2.1.7 T5 BETWEEN 2.0 AND 28 VOLTS AND PIN 7 MORE THAN 4.0 VOLTS a) Turn the machine OFF! b) Referring to the Component List below, swap them in, one at a time, then in between continue to part c to see if the new component fixed the problem.
Page 277 T- 2.1.8 T5 LESS THAN 2.0 VOLTS pin 6 Per the Figure below, measure again at the Power Logic Board’s X2 cable, (TOP row, three pins from the REAR of the machine). TWO (2) possible scenarios: page 278 IF (and ONLY if) 9.0 volts DC OR MORE: Proceed to , procedure number T- 2.6.0.
Page 278 T- 2.2.0 PIN 6 LESS THAN 9.0 VOLTS DC / ISOLATE POWER LOGIC BOARD a) Spread the card cage side panels open then gently drop the front panel down! Sensor Board b) Per the Figure below, at the bottom of the , a row of pins extend horizontally, turn 90 degrees downward, and connect to the Sensor Board’s motherboard connector.
Page 279 T- 2.2.1 SENSOR BOARD PIN C1 MORE THAN 9.0 VOLTS Turn the machine OFF! Set the meter to AC voltage (~ V, V known good c) Swap in a Sensor Board (see Figure 4A, page 9). d) Enter Service Mode → Options → Hardware Options. Place the ‘X’ into the “Yes”...
Page 280 c) Per the Figure below, measure at the back side of the SENSOR BOARD’S X2 pin 13 connector at (bottom row, 7 pins from the rear of machine). d) Figure right, does the meter’s numeric AND units display KΩ read more than 12,000 Ω (12.0 KΩ...
Page 281 T- 2.2.2 GOOD SIGNAL FROM SENSOR BOARD PIN C1 pin 6 Per the Figure below, measure again at the Power Logic Board’s X2 cable, (TOP row, three pins from the REAR of the machine). A good signal is 9.0 volts OR MORE. TWO (2) possible scenarios: page 264 IF (and ONLY if) 9.0 volts DC OR MORE: Proceed to , procedure number...
Page 282 T- 2.6.0 HEATER VOLTAGE LESS THAN 10.0 VOLTS / ISOLATE POWER SUPPLY COMPONENTS a) Turn the machine OFF and UNPLUG it. CAUTION! Electrocution hazard if NOT unplugged! b) Figure below, open the power supply to see the Power Control board. Figure 47 –...
Page 283 T- 2.6.2 ISOLATE POWER CONTROL BOARD A) Figure below, lay the power supply panel down to see the component side of the Power Control board. Figure 48 – Power Control Board Per the Figure above , TWO (2) checks: CHECK #1: At connector K1 and K2, gently yank on both wires to ENSURE they are securely attached! CHECK #2: Do resistors R10 and R11 show signs of burning? Burning located! Replace BOTH the Power Control Board AND the Triac*.
Page 284 T- 2.6.5 NO BURNING AT R10 AND R11 / ISOLATE HEATER SWITCH Set your volt meter to RESISTANCE (Ω)! B) Remove the Power Control board from its white clips. C) Lay the power supply panel down to see the rear (solder) side of the board. PER the Figure below , TWO (2) measurements: Measurement #1: BETWEEN ST13 AND ST7.
Page 285 T- 2.6.6 HEATER SWITCH OKAY / ISOLATE HEATER CONNECTIONS Ω Per the Figure below , measure BETWEEN K1 and K2. Between 9.0 and 15.0 Between 9.0 and 15.0 Ω! The Heater Connections are OKAY! See procedure number T- 2.6.7 (page 281). More than 15.0 Ω! Check the heater wires for a ‘broken circuit’...
Page 286 T- 2.6.8 HEATER COMPONENTS SO FAR OKAY a) If troubleshooting a Dialysis Program problem return to DIALYSIS PROGRAM (“Select Program” → ‘Dialysis’ → ‘CONFIRM’). If a Heat Disinfect problem return to HEAT DISINFECT Set your volt meter to AC voltage (~ V, V c) Figure right, at the distribution board’s Heater Connector, measure again between the BLUE and BROWN wires! More than 100 volts AC now?
Page 287 T- 3.0.0 IN HEAT DISINFECT TEMPERATURE DID NOT REACH 80° C a) Without screwing in the rear panels, install the hydraulics into the cabinet! Place the machine in HEAT DISINFECT! c) Watch the screen’s [Temperature] window for fifteen (15) minutes OR until if it increases to 50° C or more.
Page 288 T- 3.0.2 ISOLATE HEATER RESISTANCE Turn the HEATER Switch OFF! Set your volt meter to RESISTANCE (Ω)! c) Figure right, measure again at the Heater Connector, between the BLUE and BROWN wires. TWO (2) possible scenarios: IF (and ONLY if) less than 8.0 Ω OR more than 13.0 Ω: ENSURING the HEATER Switch was OFF before measuring, the heater is bad.
Page 289 Drain Flow continues! Read this step before performing it! The previous Valve #30 is probably good. The Actuator-Test Board is bad. After replacing the board return to (ABOVE) procedure number T- 3.0.0 (page 283) to see if this fixes the temperature problem! No Drain flow stopped! Return to (ABOVE) procedure number T- 3.0.0...
Page 290 T- 3.0.6 VERIFY TEMPERATURE a) “No Water” OR Flow Error alarms turn the heater off! If either occur from here forward address them FIRST!! b) Allow fifteen (15) FULL minutes OR until if the external meter reads 50° C or more. TWO (2) possible scenarios below: IF (and ONLY if) DOES NOT achieve 50°...
Page 291 80° C or more! The Heater is good! See procedure number T- 3.0.8 (page 287). DOES NOT achieve 80° C or more! Either incoming water is extremely cold (less than 12° C) OR you made an error and Heater voltage is NOT more than 100 volts AC OR the Heater is bad! T- 3.0.8 HEATER IS GOOD / TROUBLESHOOT HEAT DISINFECT ‘ACTUAL’...
Page 292 T- 3.0.9 METER TEMPERATURE REACHES 80° C / ISOLATE DISPLAY ENSURING the meter’s reading maintains at 80° C or more, TWO (2) possible scenarios: IF (and ONLY if) the screen’s [Temperature] window is 80° C or more: The temperature problem is no longer occurring! 2) IF the screen’s [Temperature] window is NOT 80°...
Page 293 T- 4.0.0 TEMPERATURE EXCEEDS 39.0° C / ISOLATE TEMPERATURE CONTROL GENTLY a) So as NOT to pull cables loose, open the card cage. Set your CALIBRATED volt meter to DC volts (V Attach the meter’s black lead to chassis ground (see Figure 2, page 4).
Page 294 T- 4.0.1 PIN 6 MORE THAN 1.0 VOLTS DC / ISOLATE POWER LOGIC BOARD To prevent damage, turn the machine OFF! b) Swap in a known good* Power Logic Board. * Known good = tested in another machine that does not allow temperature to exceed 39°.0 C! Set your volt meter to measure AC voltage (~ V, V d) Turn the machine on and return to Dialysis Program (“Select Program”...
Page 295 T- 4.0.4 ISOLATE NTC #2 CONNECTIONS Turn the machine OFF!! 274 Ω b) Per the Figure right, place the TWO-RESISTOR plug, from the , into the distribution board position from the left, “CON-NTC”. Set your volt meter to measure resistance (Ω)! ENSURE the black lead remains attached to chassis ground (see Figure page 4)!
Page 296 T- 4.3.0 PIN 6 LESS THAN 1.0 VOLT / ISOLATE FOR A ‘SHORTED’ HEATER TRIAC CAUTION! a) Turn the machine OFF and UNPLUG it! Electrocution hazard if not unplugged! b) Figure right, lay the Power Supply’s rear panel down. c) Remove the Power Control board from the white plastic clips to access the board’s rear (solder) side.
Page 297 T- 4.4.0 CHECK TEMP DISPLAY CALIBRATION (1) a) Place the machine into Service Mode → Options → Hardware Options. b) Does the ‘Yes’ box at ‘Temp Comp’ have a blue ‘X’ in it? Place the ‘X’ in the “No” box and press ‘CONFIRM’ (the ‘X’ turns blue).
Page 298 T- 4.5.0 ISOLATE TRIAC / POWER CONTROL BOARD a) Turn the machine OFF and UNPLUG it. CAUTION! Electrocution hazard if not unplugged! b) Figure right, unplug the Triac’s orange wire from the Power Control board's GATE connector ST 9. c) To avoid damage wrap black tape around the Triac’s female orange wire terminal! d) Plug the machine in.
Page 299 T- 5.0.0 CHECK TEMP (SCREEN 4) From debug screen 4, is TEMP LESS THAN 1.0? TEMP is less than 1.0! See procedure number T- 5.0.1 (page 295). page 297 TEMP is more than 1.0! Proceed to , procedure number 5.0.3. T- 5.0.1 TEMP LESS THAN 1.0 Turn the machine OFF! b) Open the card cage.
Page 300 LESS than 300 Ω! See procedure number T- 5.0.2 (page 296). No MORE than 300 Ω! ENSURING the machine was OFF, prior to measuring, see parts a THROUGH d: 274 Ω TWO-RESISTOR SET a) ENSURE the plug, from the , is in the position, from the left, “MON-NTC”.
Page 301 T- 5.0.3 CHECK DEBUG SCREEN 4 VALUES 6.04 KΩ Leaving the plug installed, call debug screen 4. Is TEMP (lower left) between 4.0 and 6.0? page 302 TEMP between 4.0 and 6.0! Proceed to , procedure number 7.0.0. TEMP is NOT between 4.0 and 6.0! See parts a and b below: 6.04 KΩ...
Page 302 T- 6.0.0 UNSTABLE TEMPERATURE / ISOLATE NTC’S a) Per the Figure below, ENSURE both NTCs’ are plugged into their distribution board positions. They may have been unplugged in a previous procedure! b) Trace EACH CABLE, from the distribution board to the NTC, to once again THOROUGHLY check for insulation damage! Insulation damage causes instability! c) See procedure number T- 6.1.0...
Page 303 T- 6.2.0 ISOLATE AIR REMOVAL SYSTEM a) Turn the water off. b) The Deaeration gauge is used next. ENSURE it reads 0 before installing it! c) After the No Water” alarm appears allow one (1) minute for the Deaeration motor to stop. d) Figure right, tee the Deaeration gauge into the Input (clear tubing) side of Deaeration Pump #20.
Page 304 T- 6.6.0 VERIFY INCOMING WATER SOURCE Is the machine connected to the: 1) SAME water source as other currently RUNNING machines that have good stable temperature OR 2) Its OWN water source, possibly a portable RO. TWO (2) possible scenarios: IF (and ONLY if) connected to the SAME water source as other machines: See procedure number T- 6.8.0...
Page 305 c) Figure below, one at a time, remove NTC #2 and NTC #3 from their hydraulic locations and check their ‘probe ends’ (Figure right). If corrosion or burning is located replace the NTC. d) Has procedure number T- 7.0.0 been performed in THIS troubleshooting session? See procedure number T- 6.9.1 (page 301).
Page 306 T- 7.0.0 ISOLATE TEMPERATURE SENSOR These are non-routine TROUBLESHOOTING procedures! Follow them exactly to avoid error! WARNING! Hydraulic alarms are not announced in Service Mode! A) Figure right, ENSURE distribution board position #4, “PH-PR”, remains VACANT! B) ENSURE Cond Cell #7 is plugged into distribution board position “X7, COND”! C) Figure right, the FOUR- RESISTOR SET is required.
Page 307 STEP #3 a) The screen should say “Connect a 1.255 K ohm resistor...” b) Place the 80° C (1.255 KΩ) plug into the distribution board position from the left. Is [Pre- Temperature Reference] between 191 and 203? Between 191 and 203! ‘Sharply press ‘CONFIRM’ then see STEP #4 (page 303). NOT between 191 and 203! ENSURE the 80°...
Page 308 T- 7.2.0 TEMPERATURE CONTROL CHECKS a) Return NTC #3’s connector to the distribution board position from the left, “MON-NTC”. b) ENSURE NTC #2’s connector is in the distribution board position from the left, “CON-NTC”. Turn the Heater Switch ON! d) Install the hydraulics into the cabinet however, there is no need to screw the rear panels in! e) Enter Service Mode →...
Page 309 T- 7.2.1 TEMPERATURE CONTROL a) ENSURE the concentrate connectors are attached to acid and LIQUID bicarb! b) From Service Mode → Calibrate Sensors → Temp Control. c) ‘Sharply’ press ‘CONFIRM’. The screen should say “3. Connect an external temperature meter to the dialysate lines”.
Page 310 T- 7.2.2 [TEMP DAC] BETWEEN 120 AND 140 / VERIFY FLOW The external flow indicator’s ‘bob’ is watched to see if it EVER, even once, stays down longer than four (4) seconds AND the external meter is watched to see if it EVER, even once, exceeds 38.9° C. WITHOUT LOOKING AWAY watch ‘bob’...
Page 311 T- 7.2.6 ‘BOB’ WAS NOT RISING BUT IS NOW / RESET INTERNAL ALARM LIMIT IMPORTANT! RETURN NTC #3’s connector to distribution board position from the left “MON-NTC”. b) Select the [TEMP DAC] data box, it turns bright yellow. c) Set [TEMP DAC] to “130” then ‘sharply’ press ‘CONFIRM’...
Page 312 T- 7.4.0 ‘BOB’ IS RISING AND FALLING / CHECK ‘ACUAL’ TEMPERATURE Based on the external meter’s reading, THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) remaining less than 33.0° C: See procedure number T- 7.4.1 (page 308).
Page 313 T- 7.5.0 VERIFY MEASURED TEMPERATURE At this point it does not matter if the external meter is 37.0° C! WITHOUT LOOKING AWAY, watch it for one (1) minute noting its highest and lowest values. TWO (2) possible scenarios: IF (and ONLY if) temperature changes more than +/- 0.2° C: ENSURING the external flow indicator’s ‘bob’...
Page 314 T- 7.5.3 TEMPERATURE CHANGES MORE THAN +/- 0.2° C / NTC #2 CHECK THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) NTC #2 was NEITHER checked NOR replaced in THIS troubleshooting session: See procedure number T- 8.0.0 (page 315) to check (or replace) NTC #2*. * To LOCATE NTC #2 refer to Figure 42 (page 218)
Page 315 T- 7.6.0 METER TEMPERATURE IS STABLE AT 37°C / CHECK NTC #3 STABILITY The screen’s [Monitor Reference] data box should be gray AND at this point it does not matter if it = 37° C! WITHOUT LOOKING AWAY, watch it one (1) minute noting its highest and lowest value. TWO (2) possible scenarios 1) or 2) below: IF (and ONLY if) [Monitor Reference] changes more than +/- 0.2°...
Page 316 T- 7.6.4 ‘SLOW FLOW‘ CALIBRATION NOTE: This calibration requires PATIENCE to avoid error! a) [TEMP DAC] = 255 and Flow Rate (Figure right) = 100 (ml/min)! The external flow indicator’s ‘bob’ may look like it is NOT moving! This is NORMAL here! b) ‘Sharply’...
Page 317 T- 7.6.6 ADJUST ‘SLOW FLOW’ MONITOR REFERENCE a) ‘Sharply’ press ‘CONFIRM’ to turn [Monitor Reference] pale yellow / white! b) Adjust [Monitor Reference] to match the meter’s maximum (i.e. between 36.9 and 37.1° C). c) CAREFUL HERE! Sharply ‘CONFIRM’ TWICE to turn [Monitor Reference] GRAY! d) Does the GRAY [Monitor Reference] data box read between 36.4 and 37.6°...
Page 318 T- 7.8.0 [MONITOR REFERENCE] CHANGES MORE THAN +/- 0.2° C a) Figure right, place the 34° C (6.808 KΩ) plug from the FOUR RESISTOR SET into the distribution board position from the left “MON-NTC”. b) TWO (2) possible scenarios , based on the screen’s [Monitor Reference] data box: IF (and ONLY if) [Monitor Reference] continues to change more than 0.2 °C per minute:...
Page 319 T- 8.0.0 ISOLATE NTC #2 This procedure checks NTC #2 resistance (Ω) response. An accurate thermometer is required. If one is not available replace NTC #2 (see Figure 54, page 315) with a known good then return to (ABOVE) procedure number T- 7.2.1 (page 305).
Page 320 Table 5 – NTC RESISTANCE Minimum Resistance Cup Temperature ( Nominal Resistance Maximum Resistance 6.142 KΩ 6.267 KΩ 6.392 KΩ 36.0 6.117 KΩ 6.242 KΩ 6.367 KΩ 36.1 6.092 KΩ 6.217 KΩ 6.342 KΩ 36.2 6.067 KΩ 6.192 KΩ 6.317 KΩ 36.3 6.042 KΩ...
Page 321: Section 5 - Conductivity / On Line Clearance Problems
SECTION 5 - CONDUCTIVITY / ON LINE CLEARANCE PROBLEMS External leaks, “No Water” and Flow Errors cause Conductivity problems. If either occur at ANY TIME address them first! To avoid error observe ALL stated times below! A) ENSURE Dialysate Flow is ON (Flow on/off lamp NOT blinking)! B) From the Home screen, ENSURE [Dialysate Flow] and has been on and set to 800 ml/min for five (5) minutes! C) If [Conductivity] is less than 12.6 mS, Figure right, ENSURE BOTH...
Page 322 L) Call the Home screen. WITHOUT LOOKING AWAY, watch [Temperature] [Temperature] AND [Conductivity] for one (1) minute. Based first on TWO (2) possible scenarios below IF between 35.5 and 38.5° C AND STABLE i.e. does NOT changes more than +/- 0.2 °C: Going forward, if [Temperature] becomes unstable address it FIRST! For now see part M.
Page 323 CO- 1.0.0 ISOLATE DIALYSATE SETTINGS A) At the bottom of the screen, select the ‘Dialysate’ tab. B) Figure below, ENSURE the ‘Selected Acid’ matches the acid connected to the machine. C) Figure below, ENSURE the Acid ‘Type’ matches the acid label. Figure 55 –...
Page 324 CO- 1.0.1 CONDUCTIVITY IS LOW / ISOLATE BICARB PUMP CONTROL Call debug screen 0. Figure right, what color is the pump’s ‘dot’, BLUE or WHITE? page 321 IF BLUE: Proceed to , procedure number 1.0.3. 2) IF WHITE: a) Select the ‘Dialysate’ tab to call the Dialysate screen. b) Figure below, is the [Bicarbonate] window MORE THAN zero (0)? page 374 [Bicarbonate] window more than zero (0)! Proceed to...
Page 325 CO- 1.0.3 CONDUCTIVITY IS LOW / ISOLATE PUMP INPUTS A) Plug BOTH connectors HARD into their rinse ports but DO NOT press any screen keys! B) Figure right, two (2) checks on BOTH wands: Check #1: ENSURE the wands are attached to the cap AND reach to the bottom of the jug(s)! Check #2: ENSURE the wand tubing is NOT kinked! C) Figure right, THREE (3) checks on BOTH concentrate CONNECTORS:...
Page 326 Procedure # CO- 1.0.3 continued: JUGS H) FIRMLY connect BOTH concentrate connectors to Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’) J) From the Home screen, set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’. K) See procedure number CO- 1.0.3.7 (page 322).
Page 327 CO- 1.0.3.8 BOTH PUMPS DRAWING CONCENTRATE / ISOLATE LEAKS ENSURE FIRM connections to the acid and bicarb jugs! B) Figure below, ENSURE no leaks from the ACID and BICARB pumps! C) Figure below, if a ‘Quick Connector’ is present, at the end of the drain tubing, an ADAPTOR is required! D) As seen in the Figure right, point the drain tubing OPENING UP at 45°...
Page 328 Scenario #1: Referring to Figure A (below), approximately 30 ml pulses that stop completely between each and every cycle i.e. Pulse → Stop → Pulse → Stop: See parts a AND b below: a) Reconnect the drain. b) ENSURING [Dialysate Flow] is ON and set to 800 ml/min, see procedure number CO- 1.0.4 (page 325).
Page 329 CO- 1.0.4 ISOLATE ACID PUMP CONTROL Open the shunt door and LEAVE IT OPEN till instructed! b) Call debug screen 0. Figure right, WITHOUT LOOKING AWAY, watch Acid versus AAcid for one (1) minute. Are they ALWAYS within +/- 3 of each other? AAcid = Acid! See procedure number CO- 1.0.4.2 (page 325).
Page 330 CO- 1.0.5.2 CHAMBER #69 SAYS “AIR”: Figure below inside the distribution board, locate the Air Sensor’s female connector! connector cap i.e. 5 position FROM THE LEFT. If CBE modified it plugs into the CBE board higher than the others! Continue to part B next page LEFT BLANK INTENTIONALLY 2008K/K2 Troubleshooting Guide Page 326...
Page 331 FIGURE BELOW FOUR-RESISTOR SET , place one of the plugs, from the into the Air position Sensor’s distribution board position i.e. * from LEFT NOTE: If CBE modified the resistor MUST into the CBE board pin for pin! ENSURE the top CBE board pin is covered by the resistor! C) If the resistor plug was placed properly, watching to thirty (30) seconds, Chamber #69’s box MUST now say “No Air”...
Page 332 CO- 1.0.6 “NO AIR” ALWAYS / ISOLATE LOADING PRESSURE ENSURING SLAM the Loading Pressure gauge (yellow connector) reads 0 psi before inserting it * it into the Acetate/Acid rinse port. * or else pressure always read low b) Loading Pressure may not cycle but is ‘OKAY’ if it achieves a peak of between 23 and 26 psi. TWO (2) possible scenarios: IF (and ONLY if) pressure is ‘OKAY’: Leaving the gauge installed, see procedure number CO- 1.0.6.2...
Page 333 CO- 1.0.7 BC SWITCH NEVER = 897 PART 2 a) BE VERY SURE the blue connector is in KNOWN GOOD bicarb; the red connector in KNOWN GOOD acid!! b) Consider using the acid and bicarb jugs from another machine that has good Conductivity! c) ENSURE [Dialysate Flow] is ON (Flow on/off lamp NOT blinking)! d) From the Home screen, ENSURE [Dialysate Flow] is set to AT LEAST 500 ml/min! e) If a problem was located in part a OR the acid AND / OR bicarb...
Page 334 CO- 1.0.8 [CONDUCTIVITY] MORE THAN 14.5 mS / ISOLATE PUMP ELECTRICAL CONNECTIONS BE CAREFUL! A) These procedures are IMPORTANT to prevent patient harm. Figure BELOW ACID AND BICARB pumps , touch the top of the to feel them BOTH mechanically stroking about every three (3) seconds! IMPORTANT! Return the BICARB (blue) connector to its rinse port! D) Call debug screen 2 and ENSURE BICOUT = 0!
Page 335 CO- 1.0.8.1 [CONDUCTIVITY] MORE THAN 14.5 mS / ISOLATE PUMP TUBING CONNECTIONS a) Per the top Figure below, trace the tubing from the red (ACID) connector to ENSURE it goes to the ACID PUMP input of the b) If ABSOLUTELY SURE the pump is plumbed correctly, see procedure number CO- 1.0.8.2 (page 332).
Page 336 CO- 1.0.8.2 CONDUCTIVITY] MORE THAN 14.5 mS / ISOLATE DRAIN STREAM. a) ENSURE Loading Pressure (Acid Rinse Port gauge) continues to reach its high of more than 22 psi! IMPORTANT! If a ‘Quick Connector’ (Figure right) is present at the end of the drain tubing an ADAPTOR is required! c) As seen in the Figure (below right), point the drain UP at 45°...
Page 337 Yes ‘Bob’ moving! See part E. No ‘Bob’ NOT moving! ENSURING the machine was in RINSE, return to Dialysis Program page 20 THEN proceed to SECTION 1 - FLOW ERRORS IN DIALYSIS PROGRAM ten (10) FULL E) Watch for minutes ENSURING a “No Water” or a Flow Error NEVER occurs! F) See procedure number CO- 1.0.8.4 (page 333).
Page 338 CO- 1.0.8.5 AFTER RINSE CONDUCTIVITY = 10.0 MS a) Select the [Dialysate Flow] window. b) Set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’. page 337 c) Allow six (6) minutes BEFORE continuing to procedure number CO- 2.0.0 ( LEFT BLANK INTENTIONALLY 2008K/K2 Troubleshooting Guide Page 334 P/N 507298 Rev.
Page 339 CO- 1.0.9 VERIFY DIALYSATE LIMITS a) Select the ‘Dialysate’ tab (Figure below). Dialysate SCREEN is based on Dialysate Composition and indicates what the ‘Actual’ Conductivity would be if everything was perfect. c) Using [Alarm Width], spread Conductivity Limits as wide as they will go and press ‘CONFIRM’. d) Using [Alarm Position], set the upper Limit to 0.5 above TCD and press ‘CONFIRM’.
Page 340 CO- 1.0.10 VERIFY ACID SETTINGS a) Select the upper left ‘Conc’ button to call the ACID Sub Screen (Figure below). This screen indicates the ‘Selected Acid’s’ Ionic Profile. ACID Sub Screen b) Does the label on the connected ACID match the Sub Screen’s Ionic Profile (Yes or No)? The label = the screen’s Ionic Profile.
Page 341 CO- 2.0.0 VERIFY PRIMARY TEMPERATURE ALARM LIMITS a) Call the Home screen. b) ENSURING [Temperature] REMAINS between 35.5 and 38.5° C, what color is its window (Figure right)? page 337 IF pale yellow/white: Proceed to , procedure number 2.0.6. page 222 T- 1.0.9 IF RED: Proceed to , procedure number...
Page 342 IMPORTANT! Place the machine into RINSE! d) Is the external flow indicator’s ‘bob’ rising at least ¼ way up in the sight tube? page 353 ‘Bob’ moving! Proceed to , procedure number 6.0.0. No ‘Bob’ NOT moving! See parts a AND b below: a) Return to Dialysis Program (“Select Program”...
Page 343 CO- 2.0.7 ‘ACTUAL’ CONDUCTIVITY BETWEEN THE ALARM LIMITS IMPORTANT! Press ‘CONFIRM’! b) Figure right, with ‘Actual’ Conductivity REMAINING BETWEEN the Limits, what color is the Conductivity window now? IF (and ONLY if) WHITE: See procedure page 340 number CO- 2.0.8 2) IF RED: Call debug screen 3 to see HICOND AND LOCOND (lower right).
Page 344 CO- 2.0.8 [CONDUCTIVITY] WINDOW IS WHITE / ISOLATE ‘OUT OF BYPASS’ FLOW IMPORTANT! If not already, close the shunt door! B) From the Home screen, ENSURE [Dialysate Flow] remains set to at least 500 ml/min! DO NOT reset alarms! D) Is the external flow indicator’s ‘bob’ rising at least ¼ way up in the sight tube? page 342 ‘Bob’...
Page 345 CO- 2.0.8.1 VALVE #24’S ‘DOT’ IS BLUE Is the external flow indicator’s ‘bob’ rising at least ¼ way up in the sight tube? ‘Bob’ moving! See procedure number CO- 2.0.9 (page 342). ‘Bob’ NOT moving. See parts a THROUGH c below: a) From the Home screen, ENSURE [Dialysate Flow] remains set to at least 500 ml/min! b) ENSURE the [Temperature] AND [Conductivity] windows are pale yellow/white.
Page 346 CO- 2.0.9 ‘BOB MOVING’ / MEASURE TEMPERATURE a) WITHOUT turning [Dialysate Flow] off, install a Temperature / Conductivity meter into the dialysate lines. IMPORTANT! Figure right, flow through the meter MUST be from bottom to top! IMPORTANT! Close the shunt door! c) Set the meter to measure temperature (°...
Page 347 CO- 3.0.0 CONDUCTIVITY IS GOOD / VERIFY DISPLAY a) If removed from a previous procedure, return Conductivity Cell #7’s connector to distribution board position “X7, COND” (Figure right). b) Call the Home screen. c) Based on the machine’s [Conductivity] window now, THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) = 17.0 mS: See procedure number...
Page 348 Figure 57 – Hydraulics Rear View CO- 3.4.0 [CONDUCTIVITY] WITHIN 0.4 OF TCD / VERIFY CONDUCTIVITY ALARM LIMITS What color is the Home screen’s [Conductivity] window now? TWO (2) possible scenarios: IF (and ONLY if) pale yellow / white: See procedure number CO- 3.5.0 (page 344).
Page 349 CO- 4.1.0 CENTRAL DELIVERY (SDS) CHECK VALVES INSTALLED? a) Remove the hydraulics from the cabinet! b) Figure below, if check valves (with white inserts) are installed in the Acid and / or Bicarb Pump input and/or output tubing REMOVE them completely and reattach all tubing with straight fittings! CAUTION! The check valves at the UF PUMP must NEVER be removed.
Page 350 CO- 4.2.0 ISOLATE CONCENTRATE INLET SYSTEMS (2). a) Return the acid and bicarb CONNECTORS HARD into their rinse ports. IMPORTANT! Place the machine into RINSE! c) ENSURE no external leaks! d) See procedure number CO- 4.2.1 (page 346). CO- 4.2.1 ISOLATE PUMP FEEDBACK a) Call debug screen 1.
Page 351 CO- 4.2.3 VERIFY CONDUCTIVITY a) From the Home screen, set [Dialysate Flow] to 800 ml/min. b) Allow six (6) minutes BEFORE continuing to part c. c) Does [Conductivity] REMAIN less than 13.0 mS? page 325 REMAINS LESS than 13.0 mS! Return to , procedure number 1.0.4.
Page 352 CO- 4.4.0 ISOLATE CONCENTRATE PICKUP SYSTEMS a) Place the concentrate connectors HARD into their rinse ports! b) Return to Rinse Program! ALLOW one (1) minute to prime the pumps. ONLY c) Per the Figure (right), place the connector’s ‘adapter plug’ into a container of water i.e.
Page 353 CO- 4.9.0 ISOLATE THE ACID / BIC PUMP(S) a) Per the Figure below, ENSURE no tubing restriction at the Acid and /or Bicarb pump. Figure 60 – Acid and Bic Pumps b) At the suspect pump(s), Per the Figure (right), TWO checks: Check #1: The metal plate has arrows to identify the Input (←) and Output (→) ports.
Page 354 CO- 5.0.0 UNSTABLE CONDUCTIVITY / CHECK PRESSURES a) ENSURE Loading Pressure (Rinse port gauge) is cycling between its PEAK of somewhere between 23 and 25 psi AND to NEVER LOWER than 11 psi. b) Temperature influences Conductivity. If it changes more than +/- 0.2° C per minute address the temperature problem first! c) Turn the machine OFF to avoid air locking the deaeration pump! d) The deaeration gauge is used next.
Page 355 ABic = Bic! See procedure number CO- 5.4.0 (page 351). Watch the Bicarbonate (BIC) pump’s ‘dot’ (Figure right) for TWO (2) minutes. TWO (2) possible scenarios: page 374 IF (and ONLY if) the ‘dot’ EVER turns white: Proceed to , procedure number 9.0.0.
Page 356 CO- 5.6.0 TROUBLESHOOTING UNSTABLE CONDUCTIVITY Proceed through the following SEVEN STEPS until a problem is located: 1. ENSURE a ‘strong’ spring was NOT accidently installed at the output ports of the acid AND bicarbonate pump. BOTH pumps get ‘weak’ springs! 2.
Page 357 CO- 6.0.0 DISTRIBUTION BOARD CHECKS / ON LINE CLEARANCE (OLC) ENABLED? a) Figure right, inside the distribution board, TWO checks: CHECK #1: ENSURE position #4, “PH-PR” is VACANT! CHECK #2: ENSURE Conductivity Cell #7 AND NTC #3’s connectors are plugged in properly.
Page 358 CO- 6.2.0 CALIBRATE / TROUBLESHOOT COND CELLS While in Dialysis, ENSURE the machine is clear of “No Water”, Flow Errors and Temperature alarms. Hydraulic alarm banners are not displayed in Service mode! These are TROUBLESHOOTING procedure! Perform EXACTLY as written to avoid error! IMPORTANT! Install the hydraulics however, there is no need to screw in the rear panels yet! IMPORTANT!
Page 359 STEP #3: Watch the external meter for thirty (30) seconds. Its reading MUST BE stable i.e. does NOT change more than +/- 0.15 mS? Conductivity is stable! Continue to STEP #4. a) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’) b) See (ABOVE) procedure number CO- 5.0.0 (page 350).
Page 360 [Conductivity] box pale yellow! See procedure number CO- 6.3.0 (page 356). [Conductivity] box remains gray! Possible problem with the Cond Cell #7 circuit. page 363 Proceed to , procedure number 7.0.0. CO- 6.3.0 COND CELL #7 STABILIZES a) Select the [Conductivity] data box, it turns bright yellow. b) Enter the external meter’s conductivity.
Page 361 CO- 6.4.0 OLC (COND CELL #13) CALIBRATION This four-point calibration sets slope for Post Dialyzer Cond Cell #13. See parts a THROUGH e below: 1,2, a) Figure right, connect the dialyzer lines to a PRIMED dialyzer IMPORTANT! The dialyzer MUST positioned vertically with the red dialyzer quick connector AT THE BOTTOM! If a dialyzer is not used OLC problems may occur! ENSURE the blood ports are tightly sealed to prevent air leaks!
Page 362 CO- 6.4.2 SECOND / THIRD / FOURTH OLC POINTS a) Unless a “COND LESS THAN…” banner appears OR an announced Flow Error occurs. the remaining three steps advance as below: • “9. Reading second point for post conductivity cell.” Within six (6) minutes the [Conductivity] box should stabilize between 13.00 and 14.00 mS causing advancement to step #10 (third point) •...
Page 363 CO- 6.5.0 “COND LESS THAN 10 or 15” BANNER OCCURING a) Recheck Loading Pressure (gauge in Rinse port). Unless there is a masked “No Water” or a Flow Error alarm pressure cycles, to between NEVER less than 11 psi and a PEAK of about 25 psi. Do NOT continue UNLESS pressure is cycling approximately EVERY THREE SECONDS! b) ENSURING the shunt door is CLOSED, if the external flow indicator’s ‘bob’...
Page 364 CO- 6.6.0 POST DIALYZER COND / TROUBLESHOOTING POST DIALYZER COND Recheck Loading Pressure (gauge in Rinse port). Unless there is an unannounced “No Water” or a Flow Error alarm pressure cycles, to about 25 psi about every three (3) seconds! Do NOT continue UNLESS cycling! ENSURING the shunt door is CLOSED, if the external flow indicator‘s ‘bob’...
Page 365 CO- 6.8.0 CONDUCTIVITY IS NOT BETWEEN 13.0 AND 14.2 Based on the external meter’s reading, TWO (2) possible scenarios: page 362 IF (and ONLY if) LESS THAN 14.5 mS: Proceed to procedure number 6.8.6. 2) IF MORE THAN 14.5 mS: See parts a THROUGH d below: a) ENSURE the blue (bicarb) connector is not accidently plugged into acid;...
Page 366 CO- 6.8.6 ISOLATE ACID PUMP a) Figure right, check the Acid Connector’s O-rings AND ENSURE the filter is clean AND the adaptor plug is screwed in tight! b) Read parts c and d before performing them. c) Perform the ACID (CONCENTRATE) PUMP VOLUME CALIBRATION per the CALIBRATION PROCEDURES booklet.
Page 367 CO- 7.0.0 TROUBLESHOOTING COND CELL #7 CIRCUIT IMPORTANT! Turn the machine OFF! 274 Ω b) Figure right, place the resistor plug, from the TWO- RESISTOR SET, into Conductivity Cell’s #7 distribution board position, “X7, COND”. c) Install a conductivity meter into the dialysate lines to measure ‘actual’ conductivity subsequently! d) Place the machine into Service Mode →...
Page 368 CO- 7.3.0 ISOLATE POSITIVE (+)12 VOLT DC SUPPLY a) CAREFULLY return Cond Cell #7 to distribution board position “X7, COND”. Turn the machine OFF c) To avoid pulling cables loose, GENTLY open the card cage. d) See procedure number CO- 7.3.1 (page 364).
Page 369 CO- 7.3.4 ISOLATE NEGATIVE (-)12 VOLT DC SUPPLY -12V Per the Figure below, measure at the TEST Connector’s (negative 12V) pin (pin 4, four pins from left). TWO (2) possible scenarios: IF (and ONLY if) between -11.0 and -13.0 volts DC: Swap in the listed components (see COMPONENT LIST below) one at a time and in between return to (ABOVE) procedure number CO- 6.2.0 (page 354) to test each component...
Page 370 CO- 8.0.0 MEASURED CONDUCTIVITY IS BAD / ‘ACTUAL’ CONDUCTIVITY CHECKS TWO (2) possible scenarios based on the external meter’s reading versus TCD: page IF (and ONLY if) LESS THAN TCD - (minus) 0.4 i.e. Conductivity is LOW: Proceed to , procedure number 8.2.0.
Page 371 Per the Figure below, trace the tubing from the red (ACID) connector to ENSURE it goes to the ACID pump g) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’). h) Set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’. See procedure number CO- 8.1.1 (page 367).
Page 372 CO- 8.2.0 ISOLATE VERY INTERMITTENT ACID PUMP CYCLES Call debug screen 0. Figure (right), WITHOUT LOOKING AWAY, watch Acid versus AAcid for one (1) minute. Are they remaining always within +/- 3 of each other? AAcid = Acid! See procedure number CO- 8.2.1 (page 368).
Page 373 CO- 8.3.0 BALANCING CHAMBER VOLUME (BCV) Figure below, the Balancing Chamber(s) Volume (BCV) MAY HAVE BEEN factory recorded, a three-digit number (example 61.3), written on the top or side of the balancing chambers (Yes or No)? BCV is recorded! See procedure number CO- 8.3.1 (page 369).
Page 374 CO- 8.4.0 ISOLATE ACID PUMP a) Turn the machine OFF! b) Figure right, ENSURE the Acid (red) AND Bicarbonate (blue) Connector’s O-rings AND ENSURE the filters are clean AND the adaptor plugs are screwed in tight c) Read parts d and e before performing them! d) Perform the ACID (CONCENTRATE) PUMP VOLUME CALIBRATION per the Calibration booklet.
Page 375 CO- 8.6.0 COND MORE THAN TCD + 0.4 / ISOLATE VALVE #29 a) Per the Figure below, clamp the tubing at Valve #29. Figure 61 – Valve #29 b) Allow fifteen (15) minutes OR until if the external meter returns to within +/- 0.4 of TCD? External meter within 0.4 of TCD! Remove the clamp from Valve #29 and allow seven (7) minutes.
Page 376 CO- 8.7.0 ISOLATE BALANCING CHAMBER DIAPHRAGMS a) BEFORE continuing to part b, NOTE this page and procedure number in case you need to return here page 535 then proceed to SECTION 19 - TESTING FOR A LEAKING BALANCING CHAMBER DIAPHRAGM. b) If a leaking balancing chamber diaphragm was NOT located in part a return to Dialysis Program (“Select Program”...
Page 377 CO- 8.9.0 ISOLATE POSSIBLE LEAKING HEAT EXCHANGER IMPORTANT! Leaving the water on turn the machine OFF! b) Per the Figure below, remove the front clear tubing from the Heat Exchanger’s nozzle. Ignore a small water crown that may appear! c) Watch the open heat exchanger nozzle for up to three (3) minutes. Is water continually dripping, possibly VERY slowly, from the Heat Exchanger’s nozzle? Dripping from Heat Exchanger! TWO (2) procedures MUST be performed! Procedure #1: With the water turned OFF, REPLACE the Heat Exchanger;...
Page 378 CO- 9.0.0 BIC DOT IS WHITE / ISOLATE BICARB DEBUG SIGNAL A) Per the Figure below, inside the distribution board, unplug the CONNECTOR CAP from the left! This is the Bicarb Reed Switches Connector, “X12, BIC-SW”. B) Using a flashlight, check inside the “BIC-SW” position for corrosion or damaged male pins as this may be the problem! C) Call debug screen 0.
Page 379: On Line Clearance (Olc) Problems
CO- 9.8.0 VERIFY BALANCING CHAMBER VOLUME Figure below, the Balancing Chamber(s) Volume (BCV) MAY BE factory recorded, a three-digit number (example 61.3), written on the top of the Balancing Chambers (Yes or No)? BCV is factory recorded! See procedure number 9.8.11 (page 375).
Page 380 CO- 9.8.3 BALANCING CHAMBER VOLUME IS NOT FACTORY RECORDED A clear, preferably glass, 100 ml graduated cylinder OR even MUCH more preferable a calibrated scale is required! DO NOT use a larger cylinder or gross error will occur!! WITHOUT turning flow off , figure right, remove the tubing from the ‘To Drain’...
Page 381 CO- 9.8.4 BAD LAB VALUES For additional information about the Acid and Bicarb Pump CHECKS read parts a through f below BEFORE performing them: a) To ENSURE the Acid and Bicarb Pump volumes are delivering within +/- 2%, you MUST perform the Test Concentrate and Bicarbonate Pumps per the Preventative Maintenance Procedures.
Page 382 CO- 10.0.00 TROUBLESHOOTING ONLINE CLEARANCE (OLC) OLC estimates UREA clearance (Kt/V) by measuring Conductivity pre and post dialyzer: LEAVE THE DOOR OPEN till a) Return the dialyzer connectors to the shunt but instructed! Per the Figure below , trace the wires from distribution board positions #13 (Post Dialyzer Cond Cell #13) AND #44 (Post Temperature Sensor NTC #44), to the sensors to perform TWO (2) checks: CHECK #1: Check the entire length for insulation damage.
Page 383 CO- 10.0.10 ISOLATE TEMP Pre Dialyzer a) Call debug screen 0. Figure right, ENSURE Cond (mS) is within 0.4 of TCD. b) ENSURE Pre Dialyzer Temp is between 35.5 and 38.5° C. c) Is Post Dialyzer Temp within 1.2° C of Pre Dialyzer Temp? Post Temp within 1.2 of Pre Temp! S ee procedure CO- 10.0.11...
Page 384 CO- 10.0.20 PROBLEM WITH POST DIALYZER TEMP / ISOLATE TEMP SENSOR #44 a) Figure right, from the distribution board, unplug the Connector cap from the left. This is Temperature Sensor NTC #44, “x44, NTC-POST”! b) Screen 0’s Post Dialyzer Temp MUST be LESS THAN 34.0°...
Page 385 [Post-Temperature Reference] more than 20! Without pressing ‘CONFIRM’ yet, see procedure number CO- 10.0.24 (page 381). [Post-Temperature Reference] is less than 20! See parts a and b below: 34° C a) ENSURE the (6.808 KΩ) plug is placed properly at position “x44, NTC-POST”. If NOT, repeat (ABOVE) procedure number CO- 10.0.22 (page 380) AND/ OR consider...
Page 386 CO- 10.0.26 TROUBLESHOOTING POST DIALYZER TEMP / POST ISOLATE NTC #44 a) Return NTC #44’s connector to distribution board position “X44, NTC-POST”. b) From the Home screen, set [Dialysate Flow] to 500 ml/min and press ‘CONFIRM’. c) Allow the Home screen’s [Temperature] display to stabilize between 35.5 and 38.5° C. d) Call debug screen 0.
Page 387 CO- 10.0.30 PROBLEM WITH POST DIALYZER COND ENSURING the shunt door is open, is screen 0’s Post Dialyzer Cond more than 10.000 mS? Post Cond more than 10.000! See procedure number CO- 10.0.32 (page 383), Post Cond less than 10.000! See procedure number CO- 10.0.34 (page 383), CO- 10.0.32 POST DIALYZER COND MORE THAN 10.000...
Page 388 CO- 10.0.36 ISOLATE POST COND CELL #13 FPRE a) From debug screen 5, changes continuously. RECORD its approximate value for reference later! b) Figure right, place Cond Cell’s #13 connector into Conductivity Cell #7’s distribution board position “X7, COND”. c) Is FPRE within +/- 200 of what was recorded in part a? FPRE within +/- 200 of what was recorded! See procedure number...
Page 389 CO- 10.0.405 VERIFY SENSOR VERSUS ACTUATOR Call debug screen 5. TWO (2) checks! Proceed according to the Yes – No choice at check #2. Check #1 CPRE (middle column) versus ACOND (upper left)): They change continually but MUST REMAIN within +/- 500 of each other? Check #2 CPRE versus CPOS (middle column)): Change continually but...
Page 390 CO- 10.0.41 PREPARE TO ANALYZE PRE AND POST CONDUCTIVITY STABILITY a) Install a ‘dummy chamber’ in the Level Detector module and RESET ALL alarms! b) Watch the screen for thirty (30) seconds. If a “Filling Program” banner occurs, allow thirty (30) seconds before continuing! MUST NOTE: Multiple “Filling Programs”...
Page 391 CO- 10.0.44 PRE DEV VALUE LESS THAN 135 / CONDUCTIVITY STABILITY a) Post Dev val (right column) is the conductivity difference between now and one (1) minute ago from Post-Conductivity Cell #13. If no alarms it changes continually! b) After no more than three (3) minutes, if not already, Post Dev val should fall to less than 70. TWO (2) possible scenarios: IF Post Dev val is OR falls to less than 70: See procedure number CO- 10.0.46...
Page 392 CO- 10.0.46 BOTH PRE AND POST COND ARE STABLE a) Pre Stbl Ct (pre-conductivity stability counter) starts at 90 and decreases one unit per second if Pre Dev val remains less than 135. If not already, after no more than two (2) minutes, it should fall to 0! b) Post Stbl Ct (post-conductivity stability counter) starts at 70 and decreases one unit per second if Post Dev val remains less than 70.
Page 393 Step # 2: Read before parts a THROUGH e BEFORE performing them: a) Turn the machine OFF then back on. b) Return to Dialysis Program with [Dialysate Flow] set to 500 ml/min. c) Allow six (6) minutes ENSURING [Conductivity] stabilizes to between 13.0 and 14.3 mS.
Page 394 CO- 10.0.50 OLC TEST STARTED / OLC SELF TEST DESCRIPTION / TROUBLESHOOTING a) Call debug screen 5. When OLC Status = 1, Conductivity Pre-Dialyzer (CPRE) followed a minute or so later by Conductivity Post-Dialyzer (CPOS) SHOULD gradually increase to more than 15000 (15.000 mS)! The initial instability causes Pre Stbl Ct AND Post Stbl Ct to increase to respectively 90 and 70.
Page 395 CO- 10.0.60 ISOLATE POST SENSORS STABILITY a) Per the Figure below, remove Post Dialyzer Temp Sensor NTC #44’s connector from distribution board position “x44, NTC-POST”. b) Using a flashlight, check the vacant “x44” position for ‘white’ corrosion and/or damaged male pins. If damage is located this may be the problem! 6.04 KΩ...
Page 396 b) Return Post Dialyzer Cond Cell #13 connector to distribution board position labeled “x13, COND-POS”. c) From debug screen 0, ENSURE Post Dialyzer Temp reads more than 35° C AND Post Dialyzer Cond MUST more than 10.000. d) See procedure number CO- 10.0.66 (page 392).
Page 397 CO- 10.0.705 ISOLATE OLC PROBLEM IMPORTANT! TURN the machine OFF! b) Place the concentrate connectors into their rinse ports c) Turn the machine on and place it into Acid Clean. d) After rinse is complete, connect to fresh concentrate and return to Dialysis Program. e) Allow six (6) minutes for Temperature and Conductivity to stabilize.
Page 398 CO- 11.0.00 RETURN SYSTEMS a) Return Pre Dialyzer Temp Sensor NTC #3s connector to distribution board position from the LEFT, “MON- NTC”. b) From debug screen 0, ENSURE Pre Dialyzer Temp reads more than 35.0° C. c) If removed from a previous procedure, return Pre Dialyzer Cond Cell #7 connector to distribution board position “x7, COND”.
Page 399 CO- 12.0.00 OLC SELF TEST PASSED / CHECK BLOOD PUMP / ADDITIONAL TROUBLESHOOTING OLC Self-Test PASSED! A conductivity-related OLC problem is not indicated HOWEVER, unstable Blood Pump rate may also cause OLC Tests to cancel. See parts a THROUGH c below: IMPORTANT! Reset ALL alarms.
Page 400 NOTE: Table B readings are affected by changing the [Dialysate Flow] rate, or turning it off, Filling Programs, Pressure Tests and Temperature or Conductivity alarms (i.e. bypass). ENSURE the machine is stable before responding to variations! Table B – Debug Screen 5 OLC Values Parameter Description Value...
Page 401: Section 6 – Concentrate Pump Errors
SECTION 6 – CONCENTRATE PUMP ERRORS The CONC (Acid) and Bic (Bicarbonate) pumps each have optical End Of Stroke (EOS) sensors that monitors the pump pistons when transported back and forth by their stepper motors. From debug screen 0, per the Figure below, if all systems are okay, the ‘Actual’ number of steps (AAcid, ABic) REMAIN within three (3) of the ‘Required’...
Page 402 Figure 63 – Distribution Board / Hydraulics Top View (Pumps) EOS- 2.0.0 ACID SYSTEM PROBLEM / ISOLATE THE ACID PUMP This procedure uses the known good bicarbonate pump to check the acid pump. IMPORTANT! Turn the machine off to prevent damage! B) Per Figure 63 above, unplug the acid pump cable from distribution board position “P16, CONC-P”.
Page 403 EOS- 3.0.0 BICARBONATE (BIC) SYSTEM PROBLEM / ISOLATE THE BIC PUMP This procedure uses the known good acid pump to check the bicarbonate pump. IMPORTANT! Turn the machine off to prevent damage! B) Per the Figure below, unplug the bicarbonate pump’s cable from distribution board position “P17, BIC-P”. CAUTION! Avoid the Heparin Pump connector at position “P18”! CAUTION! C) Plug the acid pump’s cable, into the bicarbonate pump’s position “P17, BIC-P”.
Page 404 EOS- 4.0.0 PUMP SYMBOL REMAINS PINK / ISOLATE THE PUMP CIRCUITS IMPORTANT! Turn the machine OFF to prevent damage! b) Per Figure 63 (page 398), return both pump cables to their distribution board positions. c) See EOS- 4.0.0, STEP #1 below: EOS- 4.0.0, STEP #1 Isolate Actuator-Test Board IMPORTANT! Turn the machine OFF to prevent damage! b) Swap in a known good Actuator-Test Board.
Page 405 EOS- 4.0.0, STEP #3 Isolate the Actuator Cable IMPORTANT! Turn the machine OFF to prevent damage! b) Swap in (or check ) a known good actuator cable*. *To LOCATE the cable refer to Figure 4A (page 9). To check the actuator cable, which pump is issuing the EOS error? page IF ACID: NOTE that four (4) ACID PUMP connections (ONLY) will be checked and proceed to SECTION 16 - CHECKING THE ACTUATOR BOARD...
Page 406 EOS- 5.0.0 BOTH PUMP SYMBOLS ARE PINK IMPORTANT! Turn the machine OFF to prevent damage! b) Per the Figure below, ENSURE BOTH pumps are installed with their output nozzles (red or blue) towards the top and the ribbon cables extending from the side. If not, this may be the problem! c) Swap in a known good Actuator-Test Board* *To LOCATE the board refer to Figure 4A, page 9).
Page 407 e) Allow thirty (30) seconds THEN, WITHOUT LOOKING AWAY, watch the pump’s symbol for two (2) minutes. Does it remain white? Pump symbol remains white! The previous pump is bad. Repeat procedure number EOS- 5.0.1 to test the alternate pump. If BOTH symbols remain white: BOTH previous pumps are bad.
Page 408: Section 7 - Cond Ref Failure Or Cond Offset Failure
SECTION 7 - COND REF FAILURE OR COND OFFSET FAILURE CR- 1.0.0 ISOLATE DISTRIBUTION BOARD Turn the machine OFF! b) Figure right, ENSURE distribution board position “X4, PH-PR” is COMPLETELY VACANT! NOTE: If the CBE board is accidentily plugged into position “PH-PR” it may destroy the Power Logic board! c) Turn the machine ON.
Page 409 e) Referring to the Figure below, locate the motherboard’s nine (9) pin TEST Connector. Voltage signals will be measured from here next. See procedure number CR- 1.0.2 (page 405). Figure 64 – TEST Connector CR- 1.0.2 ISOLATE POSITIVE (+)12 VOLT DC SUPPLY IMPORTANT! Set your CALIBRATED volt meter to DC Voltage (V Connect the meter’s black lead to chassis ground (see Figure 2...
Page 410 CR- 1.0.4 BETWEEN -11.0 AND -13.0 VOLTS / ISOLATE CELLS CALIBRATION A) Turn the machine OFF. DO NOT allow the acid and LIQUID bicarb to run empty subsequently! C) Place the machine into Service Mode → Calibrate Sensors → Cond Cells. D) ENSURING the external flow indicator’s ‘bob’...
Page 411 CR- 1.0.9 ISOLATING NEGATIVE (-) TWELVE VOLTS IMPORTANT! To avoid damage turn the machine OFF! b) Figure below, at the rear of the card cage, ENSURE the Blood Pressure Module cable, is NOT reverse connected with another module! If it is, correct this situation then re-measure -12 volts as this may be the problem! IMPORTANT! Blood Pressure...
Page 412 CAUTION! Due to the time consuming work that may be performed if the following resistance reading is misinterpreted proceed VERY carefully. Do NOT read just the meter’s numeric display, read ALSO its UNITS (“Ω”, “KΩ”, “MΩ”) AND the location of its decimal point! Ω...
Page 413: Section 8 - Filling Program (Air Leak) Problems
SECTION 8 - FILLING PROGRAM (AIR LEAK) PROBLEMS Filling Programs NORMALLY occur when air is sensed by Chamber #69’s Air Sensor #6 i.e. Chamber #69’s text box says “Air”. They are indicated with a “Filling Program” or “10 Fill Pgm in 1 Hr” or “TMP Is Low” banner. Also, debug screen 1’s FILACT = 1.
Page 414 FIL- 1.0.0 ISOLATE AIR SENSOR CIRCUIT / POSSIBLE LEAKS Going forward, if a “No Water”, Flow Error, Temperature or a Conductivity EVER occur address them first! a) Figure below, remove the Distribution Board’s cover. b) Using a flashlight, ENSURE the Air Sensor’s female connector is plugged PROPERLY* into its Distribution Board position i.e.
Page 415 Figure below , ENSURE the Air Sensor Connector’s brown and blue wires terminate tightly into the probes at the top Chamber #69, brown wire to the top probe; blue to the bottom! NOTE: If the wires are loose OR not connected properly this may be the problem! d) Very small external leaks cause BIG problems! Be THROUGH! THREE (3) leak checks: CHECK #1 Figure right, the ENTIRE length of the...
Page 416 FIL- 1.0.1 ISOLATE AIR REMOVAL SYSTEM a) Turn the machine OFF! b) The Deaeration gauge is used next. ENSURE it reads 0 inHg before installing it! c) Figure below, tee the gauge into the Inlet (clear tubing) side of the Deaeration Pump! d) Turn the machine on and return to Dialysis Program (“Select Program →...
Page 417 FIL- 1.0.3 DEAERATION PRESSURE OKAY (2) Because the machine was off, [Conductivity] will be unstable! The following procedure requires three (3) minutes during when [Conductivity] MUST stabilize to between 13.0 and 14.4 mS! OPEN THE SHUNT DOOR AND LEAVE IT OPEN TILL INSTRUCTED! b) Call debug screen 0.
Page 418 FIL- 1.0.6 PRE AND POST COND NOT WITHIN 0.4 OF EACH OTHER Figure below, to the right of Pre Dialyzer Cond Cell #7, is Post Dialyzer Cond Cell #13 present? Cond Cell #13 present! See procedure number FIL- 1.0.7 (page 414). page 416 Cond Cell #13 NOT present! Proceed to , procedure number...
Page 419 Cables were OKAY! See procedure number FIL- 1.0.8 (page 415). Problem with a cable! After the repair, perform parts a THROUGH d below: a) Turn the machine OFF then allow even (7) minutes BEFORE continuing to part b. b) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! c) Allow Conductivity to increase to more than 13.0 mS.
Page 420 FIL- 2.0.0 VERIFY DIALYSATE SETTINGS IMPORTANT! CLOSE THE SHUNT DOOR! b) Is the external flow indicator’s ‘bob’ moving up and down in the sight tube? ‘Bob’ moving! See procedure number FIL- 2.0.1 (page 416). No a) At the bottom of the screen, select the ‘Dialysate’...
Page 421 b) Figure below, remove the UF Pump’s output (TOP) tubing from the location shown! c) Looking at the UF Pump’s vacant OUTPUT nozzle, TWO (2) possible scenarios: IF (and ONLY if) no fluid from the UF Pump: Reattach the tubing then see procedure number FIL- 2.0.2 (page 418).
Page 422 FIL- 2.0.2 ‘BOB’ MOVING / ISOLATE POSSIBLE AIR LEAK (1) Figure right, USING A FLASHLIGHT, look for air bubbles MOVING through the dialyzer lines. Air seen? page 490 Air seen! Proceed to SECTION 11 - INDUCED AIR LEAK TESTS. No air! See procedure number FIL- 2.0.3 (page 418).
Page 423 FIL- 2.0.4 NO AIR SEEN / ISOLATE FILLING PROGRAM Call debug screen 1. WITHOUT LOOKING AWAY watch FILACT (middle column) for up to two (2) minutes. If EVER = 1, even just once, indicates a Filling Program! TWO (2) possible scenarios: 421, IF (and ONLY if) FILACT EVER = 1: Proceed to page procedure number...
Page 424 FIL- 2.0.6 ALARMS RESET / ISOLATE PRESSURE TEST a) CLOSE the shunt door! b) During this procedure you will look for air again through the INPUT TUBING at Chamber #69 but THIS TIME while the Pressure Test’s “Get Neg TMP” AND “Neg Flow On” banners are up as this is when air may be pulled in through a leak somewhere! c) RESET all alarms! d) Select the [Test &...
Page 425 FIL- 2.1.0 NO AIR SEEN BUT FILACT = 1 / ISOLATE SUPPLY VOLTAGES a) Call debug screen 1, TWO (2) voltage checks: Check #1: 5V Est. (right column): Between 4.7 and 5.3? Check #2: 12V Est. (right column): Between 11.7 and 12.3? b) Are BOTH in range AND stable i.e.
Page 426 IMPORTANT! Allow thirty (30) seconds BEFORE continuing to part e e) Based on debug screen’s FILACT now, TWO (2) possible scenarios: IF (and ONLY if) FILACT ALWAYS = 0: See procedure number FIL- 2.4.0 (page 423). 2) IF FILACT = 1 or cycles between 0 and 1: Perform parts a THROUGH c below: a) ENSURE the plug is placed PROPERLY in the Air Sensor’s position! If CBE equipped, using a flashlight, ENSURE the plug covers ALL CBE board pins especially the TOP pin! If FILACT remains = 1 see part b! If FILACT now = 0 always see procedure number...
Page 427 FIL- 2.4.0 FILACT = 0 / ISOLATE POSSIBLE FLOW PROBLEM a) Call debug screen 6 to locate BC Switch (middle column). If EVER = 897 or more, even just once, indicates a masked Flow Error! In any event see part b. b) WITHOUT LOOKING AWAY, watch BC Switch for two (2) minutes.
Page 428 FIL- 2.4.4 FILACT = 1 a) Figure right, swap in a known good Air Sensor Connector. Figure below SURE , be to plug the new Air Sensor’s Connector into its distribution board position PROPERLY! If CBE equipped, using a flashlight, ENSURE the connector covers ALL CBE board pins, especially the TOP pin! c) Figure right, connect the new Connector’s wires together.
Page 429 FIL- 3.0.0 FILACT = 0 / CREATE VENOUS PRESSURE This procedure creates Venous Pressure to ensure Valve #25 remains open for the subsequent test: Turn Dialysate Flow OFF (Dialysate Flow on/off lamp blinks)! b) Call debug screen 0. ENSURE all eight balancing chamber valves (#31 through #38) ‘dots’ are REMAINING white (Flow is Off)! IMPORTANT! Dialysate Flow MUST REMAIN OFF till instructed otherwise! Figure below...
Page 430 FIL- 3.1.0 PRESSURE TEST HYDRAULICS (1) a) Figure right, connect the Four-Way Assembly (P/N 150034) to the dialyzer connectors. b) Place the Four-Way at dialyzer level! ENSURE a transducer protector IS NOT in the ‘to syringe’ tubing segment! c) If using a NEO-2 attach to the +Port (top, red port). If using a 90XL attach to the Pressure Module’s Gauge Port.
Page 431 FIL- 3.5.0 -250 MMHG HELD / ISOLATE VALVE #43 FLOW IMPORTANT! Return the dialyzer lines to the shunt and close the door! IMPORTANT! Turn Dialysate Flow on (Flow on/off lamp STOPS blinking)! c) Figure right, separate the Air Sensor Connector’s brown and blue wires.
Page 432 FIL- 3.6.0 600 ML/MIN COLLECTED / VERIFY FILLING PROGRAM a) Reconnect the machine’s drain tubing to the station drain! b) ENSURING Dialysate Flow is on, ENSURE a good drain connection by either ‘listening’ for drain flow or visually verifying it! IMPORTANT! Return the Air Sensor Connector’s wires to their probes on top of Chamber #69 i.e.
Page 433 FIL- 3.6.2 FILACT = 1 / CHECK FOR AIR AT CHAMBER #69 Figure below, watching for two (2) minutes, are air bubbles seen MOVING INTO Air Removal Chamber #69 now? page 490 Air seen! Proceed to SECTION 11 - INDUCED AIR LEAK TESTS to locate the source of the air leak! No air seen! Watch FILACT again for one (1) minute or until it EVER = 1! THREE (3) possible...
Page 434 FIL- 3.7.0 FILACT = 1 CONSTANT OR INTERMITTENT READ THIS PROCEDURE before performing it: To avoid damage turn the machine OFF! B) SEVEN (7) possible bad components (see Component List below). One at a time, swap in each with known good then in between, continue with parts C through H to test each new component. Component List: 1) CBE board;...
Page 435 FIL- 4.0.0 FILACT = 0 / FINAL ‘FILLING PROGRAM’ CHECKS Call the Home screen. Figure right, if the TMP window is RED a TMP alarm is present. TWO (2) possible scenarios: IF (and ONLY if) the TMP window is WHITE: See procedure number FIL- 4.0.2 (page 431).
Page 436 FIL- 5.0.0 AIR SEEN AT CHAMBER #69 Call debug screen 1. Look at FILACT (middle column). TWO (2) possible scenarios: IF (and ONLY if) FILACT = 0: See procedure number FIL- 5.1.0 (page 433). 2) IF FILACT = 1! See parts a THROUGH c below: Figure below , place one of the resistor plugs, from the FOUR-RESISTOR SET into Air Sensor Connector’s distribution board position.
Page 437 FIL- 5.1.0 FILACT = 0 / ISOLATE VENOUS PRESSURE (VEN) Turn Dialysate Flow OFF i.e. Flow on/off lamp blinks! b) Call debug screen 0. ENSURE all eight balancing chamber valves (#31 through #38) ‘dots’ are REMAINING white (Flow is Off)! IMPORTANT! Dialysate Flow REMAINS OFF till instructed! Per the Figure below , attach a syringe with a piece of tubing attached that will fit SNUG to the...
Page 438 FIL- 5.2.0 VEN MORE THAN 400 a) Figure right, connect the Four-Way Assembly (P/N 150034) to the dialyzer connectors. b) Place the Four-Way at dialyzer level! ENSURE a transducer protector IS NOT in the ‘to syringe’ tubing segment! c) If using a NEO-2 attach to the +Port (top, red port).
Page 439 FIL- 5.4.0 -250 NOT ACHIEVED OR IT DID NOT HOLD / ISOLATE FOUR-WAY Figure right , clamp BOTH Four-Way dialyzer Line tubing segments. b) Can you achieve -250 mmHg and HOLD it (+/- 15 mmHg for one minute) now? IMPORTANT! -250 achieved and HOLDS! Remove BOTH clamps from the Four-Way page 466...
Page 440 FIL- 5.5.0 -250 MMHG HOLDS a) Call debug screen 0. b) Figure right, if (and ONLY if) Valve #25’s ‘dot’ is BLUE continue to part c. If NOT blue return to (ABOVE) procedure number FIL- 5.1.0 (page 433). PDial c) Figure right, look at screen 0’s data window.
Page 441 FIL- 6.0.0 PDIAL DOES NOT AGREE WITH THE METER a) To prevent wetting the meter’s transducer protector clamp the ‘to meter’ tubing segment! b) Turn Dialysate Flow ON (Dialysate Flow on/off lamp STOPS blinking). c) From the Home screen, set [Dialysate Flow] to 500 ml/min and press ‘CONFIRM’. d) Enter Service Mode →...
Page 442 FIL- 6.2.0 “OPERATOR ERROR” OCCURRED / TROUBLESHOOT DIALYSATE PRESSURE a) ENSURE the transducer protector, at the external meter, is not WET or consider replacing it! b) Return the Dialyzer lines to the shunt and close the door. c) Turn the machine OFF. d) Turn the machine on and return to Dialysis Program (“Select Program”...
Page 443 FIL- 7.0.0 ISOLATE AIR LEAK a) Remove the Four-Way. IMPORTANT! Return the Dialyzer lines to the shunt door! c) Turn the machine OFF! d) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! e) From the Home screen, set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’. Allow [Conductivity] to increase to more than 13.0 mS! g) Figure below, is air still seen at Chamber #69? page 490...
Page 444: Section 9 - Tmp (Pressure) Problems
SECTION 9 - TMP (PRESSURE) PROBLEMS A) If the drain tubing is transparent, look through its ENTIRE length for possible bio-growth restrictions. B) Call the Home screen. [Venous Pressure] MUST be between -10 and 10 mmHg! C) The Treatment Clock (Figure right) MUST be off i.e. “Tx Paused”! D) ENSURE Dialysate Flow has been ON (Flow on/off lamp NOT blinking) for six (6) minutes.
Page 445 N) Figure right, if necessary adjust the Conductivity Limits until the ‘Actual’ Conductivity is CENTERED between them. IMPORTANT! Press ‘CONFIRM’. P) Allow up to three (3) minutes for the Conductivity window to turn white indicating no Conductivity alarms! IMPORTANT! CLOSE THE SHUNT DOOR! R) Call debug screen 2.
Page 446 TMP- 1.0.0 ‘BOB MOVING’ / ISOLATE POSSIBLE AIR LEAK a) Small air leaks cause BIG problems! TWO (2) checks. Be THROUGH! CHECK #1: Using a flashlight, ENSURE no air bubbles moving into the machine through the acid and bicarb inlet tubing! CHECK #2: ENSURE the external flow indicator’s (sight tube) fittings are tight! b) Call debug screen 1.
Page 447 IS NOT PDIA OR ADIA is between 3.0 and 6.0 continued: b) Continuous flow, more than 0.2 ml per minute, from the connector? Yes Continuous flow! A) Return the connector to the shunt and close the door; page 527 B) Turn the machine OFF; C) Proceed to SECTION 18A –...
Page 448 TMP- 1.0.4 ISOLATE LOADING PRESSURE ENSURE the Loading Pressure gauge (yellow connector) reads 0 psi before inserting it! SLAM * the gauge into the red Acetate/Acid rinse port. *OR ELSE pressure will not be read correctly! c) Loading Pressure is ‘OKAY’ if it achieves a PEAK of between 23 and 25 psi AND never cycles below 11 psi.
Page 449 TMP- 1.0.5 LOADING PRESSURE OKAY / ISOLATE AIR REMOVAL SYSTEM Turn the water OFF! b) The Deaeration gauge is used next. ENSURE it reads 0 inHg before installing it! c) Allow a “No Water” alarm to occur THEN, after one (1) minute, the deaeration motor stops.
Page 450 TMP- 2.0.0 DEAERATION PRESSURE OKAY Turn the water OFF! b) Figure right, ENSURE the external flow indicator’s inner tapered tube is NOT scored (i.e. tube really ‘cloudy’). If scored, replace it! c) Allow a “No Water” alarm to occur THEN, after one (1) minute, the deaeration motor stops.
Page 451 TMP- 2.0.1 POSITIVE PRESSURE LEAK CHECKS Small external leaks cause BIG problems! For the following USE A FLASHLIGHT! FEEL AROUND! NOTE: Not being THROUGH may cost unnecessary troubleshooting time! a) THREE (3) leak checks: CHECK #1: Figure right, the ENTIRE length of the dialyzer lines ESPECIALLY the quick connectors! CHECK #2: The ENTIRE hydraulic compartment!
Page 452 TMP- 2.0.2 POSITIVE PRESSURE LEAK TEST CONTINUED a) Figure below, THROUGHLY ENSURE no leaks at the UF, Acid and Bicarbonate (Bic) Pumps including their input and output tubing! b) See procedure number TMP- 2.0.3 (page 449). Figure 69 – Hydraulics Top View, Pumps LEFT BLANK INTENTIONALLY 2008K/K2 Troubleshooting Guide Page 448...
Page 453 TMP- 2.0.3 NO EXTERNAL PUMP LEAKS / ISOLATE FILLING PROGRAM (FILACT) a) Return the concentrate connectors to acid and bicarb. b) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM)! c) Call debug screen 1. Is FILACT (middle column) = 1? page 452 FILACT = 1! Proceed to , procedure number...
Page 454 c) Figure below, ENSURE the Air Sensor Connectors wires terminates with the brown wire to the TOP male probe on top of Chamber #69 AND the blue wire to the bottom probe! IMPORTANT! Allow up to three (3) FULL minutes for FILACT to = 1. Does FILACT go to 1? FILACT = 1! Perform part A and B below: IMPORTANT!
Page 455 TMP- 2.0.4 FILACT REMAINING = 0 a) Figure right, from here forward, if (and ONLY if) a “Dial Valve Failure” OR “Act Byp Valve Fail” banner EVER page 652 appears proceed to Section 26 IMPORTANT! Turn the machine OFF to prevent damage! Figure right , at the TOP of the distribution board, ENSURE the Sensor...
Page 456 TMP- 2.0.5 FILACT WAS OR IS = 1 This procedure ENSURES Valve #43 is not sticking closed AND allows Conductivity to increase: IMPORTANT! From the Home screen, select the [Dialysate Flow] window! b) Set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’! c) Call debug screen 0.
Page 457 The UF ‘dot’ blinks blue! If SURE the green UF lamp was OFF, the Actuator-Test Board may be bad! Figure 70 below No The ‘dot’ REMAINS white! , remove the UF Pump’s output (TOP) tubing! Look at the UF Pump’s nozzle! TWO (2) possible scenarios: IF (and ONLY if) NO fluid output from the nozzle! A) Reattach the tubing! B) See procedure number TMP- 2.0.7...
Page 458 TMP- 2.0.8 ISOLATE ACCURATE DIALYSATE FLOW IMPORTANT! Press the “1” key for five (5) seconds. Allow forty five (45) seconds, BEFORE continuing to part c) Call debug screen 5. (Figure right) REMAINS = 1 if dialysate flow is stable. d) Watch for two (2) minutes OR until if it EVER = 0.
Page 459 page 456 IF (and ONLY if) WHITE: Proceed to , procedure number TMP- 2.0.16. IF RED: See procedure number TMP- 2.0.10 (page 455). TMP- 2.0.10 TMP WINDOW RED a) TMP is UNSTABLE if ANY one or more of the three (3) conditions below occur: Condition #1: Figure right, if a positive (‘+’) sign* appears in the TMP window.
Page 460 TMP- 2.0.16 ISOLATE TMP Turn Dialysate Flow OFF i.e. Flow on/off lamp blinks! b) Call debug screen 0. If (and ONLY if) ALL EIGHT (8) Balancing Chamber Valve ‘dots’ (#31 - #38) are REMAINING WHITE i.e. Dialysate Flow is OFF see part d! NOTE: If the Balancing Chamber Valves are NOT remaining white allow debug screen 1’s FILACT = 0 then they will! Leaving Flow OFF till instructed see procedure number...
Page 461 TMP- 2.2.5 ACHIEVE NEGATIVE PRESSURE a) Figure right, connect the Four-Way Assembly (P/N 150034) to the dialyzer connectors. b) Place the Four-Way at dialyzer level! c) ENSURE a transducer protector IS NOT in the ‘to syringe’ tubing segment! d) If using a NEO-2 attach to the + (top, red) port. If using a 90XL attach to the module’s Gauge Port! e) DO NOT allow tension in the Four-Way tubing segments!
Page 462 IMPORTANT! -250 mmHg holds! A) Remove the clamps from both Four-Way tubing page 466 segments then; B) Leaving [Dialysate Flow] off, proceed to , procedure number TMP- 4.0.0. -250 could not be achieved or did NOT hold! Either the transducer protector is wet OR a Four- Way assembly tubing connection is leaking! See parts A and B below: Locate and repair the leak.
Page 463 TMP- 2.2.8 -250 mmHg HOLDING / ISOLATE DIALYSATE PRESSURE (PDIAL) a) ENSURING the external meter remains about -250 mmHg, call debug screen 0. b) Figure right, if (and ONLY if) Valve #25’s ‘dot’ is BLUE continue to part c. If NOT blue, return to (ABOVE) procedure number TMP- 2.0.17 page 456 PDial...
Page 464 TMP- 2.3.2 POSITIVE PRESSURE TEST a) CLAMP the external meter’s tubing segment! The external meter is invalid during the next test! PDial b) SLOWLY PUSH on the syringe plunger until screen 0’s = between positive (+)300 and (+)325! WARNING! DO NOT exceed +325 mmHg! PDial c) Clamp the Four-Way Assemblies ‘to syringe’...
Page 465 TMP- 2.3.4 PDIAL HOLDS / ISOLATE BALANCING CHAMBER VALVES a) A procedure, in different Section of the Guide, is performed next. NOTE this page and procedure number as you may prompted to return to here. page 527 b) BEFORE continuing to part c, proceed to , to perform SECTION 18A –...
Page 466 TMP- 3.0.0 ISOLATE DIALYSATE PRESSURE TRANSDUCER a) Figure below, trace the cable from distribution board position X9, “PDIAL” to the (blue) Dialysate Pressure Transducer to ENSURE it has not been reversed connected with another hydraulic component. b) Call debug screen 1. ENSURE FLWP (upper right column) = 255 constant i.e. Dialysate Flow is “OFF”. c) Remove the red dialyzer connector from the shunt door and place it at dialyzer level.
Page 467 TMP- 3.1.0 ACFS BETWEEN 3.5 AND 6.0 / ISOLATE DIALYSATE PRESSURE TRANSDUCER This procedure uses the CFS transducer (known good) to check the dialysate pressure transducer. a) Per the Figure right, unplug the Dialysate Pressure Transducer #9 from distribution board position “x9, PDIAL”.
Page 468 TMP- 3.4.0 ACFS NOT BETWEEN 3.5 AND 6.0 / ISOLATE PDIA From debug screen 10, based on PDIA (middle column). TWO (2) possible scenarios: IF (and ONLY if) PDIA = less than 4.0: See procedure number TMP- 3.5.0 (page 464). page 465 2) IF PDIA = more than 6.0: Proceed to , procedure number...
Page 469 TMP- 3.6.0 PDIA MORE THAN 6.0 / ISOLATE TRANSDUCER #9 / POSSIBLE OPEN a) A known good pressure sensor, from your spare parts, is required to isolate the dialysate pressure circuit from the sensor circuit. To ENSURE the sensor is known good, when it is plugged into distribution board position X9, “PDIAL”, on ANOTHER machine that is not exhibiting TMP problems, it will drive the machine’s debug screen 10 PDIA to between 3.5 and 6.0.
Page 470 TMP- 4.0.0 ISOLATE VALVE #43 a) Call debug screen 0. ENSURE all eight balancing chamber valves (#31 through #38) ‘dots’ are REMAINING white i.e. Dialysate Flow OFF! CAREFUL HERE! Figure 71 A (below), DOUBLE clamp the OUTPUT tubing at Valve #43’s NOTE: nozzle.
Page 471 TMP- 4.2.0 ISOLATE SECONDARY CIRCUIT a) Open the shunt door to close valve #24 and #25. This isolates the external dialysate lines (see Figure 71 C (below)). b) Attempt to achieve -250 mmHg then clamp the syringe tubing. Can you achieve -250 and HOLD it (+/- 15 mmHg per minute) now? page 468 -250 mmHg achieved and HOLDS! Proceed to...
Page 472 TMP- 4.4.0 -250 HOLDS / ISOLATE CHAMBER #69 IMPORTANT! Close the shunt door! b) CAREFUL HERE! Per Figure 72 A below, clamp the tubing attached to the rear side of Chamber #69 c) Can you achieve -250 mmHg and HOLD it (+/- 15 mmHg per minute) now (Yes or No)? -250 mmHg achieved and HOLDS! Remove ALL clamps! Chamber #69 OR its tubing OR valve #43’s O-ring is leaking.
Page 473 TMP- 4.5.0 ISOLATE ‘FROM BALANCING CHAMBER’ CIRCUIT a) Figure below, (CAREFUL HERE!) clamp VALVE #26’s INPUT tubing. b) Can you achieve -250 mmHg and HOLD it (+/- 15 mmHg per minute) now (Yes or No)? -250 mmHg achieved and HOLDS! There is a leak between the top balancing chamber ®...
Page 474 TMP- 6.0.0 CALIBRATE DIALYSATE PRESSURE NOTE: This is NOT a routine Dialysate Pressure calibration. Follow the procedures exactly to prevent making an error! a) To prevent wetting the meter’s transducer protector clamp the ‘to meter’ tubing segment! b) From the Home screen, set [Dialysate Flow] to 500 ml/min and press ‘CONFIRM’. c) Enter Service Mode →...
Page 475 TMP- 6.1.0 CREATE NEGATIVE PRESSURE The screen says “6. Pressurize until dialysate pressure reads -250 mmHg….”. PULL on the syringe plunger to achieve negative (-)250 +/- 5 mmHg on the external meter. Clamp the Four-Way’s syringe tubing segment to keep this pressure. ENSURING the external meter = -250 +/- 5 mmHg, is the screen’s [Dial Pressure Reference] window between 130 and 150? [Dial Pressure Reference] is between 130 and 150! See part E.
Page 476 TMP- 6.5.0 “OPERATOR ERROR” OCCURRED / TROUBLESHOOT DIALYSATE PRESSURE a) ENSURE the transducer protector, at the external meter, is not WET or consider replacing it! b) Return the Dialysate lines to the shunt and close the door. c) Turn the machine off and back on. d) Return to Dialysis Program (“Select Program”...
Page 477 TMP- 9.0.0 VALVE #28 LEAKING / ISOLATE ACTUATOR-TEST BOARD ® DiaSafe filter ‘Test Valve’ #28 is leaking: a) Figures right and below, trace the wires from Valve #28’s distribution board position (“V28, SAMPLE”) to ensure it connects to the correct valve. b) Unplug Valve #28 from distribution board position “V28, SAMPLE”.
Page 478: Section 10 - Pressure Tests Failing
SECTION 10 - PRESSURE TESTS FAILING The Pressure (Holding) Tests (PHT) checks the hydraulic system for leaks which could compromise patient fluid removal! These procedures troubleshoot ALL PHT failures: A) Per the Figure below, the Automated Tests consist of two discrete tests: 1) Alarms Tests AND 2) Pressure Holding Tests (Negative and Positive).
Page 479 PHT- 1.0.0 “GET NEG TMP” LASTING FOREVER / ISOLATE UF PUMP Call debug screen 1 to see ATMP (Figure right). It should increase to about -250 during “Get Neg TMP” and if it does “Neg Flow On” appears. If the “Get Neg TMP” banner is still up see part C. If NOT even if they pass allow the Tests to finish THEN, page 476...
Page 480 PHT- 1.5.0 INITIAL PHT CHECKS a) Call the Home screen. With the Level Detector’s P port vacant, (Figure right) Venous Pressure MUST = 0 mmHg! b) With [Dialysate Flow] set to 500 ml/min or more: • [Temperature] MUST be stable* between 35.0 and 39.0° C! •...
Page 481 PHT- 1.5.2 PRESSURE HOLDING TEST (PHT) THEORY DO NOT START THE TESTS TILL INSTRUCTED! B) Understanding Pressure Holding Test (PHT) theory (steps 1 – 5 below) aids troubleshooting. If already familiar with PHT theory see procedure number PHT- 2.0.0 (page 478) C) Call debug screen 1 to locate ATMP AND FILACT.
Page 482 PHT- 2.0.0 START PRESSURE TESTS a) RESET ALL alarms! b) At the bottom of the screen, select the [Test & Options] tab. TWO (2) possible scenarios: IF the [Pressure Test] button is BLUE: Select [Pressure Test] THEN press ‘CONFIRM’ then IMMEDIATELY continue to procedure number PHT- 2.0.1 (page 478).
Page 483 PHT- 2.0.3 FILACT ALWAYS = 0 TWO (2) possible scenarios: IF (and ONLY if) “Get Neg TMP” is NOT up! See procedure number PHT- 3.0.0 (page 480). 2) IF “Get Neg TMP” is still up! See parts a AND b below: a) Figure right, remove the Fluid Sample Connector from its port and hold it UP as shown! b) ENSURING “Get Neg TMP”...
Page 484: Fail Neg Stabilize
PHT- 3.0.0 “NEG FLOW ON” APPEARED Allow the tests to finish! Do BOTH Pressure Tests (Positive and Negative) pass? IMPORTANT! page 484 BOTH pass! Proceed to , procedure number PHT- 4.0.0. “Pressure Test Failed”! At the bottom of the screen, select the [Test & Options] tab. TWO (2) possible scenarios: IF “Fail: Remove Air”...
Page 485 h) When “Get Pos TMP” MOMENTARILY appears ATMP should drop to between +300 and +500. When “Pos Flow Off” first appears a twenty (20) second stabilization period begins. ATMP should settle between +180 and +350. NOTE: If FILACT EVER = 1 during “Pos Flow Off” NOTE this! NOTE: If ATMP does not remain between +180 and +350 “Fail Pos Stabilize”...
Page 486 page 409 IF FILACT EVER ‘1’ (even if only once):. Proceed to SECTION 8 – FILLING PROGRAM PROBLEMS page 440 IF FILACT ALWAYS ‘0’! Proceed to , SECTION 9 – TMP (PRESSURE) PROBLEMS. PHT- 3.1.3 PRESSURE TEST FAILS AND ATMP INCREASED TO MORE THAN -400 a) Remove the UF Sample Connector (Figure right) AND hold it so that you can observe UF PUMP output! simultaneously...
Page 487 PHT- 3.1.5 ALL OTHER SCENARIOS / PRESSURE TEST FAILED ® Has the DiaSafe filter been replaced in THIS Troubleshooting session? page 440 ® The DiaSafe filter has been replaced! Proceed to SECTION 9 – TMP (PRESSURE) PROBLEMS ® a) Replace the DiaSafe filter preferably with one from another machine that is passing Pressure Tests.
Page 488 PHT- 4.0.0 BOTH PRESSURE TESTS PASS ENSURE the Loading Pressure gauge (yellow connector) reads 0 psi before inserting it! SLAM the gauge into the red Acetate/Acid rinse port. *ELSE pressure will not be read correctly c) Loading Pressure is ‘OKAY’ if it cycles between a peak of somewhere between 23 and 25 psi AND NEVER lower than 11 psi at its lowest.
Page 489 PHT- 4.2.0 LOADING PRESSURE OKAY a) Turn the water off and allow a “No Water” alarm to occur. b) The Deaeration gauge is used next. ENSURE it reads 0 inHg BEFORE installing it! c) Allow one (1) minute for the deaeration motor to stop. d) Figure right, tee the gauge to the Inlet (clear tubing) of the Deaeration Pump.
Page 490 PHT- 4.4.0 REPEAT PRESSURE TESTS Call debug screen 1. While watching the screen banners , ATMP AND FILACT allow the tests to finish. Do BOTH (Negative and Positive) pass? IMPORTANT! BOTH pass! See procedure number PHT- 4.5.0 (page 486). No Pressure Test Failed! Return to (ABOVE) procedure number PHT- 3.1.2 (page 481) to analyze the failure(s).
Page 491 PHT- 4.6.0 UF INTEGRITY TEST PASSED a) Return the UF Pump’s tubing. b) Was the machine originally pulled for service because of reported “On Line PHT Failed”? On Line PHT Failed! See procedure number PHT- 4.7.0 (page 487). page 488 See procedure number PHT- 5.0.0 PHT- 4.7.0 ON LINE PHT FAILED / DIAGNOSTIC VALVE LEAK TESTS / VALVE #24 AND #25...
Page 492 PHT- 5.0.0 ALL PRESSURE TESTS PASSED BOTH Pressure Tests and the UF INTEGRITY TEST passed. See steps 1 through 6 below: 1) Check UF PUMP (1 ml/stroke volume) per the Preventative Maintenance Procedures booklet. 2) Verify accurate TMP by performing the Venous and Transmembrane Pressure checks in the Preventative Maintenance Procedures booklet! 3) Read step 3 completely BEFORE performing it! Check Flow Pressure Calibration per the Calibration It MUST be set to between 35 and 36 psi!
Page 493: Fail Get Neg Tmp
• NPHT: A count down timer that begins at 720 seconds (12 minutes). When it reaches 0 On Line PHT tests are performed. • PHTACT: = 1 when the On Line PHT is running; 0 when not running • PHT0: Leak test results of the first BC valve cycle, depending upon which valve cycle was active when the test began.
Page 494: Section 11 – Induced Air Leak Tests
SECTION 11 – INDUCED AIR LEAK TESTS These procedures use negative pressure to locate an air leak. Use a flashlight to look THROUGH tubing. If air is seen continue against the direction of flow (Figure below), to the next component until air bubbles are not seen.
Page 495 AIR- 1.0.1 CHECK FOR AN AIR LEAK AT FILTER #73 Figure below, for two (2) minutes, watch through the OUTPUT (to machine) side of Dialysate Filter #73. This is Location #1 (L1). Air bubbles seen? Air seen at L1! See procedure number AIR- 1.0.2 (page 492).
Page 496 AIR- 1.0.2 AIR SEEN AT L1 (OUTPUT FILTER #73) Referring to Table 9 below, ensuring TMP is between 300 and 340 mmHg: Table 8 – Air Checks (1) Location Location Description If air is seen go to: If air is NOT seen the leak is from: Post Sample Port Dialysate Filter #73 (Figure 75, page 491)
Page 497 AIR- 1.0.3 AIR AT L1 / CHECK FOR AIR INPUT CHAMBER #69 Figure below, ensuring TMP is between 300 and 360 mmHg, for two (2) minutes, watch through the INPUT rear side tubing at the of Chamber #69 (Location #10 (L10)). Air bubbles seen? Air seen at L10! See procedure number AIR-1.0.4 (page 494).
Page 498 AIR- 1.0.4 AIR SEEN AT L10 / TRACE UPSTREAM FROM CHAMBER #69 Table 10 below, ensuring TMP is between 300 and 360 mmHg, for two (2) minutes, watch for air starting at Location #11 (L11). Table 9 – Air Checks (2) Location Description If air is seen go to:...
Page 499 AIR- 1.0.5 AIR SEEN FROM PRE-DIALYZER COND CELL #7 Figure below ensuring TMP is between 300 and 360 mmHg, watch through the outlet (clear) tubing at BOTH balancing chamber valves #31 AND #33. Is air coming from 1) ONE OR 2) BOTH valves? IF ONLY ONE: TWO (2) possibilities: 1) Bad O-ring connection between the valve and the balancing chamber;...
Page 500: Section 12 – Induced Positive Pressure Tests
SECTION 12 – INDUCED POSITIVE PRESSURE TESTS During these procedures hydraulic systems are checked for external leaks. USE A FLASHLIGHT! BE THOROUGH! FEEL AROUND! Small leaks may take several minutes to become obvious and cause BIG problems! Place the machine into RINSE! This creates positive pressure in the secondary circuit! 2.
Page 501 4. Per the Figure below, check the DiaSafe ® filter’s headers. If no leaks continue to step #5. ® 5. Look for small leaks, from the tubing and tubing fittings, INSIDE the DiaSafe housing! If no leaks continue to step #6. ®...
Page 502: Section 13 - Deaeration Problems
SECTION 13 - DEAERATION PROBLEMS DAIR- 1.0.0 ISOLATE ACTUATOR-TEST BOARD CONTROL a) Enter Service Mode → Calibrate Hydraulics → Deaeration Pressure but DO NOT press ‘CONFIRM’ yet! b) Per the Figure below, ENSURE the [PUMP RATE] box = 0! Figure 83 – Calibrate Deaeration Pressure Screen DEAERATION MOTOR’S c) Figure right, is the shaft rotating (Yes or No)?
Page 503 Loading Pressure less than 16 psi continued: c) Return to Dialysis Program (“Select Program” →‘Dialysis’ → ‘CONFIRM’)! page 116 d) Proceed to , procedure number 15.0.0. DAIR- 2.0.0 LOADING PRESSURE 16 PSI OR MORE a) This is NOT a routine calibration! Follow the instructions to avoid error! NOTES: 1) Loading and Deaeration pressure are calibrated until BOTH are in range.
Page 504 Figure 84 – Hydraulics Rear View DAIR- 4.0.0 ISOLATE VALVE #39 If Valve #39 is sticking open target Deaeration Pressure CANNOT be achieved: a) Per the Figures above AND right locate Valve #39 on the BOTTOM of the hydrochamber. b) Figure right, clamp Valve #39’s clear tubing at the location seen.
Page 505 DAIR- 4.0.1 RECHECK VALVE #39 IMPORTANT! Remove the clamp from Valve #39. Do pressures remain at target? Target pressures remain! A) Press CONFIRM to save the calibration! B) Turn the machine off. C) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → CONFIRM).
Page 506 DAIR- 5.0.0 ISOLATE THE DEAERATION PUMP HEAD IMPORTANT ! Remove the clamp from Valve #39. b) Press ‘CONFIRM’ twice to return to the “Calibrate Hydraulics” menu. DO NOT c) Select Deaeration Pressure but press any keys. The [PUMP RATE] box MUST = 0 before continuing to part d. d) Referring Figure 84 (page 500) AND the Figure right,...
Page 507: Section 14 - Uf (Ultrafiltration) Pump Problems
SECTION 14 - UF (ULTRAFILTRATION) PUMP PROBLEMS UF- 1.0.0 ISOLATE UF CIRCUIT The UF Pump ‘dot’ toggles between white and blue when the UF Pump strokes. It THREE (3) checks! Answer for all three below Check #3: should NOT be constantly blue! Check #1: Does the “UF Pump Alarm”...
Page 508 UF- 1.4.0 ALL FIVE CHECKS OKAY / ISOLATE UF HYDRAULICS a) If the Automated Tests are running (screen reads “Test:.…) turn the machine OFF! RINSE! b) Return the concentrate connectors to their rinse ports and place the machine into ENSURE the external flow indicator’s ‘bob’...
Page 509 Pump calibrates okay! See procedure number UF- 2.1.0 (page 505). No Pump does NOT calibrate! See procedure number UF- 4.0.0 (page 507). Figure 86 – UF Pump Adjustment UF- 2.1.0 UF PUMP CALIBRATES OKAY / ISOLATE UF CIRCUIT IN DIALYSIS a) Plug into concentrate and return to Dialysis Program (“Select Program”...
Page 510 page 510 BOTH Pressure Tests pass! Proceed to , procedure number 7.0.0. page 440 Both tests DO NOT pass! Proceed to SECTION 9- TMP (PRESSURE) PROBLEMS to perform related pressure/leak checks. UF- 3.0.0 INADEQUATE UF PUMP OUTPUT a) Per the Figure right, trace the UF Pump’s cable to distribution board position “P22, UF-P”.
Page 511 UF- 4.0.0 ISOLATE UF PUMP (#22) MECHANICS a) Turn the machine OFF and disassemble the UF Pump. b) Per the Figure right, TWO checks: Check #1: ENSURE a STRONG spring is under the OUTPUT (colored) nozzle AND its seal is pointing INTO the pump;...
Page 512 UF- 5.0.0 CHECK UF PUMP FOR ‘OPEN CIRCUIT’ a) Turn the machine OFF! b) Per the Figure right, ENSURE the UF Pump is plugged PROPERLY into distribution board position “P22, UF-P”! c) Trace the UF Pump’s wiring to distribution board position “P22, UF-P”...
Page 513 UF- 6.0.0 CHECK UF PUMP FUNCTION a) Place the machine into RINSE and ENSURE the external flow indicator’s ‘bob’ is moving up and down. b) Ensuring NO LEAKS, per the Figure right, remove the Ultrafiltrate Output Sample Connector from its port to observe UF Pump output.
Page 514 Procedure UF- 6.1.0 continued (Does the UF Pump calibrate to between 23.9 and 24.1 ml?): page 505 Pump calibrates! Proceed to , procedure number 2.1.0. Replace the UF Pump with a known good and repeat (ABOVE) procedure page 509 UF- 6.0.0 UF- 7.0.0 BOTH PRESSURE TESTS PASS / UF PUMP INTEGRITY TEST This IMPORTANT procedure checks the UF Pump’s ‘strong’...
Page 515: Section 15 - Blood Leak Problems
SECTION 15 - BLOOD LEAK PROBLEMS The Blood Leak Detector #8 detects blood as little as 0.35 ml / Liter! If a patient is on the machine, before ® considering service, check for a ‘real’ blood leak using a Hemastix strip or equivalent per clinic procedure.
Page 516 BL- 1.0.5 BLOOD LEAK ALARM? Is the Blood Leak alarm still present (Yes or No)? Press and release the ‘RESET’ key up to three (3) times in twenty (20) second intervals. TWO (2) possible scenarios: IF the Blood Leak alarm clears: See procedure number BL- 1.0.6 (page 512).
Page 517 BL- 2.0.0 BLOOD LEAK ALARM PRESENT (CHECK FOR AIR) IMPORTANT! using a flashlight Air in dialysate cause false blood leak alarms. Per the Figure below, watch for air bubbles through the Blood Leak Sensor’s TO AND FROM tubing for one (1) minute each? Air seen! See procedure number BL- 3.0.0 (page 514).
Page 518 BL- 3.0.0 AIR SEEN Per the Figure right, are air bubbles MOVING into the machine through the clear acid and / or bicarb Inlet Tubing? Air seen! A) If using a jugs ensure they are full AND the wands reach the bottom of the jugs; B) Check the acid and / or bicarb connector’s O-rings and plug;...
Page 519 BL- 3.0.5 AFTER INDUCED POSITIVE PRESSURE TESTS . IMPORTANT! a) Other procedures, in different Sections of the Guide, are performed next NOTE this page and procedure number (BL- 3.0.5) because you may prompted to return to here page 496 b) Before continuing to part c, proceed to , to perform SECTION 12 - INDUCED POSITIVE PRESSURE TESTS...
Page 520 BL- 4.0.0 NO AIR SEEN / ISOLATE BLOOD LEAK DETECTOR #8 a) If automated tests are running (screen reads “Test: …) allow them to finish before continuing! b) Call debug screen 4 to see LEAK and DIMN. FIVE (5) possible scenarios, 1) or 2) or 3) or 4) or 5) below: IF LEAK is between 4.5 and 5.2 AND DIMN between 4.0 and 6.0: This is normal! Acid clean then Bleach Disinfect.
Page 521 BL- 4.4.4 ISOLATE BLOOD LEAK DETECTOR IMPORTANT! To prevent damage turn the machine off! Figure right , at the distribution board, between and below positions #7 and #9, unplug the Blood Leak ribbon Cable! Using a flashlight, check the vacant connector. If ‘white’...
Page 522 BL- 5.0.0 CHECK BLOOD LEAK CAUTION! DC voltages are about to be measured* at pins that are VERY close to others and touching them together with a standard meter lead WILL DAMAGE the Sensor board. As instructed below make your RED meter lead a PROTECTED lead! * NOTE: If you do NOT wish to check voltages see procedure number BL- 6.0.0 (page 520) otherwise DO NOT CONTINUE UNTIL YOU HAVE A...
Page 523 E) Per the Figure below AND as directed in Table 11 below, measure from the solder (back) side of the Sensor Board’s X2 connector starting at pin #2: Figure 90 – Electronic Card Cage (Sensor Board) Table 10 – Sensor Board ‘X2’ DC Voltage Checks (Refer also to Figure X2 Pin X2 Pin Location...
Page 524 BL- 6.0.0 BLOOD LEAK ALARM WILL RESET? Press and release the ‘RESET’ key up to three (3) times in twenty (20) second intervals. TWO (2) possible scenarios below: IF the Blood Leak alarm CAN be cleared: The most likely cause of a false blood leak alarm is “air in dialysate”...
Page 525: Section 16 - Checking The Actuator Board Cable
SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE The 50-conductor actuator cable runs between the distribution board and the Actuator-Test Board. Check ONLY the NOTED above component connection(s)! a) Per the Figure below, this procedure checks the cable by measuring conductor resistance (Ω) from one end (distribution board) to the other (Actuator-Test Board).
Page 526 Figure 92 – Electronic Card Cage (Actuator-Test Board) Place the second meter on the matching numbered PIN on the solder (rear) side of the P2 connector. Ω Some components require checking multiple conductors. 2.0 or less for ALL required conductors? The cable is good! Return it the distribution board.
Page 527 Table 12 – VALVES Cable Plug / Actuator-Test Board P2 Pin Locations VALVE# PLUG/PIN # PLUG / PIN LOCATION 41 (27) Top row, 10 pins from the screen Bottom row, 11 pins from the screen Top row, 11 pins from the screen Bottom row, 10 pins from the screen Top row, 9 pins from the screen Bottom row, 8 pins from the screen...
Page 528: Section 17 - Checking The Sensor Board Cable
SECTION 17 - CHECKING THE SENSOR BOARD CABLE The 34-conductor Sensor Board cable runs between the distribution board and the Sensor Board. Check ONLY the NOTED component connection(s)! a) Per the Figure (below), this procedure checks the cable by measuring conductor resistance (Ω) from one end (distribution board) to the other (Sensor Board).
Page 529 Per the Figure below, the cable terminates at the Sensor Board’s X2 connector. The solder (rear) side PINS are in two rows. Odd numbered in the bottom, even numbered in the top. NOTING the reference to the ‘Rear of Machine’ locate the appropriate PIN number per Table 14 (page 525).
Page 530 Table 14 continued: BICARB EOS Bottom row, 6 pins from the front of machine AIR SENSOR Bottom row, 3 pins from the rear of machine BLOOD LEAK TEST (1 of 5) Top row, first pin from the rear of machine BLOOD LEAK CAL DIMNESS (2 of 5) Bottom row, 2 pins from the rear of machine BLOOD LEAK CAL BL (3 of 5)
Page 531: Section 18A - Diagnostic Valve Leak Tests
SECTION 18A - DIAGNOSTIC VALVE LEAK TESTS Perform these tests ONLY as directed previously. Arbitrary performance may yield erroneous results! ONLY the Balancing Chamber Valves, #31 through #38, will be tested! Do NOT run “auto” which tests all valves! A. AUTOMATED LEAK TEST PREPARATION a) Return both dialyzer connectors to the shunt and close the door! IMPORTANT! Return the concentrate connectors to the rinse ports and go to RINSE PROGRAM!!
Page 532 Table 14 – Leak Test Scenarios Observed Scenario: Your Response: If ALL valves PASS Return to the NOTED procedure that brought you here If ONLY one valve fails See procedure number AUTOTEST- 7.0.0 (page 532) If ONLY Valves #31 and #35 fail See procedure number AUTOTEST- 7.0.0 (page 532)
Page 533 Strong pulses! See procedure number AUTOTEST- 3.0.0 (page 529). Very weak or no pulses! See parts a THROUGH c below: a) Turn the machine OFF. b) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! page 503 c) Proceed to...
Page 534 AUTOTEST- 3.1.0 CREATE NEGATIVE PRESSURE a) The screen says “6. Pressurize until dialysate pressure reads -250 mmHg…”. b) PULL on the syringe plunger. Can you achieve between -248 and -252 mmHg on the external meter? Between -248 and -252 on the meter. See procedure number AUTOTEST- 3.2.0 (page 530).
Page 535 AUTOTEST- 5.0.0 EXTERNAL METER PRESSURE IS GOOD / CONTINUE CALIBRATION a) ENSURING the meter is still between -248 and -252 mmHg, press ‘CONFIRM’. b) Figure right, TWO (2) possible scenarios based on if an “Operator Error” banner occurs: IF (and ONLY if) “Operator Error” occurs: See procedure number AUTOTEST- 6.0.0 (page 531).
Page 536 AUTOTEST- 7.0.0 ISOLATE ACTUATOR-TEST BOARD / VALVES(S) TWO (2) possibilities: 1) Bad Actuator-Test Board OR; 2) Bad valve(s) i.e. mechanically ‘stuck open’. a) Turn the machine off and swap in a known good Actuator-Test Board (see Figure 4A, page 9). b) Repeat the Diagnostic Valve Leak Test on the leaking valve(s).
Page 537: Section 18B - Manual Balancing Chamber Valve Leak Tests
SECTION 18B - MANUAL BALANCING CHAMBER VALVE LEAK TESTS A. These tests should be performed if a leaking balancing chamber valve is strongly suspected and Diagnostic Valve leak test did not identify it or to validate an Diagnostic Valve leak failure. B.
Page 538 Figure 96 – Balancing Chamber Valves BOTTOM SIDE LEAK PROCEDURE (Valves #35 through #38) Theory: The following procedures open the top side valves, one at a time, using 24 volts from valve 30’s distribution board connector. Because the deaeration pump and Flow Pump are running the bottom balancing chamber valves are pressurized.
Page 539: Section 19 - Testing For Leaking Balancing Chamber Diaphragm
SECTION 19 - TESTING FOR LEAKING BALANCING CHAMBER DIAPHRAGM A torn balancing chamber diaphragm will cause Flow Errors and/or Temperature and/or Conductivity problems and/or OLC problems BC LEAK- 1.0.0 PREPARATION a) Call debug screen 5. If the debug screens do not appear press the ‘Escape’ key then call screen 5.
Page 540 Between 35 and 36 psi! See procedure number BC LEAK- 2.0.0 (page 536). Is NOT between 35 and 36 psi! ENSURING the machine was in RINSE AND no leaks, TWO (2) possible scenarios: page IF (and ONLY if) pressure is too low: DO NOT calibrate instead proceed to 9.0.23 , procedure number see 2) IF pressure is too high! Perform parts a AND b below:...
Page 541 e) Remove the blue dialyzer connector from the shunt door and drop it into the empty bucket. DO NOT Place the red dialyzer connector into the bucket of acid concentrate but close the shunt door! Rinse must NOT interrupt! The blue connector MUST be delivering flow into its bucket! g) WITHOUT LOOKING AWAY, watch FPRE for up to three (3) minutes.
Page 542 BC LEAK- 3.0.0 DIAPHRAM LEAK TEST Two (2) buckets are required, one empty and the other filled with one gallon of ACID CONCENTRATE. Place both buckets on the floor and read the procedures before continuing: a) Place the machine into RINSE. If the external flow indicator’s ‘bob’ is not moving up and down these tests are invalid! b) Call debug screen 5.
Page 543 FPOS more than 7000! See procedure number BC LEAK- 3.2.0 (page 539). FPOS less than 7000. See (ABOVE) procedure number BC LEAK- 1.1.0 (page 535) to check the Flow Pump. BC LEAK- 3.2.0 PERFORM DIAPHRAGM LEAK TEST WITHOUT LOOKING AWAY, NOW watch FPRE for up to three (3) minutes. Does it EVER, even if only once, increase or fluctuate to MORE THAN four thousand (4000)? FPRE fluctuates to 4000 or more! A torn balancing chamber diaphragm is indicated.
Page 544: Section 20 – Troubleshooting Overflow From The Vent Tubing
SECTION 20 – TROUBLESHOOTING OVERFLOW FROM THE VENT TUBING IMPORTANT! Turn the machine OFF! B) ENSURE the Vent Tubing is NOT clamped! C) Plug BOTH the ACID AND BICARB connectors into their rinse ports. TURN THE MACHINE ON! E) Figures above, does MASSIVE OVERFLOW, more than 600 ml per minute, occur (Yes or No)? page 548 Massive overflow! Turn the machine OFF then proceed to , procedure number...
Page 545 If Flow Error EVER = 1, even just once, a masked Flow Error is occurring! WITHOUT LOOKING AWAY watch it for three (3) minutes or until it EVER = 1. TWO (2) possible scenarios: IF Flow Error EVER = 1, even just once! DO NOT troubleshoot overflow instead troubleshoot the flow error! Refer to the Table of Contents for whatever program the machine is in.
Page 546 OVER- 2.0.0 ISOLATE POTENTIAL FLOW RECIRC ERROR Is the machine currently in Heat Disinfect? In Heat Disinfect! See procedure number OVER- 2.0.1 (page 542): No NOT in Heat Disinfect! See procedure number OVER- 2.0.2 (page 542). OVER- 2.0.1 IN HEAT DISINFECT a) Press ‘Escape’...
Page 547 OVER- 3.0.0 ISOLATE INLET WATER PRESSURE (Slow Overflow) IMPORTANT! Turn the water OFF! b) This procedure uses a psi pressure gauge. ENSURE it reads 0 psi before installing it. c) Per the Figure below, install the gauge at Inlet Pressure Regulator #61. Figure 100 –...
Page 548 OVER- 3.0.1 ISOLATE INLET PRESSURE REGULATOR (Slow Overflow) This procedure checks the Regulator #61’s ability to maintain pressure over time. IMPORTANT! Leaving the water on, turn the machine OFF! b) NOTE gauge pressure for use later. It MUST NOT be more than 22 psi! c) Allow up to fifteen (15) minutes! Does pressure increase more than 2 psi above what was noted in part b (Yes or No)? Pressure increased more than 2 psi! TWO (2) possibilities: 1) Incoming water pressure...
Page 549 IMPORTANT! Allow fifteen (15) seconds then watch the tubing opening for up to five (5) minutes. Is there flow or dripping (possibly slowly) from it? Flow or dripping seen! See procedure number OVER- 4.0.1 (page 545). page 546 No No flow OR dripping seen! See procedure number OVER- 5.0.0 OVER- 4.0.1 FLOW OR DRIPPING a) Figure right, unplug Valve #41 from...
Page 550 OVER- 5.0.0 ISOLATE VALVE #39 (Slow Overflow) Valve #39 opens in Cleaning Programs and Deaeration pressure should be NOWHERE NEAR -24 inHg! This is especially important for Heat Disinfect to prevent boiling which would cause overflow! IMPORTANT! Re-attach Valve #41’s the ‘air gap tower’ tubing. b) The deaeration gauge is used next.
Page 551 OVER- 5.2.0 HEAT DAMAGE CHECKS IMPORTANT! Turn the machine OFF to prevent electrocution! b) Per the Figure right, remove the heater and check its opening into the top of the hydrochamber for damage i.e. melting. If (and ONLY if) damage is LOCATED replace the hydrochamber.
Page 552 OVER- 6.0.0 MASSIVE OVERFLOW (More than 600 ml per minute) a) With the machine OFF, perform INITIAL CHECKS (page 6) and return here if a problem is NOT located. b) Figure right, unplug the Deaeration Pump #20 from distribution board position “P20, Degas-P”. c) If (and ONLY if) an “Actuator Board No Echo”...
Page 553 Figure below, if the deaeration pump head is oriented properly its ‘ID Decal’ is either on top or front. If on the front it MUST be right side up. If the head is oriented correctly see (ABOVE) procedure number OVER- 5.2.0 (page 547): Deaeration motor is rotating clockwise! NOTE ONLY the DEAERATION MOTOR will page 130...
Page 554 OVER- 7.0.0 ISOLATE VALVE #41 Figure right, unplug valve #41 from distribution board position #27 (“V27, “IN-V”). TWO (2) possible scenarios: IF massive overflow STOPS: See procedure number OVER- 7.0.1 (page 550). 2) IF massive overflow does NOT stop: ENSURING Valve #41 was unplugged, perform parts AND b below: a) Turn the water OFF! Referring...
Page 555 OVER- 8.0.0 ISOLATE INLET WATER PRESSURE High inlet water pressure can damage a Heat Exchange! IMPORTANT! Turn the water OFF! This procedure uses a psi pressure gauge. ENSURE it reads 0 psi before installing it! Per the Figure below, install the gauge at Inlet Pressure Regulator #61. Figure 104 –...
Page 556 OVER- 8.2.0 MAXIMUM PRESSURE IS BETWEEN 18 AND 20 PSI / ISOLATE PRESSURE REGULATOR This procedure checks Pressure Regulator #61’s ability to maintain pressure over time. IMPORTANT! Turn the machine OFF! b) Leave the water ON! c) NOTE gauge pressure then allow fifteen (15) minutes before continuing! d) Does pressure increase more than 2 psi over what was noted in part c? Pressure increased more than 2 psi! TWO (2) possibilities: 1) Incoming water pressure is more than 105 psi OR;...
Page 557: Section 21 – Hydraulic Leaks
SECTION 21 – HYDRAULIC LEAKS NOTE: These procedures do NOT troubleshoot Vent Tubing overflow! IMPORTANT! Turn the machine OFF! B) ENSURE the ‘Incoming Water’ and ‘To Drain’ tubing (Figure right) are not reversed connected! C) ENSURE the ‘To Drain’ tubing is not kinked AND, if using a drain ’Quick Connector’, it is attached PROPERLY to the station drain! D) Reattach any ‘blown off’...
Page 558 LEAKING- 1.0.0 UF TUBING BLOWING OFF a) ENSURE the tubing to and from UF Check Valve #63 is NOT restricted! b) In the next procedure, but NOT YET, the machine will be placed into RINSE HOWEVER, if a leak occurs DO NOT turn the machine off but instead, “Interrupt”...
Page 559 LEAKING- 1.1.0 ISOLATE FOR HIGH LOADING PRESSURE ENSURING the water is on, this procedure checks if VERY Loading Pressure may be causing a leak! SLAM a) ENSURING the Loading Pressure gauge (yellow connector) reads 0 psi before inserting it, * it into the red Acetate/Acid rinse port.
Page 560 IF from RINSE PORT tubing: Secure tubing connections with tie wraps. Figure 105 B (page 557), IF from Regulator #61 OR Valve #41 (not including the Heat Exchanger): A) Ensure incoming water pressure is not exceeding 100 psi; B) Check Inlet Water Pressure Regulator per the CALIBRATION PROCEDURES booklet;...
Page 561 Figure 105 B – Hydraulics Top View Figure 105 C – Balancing Chamber Valves 2008K/K2 Troubleshooting Guide Page 557 P/N 507298 Rev. H...
Page 562 LEAKING- 2.0.0 SECONDARY SIDE LEAK / DIALYSATE SAMPLING OPTION? a) From the Service Mode menu, select the ‘Options’ button. b) Select the ‘Hardware Options’ button. c) Does the “Yes” box at Dialysate Sampling (Figure right) have a blue ‘X’ in it? Dialysate Sampling = “Yes”! See procedure number LEAKING- 2.1.0 (page 558).
Page 563 LEAKING- 3.0.0 LEAK IN CLEANING PROGRAM / ISOLATE SPECIAL VALVE ERROR a) Press ’CONFIRM’ to return to the Main Service Mode menu. b) Select the screen’s ‘Options’ button. Valve c) Call debug screen 0. IGNORING the top window (Flow Error) look at Error (2 window down) .
Page 564 LEAKING- 3.2.0 CONTINUE TO ISOLATE LEAK With the machine OFF! FIVE (5) possible scenarios 1) or 2) or 3) or 4) or 5) below: ® Figure right, if (and ONLY if) the DiaSafe filter was leaking from its blue headers: A) ENSURE the packing tabs are not present; B) Replace the filter! Per the Figure below, IF (and ONLY if) Flow Relief Valve #78 was leaking: See procedure number LEAKING- 3.3.0...
Page 565 LEAKING- 3.3.0 LEAK BETWEEN FLOW PUMP AND BALANCING CHAMBER VALVES #36 or #38 a) Secure the tubing clamps at Valves #36* and #38*. * To LOCATE these Valves refer to the Figure previous page! b) A psi gauge is used next. ENSURE it reads 0 psi before installing it! c) Per the Figure below, install the gauge at the Flow Pump’s OUTPUT (white) tubing.
Page 566 LEAKING- 4.0.0 ISOLATE DRAIN FLOW (VALVE #30) IMPORTANT! A 60 ml luer lock syringe, FILLED with water is REQUIRED here! a) Without causing tension on cables and tubing, move the hydraulics as far away from the cabinet as possible! b) ENSURE the distribution board cover is on! c) Per Figure 107 below, check through Valve #30’s INPUT and OUTPUT tubing for restrictions.
Page 567 LEAKING- 4.0.1 CANNOT PUSH ALL 60 ML THROUGH THE SAMPLE PORT a) Remove the syringe from the Sample Port and fill it with water. b) Per the Figure right, remove Valve #30’s INPUT tubing! c) Attach a tubing segment to the syringe that will fit snug onto the syringe AND Valve #30’s INPUT nozzle.
Page 568 LEAKING- 5.0.0 ‘TO DRAIN’ PATH OKAY / ISOLATE VALVE #24 a) A 1000 ml graduated cylinder is required! b) ENSURE the external flow indicator’s ‘bob’ is at the bottom of the sight tube! c) Flow from the shunt door and the flow through the indicator will be checked. Parts d through f MUST be performed QUICKLY so read them BEFORE performing! RINSE d) Place the machine into...
Page 569 ® IF (and ONLY if), during this procedure, tubing ‘blew off’ the DiaSafe filter or the top side Balancing Chamber Valves (see Figure below): A) Turn the machine off; B) Reattach and tie wrap all tubing; c) Repeat (ABOVE) procedure number LEAKING- 5.1.0 (page 564).
Page 570 LEAKING- 5.3.0 VALVE #26 OKAY / ISOLATE VALVE #29 IMPORTANT! Reattach Valve #26’ its tubing! b) Figure right, screw the 60 ml syringe, filled with water, onto the Fluid Sample Port. c) This procedure is time sensitive! Read parts d through g BEFORE performing them!! IMPORTANT! Return to RINSE Program! e) Call debug screen 0.
Page 571 LEAKING- 5.5.0 VALVE #29 IS OKAY / ISOLATE FOR A ‘PARTIAL’RESTRICTION IMPORTANT! Turn the machine OFF then back on. RINSE b) If the screen’s Heat Disinfect button is BLUE go to Heat Disinfect. If gray go to c) Allow ONE (1) FULL minute for debug screens to update! d) Call debug screen 10 (Figure right) to locate PDIA e) WITHOUT LOOKING AWAY, watch...
Page 572 LEAKING- 6.0.0 LOADING PRESSURE IS HIGH / ISOLATE VALVE#65 FOR DEBRIS With the machine OFF , referring to Figure 105 A (page 556), turn Loading Pressure Valve’s #65’s adjustment nut COUNTERCLOCKWISE to the point that it is almost all the way out i.e. maximum number of threads showing! b) Reconnect and tie wrap ALL ‘blown off’...
Page 573 LEAKING- 7.0.0 “SAMPLE BAG CONNECTED?” / ISOLATE DIALYSATE SAMPLING OPTION A leak was occurring in a Cleaning Program (Rinse, Heat Disinfect, etc.) and you saw the “Sample Bag Connected?” banner on the screen. a) Turn the machine on. When “Press CONFIRM For Service Mode” appears press ‘CONFIRM’. The screen says “Machine In Service Mode”.
Page 574: Section 22 - "Wd: Fail Long Pulse" Or "Wd: Fail Short Pulse
SECTION 22 - “WD: FAIL LONG PULSE” OR “WD: FAIL SHORT PULSE” Turn the machine OFF for two (2) seconds, then back on. TWO (2) possible scenarios 1) or 2) below: IF “WD: Fail Long Pulse” OR “WD: Fail Short Pulse” does NOT reoccur: Turn the machine off and on ten (10) times allowing twenty (20) seconds in between as the problem may be intermittent! If “WD”...
Page 575 WD- 1.0.0 ISOLATE 24V- B POWER SUPPLY a) Per the Figure below, locate the motherboard’s nine (9) pin TEST Connector. b) Spread the card cage side panels open then gently drop the front panel down to access the motherboard’s nine (9) pin TEST Connector. pin 8 c) Measure at (second pin from right) as seen in the Figure above.
Page 576 WD- 1.0.1 ISOLATE CONTROL SIGNAL a) Per the Figure below, locate IC2 at the top edge of the Power Logic Board. Figure 108 – Power Logic Board / R10 b) Under IC2 are three resistors, top to bottom R8, R9 and c) Measure at the RIGHT side of , at the location shown in Figure...
Page 577 b) Per the Figure below, open the power supply. TWO (2) checks: CHECK #1: Inspect the entire length of the 24V Power Harness. If burning or damage is located this may be the problem! CHECK #2: Inspect the surface of and all wires attached to the Power Control Board. If burning or damage is located this may be the problem! Figure 109 –...
Page 578 WD- 1.0.4 CHECK FOR POWER CONTROL BOARD ‘SHORT’ Turn the machine ON. TWO (2) possible scenarios: IF (and ONLY if) “WD: Fail Long Pulse” OR “WD: Fail Short Pulse” does NOT reoccur: Turn the machine off and on several times, allowing 40 seconds in between, If “WD: Fail Long Pulse” OR “WD: Fail Short Pulse”...
Page 579 WD- 1.0.6 TROUBLESHOOT POWER SUPPLY / CARD CAGE Referring to the Component List below, perform parts a and b: a) Turn the machine OFF and swap in each component, one at a time, starting with the 24V Harness. b) Turn the machine on. If (and ONLY if) the WD: Fail Long Pulse” OR “WD: Fail Short Pulse” reoccurs AND there is more than 3.0 volts at the Functional Board’s P4 connector pin 1, continue through the list until the WD alarm no longer occurs.
Page 580: Section 23 – Heater Relay Test Fail
SECTION 23 – HEATER RELAY TEST FAIL This is NOT a Heater or Triac problem! From “Select Program”, for eight (8) seconds after selecting ‘Dialysis’ then ‘CONFIRM, the Function Board turns the heater circuit off using Heater Relay (RL3) located on the Power Control board. If the Function Board receives a signal that heater current is present during this period it issues a “HEATER RELAY TEST FAIL”.
Page 581 HEATER RELAY- 1.0.1 TEST YOUR VOLT METER a) IMPORTANT! Set your CALIBRATED volt meter to AC voltage (~ V, V b) Figure right, measure at the wall plug. The meter MUST read more than 100 volts AC! c) See procedure number HEATER RELAY- 1.0.2 (page 577).
Page 582 “HEATER RELAY TEST FAIL” reoccurs! See procedure number HEATER RELAY- 1.0.3 (page 578). No “HEATER RELAY TEST FAIL” did NOT reoccur! See procedure number page 583 HEATER RELAY- 3.0.0 HEATER RELAY- 1.0.3 ISOLATE HEATER OFF LOGIC a) Turn the machine OFF! IMPORTANT! Turn the HEATER Switch off! c) Turn the machine on AND return to Dialysis Program (“Select Program”...
Page 583 HEATER RELAY- 2.0.0 ISOLATE DIODE 17 (D17) A bad diode 17 (D17) destroys Power Logic Boards. See parts a THROUGH h below: Caution! a) Turn the power off and unplug the machine! Electrocution hazard if not unplugged! b) Per Figure 111 below, open the power supply to see the component side of the Power Control board.
Page 584 Diode 17 is BAD continued: b) After BOTH boards are replaced, slide the power supply in but do not screw it in yet! c) Plug the machine in. d) Turn the machine on and return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’).
Page 585 HEATER RELAY- 2.0.1 DIODE 17 IS GOOD a) Reconnect the Power Control board’s cables. b) Slide the power supply back into the cabinet but DO NOT mount it yet! c) Turn the machine off and swap in a known good Power Logic Board. To LOCATE the Power Logic board refer to Figure 4A (page 9).
Page 586 HEATER RELAY- 2.0.2 HEATER RELAY TEST FAIL REOCCURED / RETEST HEATER CONTROL a) Ensuring the machine is off, two (2) people are required for this procedure! IMPORTANT! Set your volt meter to AC voltage (~ V, V DO NOT c) Turn the machine on but, when “Select Program” appears, push “Dialysis’...
Page 587 HEATER RELAY- 3.0.0 “HEATER RELAY TEST FAIL” INTERMITTENT Turn the machine off for two (2) seconds then back on. Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’). If (and ONLY if) “HEATER RELAY TEST FAIL” reoccurs see procedure number HEATER RELAY- 3.1.0 (page 583).
Page 588: Section 24 – "Diasafe Test Failed
SECTION 24 – “DIASAFE TEST FAILED” ® A) If a DiaSafe test is running allow it to finish BEFORE CONTINUING to part B. It is NORMAL for Flow ® Error = 1 WHILE a DiaSafe test is running! B) Using a flashlight, ENSURE no air bubbles flowing into the machine through the Acid and Bicarbonate inlet tubing.
Page 589 DIASAFE- 3.0.0 PRESSURE TESTS PASS A) Figure right, ENSURE Valve #28 is plugged PROPERLY into distribution board position, “V28”! Figure below , inside the hydraulics and the ® rear side of the Diasafe housing, ENSURE ‘TUBE A’ goes to VALVE #24 AND ‘TUBE B’ goes to VALVE #26! ®...
Page 590 Reset ALL alarms! F) Select the screen’s lower [Test & Options] tab. G) Select the ‘Diasafe Test’ button. H) Press ‘CONFIRM’ to start the test then allow it to finish! TWO (2) possible scenarios: IF (and ONLY if) “Diasafe Test Passed”: Repeat the test once more as the failure may be intermittent! If it passes again DO NOT continue! 2) IF “Diasafe Test Failed”: a) Call the Home screen.
Page 591 DIASAFE- 4.0.0 DIASAFE TEST FAILED / ISOLATE ATMP AND FILLING PROGRAM RESET ALL alarms! B) Turn the Blood Pump on so that it is rotating at more than 100 ml/min. C) Call debug screen 1. ATMP AND FILACT will be watched below. If FILACT EVER = 1 may indicate a hydraulic air leak causing ATMP to be unstable or not reach its specified goal of 300! D) To avoid error read parts E and F BEFORE performing them.
Page 592 DIASAFE- 5.0.0 ATMP STAYS 300 OR MORE / ISOLATE DIASAFE FILTER #92 a) Figure below, remove FILTER #92 from Valve #28’s tubing. ® DiaSafe Filter / Valve #28 / Filter #92 b) Press ‘Esc’ to return to the Home screen. c) ENSURE no air flowing through the external flow indicator.
Page 593 ® DIASAFE- 6.0.0 ISOLATE DIASAFE TEST VALVE #28 air-filled a) An 60 ml syringe is REQUIRED! b) ENSURE the syringe plunger moves freely back and forth inside the barrel! c) Move the syringe plunger to the 40 ml mark. d) Figure below, attach the syringe to Valve #28’s tubing. Reset ALL alarms! one (1) minute ®...
Page 594 a) Trace Valve #28’s wires from the distribution board to the valve’s (black) solenoid. THREE (3) checks: Check #1: If a wire is pinched or insulation is damaged this may be the problem! Check #2: If the wires DO NOT terminate properly at the solenoid terminals this may be the problem! Check #3: If the solenoid terminals are corroded this may be the problem! b) Figure right, open Valve #28’s female...
Page 595 DIASAFE- 7.0.0 VALVE #28 OKAY a) Return FILTER #92 to Valve #28! b) See procedure number DIASAFE- 8.0.0 (page 591). DIASAFE- 8.0.0 DIASAFE TUBING ATTACHED PROPERLY a) This procedure uses a psi pressure gauge. ENSURE it reads 0 psi before installing it! b) Figure right, tee the gauge between the Flow Pump's OUTPUT nozzle and its WHITE tubing.
Page 596 DIASAFE- 9.0.0 GOOD FLOW PUMP PRESSURE / PRESSURE TEST VALVE #26 a) Place the machine into Service Mode → Diagnostics → Valve Leak Test. b) Allow the screen’s [Test Status] data box = “Ready”. c) Select the [Valve Number] data box. d) K machine use the up/down arrow keys until [Valve Number] = Valve #26;...
Page 597: Section 25 - Troubleshooting Power Distribution
SECTION 25 - TROUBLESHOOTING POWER DISTRIBUTION BEFORE continuing to part B, perform INITIAL CHECKS (page B) If troubleshooting the screen ‘remaining black’, if air is felt from the Power Supply vents (Figure right) = fan running = MACHINE IS ON! C) Figure right, the Main Power Switch does not turn the machine on but must be on to turn the machine on! It MUST REMAIN ON for all procedures! D) Proceed according to the OBSERVED symptom ONLY! Listed below are...
Page 598 IF the machine NEVER turns on i.e. fan NEVER runs: Perform parts a THROUGH d below: a) If the fan IS NOT running continue to part b. If the fan IS RUNNING but, after fifty (50) seconds, the page 598 screen REMAINS BLACK proceed to , procedure number C.0.0.
Page 599 P- A.0.0 ISOLATE POWER CORD / PLUG / STRAIN RELIEF a) Unplug the machine! b) Inspect the power plug and cord for burning or other damage. c) Per the Figure below, inspect the strain relief for damage. d) Plug into the known good GFI outlet. e) See procedure number P- A.2.0 (page 595).
Page 600 P- A.4.0 ISOLATE ‘HEATER CIRCUIT’ CAUTION! Turn the machine OFF! Electrocution hazard if NOT turned off! b) Figure right, at the Distribution board’s Heater Connector, TWO (2) checks: Check #1: TOP: From right-to-left, wires MUST be brown (hot), Blue (neutral), Green/yellow stripped (ground).
Page 601 P- B.0.0 ISOLATE POWER SYSTEMS a) Figure right, ENSURE the distribution board position from the left, “x4, PH-P”, IS VACANT! If NOT, this may be the problem! b) To avoid pulling cables loose, GENTLY open the card cage. c) Per Figure 113A below, at the rear of the card cage, ENSURE the 24V POWER harness is plugged in securely with the orange wire to the left.
Page 602 P- C.0.0 ISOLATE SCREEN PROBLEMS (1) IMPORTANT! To prevent damage turn the machine off! b) Figure below, at the rear of the card cage, trace the cable from Blood Pressure Module to ENSURE it is NOT reverse connected with another module! If it is this may be the problem! page 599 c) Proceed to , procedure number P- E.0.0.
Page 603 P- E.0.0 PREPARE TO ISOLATE +12 AND +5 VOLT SUPPLIES a) To avoid pulling cables loose, GENTLY open the card cage. b) ENSURE the 24V POWER harness remained plugged in. c) Spread the card cage side panels open then gently drop the front panel down. d) Per the Figure below, locate the Power Logic board AND the motherboard’s nine (9) pin TEST Connector.
Page 604 e) Per the Figure right AND Table 16 below, measurements at the TEST Connector’s +5V AND +12V pins. TWO (2) possible scenarios: BOTH IN RANGE IF (and ONLY if) RECORD the +12V measurement then see procedure number P- F.0.0 (page 601). 2) ANY BAD measurement: See Table 17 below and...
Page 605 P- F.0.0 MEASURED +12 AND +5 VOLTS ARE GOOD / VERIFY SYMPTOM Proceed according to the OBSERVED symptom ONLY! Ten (10) possible symptoms: IF “24V Low” OR “24V High” OR “WD: 24V Rcvr Err Short” OR “WD: 24V Rcvr Err Long”: From page 617 here on these are called “24V”...
Page 606 P- F.1.0 TROUBLESHOOT SCREEN PROBLEM a) Turn the machine OFF! b) Per the Figure below, ENSURE the aluminum-looking Data Display Cable (P/N 190194), between the functional board and the screen, is plugged in CORRECTLY at BOTH sides. c) Turn the machine on and allow fifty (50) seconds. If the screen continues to display ‘weird’ or NOTHING continue to part d.
Page 607 P- F.2.0 SCREEN REMAINS ‘BLACK’ / ISOLATE +12 AND +5 VOLTS AT BACKLIGHT CONVERTER Per the Figure below, measure for +5 AND +12 volts DC (V ) inside the backlight converter connector. BE CERTAIN the meter lead contacts the metal portion of the connector! TWO (2) measurements: Measurement #1: Where the red wire is connected.
Page 608 P- F.4.0 BOTH +12 AND +5 VDC LOW / ISOLATE 24 VOLTS DC AT POWER LOGIC BOARD IMPORTANT! ENSURE the machine is on (fan running)! CAUTION! DC voltages (V ) are about to be measured at pins that are VERY close to others and touching pins together WILL CAUSE DAMAGE! As directed in the Figure below, make your RED meter DO NOT CONTINUE UNTIL YOU HAVE DONE THIS! lead a PROTECTED lead!
Page 609 BOTH more than 23.0 volts! Proceed to page , procedure number G.0.0. No BOTH are less than 23.0 volts! TWO (2) possible scenarios: IF (and ONLY if) BOTH are less than 23.0 volts: See procedure number P- F.5.0 (page 605). 2) IF AT LEAST one is more than 23.0 volts: The Power Logic X2 ribbon cable may be bad.
Page 610 P- F.6.0 CHECK TRANSFORMER OUTPUT CAUTION! a) Turn the machine off and UNPLUG it. Electrocution hazard if not unplugged! b) Slide the power supply away from the cabinet. c) ENSURE all cables are plugged in securely! If not, this may be the problem! d) Remove the two front screws, un-mount the Power Control Board from its four plastic clips e) Lay the supply’s rear panel down to access to the...
Page 611 P- F.7.0 ST 12 LESS THAN 23.0 VOLTS/ ISOLATE MODULES / PUMPS IMPORTANT! To prevent damage, turn the machine OFF! b) Figure below, unplug the ACTUATOR Cable from the distribution board. ENSURE the meter’s black lead remains connected to chassis ground! IMPORTANT! Turn the machine ON (fan running)! e) Figure below, measure again from the rear side of the Power Control Board’s ST12 connector.
Page 612 P- F.8.0 ST 12 STILL LESS THAN 23.0 VOLTS IMPORTANT! To avoid damage, turn the machine OFF! including the Blood Pressure module Figure below, unplug the modules ONLY, IMPORTANT! Reconnect the Actuator Cable! IMPORTANT! Turn the machine on (fan running)! e) Measure again from the rear side of the Power Control Board’s ST12 connector.
Page 613 P- G.0.0 ISOLATE POWER LOGIC BOARD IMPORTANT! To prevent damage turn the machine OFF! b) Figure below, trace the cable from the Blood Pressure Module to ENSURE it is NOT reverse connected with another module! If it first correct this problem THEN re-measure +5 and +12 volts as this may be the problem! c) See procedure number P- G.2.0 (page 609).
Page 614 P- G.5.0 ORIGINAL SYMPTOM STILL PRESENT / ISOLATE MODULES NOTE: The previous Power Logic Board is probably good! IMPORTANT! To prevent damage turn the machine OFF! Per the Figure previous page MODULES ONLY , unplug the , including the Blood Pressure module! IMPORTANT! Turn the machine ON (fan running)! If possible, return to Dialysis OR Heat Disinfect.
Page 615 P- G.5.2 SYMPTOM STILL PRESENT / ISOLATE FUNCTIONAL / POWER LOGIC BOARD DEVICES IMPORTANT! The machine MUST be OFF to prevent damage! Per the Figure below , device cables along the TOP EDGE of the Functional AND Power Logic boards will be unplugged next. To prevent damage when eventually returning them, RECORD where they belong BEFORE continuing to part c! DO NOT c) Unplug the cables but...
Page 616 Screen on and / or good voltages continued: IMPORTANT! To prevent damage turn the machine OFF! B) Your choice, referring to Figure 117 (page 611), plug ONE of the cables back in to where it belongs as recorded above. C) Turn the machine on (fan running)! D) If possible, return to Dialysis Program OR Heat Disinfect.
Page 617 P- G.5.4 SYMPTOM REOCCURS / ISOLATE HYDRAULIC SENSORS IMPORTANT! To prevent damage turn the machine OFF! b) To isolate ALL hydraulic sensors at the same time, Figure below, unplug the Sensor board’s ribbon cable! IMPORTANT! Turn the machine on (fan running)! Dialysis Program d) If possible go to or RINSE (DO NOT go to Heat Disinfect)!
Page 618 P- G.5.5 SYMPTOM NOT PRESENT / ISOLATE SENSORS AND PUMPS IMPORTANT! To prevent damage turn the machine OFF! IMPORTANT! Reconnect the Sensor Board cable! c) One of 13 Sensors (NTC #2 - NTC #44) or one of five (5) Pumps (#16 - #22) may be causing the problem.
Page 619 P- G.5.6 SYMPTOM STILL PRESENT / ISOLATE THE ACTUATOR CABLE IMPORTANT! To prevent damage turn the machine OFF! IMPORTANT! Return the ribbon cable to the Sensor Board. c) Figure below, unplug the Actuator-Test board’s ribbon cable. IMPORTANT! Turn the machine on (fan running)! e) If possible, place the machine in Dialysis Program.
Page 620 P- G.5.9 SYMPTOM STILL PRESENT To prevent damage turn the machine OFF! B) Reconnect the Actuator ribbon cable to to the Actuator-Test board C) Using ESD precautions, per the Board List below, your choice swap in ONE of the card cage circuit boards with known good, then in between see part D to test the board.
Page 621 P- H.0.0 VERIFY SERVICE MODE This procedure attempts to place the machine into Service Mode. Some problems may not allow it! a) Turn the machine off then back on. When “Press CONFIRM for Service Mode” appears press ‘CONFIRM’. The screen says “Machine in Service Mode”. b) Allow forty (40) seconds! Does the Main Service Program menu appear? Service menu appears! See procedure number P- H.1.0...
Page 622 P- H.1.2 TROUBLESHOOT VOLTAGE DETECTION PROBLEM Either “Operator Error” occurred OR 5V EST AND / OR 12V EST were not in range. These procedures determines if a component may be ‘dragging’ +12 and / or +5 high or low: IMPORTANT! To prevent damage turn the machine OFF! MODULES ONLY b) Figure below, unplug ALL , including the Blood Pressure module!
Page 623 P- H.1.3 ISOLATE HYDRAULIC SENSORS IMPORTANT! To prevent damage turn the machine OFF! b) CAREFULLY return the module cables to their positions. * CAUTION! DO NOT a plug a module, other than the Blood Pressure Module, into the Blood Pressure or Colin position! DO NOT plug the Blood Pressure Module into another module’s position! Per the Figure below c) CAREFUL HERE!
Page 624 P- H.1.4 ISOLATE FUNCTIONAL BOARD DEVICES IMPORTANT! To prevent damage turn the machine OFF! b) Device cables along the TOP EDGE of the Functional Board AND Power Logic Board will be unplugged Per the Figure below next. , to prevent damage when eventually returning them, RECORD where they are plugged in BEFORE continuing to part c.
Page 625 P- H.1.5 SYMPTOM STILL PRESENT To avoid damage, turn the machine off! b) Return the Functional and Power Logic board device cables to EXACTLY as recorded above! c) Referring to see Figure 4A and NOTE A (page 9), if (and ONLY if) the machine is equipped with the New Style Power Logic Board (i.e.
Page 626 P- H.1.7 ISOLATE CARD CAGE IMPORTANT! To prevent damage, turn the machine OFF! B) Using ESD precautions, your choice, per the Board List below, swap in ONE of the card cage circuit boards with known good, then continue to part C to test it. BOARD LIST: 1) Actuator-Test Board;...
Page 627 P- H.3.0 ISOLATE 24 VOLT CONNECTIONS TURN THE MACHINE OFF! b) Open the power supply enough to see the top edge of the Power Control Board (Figure right). c) ENSURE the 24V Power Harness is connected SECURELY, pin for pin, to its connector! d) See procedure number P- H.3.1...
Page 628 2) IF any “24V” alarm OR “Loading Software….Please Wait” lasts longer than one (1) minute: page 625 Proceed to , procedure number H.4.5. 3) IF a “24V” alarm has never occurred but “Failed Sending Data To Actuator Board” has: If the “Actuator Board”...
Page 629 P- H.4.5 +24 VOLT- A TROUBLESHOOTING a) Spread the card cage panels open then gently drop the front panel down. b) ENSURE the volt meter’s black lead remains attached to chassis ground! c) ENSURE the machine in on (fan running)! Figure below , place the red meter lead into the RIGHT SIDE socket of the motherboard’s white, two...
Page 630 P- H.4.6 BETWEEN 23.0 AND 28.0 VOLTS / MONITOR 24 VOLTS DO NOT a) With the “Select Program” banner up select the screen‘s ‘Dialysis’ button but press CONFIRM yet! b) Call debug screen 10. Figure right, 24V is the ‘real time’ reading from the +24 volt supply.
Page 631 P- H.4.8.2 REMAINS STABLE AND NO ALARMS OCCUR / HEAT-RELATED PROBLEM? a) Place the machine into Heat Disinfect then call debug screen 10 to watch the 24V window. b) WITHOUT LOOKING AWAY, watch the volt meter until if the program completes. c) Does the measurement become unstable AND/OR does a “24V”...
Page 632 P- 1.0.0 MACHINE NEVER TURNS ON (FAN NEVER RUNS) IMPORTANT! Set your CALIBRATED volt meter to DC voltage (V Connect the meter’s black lead to chassis ground (see Figure 2 (page 4)). c) Per the Figure below, locate regulator at the TOP EDGE of the Power Logic Board. TWO (2) measurements may be made at T1 depending on the first! TOP pin d) MEASUREMENT 1: From the REAR side of T1’s...
Page 633 Between 4.0 and 6.0 volts! See procedure number P- 1.0.2 (page 629). IS NOT between 4.0 and 6.0 volts! The Power Logic Board is bad (card cage, first circuit board from the left). P- 1.0.2 PIN 3 BETWEEN 4.0 AND 6.0 VOLTS / ISOLATE POWER ON/OFF CIRCUIT a) Spread the card cage side panels open then gently drop the front panel down.
Page 634 P- 1.0.3 PIN 4 IS NOT BETWEEN 4.0 AND 6.0 VOLTS Figure 122 a) Figure right, unplug the sixteen (16) pin Switch Matrix Cable. pin 4 b) Figure right, measure again at . Between 4.0 and 6.0 volts DC now (Yes or No)? Between 4.0 and 6.0 volts! Replace the front panel.
Page 635 P- 1.0.4 PIN 4 BETWEEN 4.0 AND 6.0 VOLTS / ISOLATE THE POWER BUTTON pin 4 a) Continuing to measure at the Switch Matrix Cable’s, , press and release the Power button three (3) times. b) Does voltage drop to LESS THAN 0.5 volts WHILE THE BUTTON IS PRESSED? Drops to LESS THAN 0.5 volts! The Power button is okay! See procedure number P- 1.0.5 (page 631).
Page 636 P- 1.0.6 X2 / PIN 3 MORE THAN 6.0 VOLTS / ISOLATE POWER LOGIC BOARD Continuing to measure at X2, pin 3 press and release the Power button. TWO (2) possible scenarios: IF (and ONLY if) goes to less than 1.4 volts DC: See procedure number P- 1.0.7 (page 632).
Page 637 P- 1.0.9 X2 / PIN 3 LESS THAN 6.0 VOLTS / ISOLATE MAIN RELAY (K1) CAUTION! Turn the machine off and UNPLUG it. Electrocution hazard if not unplugged! Slide the power supply away from the cabinet to see the Power Control board inside. ENSURE the cables, along the top edge of the board, are plugged in securely.
Page 638 P- 1.1.0 ISOLATE POWER LOGIC BOARD CABLE (PIN 4) a) Turn the machine off and UNPLUG it. CAUTION! Electrocution hazard if not unplugged! b) Slide the power supply away from the cabinet to see the Power Control Board inside. c) ENSURE ALL cables are plugged in securely. If not, this may be the problem! d) Figure right, un-mount the board from its white plastic clips.
Page 639 P- 1.2.0 PIN 4 LESS THAN 10 VOLTS / ISOLATE MAIN LINE FUSES 6.3 AMP FUSES Unplug the machine! CAUTION! Electrocution hazard if not unplugged! b) IMPORTANT! Set your CALIBRATED volt meter to RESISTANCE (Ω)! Ω c) To determine the meter’s resistance touch its leads together. The meter MUST read less than 1.0 Subtract this reading from all subsequent measurements! ACROSS Figure below...
Page 640 IMPORTANT! Set your CALIBRATED volt meter to measure AC (~) voltage d) Figure right, measure at the solder side of the Power Control Board, BETWEEN ST1 and ST2. This is the power cord after the Main Power Switch. e) More than 100.0 volts AC (Yes or No)? More than 100 volts AC! Figure below, ENSURE the Power Logic Cable is plugged in securely AND is NOT...
Page 641 P- 1.2.2 FUSES MORE THAN 1.0 Ω OR “OL” / TROUBLESHOOT BAD FUSES a) Replace the bad 6.3 Amp fuse(s). Call Fresenius Technical Services to ENSURE you are using the updated fuses! IMPORTANT! Plug the machine in! c) Push and hold the Power button for two (2) seconds. Does the machine turn on now (fan running)? One or both of the fuses were bad.
Page 642 P- 2.0.0 INITIALIZATION DOES NOT COMPLETE / ISOLATE PUMPS IMPORTANT! To prevent damage, turn the machine OFF! unplug the ACTUATOR CABLE b) Figure below from the distribution board. c) Turn the machine on (fan running). Does System Initialization reach 100%? System Initialization reaches 100%! See ISOLATING THE PUMPS this page.
Page 643 P- 2.0.1 SYSTEM INITIALIZATION DOES NOT REACH 100% IMPORTANT! Turn the machine OFF! IMPORTANT! Reconnect the ACTUATOR cable. Figure below ALL MODULES ONLY , behind the card cage, unplug the including the Blood Pressure module! d) From here forward, ignore “Art BP No Comm” OR “Blood Still Sensed!” if they occur! e) Turn the machine ON (fan running).
Page 644 P- 2.0.2 SYSTEM INITIALIZATION DOES BOT REACH 100% / ISOLATE +24 V-A a) Spread the card cage side panels open then gently drop the front panel down to access the motherbord’s white two (2) pin, +24V-A connector (Figure below). Figure 128 – Card Cage TEST Connector (24V-A) Per the Figure above , place the red meter lead into the right hand socket of the +24V-A connector.
Page 645 P- 2.0.3 ISOLATE ‘SWITCHED’ 24 V-B IMPORTANT! TURN THE MACHINE OFF! b) Figure below, locate the motherboard’s nine (9) pin TEST connector. Figure 129 – Card Cage / TEST Connector / 24V-B c) TIGHTLY HOLD the red meter lead on the TEST connector’s pin 8 (2 pin from the right).
Page 646 IF (and ONLY if) REMAINS BETWEEN 3.0 and 23.0 volts : TWO (2) possibilities: 1) Bad 24 volt switch (IC4)* OR 2) Bad thermal (BROWN) fuse S18 * To LOCATE IC4 AND fuse S18 refer to Figure 132 (page 651). With the machine off, the fuse can be checked by measuring RESISTANCE (Ω) BETWEEN its two terminals.
Page 647 P- 2.0.5 ISOLATE POWER LOGIC CABLE ENSURE the machine is on (fan running)! CAUTION! Signals will be measured at pins that are VERY close to others and touching them together, with a standard meter lead, WILL CAUSE DAMAGE! As directed below, make your RED DO NOT CONTINUE UNTIL YOU HAVE DONE THIS! meter lead PROTECTED! Per the...
Page 648 P- 2.0.6 ISOLATE 24 VOLT SWITCH IMPORTANT! Turn the machine OFF! TIGHTLY HOLD Per the Figure previous page, the meter lead at the solder (rear) side of Power pin 1 Logic Board’s X2 connector, (bottom row, first pin from the REAR of the machine). WITHOUT LOOKING AWAY Looking for pin 1 to fall below 1.0 volts AT LEAST ONE (1) TIME, FROM THE METER...
Page 649 P- 2.0.7 ISOLATE ‘WATCH DOG OUTPUT’ IMPORTANT! Turn the machine OFF! Per the Figure below, locate IC2 at the top edge of the Power Logic Board. Under IC2 are three resistors, top to bottom R8, R9 and R10. Figure 131 – Power Logic Board/ R10 TIGHTLY HOLD the meter lead at resistor #10 (R10) at the location shown in the Figure above.
Page 650 P- 2.0.8 ISOLATE ACTUATOR-TEST BOARD ‘SET’ SIGNAL To avoid damage, turn the machine OFF! b) Swap in a known good Actuator-Test Board*. * To LOCATE the Actuator-Test board refer to Figure 6 (page 19). c) Turn the machine on and allow forty (40) seconds. Does System Initialization reach 100%? System Initialization reaches 100%! The previous Actuator-Test Board is bad.
Page 651 P- 3.0.0 MACHINE TURNS ITSELF OFF a) ENSURE the machine is OFF! b) To avoid pulling cables loose GENTLY open the card cage. c) Spread the card cage side panels open then gently drop the front panel down. Per the Figure below , TWO (2) checks: CHECK #1: ENSURE the twenty-four (24) pin Front Panel Data Cable is plugged in properly between the motherboard and the Front Panel Interface board.
Page 652 P- 3.0.1 REMAINS ON FOR AT LEAST 30 SECONDS With the machine on, QUICKLY unplug the sixteen (16) pin, Switch Matrix Cable from the Front Panel Interface board. TWO (2) possible scenarios: IF the machine stays on after unplugging the cable: Place the machine into Heat Disinfect and with the shunt door open allow up to one (1) hour.
Page 653 P- 4.0.0 ISOLATE THE POWER SUPPLY CAUTION! To prevent an electrocution hazard unplug the machine! b) Figure right, trace the cables between the Acid, Bicarb AND UF Pumps and the distribution board to ENSURE they are NOT pinched or damaged! c) Figure below, trace the cables between the modules and the rear of the card cage to ENSURE they are not pinched or damaged!
Page 654 d) Open the power supply to see the Power Control board. e) Figure below, ENSURE ALL cables are plugged in securely at the Power Control Board. If not, this is may be the problem! Check the Power Control board cables and wires for signs of burning or damage! This may be the problem! g) Check the board’s component (front) and solder (rear) surfaces for signs of burning or damage.
Page 655 Figure 132 – Inside the Power Supply 2008K/K2 Troubleshooting Guide Page 651 P/N 507298 Rev. H...
Page 656 SECTION 26 – VALVE #1 OR VALVE #2 FAIL NOTE: If the shunt door is partially open may cause “Dialyze Valve Fail 1”. IMPORTANT! The problem may be heat related. Observe all stated times to avoid error! CAUTION! To avoid damage, turn the machine OFF! B) Figure below, remove the distribution board cover.
Page 657 DVF- 1.0.0 ISOLATE VERR / SPECIAL VALVE ERROR #38 a) ENSURING the machine is OFF, to avoid pulling cables loose, GENTLY open the card cage! IMPORTANT! Set your CALIBRATED volt meter to RESISTANCE (Ω). Connect the meter’s black lead to chassis ground (see Figure 2 (page 4)).
Page 658 page 657 “Dial Valve Failure” OR “Act Byp Valve Fail” OCCURS! Proceed to , procedure number DVF- 4.0.0 “Dial Valve Failure” OR “Act Byp Valve Fail” DOES NOT occur! See procedure number DVF- 1.2.0 (page 654). DVF- 1.2.0 DIAL VALVE FAILURE OR ACT BYP VALVE FAIL DOES NOT OCCUR Do not reset alarms! b) Call debug screen 1.
Page 659 DVF- 2.0.0 VERR = 0 / ISOLATE VALVE #24 OPEN CIRCUIT Call debug screen 2 to see DIAVLO (Figure below). THREE (3) possible scenarios 1) or 2) or 3) below: IF (and ONLY if) DIALVLO REMAINS ALWAYS = 1: Electrical problem with Valve #24. Proceed to page 657 , procedure number DVF-...
Page 660 DVF- 2.1.0 ISOLATE VALVE #24 SHORT CIRCUIT a) ENSURE a “No Water” alarm NEVER appears! b) Call debug screen 0. WITHOUT LOOKING AWAY, watch Flow Error, for three (3) minutes. If EVER = 1, even if only once, indicates a Flow Error.
Page 661 DVF- 4.0.0 ISOLATE VALVES #24 AND #43 SOLENOID CIRCUITS (1) IMPORTANT! Turn the machine OFF! b) Per the Figure below, THREE (3) checks while tracing Valve #43’s AND #24’s wires from the distribution board to BOTH valves inside the hydraulics. CHECK #1: ENSURE no ‘pinched’...
Page 662 IF (and ONLY if) BOTH valves between 40 and 100 Ω: See procedure number DVF- 4.2.0 (page 658). 3) IF ONE OR BOTH is less than 40 OR more than 100 Ω: Replace the valve AND its blue wiring harness. DVF- 4.2.0 BOTH VALVES BETWEEN 40 AND 100 Ω...
Page 663 DVF- 4.2.2 BOTH MEASUREMENTS BETWEEN 40 AND 100 Ω a) Turn the machine ON. b) Return to Dialysis Program (“Select Program” → ‘Dialysis’ → ‘CONFIRM’)! c) If (and ONLY if) a “Dial Valve Failure” OR “Act Byp Valve Fail” alarm banner reoccurs see procedure number DVF- 4.3.0 (page 659).
Page 664 DVF- 5.0.0 PIN 43 (VALVE #38) LESS THAN 40 Ω Figure below Valve #38 , unplug from the distribution board. b) Using a flashlight, check inside the vacant distribution board position. If corrosion or damage is located the distribution board needs to be replaced! Leave Valve #38 unplugged until instructed.
Page 665: Section 27 - "Act Blood Pump Failed
SECTION 27 - “ACT BLOOD PUMP FAILED” A) Turn the machine off and back on. If (and ONLY if) “Act Blood Pump Failed” alarm reoccurs proceed to part B. IMPORTANT! Perform INITIAL CHECKS (page 6)! C) See procedure number ABPF- 1.0.0 (page 661).
Page 666 More than 23.0 volts DC seen! If (and ONLY if) the “Act Blood Pump Failed” reoccurred, THREE (3) possible bad components (see Component List below). Swap in each component in one at a time and, in between, see if the “Act Blood Pump Failed” reoccurs. Continue through the list until “Act Blood Pump Failed”...
Page 667 ABPF- 1.0.4 ISOLATE POWER CONTROL BOARD OUTPUT a) Turn the machine off and UNPLUG it. CAUTION! Electrocution hazard if not unplugged! b) Slide the power supply away from the cabinet. Figure right, inside is the Power Control Board where the 24V Power Harness terminates.
Page 668 Figure 134 24 V Power Harness – 2008K/K2 Troubleshooting Guide Page 664 P/N 507298 Rev. H...
Page 669: Section 28 – Heat Exchanger Leaking Externally
SECTION 28 – HEAT EXCHANGER LEAKING EXTERNALLY A) Per the Figure below, if the HEAT EXCHANGER’S ‘center screws’ and nuts are not tight this may be problem! B) A psi pressure gauge is required! ENSURE it reads 0 psi before installing it! IMPORTANT! Turn the water OFF.
Page 670 Watching for thirty (30) seconds to ENSURE a “No Water” or Flow Error NEVER occurs, is gauge pressure cycling to a consistent peak of between 18 and 20 psi? Peak between 18 and 20 psi! See procedure number HEATEX- 2.0.0 (page 666).
Page 671 APPENDIX A - TARGET DEAERATION PRESSURES PER GEOGRAPHICAL AREA CITY FT. ELEVATION CITY FT. ELEVATION Albuquerque, NM 5,311 Little Rock, AR Atlanta, GA 1,010 Los Angeles, CA Atlantic City, NJ Louisville, KY Baltimore, MD Memphis, TN Bismarck, ND 1,647 Miami, FL Boise, ID 2,838 Milwaukee, WI...
Page 672: Appendix B - Calibrate If Replaced
APPENDIX B - CALIBRATE IF REPLACED Components may need to be replaced to repair the machine. The following table indicates calibrations that must be performed in this event. K Calibration Replaced Component Then Calibrate Procedures Section # - Display Assembly (i.e. screen) - Touch Screen Calibration - Deaeration Pump Head (#20) - Deaeration and Loading...
Page 673: Appendix C - Blood Pump Error Codes
APPENDIX C - BLOOD PUMP ERROR CODES 2008K/K2 Troubleshooting Guide Page 669 P/N 507298 Rev. H...
Page 674 APPENDIX C CONTINUED NOTE! Additional Blood Pump Dip-Switch settings can be found in the Arterial Pressure Calibration of the 2008 Calibration booklet. 2008K/K2 Troubleshooting Guide Page 670 P/N 507298 Rev. H...
Page 675 COMMON CONVERSIONS PRESSURE 1 Bar 29.53 inHg 1 inHg 25.4 mmHg 1 Psi 51.72 mmHg VOLUME 1 FLUID OUNCE 29.6 MILLILITERS 1 U.S QUART 0.946 LITERS 1 U.S. GALLON 3.8 LITERS 0.034 FLUID OUNCES 1 MILLILITER 1.057 QUARTS 1 LITER 0.26 U.S.
Page 676 Fresenius Medical Care North America Manufactured by: Fresenius USA, Inc. 4040 Nelson Avenue Concord, CA 94520 http://www.fmcna.com 800 227-2572...

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