TROUBLESHOOTING FRESENIUS 4008S HEMODIALYSIS MACHINE

General Guidelines:

1) Make sure that the following errors / alarms are not present before running the T1 test. a) Power Failure b) Dialines not conn c) Shunt cover open d) Connect conc.Line e) Blood sensed by OD f) Flow alarm g) Water alarm

2) When T1 test fails, press pre ss “Test” key again and note the displayed error code before proceeding

to technical manualfor further clues.

3) If more than 1 test fails select “Test Service” ON (PCB LP 632 DIP switch array 1, SW 4 ON) & do the

test individually to get the error c odes of the concerned test fail.

Test Equipments:

a) Hemodialysis tester b) Pressure guage c) Graduated Measuring jar (100ml ,1000ml) d) Flashlight. e) Digital multimeter

Pressure Units:

1Bar = 14.5 psi =749.94mmHg

The Order of Troubleshooting :

1) Water Alarms 2) Flow Alarms 3) Upper Flow Alarm 4) Temperature 5) Conductivity 6) Blood Leak 7) Pressure Holding Test Failures. 8) TMP Continuous Alarms 9) Hydraulic Test Fails 10) Blood Pump Errors / Level Detector Alarms /Arterial Alarms/ Venous Alarms /Heparin Pump Errors/ Diasafe Errors 11) Ultra Filtration Errors 12) Battery Fail

S NO.

Error

Possible Causes

Tips

Remarks

1

Water Alarm

a) No Water

a) Water

UseDiagnostics

Supply/ Low

InletPressure(0.95 Program to check

Pressure.

to 1.05 Bar)

the water Flow Path.

b) Pressure Regulator (61) c) Check the Inlet Filter

c) Check Valve 41

d) Water Inlet Valve(41) 2

Flow Alarm

a) Blocked filter b) Defective valve/pump (valve resistance 50 to 80 Ohms)

a) Verify flow 300, a) Create flow from 500, 800

diagnostics.

b) Calibrate if

b)Verify Loading

required.

pressure (1.2 – 1.45 Bar)

c) Calibration 3

Upper Flow Alarm a) Degassing filter b) Degassing pressure c) Flow calibration

4

Temperature i) High temperature

a) Incomingwater

a)Incomplete hot

temperature

disinfection can be a

b) Temp Calib

reason!

a) Temp Calib a) Flow errors can

ii) Low temperature

lead to Low Temp b) Heater Rod.

Alarm! b) Heater rod resistance around 30 Ohms

S NO.

Error

5

Conductivity

Possible Causes

i) Low Conductivity a) Dilution Ratio.

Tips

Remarks

a) Verify Dilution

a)Normally

Ratio in Set Up

1+35.83(Nacl26);

Menu

depends on the A & B part

b)Concentrate or Bicarbonate

b) Wrong or

b) Provided the

Expired Solution?? concentrate and BIC strokes and suction is OK c) Calibrate if

c) Conc. & BIC

required

c) Ref: CalibrationMixing System

pump strokes and output?? d) Calibrate the d) Conc and BIC pump spring set

d) Replace if

Conc and BIC pumps

required

after replacing the springs. Use the

broken??

graduated measuring Jar to measure the stroke volume.

e) Conductivity (Display ) Calibration

e) Temperature and Conductivity (display) Calibration

f) Faulty Conc or BIC Pump

a)Flow Errors

a) Verify flow ,Calibrate if required

b) Verify Dilution ii) High

c) Ref: Set up-

b)Dilution

Conductivity

c) Wrong or Expired Solution??

c) Concentrate or Bicarbonate

d) Temperature and Conductivity (display) Calibration

d) Conductivity (Display ) Calibration

Dilution

S NO.

Error

Possible Causes

6

TMP / Dial Pressurea) Dialyser

Tips

Remarks

a) Replace Dialyser.

membrane defects

b) Dial Pressure Calibration Required.

b)Continuous TMP Alarm / Pressure fail indicates Dial Pressure Calibration

a)Adjust 0 mmHg ( LP 633 Pot P3) and do dial pressure calibration.

7

Blood Leak

Blood Leakand

Adjust both to 5

Dimness

Volts.

Calibration

8

Pressure Holding Test

a) Leakage in

a) Observe for

a) Use a flash light.

Hydraulic system. leaks during Positive pressure

i) Positive Pressure Errors

b) Dial Pressure

test or Induced

b) Do Dial Pressure

pressure test.

calibration only if the error code

Calibration

indicates dial pressure calibration.

a) UF filter blockage

b) Use the graduated

ii) Negative Pressure Errors

measuring Jar. b) UF Pump Calibration

c) Observe/ Replace Spring set

c) Broken UF Pump d) Check tightness Spring set

of hoses

d) Use Diagnostics program

d) Minute Leakage in Hydraulic system

S NO.

Error

Possible Causes

9

Hydraulic Test Fail a) Rinse Filters 148 a) Replace Filters if a) 3 minutes before & 149

needed. b) Most cases

i)Rinse Failure Alarm

Tips

b)Rinse Valves 91,99,100

Remarks

the end of cleaning program.

pressure leak due to loose hose at these valves OR Leak from Conc and BIC pick up line rubber seals. c) Check PS 134 from Diagnostics.

c) Bibag Pressure switch 134 a) Clogged Filter 210

a) 1 minute before the end of cleaning program.

ii) V39 Failure.

10

i) Blood Pump

a) BP Power cord

Errors

a) Replace power

a) Power cord is

cord

the one connecting control board to motor

b) Jammed Motor b) Replace bearing c) Do complete

c) Control Board

arterial calibration and BP speed calibration after replacing the control board

a) Air Detector

a) Calibrate Air ii)Level detector Alarm

iii) Arterial Pressure Alarms

detector a) Arterial Pressure calibration

S NO.

Error

10 Contd…

iv) Venous Pressure a) Transducer Alarms

Possible Causes

Tips

Remarks

Partially clogged

Protector ( P Ven) female connection.

b) Venous Pressure calibration

c) Venous Line set. a) Mechanical problem of gear

v) Heparin Pump

a) Manually rotate

Errors

the gear to Top or bottom end and a)F 03/ F02

retest the pump a) Dial Pressure calibration required

vi) Diasafe Errors b)F 34/ 43

b) Damaged Diasafe Filter a)

c) Diasafe Pressure Transducer

c) Replace Diasafe filter.

11

Ultrafiltration Errors. i) Less fluid removal

a)UF Pump filter (74) b) UF Pump Calibration c) UF pump spring set d) UF Pump

b) Verify

b) Verify the stroke

Calibration

volume(1ml/

c)Replace if required d) Replace if defective.

12

Battery Fail.

a) Battery

a) BatteryVol. 18 V .

b) BatteryFuse (3.15 A) c) LP 647

c) LP 647 is in the Power supply module.

stroke)

Diagnostics Program

1) On the service switch 2) Enter Diagnostics- Write outputs – Write Digital outputs – CPU 1 : Digital outputs.

Rinsing V 84 ( Disinfection Valve)

1) On V 87, 30, 32, 34, 36, 38, 84 (On - 1111) 2) Start Flow Pump (FP On - 0000)

Creating the Flow

1) Switch On V 24, 24 B, 30,31,32,33,34,35,36,37,38,87 2) Start Flow Pump and Degassing pump 3) Set On FL_ SW_ EN (Float Switch Enable)

Note: Balancing Chamber inlet /outlet valve combination can be switched off one group at a time to locate the faulty BC valve, if any.