TROUBLE SHOOTING GUIDE FOR FRESENIUS 4008 HEMODIALYSIS UNITS
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 “Test” key again and note the displayed error code before proceeding to technical manual for 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 codes of the concerned test fail.
Test Equipments: a) Hemodialysis tester b) Pressure gauge 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. 1
Error
Possible Causes Tips a) No Water a) Water Inlet Supply/ Low Pressure(0.95 to 1.05 Bar) Water Alarm Pressure. b) Pressure Regulator (61) c) Check the Inlet Filter d) Water Inlet Valve (41)
c) Check Valve 41
Remarks Use Diagnostics Program to check the water Flow Path.
2
3
Flow Alarm
Upper Flow Alarm
a) Blocked filter a) Verify flow 300, 500, 800 b) Defective valve/pump b) Calibrate if (valve resistance required. 50 to 80 Ohms)
a) Create flow from diagnostics. b)Verify Loading pressure (1.2 – 1.45 Bar)
c) Calibration a) Degassing filter b) Degassing pressure
4
c) Flow calibration Temperature a) Incoming water temperature a) High temperature b) Temp Calib
a) Incomplete hot disinfection can be a reason!
a) Temp Calib
a) Flow errors can lead to Low Temp Alarm!
b) Low temperature
b) Heater rod resistance around 30 Ohms
b) Heater Rod.
S NO.
Error
5
Conductivity
Possible Causes
i) Low a) Dilution Conductivity Ratio.
b) Concentrate or Bicarbonate
c) Conc. &
Tips
Remarks
a) Verify Dilution a)Normally Ratio in Set Up 1+35.83(Nacl26);depends Menu on the A & B part
b) Wrong or Expired Solution??
b) Provided the concentrate and BIC strokes and suction is OK c) Ref: CalibrationMixing System
BIC pump strokes and output??
c) Calibrate if required
d) Conc and BIC pump d) Replace if spring set required broken??
d) Calibrate the Conc and BIC pumps after replacing the springs. Use the graduated measuring Jar to measure the stroke volume.
e) Conductivity (Display ) Calibration e) Temperature and Conductivity (display) Calibration a) Verify flow f) Faulty ,Calibrate if Conc or BIC required Pump
b) Verify Dilution a)Flow Errors
b)Dilution c) Concentrate or ii) High Conductivity Bicarbonate d) Conductivity (Display ) Calibration
c) Wrong or Expired Solution?? d) Temperature and Conductivity (display) Calibration
c) Ref: Set up- Dilution
S NO. 6
Error TMP / Dial Pressure
Possible Causes a) Dialyser membrane defects
Tips
Remarks
a) Replace Dialyser.
a)Adjust 0 mmHg ( LP 633 Pot P3) and do dial pressure calibration.
b) Dial Pressure Calibration Required.
b)Continuous TMP Alarm / Pressure fail indicates Dial Pressure Calibration Blood Leak Adjust both to 5 and Dimness Volts. Calibration
7
Blood Leak
8
Pressure a) Leakage in a) Observe for a) Use a flash light. Holding Test Hydraulic leaks during system. Positive pressure test or Induced pressure test. b) Do Dial Pressure calibration only if the error b) Dial code indicates dial pressure Pressure i) Positive calibration. Calibration Pressure Errors
a) UF filter blockage
b) Use the graduated measuring Jar.
b) UF Pump Calibration ii) Negative Pressure Errors
c) Observe/ Replace Spring c) Broken UF set Pump Spring
d) Use Diagnostics program
set
d) Check tightness of hoses
d) Minute Leakage in Hydraulic system
S NO. 9
Error
Possible Tips Remarks Causes Hydraulic a) Rinse a) Replace Filters a) 3 minutes before the end Test Fail Filters 148 & if needed. of cleaning program. 149 b) Most cases pressure leak due to loose hose at i)Rinse these valves Failure Alarm b)Rinse Valves 91,99,100 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
ii) V39 Failure.
a) 1 minute before the end of cleaning program.
10
i) Blood a) BP Power a) Replace power a) Power cord is the one Pump Errors cord cord connecting control board to motor
b) Jammed Motor
b) Replace bearing
c) Control Board
a) Air Detector ii)Level detector Alarm
iii) Arterial Pressure Alarms
a) Arterial Pressure calibration
a) Calibrate Air detector
c) Do complete arterial calibration and BP speed calibration after replacing the control board
S NO.
Error
10 Contd…
iv) Venous Pressure Alarms
Possible Tips Remarks Causes a) Transducer Partially clogged Protector ( P female connection. Ven)
b) Venous Pressure calibration
c) Venous Line set. a) Mechanical problem of gear a) Manually rotate v) Heparin the gear to Top or Pump Errors bottom end and retest the pump a) Dial Pressure calibration required a)F 03/ F02 b) Damaged Diasafe Filter
vi) Diasafe Errors
a) b)F 34/ 43
c) Diasafe Pressure Transducer 11
c) Replace Diasafe filter.
Ultrafiltration Errors. i) Less fluid removal
a)UF Pump filter (74) b) UF Pump Calibration b) Verify
b) Verify the stroke volume (1ml/ stroke)
c) UF pump spring set
Calibration
c)Replace if d) UF Pump required
12
Battery Fail. a) Battery
d) Replace if defective. a) Battery Vol. 18 V.
b) Battery Fuse (3.15 A) c) LP 647
c) LP 647 is in the Power supply module.
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.
