Fresenius Medical Care 2008K2 User manual

2008K/K
2
HEMODIALYSIS
SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 507298 Rev. H

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: __________________________________

2008®K/K2
HEMODIALYSIS SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 507298 Rev. H
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

2008K/K2Technical Troubleshooting Guide
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.
Fresenius Medical Care, the triangle logo, 2008K, 2008K2, and DIASAFE are trademarks of
Fresenius Medical Care Holdings, Inc., and/or its affiliated companies. All other trademarks are the
property of their respective owners.
Caution: US Federal law restricts this device to sale only by or on the order of a physician.
Frequency, duration, and parameters of treatment are to be determined by the prescribing
physician.
Installation, maintenance, calibration and other technical information may be found in the
2008K Technician’s Manual (P/N 490049) or the 2008K2Technician’s Manual (P/N 490137).
Contact Fresenius Medical Care Technical Support for applicable Field Service Bulletins. The
spare parts manual for the model 2008K and 2008K2other information may be found on our web
site at www.fmcna.com
Indications for Use: The 2008K and 2008K2hemodialysis machines are indicated for acute and
chronic dialysis therapy.

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 1
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............................................................................................................................... 16
SECTION 1 – FLOW ERRORS IN DIALYSIS PROGRAM....................................................................... 20
SECTION 2 – “NO WATER” ALARM...................................................................................................... 141
SECTION 3 - FLOW ERRORS IN A CLEANING / DISINFECTION PROGRAM ................................... 155
SECTION 4 - TEMPERATURE PROBLEMS.......................................................................................... 214
•"TEMP OVER 95 DEGREES" IN HEAT DISINFECT
SECTION 5 - CONDUCTIVITY / ON LINE CLEARANCE PROBLEMS................................................. 317
•BAD DIALYSATE LAB VALUES
•ON LINE CLEARANCE (OLC) PROBLEMS
SECTION 6 – CONCENTRATE PUMP ERRORS.................................................................................. 397
•"ACID PUMP NO EOS" OR "ACID PUMP ALWAYS EOS"
•"BIC PUMP NO EOS" OR "BIC PUMP ALWAYS EOS"
SECTION 7 - COND REF FAILURE OR COND OFFSET FAILURE..................................................... 404
SECTION 8 - FILLING PROGRAM (AIR LEAK) PROBLEMS................................................................ 409
SECTION 9 - TMP (PRESSURE) PROBLEMS...................................................................................... 440
SECTION 10 - PRESSURE TESTS FAILING ........................................................................................ 474
•"FAIL GET NEG TMP"
•"FAIL NEG STABILIZE"
•"FAIL NEG FLOW ON"
•"FAIL GET POS TMP"
•"FAIL POS STABILIZE"
•"FAIL POS FLOW OFF"
•"ONLINE PHT FAILED"
SECTION 11 – INDUCED AIR LEAK TESTS......................................................................................... 490
SECTION 12 – INDUCED POSITIVE PRESSURE TESTS.................................................................... 496
SECTION 13 - DEAERATION PROBLEMS............................................................................................ 498
SECTION 14 - UF (ULTRAFILTRATION) PUMP PROBLEMS .............................................................. 503
SECTION 15 - BLOOD LEAK PROBLEMS............................................................................................ 511
Continued on next page

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 2
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............................... 535
SECTION 20 – TROUBLESHOOTING OVERFLOW FROM THE VENT TUBING................................ 540
SECTION 21 – HYDRAULIC LEAKS...................................................................................................... 553
SECTION 22 - “WD: FAIL LONG PULSE” OR “WD: FAIL SHORT PULSE”.......................................... 570
SECTION 23 – HEATER RELAY TEST FAIL......................................................................................... 576
SECTION 24 – “DIASAFETEST FAILED”.............................................................................................. 584
SECTION 25 - TROUBLESHOOTING POWER DISTRIBUTION .......................................................... 593
1) MACHINE ‘BLOWS’ THE WALL BREAKER (GFI)
2) 24V LOW OR “24V HIGH
3) “5V LOW OR 5V HIGH”
4) “12V POWER FAIL”
5) SCREEN REMAINS BLACK
6) MACHINE TURNS ITSELF OFF
7) MACHINE NEVER TURNS ON
8) SCREEN TURNS ON BUT DISPLAYS NOTHING
9) “FAILED SENDING DATA TO ACTUATOR BOARD”
10) SCREEN DISPLAYS 'WEIRD DATA'
11) SCREEN NEVER STOPS SAYING “LOADING SOFTWARE…PLEASE WAIT
SECTION 26 – VALVE #1 OR VALVE #2 FAIL...................................................................................... 652
•"ACT BYP VALVE 1 FAIL"
SECTION 27 - “ACT BLOOD PUMP FAILED”........................................................................................ 661
SECTION 28 – HEAT EXCHANGER LEAKING EXTERNALLY ............................................................ 665
APPENDIX A - TARGET DEAERATION PRESSURES PER GEOGRAPHICAL AREA........................ 667
APPENDIX B - CALIBRATE IF REPLACED........................................................................................... 668
APPENDIX C - BLOOD PUMP ERROR CODES................................................................................... 669

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 3
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. It is assumed the troubleshooter knows how to use a multimeter (Volts DC / Volts AC / Resistance).
E. DO NOT calibrate or swap parts unless instructed. NEVER swap parts between malfunctioning
machines! Parts should be tested (known good) in another machine before swapping them in.
F. Calibration(s) may be required after replacing a component. Refer to Appendix B (page 668).
G. Perform FINAL CHECKS (page 12) before returning the machine to clinical service.
H. Be CAREFUL to maintain your current location as you proceed AND read each procedure before
performing it. Pay attention to ‘CAUTIONS’ and ‘NOTES’!
I. Troubleshooting procedures are arranged as a ‘flow chart’. ENSURE you go to the CORRECT
procedure number as prompted. You CANNOT necessarily read down the page as sometimes
procedures on that page are SKIPPED.
J. Sometimes procedures ‘call’ another procedure in a different Section. NOTE the current procedure and
page number BEFORE proceeding to the ‘called’ procedure!
K. If multiple ‘possibilities’ are suggested (example: TWO (2) possible bad components: 1) Bad Actuator-
Test Board; 2) Bad Functional Board), swap the listed components, with known good, one at a time,
starting with the first component in the list. In between test the machine to see the new part fixes the
problem. If NOT continue through the list until the machine is fixed.
L. Hydraulic components can be isolated via the DISTRIBUTION BOARD. Referring to Figure 1(page 4):
There are three (3) Distribution Board sections: 1) Sensors; 2) Pumps; 3) Valves
Electronic hydraulic components each have labeled connector positions as referenced in the 2008
Flow Diagram. Labels are printed above or below each position. For example, Float Switch #5 is
labeled “X5, FLOAT-SW”, temperature sensor NTC #2 is labeled “X2, CON-NTC”, etc.
From left-to-right, positions start at #2 [example: NTC #2, labeled “X2, CON-NTC”]. There is no
position #1! Post Dialyzer Temperature Sensor #44 plugs into position #14; Valve #41 plugs
into position #27
The plastic connector caps should be labeled to match the position
There are several VACANT positions! When removing a connector NOTE its position and label.
Be CAREFUL to return all connectors to their correct positions!
Turn the machine off BEFORE unplugging OR plugging RIBBON cables. These include the
SENSORS, ACTUATOR, Acid (#16) and Bicarbonate (#17) Pumps, Blood Leak Sensor (#8),
Heparin Pump (#18) and the Blood Pressure Module
Continued on next page

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 4
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
M. Figure below, if asked to measure DC voltages (VDC) and in some cases resistance (Ω) connect the
meter’s ground (black) lead to the card cage (i.e. chassis ground).
Figure 2 – Chassis Ground
End of Using the Troubleshooting Guide

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 5
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. Blood Leak
9. Pressure Test Failures
1. External HYDRAULIC LEAKS can cause all problems below it. If a leak is seen eliminate it before
troubleshooting any problem below it!
NOTE: Vent tubing overflow may occur with Flow Errors, Filling Programs, and “TMP is Low” alarms.
2. “NO WATER” alarms may cause Flow Errors. ENSURE a “No Water” alarm NEVER occurs before
troubleshooting any problem below it.
3. FLOW ERRORS turn the heater off. Ensure the machine remains clear of FLOW ERRORS before
troubleshooting temperature. If dialysate flow is unstable temperature will be unstable!
4. TEMPERATURE compensates conductivity. Ensure TEMPERATURE is between 35.5 and 38.5° C and
stable i.e. not changing more than 0.2º C per minute before troubleshooting conductivity. If
TEMPERATURE is unstable Conductivity will be unstable which will also cause OLC to cancel!
5. In Dialysis Program, low CONDUCTIVITY will cause a false ‘air in dialysate’ signal from Chamber #69’s
Air Sensor #6 which causes Filling Programs. Do not troubleshoot a Filling Program unless
CONDUCTIVITY is between 13.0 and 14.4 mS!
6. In Dialysis Program*, if Chamber #69’s Air Sensor #6 senses ‘air in dialysate’ a FILLING PROGRAM
occurs. Valve #43 opens to vent Chamber #69 to drain and therefore TMP will decrease. Do not
troubleshoot a “TMP is Low” alarm if the machine is in a FILLING PROGRAM!
* NOTE: In all Cleaning Programs ‘air in dialysate’ is invalid. FILLING PROGRAM does NOT occur!
7. TMP alarms may occur if there is an external leak or ‘air in dialysate’. Do not troubleshoot TMP alarms
unless you are sure there are no leaks AND good Temperature and Conductivity.
8. ‘Air in dialysate’ may cause false BLOOD LEAK alarms. Also, if Conductivity and/or a Temperature
alarm are present ‘bypass’ occurs i.e. Valve #24 closed, Valve #26 open. In this event Blood Leak
Sensor #8 is bypassed. Ensure all alarms above BLOOD LEAK remain clear before troubleshooting
BLOOD LEAK.
9. PRESSURE TESTS may fail if any problem above it occurs. ENSURE the machine remains clear of all
other hydraulic alarms before troubleshooting PRESSURE TEST FAILURES.
End of ‘The Order of Troubleshooting’
Refer to the TABLE OF CONTENTS to locate the symptom.

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 6
INITIAL CHECKS
1) To prevent shock, turn the machine OFF!
2) Figure below, remove the DISTRIBUTION BOARD cover:
a) ENSURE the Sensors and Actuator cables are plugged in
securely AND are not damaged.
b) Figure right, ENSURE position “X4-PH-PR” is VACANT!
c) Using a flashlight, check the distribution board. If
corrosion is located replace it!
d) Figure right, ENSURE the black Power Ground (PGND)
wire is plugged in securely and shows no signs of burning
e) Figure below, ENSURE all female distribution board
connectors*are plugged in PROPERLY to their correct
positions!
* If CBE modified the Air Sensor’s connector plugs into
the CBE board under the connector. The CBE board
positions the Air Sensor Connector two-pins higher
than the other connectors! CBE = Change Being
Effected
Parts 3 through 6 next page
Figure 3 - CBE

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 7
3) To avoid pulling cables loose, gently open the CARD CAGE:
a) 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!
b) Figure below, trace the cable from the Blood Pressure Module to
ENSURE it is NOT reverse connected with another module!
c) ENSURE no damaged module cables!
4) Referring to Figure 4A (page 9) perform parts a through e:
a) ENSURE the Actuator, Sensors and Power Logic Board ribbon cables are plugged in securely!
b) ENSURE no foreign objects (screws, etc.) are laying on the surface of the motherboard!
c) Using a flashlight, CAREFULLLY check the surface of the motherboard. If corrosion or signs of
burning is located the motherboard needs to be replaced!
d) Clean dust from the surface of the motherboard.
e) Press down HARD on the circuit boards to ensure good connections to the motherboard.
5) Close the card cage!
Continued on next page

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 8
6) Are you troubleshooting a voltage problem (example “24V Low”) OR Acid and / or Bicarb Pump “EOS”
or ‘pink pump symbol’ problem?
Yes Continue to step #7.
No 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!
7) Unmount and slide the Power Supply ¼
way out away from the cabinet. DO NOT
let it fall out!
8) Figure right, at the top of the Power
Control board ensure the Power Logic
and 24V Power cables are plugged in
securely.
9) Clean excessive dust from the rear
(solder) side of the board.
10) Slide the Power Supply back into the
cabinet.
11) Plug the machine in.
12) 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.
END OF ‘INITIAL CHECKS’

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 9
Figure 4A –Card Cage
1– Test Connector (9 pins) on motherboard; 2– Power Logic Board SEE NOTE A (page 9) ; 3– Actuator-Test
BoardSEE NOTE B (page 11); 4– Functional Board; 5– Vacant SEE NOTE B (page 11); 6– Sensor Board
NOTE A
-12 volts DC is required for the Sensor Board’s conductivity circuits and the Blood Pressure Module:
•Referring to the Figure 4B (next page), if the machine is equipped with the Old Style Power Logic
Board the miniature -12 volt ‘Convertor Board’ is required. This board plugs into the motherboard’s
nine (9) pin TEST Connector (#1).
•If equipped with the New Style Power Logic Board (released in 2008) the -12 volt supply is
incorporated into the Power Logic Board and the ‘Convertor Board’ is NOT necessary.
•Both the Old and New Style Power Logic Boards are compatible with 2008K and K2machines but
CAUTION must be exercised. If an Old Style Power Logic Board is installed in a machine
equipped with the New Style Power Logic Board the ‘Convertor Board’ MUST ALSO be installed
otherwise a “Cond Ref” or “Cond Offset” error will occur. If a New style Power Logic Board is
placed into a machine equipped with the Old Style Power Logic Board the ‘Convertor Board’
should be removed!

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 10
Figure 4B – Old / New Style Power Logic Board
P/N 190214
P/N 190099
P/N 190246

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 11
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. REV H is NOT compatible with the old style Actuator board!
•The Actuator-Test Board combines the functions of the Old Style Actuator and Test Board and uses
motherboard slot #3(see Figure 4A, page 9). To use the ‘combined’ feature the machine must be
equipped with Functional board software 3.29 or greater.
•If an different Actuator-Test Board is swapped in and will be left in the machine a VOLTAGE
DETECTOR CALIBRATION (page 14) should be performed.
Figure 4C – Old / New Style Actuator Board

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 12
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’ Vent Tubing
segment is NOT restricted as shown!
5) Return the rear panels ENSURING the Vent
Tubing remains extended out six (6) inches!
6) Turn the machine on and ENSURE the audible
alarm reports during “System Initialization”.
7) Return to Dialysis Program (“Select Program” →
‘Dialysis’ → ‘CONFIRM’)!
8) Allow [Temperature] to stabilize between 35.5
and 38.5° C AND [Conductivity] to between
13.0 and 14.2 mS.
9) From the Home screen, set [Dialysate Flow] to 800 ml/min and press ‘CONFIRM’.
10) ENSURE the external flow indicator’s ‘bob’ is rising and falling in the sight tube!
11) Check Temperature, Conductivity and pH per the Preventative Maintenance Procedures booklet.
12) Perform the automated Alarms/Pressure Tests per Preventative Maintenance Procedures booklet. Do
NOT return the machine to clinical service unless all tests pass!
13) Place the acid connector into a jug of water and allow [Conductivity] to fall to 10 mS.
14) ENSURE the external flow indicator’s ‘bob’ is NOT moving (i.e. Valve #24 is closing).
15) If clinic procedures requires it perform an electrical safety check (i.e. leakage current).
16) Perform Acid Clean and/or Bleach or Heat Disinfection per clinic policy.
End of ‘Final Checks’

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 13
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
•One 25 ml burette with 0.1 ml graduations (P/N 290104)
•Flashlight
•Calibrated Temperature / Conductivity / Pressure (Dialysate) Meter
•Optional: Figure below, Magnetic (Mag) Probe to check valve solenoid magnetism. The Probe can
be obtained from www.stanleysupplyservices.com (P/N 127-800).
Figure 5 - Mag Probe
END OF ‘TEST EQUIPMENT’

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 14
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.
E) Set your CALIBRATED volt meter to volts DC.
F) Connect the meter’s black lead to chassis ground (refer to Figure 2, page 4).
G) Spread the card cage side panels open then gently drop the front panel down to access the
motherboard’s nine (9) pin TEST Connector (Figure below).
H) Measure from the TEST Connector’s +12V pin (pin 5, five pins from the left).
I) Select the screen’s [12 volt set] data box. It turns bright yellow
J) Enter the MEASURED value in the box.
K) ‘Sharply’ press ‘CONFIRM’.
L) ENSURE the [12 Volt Set] data box is pale yellow /white.
M) Sharply press ‘CONFIRM’ again. Figure right, does an
“Operator Error” banner appear?

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 15
Yes “Operator Error” occurs! Proceed to page 618, procedure number P- H.1.2.
No “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….”.
O) Based on the screen’s[5V EST] AND [12V EST] windows, TWO (2)
CHECKS:
Check #1: Is [5V EST]between 4.8 and 5.2?
Check #2: Is [12V EST] between 11.7 and 12.3?
Yes (to BOTH): Press CONFIRM to save the calibration THEN see part P.
No (to one OR both): Proceed to page 618, procedure number P- H.1.2.
END OF ‘VOLTAGE DETECTOR CALIBRATION’

2008K/K2 Troubleshooting Guide
P/N 507298 Rev. H
Page 16
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” during System Initialization. T and C Mode negates these Errors so these boards can
be tested without having to perform calibrations.
a) Enter Service Mode → Options → Hardware Options.
b) Next to T and C Mode place the ‘X’ in the “Yes” box then press ‘CONFIRM’.
The ‘X’ MUST turn blue!
c) Turn the machine off then back on.
d) When the “Select Program” screen (1) appears, “Machine in T and C Mode” appears and upon
returning to Dialysis Program, the Home Screen’s (3) [UF Goal] and [UF Time] windows display “N/A”.
End of ‘How to Enter T and C Mode’