Fresenius Medical Care 2008T BlueStar User manual

2008T
HEMODIALYSIS
SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 490292 Rev. A

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®T
HEMODIALYSIS SYSTEM
TROUBLESHOOTING
GUIDE
Part Number 490292 Rev. A
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 2017 Fresenius Medical Care North America, All Rights Reserved

2008T Technical 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, 2008T, 2008, bibag 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
2008T Technician’s Manual, P/N 490130
Contact Fresenius Medical Care Technical Support for applicable Field Service Bulletins. The
spare parts manual for the model 2008T and other information may be found on our web site at
www.fmcna.com
Indications for Use: The 2008T hemodialysis machine is indicated for acute and chronic dialysis
therapy.

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 1
TABLE OF CONTENTS Page #
USING THE TROUBLESHOOTING GUIDE...............................................................................................3
THE (HYDRAULIC) 'ORDER' OF TROUBLESHOOTING..........................................................................6
INITIAL CHECKS........................................................................................................................................7
FINAL CHECKS BEFORE RETURNING THE MACHINE TO CLINICAL SERVICE ...............................15
TEST EQUIPMENT...................................................................................................................................16
VOLTAGE DETECTOR CALIBRATION ...................................................................................................17
OPERATING MODES...............................................................................................................................19
SECTION 1 – FLOW ERRORS IN DIALYSIS PROGRAM.......................................................................23
SECTION 2 – “NO WATER” ALARM......................................................................................................152
SECTION 3 - FLOW ERRORS IN A CLEANING / DISINFECTION PROGRAM ...................................166
SECTION 4 - TEMPERATURE PROBLEMS..........................................................................................232
•"TEMP OVER 95 DEGREES" IN HEAT DISINFECT
SECTION 5 - CONDUCTIVITY / ON LINE CLEARANCE PROBLEMS.................................................334
•BAD DIALYSATE LAB VALUES
•ON LINE CLEARANCE (OLC) PROBLEMS
SECTION 6 – CONCENTRATE PUMP ERRORS..................................................................................441
•"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 .....................................................448
SECTION 8 - FILLING PROGRAM (AIR LEAK) PROBLEMS................................................................452
SECTION 9 - TMP PROBLEMS .............................................................................................................483
SECTION 10 - PRESSURE TESTS FAILING ........................................................................................517
•"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.........................................................................................534
SECTION 12 – INDUCED POSITIVE PRESSURE TESTS....................................................................541
SECTION 13 - DEAERATION PROBLEMS............................................................................................543
SECTION 14 - UF (ULTRAFILTRATION) PUMP PROBLEMS ..............................................................548
SECTION 15 - BLOOD LEAK PROBLEMS............................................................................................556
Continued on next page

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 2
TABLE OF CONTENTS (CONTINUED) Page #
SECTION 16 - CHECKING THE ACTUATOR BOARD CABLE.............................................................566
SECTION 17 - CHECKING THE SENSOR BOARD CABLE..................................................................569
SECTION 18A - DIAGNOSTIC VALVE LEAK TESTS............................................................................572
SECTION 18B - MANUAL BALANCING CHAMBER VALVE LEAK TESTS..........................................578
SECTION 19 - TESTING FOR LEAKING BALANCING CHAMBER DIAPHRAGM...............................580
SECTION 20 – TROUBLESHOOTING OVERFLOW FROM THE VENT TUBING................................585
SECTION 21 – HYDRAULIC LEAKS......................................................................................................598
SECTION 22 - “WD: FAIL LONG PULSE” OR “WD: FAIL SHORT PULSE”..........................................615
SECTION 23 – HEATER RELAY TEST FAIL.........................................................................................621
SECTION 24 – “DIASAFETEST FAILED”..............................................................................................629
SECTION 25 - TROUBLESHOOTING POWER DISTRIBUTION ..........................................................638
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......................................................................................711
•"ACT BYP VALVE 1 FAIL"
SECTION 27 - “ACT BLOOD PUMP FAILED”........................................................................................720
SECTION 28 – HEAT EXCHANGER LEAKING EXTERNALLY ............................................................725
SECTION 29 – “BIBAG: VALVE 1 OR 2 ERROR”..................................................................................727
SECTION 30 – “V104/V108 STUCK CLOSED” OR V104 ER C = 1......................................................729
SECTION 31 – VALVE 104 OR VALVE 105 ERROR ............................................................................744
SECTION 32 – “V105 STUCK CLOSED” OR V105 ER C = 1...............................................................746
SECTION 33 - “BIBAG: VENT TOO LONG”...........................................................................................754
APPENDIX A - TARGET DEAERATION PRESSURES PER GEOGRAPHICAL AREA........................757
APPENDIX B - CALIBRATE IF REPLACED (non-bibag components) ..................................................758
APPENDIX C CALIBRATE IF REPLACED (bibag components)............................................................759
APPENDIX D - BLOOD PUMP ERROR CODES ...................................................................................760

2008T Troubleshooting Guide
P/N 490292 Rev. A
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 758) and
Appendix C(page 759).
G. Perform FINAL CHECKS (page 15) 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

2008T Troubleshooting Guide
P/N 490292 Rev. A
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
N. Procedures may vary depending on if the machine is equipped for bibag. See the following page:

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 5
bibag(on line bicarb preparation system) [refer to the Figure below]
Machine Front View
Equipped for bibag
Hydraulics Front View
bibag Valves
Hydraulics Front View
bibag Sensors
Figure 3 – bibagComponents
End of ‘Using the Troubleshooting Guide’

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 6
THE (HYDRAULIC) 'ORDER' OF TROUBLESHOOTING
Understanding the ‘Order of Troubleshooting’ will lead to the root cause of a problem and NOT its effects.
1. External hydraulic leaks
2. No Water
3. Flow Errors
4. Temperature
5. Conductivity
6. Filling Programs (air sensed in the hydraulics)
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
alarms before troubleshooting PRESSURE TEST FAILURES.
End of ‘The Order of Troubleshooting‘
Refer to the TABLE OF CONTENTS to locate the symptom.

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 7
INITIAL CHECKS
1) CAUTION! To prevent shock, turn the machine OFF.
2) Figure below, remove the DISTRIBUTION BOARD cover:
a) ENSURE the Sensors and Actuator ribbon cables are
plugged in PROPERLY.
b) Figure right, ENSURE position “X4-PH-PR” is VACANT!
c) Using a flashlight, inspect the Distribution Board surface
for corrosion or burning.
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
moves the Air Sensor Connector two-pins higher than
the others! CBE = Change Being Effected
Parts 3 through 6 next page

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 8
3) To avoid pulling cables loose, gently open the CARD CAGE:
a) Figure right, 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) Inspect the entire length of ALL module cables for damage!
4) Inside the card cage, perform parts a through f below:
a) ENSURE all ribbon cables are plugged in PROPERLY.
b) Inspect the entire length of ALL cables for damage.
c) Using air, clear excessive dust from the surface of the motherboard*. *To LOCATE the motherboard
refer to Figure 4A (page 10).
d) ENSURE no foreign objects (screws, etc.) are laying on the surface of the motherboard!
e) Using a flashlight, inspect the surface of the motherboard for corrosion or burning!
f) Press down HARD on ALL circuit boards to ensure good connections to the motherboard.
5) CAUTION! Close the card cage!
Part 6 next page

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 9
6) Are you troubleshooting a voltage problem (example: “24V Low”) OR an 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) To avoid electrical shock, unplug the machine!
8) Slide the Power Supply ¼ way out away from the cabinet. DO NOT let it fall out!
9) Figure right, at the top of the Power
Control board ensure the Power Logic
and 24V Power cables are plugged in
securely.
10) Using compressed air clear excessive
dust from the board surfaces.
11) Slide the Power Supply back into the
cabinet.
12) Plug the machine in.
13) 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.

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 10
Figure 4A –Card Cage
1– 9 pin Test Connector;2– Power Logic Board NOTE A (page 10); 3 – Actuator-Test Board NOTE B (page 11),
4– Functional Board; 5– User Interface (UI-MICS) Board; 6– Sensor Board
NOTE A - POWER LOGIC BOARD
Figure below, ENSURE the correct Power Logic Board is installed!
Figure 4B – Power Logic Board
P/N 190246

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 11
NOTE B – ACTUATOR-TEST BOARD AND IF bibag EQUIPPED INTERFACE BOARD
A) Unless whatever problem you are troubleshooting will not allow entering Service Mode, if the Actuator-
Test Board is replaced, the Voltage Detector Calibration should be performed! See VOLTAGE
DETECTOR CALIBRATION (page 17).
B) Figure below, if equipped with a bibag Connector the ‘Interface Board’ is piggy backed to the
component side of the Actuator-Test Board. It interfaces the bibag hydraulic components, Actuator-Test
Board and the bibag Distribution Board and Distribution Box 2.
Figure 4C – bibag Interface Board

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 12
bibag Interface Board INSTRUCTIONS:
A) TURN THE MACHINE OFF!
B) Figure below, inside the card cage, the bibag Interface circuit board piggybacks onto the Actuator-Test
Board (2nd circuit board from the left)!
C) ENSURE the bibag Interface Board is connected securely to the Actuator-Test Board! If not this may
be the problem!
D) ENSURE the bibag Interface Board’s 26 AND 20 Pin Ribbon cables are plugged in securely! If not this
may be the problem!
E) Using a flashlight, inspect the 26 AND 20 Pin Ribbon cables for signs of damage. If damage is located
this may be the problem!
F) If the Troubleshooting Guide has instructed you to ‘swap in’ the bibag Interface board use ESD
protection AND ENSURE the new board is known good!

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 13
Figure 4D - bibag Distribution Board and Distribution Box 2
bibag Connector

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 14
Figure 4E - Block Diagram Card Cage to Display Assembly

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 15
FINAL CHECKS BEFORE RETURNING THE MACHINE TO CLINICAL SERVICE
1) Remove all test equipment from the distribution board and ENSURE all female connectors are plugged
in properly.
2) Reinstall the distribution board cover.
3) To help locate future leaks clean spills from hydraulic drawer and floor.
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 about 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’ → ‘Enter’)!
8) Allow [Temperature] to stabilize between 35.1 and 38.9° C; [Conductivity] to between 13.0 and 14.2
mS.
9) From the Home screen, set [Dialysate Flow] to 800 ml/min and press ‘Enter’!
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’

2008T Troubleshooting Guide
P/N 490292 Rev. A
Page 16
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)
•EXTENDER BOARD (P/N 190600)
•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’