Fresenius Medical Care 4008 HDF User manual

CareFresenius Medical
4008 HDF
Technical Manual

4008 HDF
Technical Manual

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 0-1Part No. 674 398 1
4008 HDF Technical Manual
The Technical Manual contains all information necessary for performing maintenance and repair work.
The 4008 HDF option reflects the latest state of technology and complies with the requirements of
EN 60601-1
Assembly, extension, adjustment, modification or repair may only be carried out by the manufacturer or
persons authorized by him.
Any inquiries should be addressed to:
Manufacturer:
Fresenius Medical Care
Deutschland GmbH
Plant Schweinfurt
Hafenstraße 9
D-97424 Schweinfurt, Germany
Tel.: [phone]
Fax: [phone]
Head office:
Fresenius Medical Care
Deutschland GmbH
Borkenberg 14
D-61440 Oberursel/Ts., Germany
Tel.: [phone]
Telex: 410805 fres d
Fax: [phone]
Local Service:

0-2 Fresenius Medical Care 4008 HDF 3/11.97 (TM)

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 0-3
How to use the Technical Manual
Search and find What? Where?
Tables Contents Pages 0-5 and at the beginning of each chapter
Purpose This manual is intended for:
– first studies (to acquire basic knowledge)
– reference purposes (for start-up, maintenance and repair)
Organization The manual is divided into 6 chapters:
0 General Notes
1 Description of machine functions
2 Technical safety checks
3 Calibration instructions
4 Circuit descriptions and circuit diagrams
5 Spare parts
Numbering system Page number 1-3 is to be interpreted as: Chapter 1, Page 3
Qualification This manual is intended for service technicians
– who are familiar with the current Operating Instructions (Operating Instruc-
tionseratiningtothisTechnicalManualareavailableunderpartno.6744061)
– who have the necessary background experience in mechanics, electrical and
medical engineering
– who have been authorized by the manufacturer to perform maintenance and
repair work
– who have access to the necessary auxiliary and measuring equipment
Restrictions The study of this manual does not represent an alternative to the training courses
offered by the manufacturer.
Manual changes Manual changes will be released as new editions, supplement sheets or product
information.
Note:
Modifications relating to circuit diagrams and component layouts (SP/BP) do not
necessarily involve a change of the footer (edition).
Refer to the index field of the respective circuit diagram or component layout for
the respective state of these diagrams. The identification on the P.C.B. permits
the user/technician to verify if the circuit diagram / component layout matches the
P.C.B. actually installed.
In general, this manual is subject to modification.

0-4 Fresenius Medical Care 4008 HDF 3/11.97 (TM)
Representation New circuit symbols are used in the circuit diagrams. Potential data given in the
circuit diagrams and setting instructions refer to the respective earth.
For example: 24 means ground for 24 V voltage.
Component marking Example:
in circuit diagrams
This refers to a resistor with a position number 75 with a resistance of 1.5 Ohm.
Thedecimalpointisreplaced byaunit symbol(toreduce thepossibilityof errors).
Resistors: Capacitors:
R1: 0.1 Ωµ1: 0.1 µF
1R5: 1.5 Ω1µ5: 1.5 µF
1K5: 1.5 kΩ1000µ: 1000 µF
Note: When repairing or exchanging replacement parts make sure to take the applica-
ble ESD precautions (e.g. EN 100 015-1).
During repair/troubleshooting in the hydraulic unit, protect the components from
dialysate.
Technical data: The technical data for the 4008 HDF option is to be found in Chapter 1 of the
Operating Instructions.
75
1R5

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 0-5
Table of contents
Section Page
1 Description of machine functions............................................................................... 1-
1.1 Description ...................................................................................................................... 1-3
1.2 Description of extended T1 test ...................................................................................... 1-8
1.3 Error messages............................................................................................................... 1-10
2 Technical safety checks............................................................................................... 2-
3 Calibration instructions ............................................................................................... 3-
3.0 General information on the calibration instructions ....................................................... 3-3
3.1 Calibrating the UF2 pump............................................................................................... 3-5
3.2 VDE inspections.............................................................................................................. 3-7
3.3 Calibrating the 4008 HDF scale...................................................................................... 3-8
3.4 Calibrating the substituate sensor .................................................................................. 3-13
3.5 Calibrating the HDF blood pump .................................................................................... 3-15
3.6 Repair instructions .......................................................................................................... 3-17
4 Circuit descriptions and circuit diagrams.................................................................. 4-
4.1 LP 625 display board ...................................................................................................... 4-3
4.2 LP 754 control board HDF .............................................................................................. 4-9
4.3 LP 760 HDF motor control .............................................................................................. 4-19
4.4 LP 761 HDF drive keyboard ........................................................................................... 4-27
4.5 LP 762 scale comm ........................................................................................................ 4-33
4.6 LP 763 SSE serial interface extender............................................................................. 4-39
5 Spare parts .................................................................................................................... 5-
5.0 How to use the spare parts catalog ................................................................................ 5-3
5.1 P.C.B.s............................................................................................................................ 5-4
5.2 Scales ............................................................................................................................. 5-6
5.3 Substituate lift ................................................................................................................. 5-8
5.4 UF2 pump / blood pump (HDF) / valve V 126................................................................. 5-10

0-6 Fresenius Medical Care 4008 HDF 3/11.97 (TM)

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 1-1
Table of contents
1 Description of machine functions
Section Page
1.1 Description .................................................................................................................... 1-3
1.1.1 Components.................................................................................................................... 1-3
1.1.2 Description ...................................................................................................................... 1-3
1.1.3 Component tests............................................................................................................. 1-3
Fig.: Block diagram ......................................................................................................... 1-4
Fig.: Flow diagram .......................................................................................................... 1-5
Fig.: Flow diagram .......................................................................................................... 1-6
1.2 Description of extended T1 test / error messages in T1 test................................... 1-8
1.2.1 Test UF-Function ............................................................................................................ 1-8
1.3 Error messages during treatment and the HDF test ................................................ 1-10
1.4 Error messages, substituate pump............................................................................. 1-13

1-2 Fresenius Medical Care 4008 HDF 3/11.97 (TM)

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 1-3
1.1 Description
1.1.1 Components
The components of the 4008 HDF option are permanently connected to the hemodialysis
machine. The 4008 HDF option comprises the following components:
–Substituate lift
–Scales (weighing range < 20 kg) with data interface and taring facility
–Substituate pump with bidirectional data interface
–UF2 pump
1.1.2 Description
The scales determine the actual weight of the substituate reserve and signals this to the
hemodialysis machine. This calculates the substituate rate depending on the set treatment time.
A substituate sensor mounted on the substituate lift recognises whether:
–Line set is fitted without substituate or
–Line set is fitted with substituate.
The substituate pump delivers the substituate solution to the venous bubble catcher. The filtrate
from the dialysis fluid circuit is removed by the UF2 pump.
1.1.3 Component tests
The scales are checked by the operator by means of a plausibility test before treatment. The
substituate sensor is tested while the 4008 HDF is filling.
The 4008 HDF test tests:
–The substituate pump
–The UF2 pump (electrically and hydraulically)
(If the 4008 HDF test is not carried out then the connections are to be tested but once).
The UF2 pump is tested cyclically during treatment.
The electric control system of the UF2 pump is checked continuously.

1-4 Fresenius Medical Care 4008 HDF 3/11.97 (TM)
Scales
CPU 1
UF2 pump Substituate
pump TMP
CPU 2
WSerial communication
Serial communication
Serial communication
Operating system Safety system
Fig.: Block diagram

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 1-5
UF2
pump UF
pump Flow
pump Dialysate
pressure
transducer
V126
V26
V24
V24b
Dialyzer
Air detector
Venous bubble catcher
Arterial
blood pump
Venous line
clamp
Substituate
pump
Substituate
sensor
Scales
Substituate
bag
Patient
Balancing chamber
LP 632
CPU 2
LP 631
CPU 1
LP 763
SSE
Serial
interface
extender
LP 633
Input
board
LP 634
Output
board
serial
interface
X632/
B24 X632/
C27 X634 R/
C11
X634 R/
A24
serial interface
serial interface and taring line
X632/
A7
X632/
C7
X632/
A29 X634 L/
A–C24
X634 L/
A–C23
X633 L/
C14
X633 L/
C23
X633 L/
B6
Control, UF2 pump
Control, UF pump
Acknowledgement, dialysate pressure
Control, UF pump
Control, UF2 pump
Acknowledgement, UF pump
Acknowledgement, UF2 pump
Acknowledgem., dialy. pressure
XHDF 2–4
X348v/4–5
X633 R/
C28–30
Fig.: Flow diagram

1-6 Fresenius Medical Care 4008 HDF 3/11.97 (TM)
Fig.: Flow diagram

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 1-7
Legend
2 Temperature sensor
3 Temperature sensor
5 Float switch
6 Level sensor
7 Conductivity measuring cell
8 Blood leak detector
9 Pressure transducer
10 Reed contact for concentrate
12 Reed contact for bicarbonate
20 UF2 pump
21 Flow pump
22 UF pump
23 Concentrate pump
24 Dialyzer valve 1
24b Dialyzer valve 2
25 Bicarbonate pump
26 Bypass valve
29 Degassing pump
30 Drain valve
31 Balancing chamber valve 1
32 Balancing chamber valve 2
33 Balancing chamber valve 3
34 Balancing chamber valve 4
35 Balancing chamber valve 5
36 Balancing chamber valve 6
37 Balancing chamber valve 7
38 Balancing chamber valve 8
41 Water inlet valve
43 Fill valve
54 Heater rod
61 Pressure reducing valve
63 Filter/water inlet
65 Loading pressure valve
66 Heater block
66a Water inflow chamber
66b Heater rod chamber
66c Float chamber
68 Balancing chamber
71 Filter/concentrate
72 Filter/bicarbonate
73 Filter/external dialysate
74 Filter/UF
75 External flow indicator
76 Filter/fill valve
Hydraulic measurement points
A Reduced water inlet pressure
B Balancing chamber loading pressure
C Flow pump pressure
D Degassing pump pressure
77 Heat exchanger
78 Relief valve
84 Disinfection valve
85 Disinfectant conncector
86 Recirculation valve
87 Discharge valve
88 Multifunction block
88a Degassing chamber
88b Secondary air separator
88c Primary air separator
89 Degassing orifice
90a Rinse chamber concentrate
90b Rinse chamber bicarbonate
91 Rinse valve
92 Vent valve
94 Concentrate suction tube
95 Bicarbonate suction tube
97 Ventilation pump
99 Rinse valve
100 Rinse valve
102 Concentrate valve in central delivery system
104 Bicarbonate valve in central delivery system
109 Temperature sensor
111 Hydrophobic filter
112 Vent valve
114 Dialysate filter
115 Disinfection valve sensor
116 Sampleing valve
117 Check valve (concentrate)
118 Check valve (bicarbonate)
119 Filter (concentrate)
120 Filter (bicarbonate)
121 Concentrate connector in central delivery system
122 Bicarbonate connector in central delivery system
123 Pressure switch for V 102
124 Pressure switch for V 104
125 Adapter plate
126 4008 HDF vent valve
148 Filter/rinse valve
149 Filter/rinse valve
150 Filter
151 Orifice
152 4008 HDF hydrophobic filter

1-8 Fresenius Medical Care 4008 HDF 3/11.97 (TM)
1.2 Description of extended T1 test / error messages in the T1 test
Possible error messages displayed in the T1 test are listed in the Technical Manual for the
hemodialysis machine. If the HDF option is installed and activated the following error codes can
also appear:
1.2.1 Test UF-Function
Test description:
CPU 1 starts up the UF2 pump at a defined rate.
CPU 2 controls the hydraulic and electrical function of the UF2 pump.
CPU 2 blocks the control line of the UF2 pump and checks for standstill.
UF2 counter check.
Figure:

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 1-9
Error description:
Error message Description
F11 UF-Function The interval between the strokes of the UF2 pump was less than
220ms.Correct delivery of the required volume is not safeguard-
ed because the stroke return travel is too short.
–A pump rate which was too high was signalled by the CPU 1.
F12 UF-Function The pulse time for the UF2 pump is less than 180 ms. Correct
delivery of the required volume is not safeguarded because the
discharge time is too short.
–Monoflop on LP 634 defect (IC 42/R65/C45).
F 13 UF-Function The pulse for the UF2 pump is longer than 500 ms. A maximum
rate of 5000 ml/h is not possible.
–Monoflop on LP 634 defect (IC 42/R65/C45).
F14 UF-Function UF2 pump not active during the test (4 s).
–Acknowledgement (UF_P2, X637/B26) →X632/C7 no LOW
pulse
–Control line (UF_P2, X634L/A–C24) →X637/B26 no LOW
pulse
F15 UF-Function The UF2 pump cannot be stopped by the CPU2.
–Control line (UF_P_EN, X632/C28) →X634R/A22 no 5 V.
–Reset input to IC 42/pin 13 on LP 634 defect.
F16 UF-Function The UF pump acknowledgement from CPU1 is faulty.
–Acknowledgement (UF_P2, X637/B26) →X633/C23no LOW
pulse
F17 UF-Function The change in pressure after a UF2 pump stroke less than
20 mmHg.
–UF2 pump mechanically defect.
–Control line (UF_P2_CRTL, X632/B24) →X634R/C11 no
HIGH pulse.
F20 UF-Function Difference in pressure between UF pump stroke and UF2 pump
stroke more than 20 %.
–Stroke rate for UF pump or UF2 pump not set correctly.

1-10 Fresenius Medical Care 4008 HDF 3/11.97 (TM)
1.3 Error messages during treatment and the HDF test
Message on the
display Cause
F321 HDF-failure
F322 HDF-failure
F323 HDF-failure
F324 HDF-failure
F325 HDF-failure
The UF pump or UF2 pump
test will not be started as long
as the level sensor (6) detects
air. The level sensor (6) will
detect air one minute after the
4008 HDF test has been se-
lected
The UF pump or UF2 pump
has carried out more than 50
strokes and still no air has
been detected.
The substituate pump runs at a
rate of 10 ml/min. to raise the
fluid level by a defined amount
in the secondary air separator
(the fluid will just be detected).
Air will still be detected after 2
minutes.
Since fluid has been recog-
nized in the secondary air sep-
arator the substituate pump
starts at a rate of 10 ml/min.
until a change in weight follows
on the scales (i.e. a jump in
grammes). There was no dif-
ference in weight established
after one minute.
If the expected change in
weight (i.e. a jump in
grammes) is higher or lower
than –1 g, the respective UF
pump test will be repeated.
The UF pump test was repeat-
ed more than 5 times.
Possible error elimination
Check level sensor (6) (de-
fect).
Check V126 (does not open,
venous bubble catcher col-
lapses), check V43 (whether
leaking or open).
Check UF pump or UF2 pump,
respectively (mech. defect).
Check substituate tubing
(clamped off, not connected to
the venous bubble catcher).
Check substituate tubing
(clamped off).
Check bag (fluctuations in air
draft)
Check scales (for drifting).

Fresenius Medical Care 4008 HDF 3/11.97 (TM) 1-11
The fluid level in the second-
ary air separator is raised
again by the substituate pump
after 100 strokes of the UF
pump or UF2 pump, respec-
tively, until fluid is detected.
Plus run-on time at a rate of 10
ml/min. for the gramme jump.
Air will still be detected after a
specific period of time (de-
pending on the delivery rate of
the substituate pump).
One UF pump did not pass the
test. The filling volume for the
secondary air separator is not
within the given tolerance of
100 ml; ±5 ml. Should the test
give a reading of over 105 ml
the cause could also be air
taken in the flow from a badly
vented dialysator.
Interval between two strokes
of the UF pump less than
220 ms.
Pulse time of a stroke of UF
pump less than 180 ml.
Pulse time of a stroke of UF
pump more than 500 ms.
Starting time for the UF pump
more than 10 seconds.
Difference between desired or
actual delivery rate of the UF
pump greater than + 10%.
UF pump stops longer than the
maximum period time.
Despite switched off ultrafiltra-
tion the change in delivery rate
of the UF pump is greater than
10 ml.
Interval between two strokes
of the UF2 pump less than
220ms.
Check substituate hose
(clamped off, not connected
with the venous bubble
catcher).
Check UF pump or UF2 pump,
respectively (not calibrated,
mechanical defect).
Check CPU 1 (defect).
Check LP 634 (regulating
monoflop defect).
Check LP 634 (regulating
monoflop defect).
Check LP 634 (regulating end
stage defect).
Check CPU 1 / CPU 2
(communication problems).
Check LP 634 (regulating end
stage defect).
Check UF pump
(interruption, control).
Check CPU 1 / CPU 2
(communication problems)
Check CPU 1 / CPU 2
(communication problems)
Check CPU 1 (defect).
F326 UF-failure
UF1 volume-Error
or
UF2 volume-Error
F327 UF-failure
F328 UF-failure
F329 UF-failure
F330 UF-failure
F331 UF-failure
F332 UF-failure
F333 UF-failure
F334 UF-failure
Message on the
display Cause Possible error elimination

1-12 Fresenius Medical Care 4008 HDF 3/11.97 (TM)
Check LP 634 (regulating
monoflop defect).
Check LP 634 (regulating
monoflop defect).
Check LP 634 (regulating end
stage defect).
Check CPU 1 / CPU 2
(communication problems).
Check LP 634 (regulating end
stage defect).
Check UF pump (interruption,
control).
Check CPU 1 / CPU 2
(communication problems).
Check CPU 1 / CPU 2
(communication problems).
Check UF pump
(spring, screen)
Check UF2 pump
(spring, screen)
Check UF pump and UF2
pump (delivery volume)
Check monitor / scales
(communication problems).
Check monitor / scales
(communication problems).
Check V24B and V43 feed-
back lines.
Check sense of rotation of as-
piration pump.
Check hydraulics unit for
leaks.
Check scales
Check substituate bag
Check substituate bag
(weight fluctuations)
Check HDF control system
(greater fluctuations)
Pulse time of a stroke of the
UF2 pump less than 180 ms.
Pulse time of a stroke of the
UF2 pump more than 500 ms.
Reaction time of the UF2
pump more than 10 seconds.
Difference in desired or actual
delivery rate of UF2 pump
greater than ±10 %.
UF2 pump stops longer than
the maximum period time.
Despite switched off 4008HDF
change in delivery rate of the
UF2 pump greater than 10 ml.
Failure of UF pump.
Failure of UF2 pump.
Volume difference between UF
pump and UF2 pump.
Balance failure recognized by
CPU2 greater than ±500 ml.
Bolus exceeded by more than
+ 20 ml, detected by CPU2.
CPU2 failed to perform the cy-
clic UF pump test within 5 min-
utes.
Weight change on the scales
during the weighing test great-
er than 2g.
The delivery rate correction
factor could still not be deter-
mined after 20 minutes treat-
ment time.
Possible error eliminationMessage on the
display Cause
F335 UF-failure
F336 UF-failure
F337 UF-failure
F338 UF-failure
F339 UF-failure
F340 UF-failure
F341 UF-failure
F342 UF-failure
F343 UF-failure
F344 HDF-failure
F345 HDF-failure
F346 HDF-failure
F348 HDF-failure
F349 HDF-failure