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.

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

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

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

Blood Leak

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.