front_rearAK200Smaint_en_4.

pdf 2004-09-13 11:38:04

Maintenance Manual
AK 200 S / AK 200 ULTRA S
05.2006

CM

MY

CY

CMY

GAMBRO
 Maintenance Manual

Preventive maintenance procedures for

AK 200 S / AK 200 ULTRA S

General ........................................................... 2:2

Test equipment ............................................. 2:3

Preventive Maintenance: Base-kit............ 2:4

Parts ................................................................ 2:4
How to exchange the parts included
in the Base-kit ................................................. 2:5
Actions to carry out after the parts
have been exchanged ...................................... 2:8

Preventive Maintenance: A-kit ............... 2:23

Parts .............................................................. 2:23
How to exchange the exterior parts
included in the A-kit ...................................... 2:24
Actions to carry out after the parts have
been exchanged ............................................. 2:25

Preventive Maintenance: B-kit ............... 2:26

Parts .............................................................. 2:26
How to exchange the parts included
in the B-kit .................................................... 2:27
Actions to carry out after the parts have
been exchanged ............................................. 2:29

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:1

Maintenance Manual
General
To ensure proper operation of the AK 200 S /
AK 200 ULTRA S, a qualified service technician
must perform a complete series of preventive
maintenance procedures at regular intervals.
The maintenance and calibration information
that you need to use is provided in this manual.
The preventive maintenance procedures have
been devised to require a minimum of time while
ensuring that the machine is maintained in
optimum operation condition.
Included in the preventive maintenance proce-
dures are checks to verify normal machine
operation. Should the machine fail to pass any of
these tests, repair or calibration might be
needed, then repeat the tests until the specifica-
tions are met.
It is mandatory to perform at least a preventive
maintenance every second year.
A yearly maintenance is recommended. The rate
of preventive maintenance might be different
due to variations of the operating environment.
The AK 200 S / AK 200 ULTRA S will perform as
designed only if it is used and maintained in
accordance with Gambro’s instructions.
Any warranties made by Gambro with respect to
the AK 200 S / AK 200 ULTRA S are void if the
equipment is not used in accordance with the
instructions provided. Gambro will not accept
responsibility for any damage or injury resulting
from improper use or maintenance or unauthor-
ized repair.
2:2
To fulfill the preventive maintenance procedures
for AK 200 S / AK 200 ULTRA S some parts must
be exchanged. The necessary parts to be ex-
changed are available in a Base-kit and two
complementary kits:
• Base-kit (K40165001)
• A-kit (K40166001): Includes exterior parts
• B-kit (K40167001): Overhauling service-kit
When performing preventive maintenance
procedures or calibrations, which require access
to the interior of the machine, you must have
proper electrostatic safety devices (i.e. wrist
grounding straps or grounding mats) in place to
prevent damage to electrostatic sensitive compo-
nents within the machine.
During repair of any of the parts in the flow
path, special care should be taken and a good
hygiene should be kept.
Note! After maintenance a disinfection program
must be performed before a treatment is per-
formed.
Checklists are provided in the Spare Parts
Instruction that is included in the maintenance-
kits. The purpose of these checklists is to record
the work done.
AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006
 Maintenance Manual

Test equipment

Test equipment needed to perform maintenance

Test equipment: Tolerance: Manufacturer: Gambro Order

number:
Conductivity measurement ± 0.1 mS/cm MESA, IBP
Pressure measurement ± 2mmHg to ± 200mmHg MESA, IBP, Druck
± 1% beyond ± 200mmHg
If BPM is installed:
± 0.8mmHg
Temperature measurement: ± 0.2ºC MESA, IBP
Digital Voltmeter ± 0.5% Fluke
Measuring glass ± 5 ml
Blood leak Calibration N/A Gambro K40169001
Cover
Gauge pin kit for blood pump rollers T = 1.1 (Stop pin = 1.1*2*0.7 = 1.5mm) Gambro K40158001
(including three different pins) T = 1.6 (Stop pin = 1.6*2*0.7 = 2.2mm)
T = 2.0 (Stop pin = 2.0*2*0.7 = 2.8mm)

T = wall thickness of the blood tubing

Gauge pin kit for blood pump rollers T = 1.1 (Stop pin = 1.1*2*0.7 = 1.5mm) Gambro K40158002
(to be ordered separately) T = 1.6 (Stop pin = 1.6*2*0.7 = 2.2mm) K40158003
T = 2.0 (Stop pin = 2.0*2*0.7 = 2.8mm) K40158004

T = wall thickness of the blood tubing

Calibration tube kit N/A Gambro K13983002
Drip chamber N/A
Tube for calibration of N/A
priming detector
Safety tester According to IEC 60601-1 Rigel, Biotec, Metron
*BPM test equipment N/A Gambro K22151001
*BPM Cuff N/A Gambro 100900141
*pH buffers ± 0.07 pH units pH 7 – 100810001
pH 9 – 100810002
BVS test tool Gambro K22281001
Magnet for blood pump cover Gambro K19049001

* If installed

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:3

Maintenance Manual Base-kit

Preventive Maintenance: Base-kit

Parts
The Base-kit (K40165001) includes all parts
necessary to fulfill the mandatory preventive
maintenance procedures for AK 200 S /
AK 200 ULTRA S.

Step Monitor Denomination Part no. Qty

2, 3 BM/FM Air filter K11503001 3
4 AC/DC Air filter K18891001 1
O-ring for BiCart- and SelectCart holder,
5, 6 FM 100319008 4
upper and lower.
7 FM O-ring for ultrafilter holders 100319029 4
7 FM Square-ring for ultrafilter holders K14920001 2
8 FM Filter BiCart holder, upper and lower (50µm) K16538C 2
9 FM Filter SelectCart holder, lower (50µm) K16538C 1
10 FM Filter after the SelectBag holder (50µm) K16538C 1
11 FM Filter heating vessel (250µm) K14944001 1
12 FM V-ring heating vessel 100318086 2
13 FM Membrane for internal pressure regulator K40153001 1
14 FM Membrane for non-return valve K17989001 1
15 FM Sample port for 6 mm tube K20219002 1
16 FM Sealing ring (Inlet unit - heating vessel) K07994001 1
16 FM Ring (Inlet unit - heating vessel) K08227001 1
17 FM Sealing for infusion port K18184001 1
18 FM Label K24092001 1

Note!
As a complement to the Base-kit, two additional
kits are available; A- and B-kit.

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Base-kit Maintenance Manual

How to exchange the parts included in

the Base-kit

1. First perform a combined heat disinfection 4. Change air filters in the AC/DC unit.
program with CleanCart C or liquid citric
acid.
Then perform a heat disinfection program in
combination with CleanCart A or a Chemical
disinfection program with sodium hypochlo-
rite. Refer to the AK 200 S or
AK 200 ULTRA S Operator’s Manual.

2. Change air filters in the Blood Monitor. 5. Change the upper and lower O-rings in the
BiCart holder.
2
3
1

o-ring

3. Change air filter in the Fluid Monitor. 6. Change the upper and lower O-rings in the
SelectCart holder.
2
3
1
o-ring

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:5

Maintenance Manual Base-kit

7. Change the O-rings and square-rings in the 10. Change the particle filter after the SelectBag
ultrafilter holders. (Only for AK 200 S with holder (50 µm).
UFD-kit and AK 200 ULTRA S)

o-ring

o-ring
square-
ring

8. Change the upper and lower filters on the 11. Change the filter for the heating vessel
BiCart holder (50 µm). (250 µm).

9. Change the lower filter on the SelectCart 12. Change the V-rings in the heating vessel.
holder (50 µm).

A B

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Base-kit Maintenance Manual

13. If ULTRA: Change the membrane for the 16. Change the sealing ring and the ring on the
internal pressure regulator. inlet unit inside the heating vessel.

Note! It is important that the sealing ring is

re-assembled with its flat side according to
this illustration.

17. If ULTRA: Change the sealing for the

14. If ULTRA: Change the membrane for the infusion port on the FM front.
non-return valve.

15. Change the sample ports. 18. Mark month and year for the next scheduled
preventive maintenance. Attach the label to
the rear cover of the machine.

05 10
06 09
07 08

05 10
06 09
07 08

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:7

Maintenance Manual Base-kit

Actions to carry out after the parts

have been exchanged
1. Check that the screws for the blood pump(s) 3. Check that the wheels are tightened.
are tightened.

4. Check that the screw for the infusion stand is

2. Check that the screws for the hose clamps on
tightened.
the water inlet and drain tube are tightened.

5. Perform the Protective Earth Test (PET)

according to instructions available in
HCEN12190, Electrical safety inspections for
AK-machines.

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 Base-kit Maintenance Manual

6. Check the protective earth resistance in BM. 8. Erase the error code buffers. Enter
Measure between TP 8 (Z0VL) on the BM- service menu > Diagnose > System >
CPU board and the earth point on the bottom Errors > Erase
plate. Measure in MΩ, should be > 1 MΩ.
The machine must be empty and switched off
during measurement.
Note! The BM must be connected to the FM.

TP4
TP5 TP9
TP7 TP10
TP11
TP17
TP14 TP18
TP12 TP22
TP13
TP6
TP8
TP15
TP16
TP21
TP3 E01342007
TP19
TP2 TP20
1074

7. Check the protective earth resistance in FM.

Measure between TP 7 (Z0VL) on the Power
distribution board and the earth point on the
back plate. Measure in MΩ, should be
> 1 MΩ . The machine must be empty and
switched off during measurement.

TP1 TP4
TP2 TP3

TP7
TP8

TP5
TP6

E01345009

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:9

Maintenance Manual
9. BPM-test
Note!
Following text is valid for machines equipped with
the SunTech blood pressure module (K24274001).
For machines equipped with the Colin blood pres-
sure module (K23564001), refer to HCEN9291,
revision 07.2005 for technical and maintenance
information about BPM.
9.1 Test method:
- Attach BPM cuff, 100900141, tight to the
BPM test equipment, K22151001.
- Start the AK 200 S / AK 200 ULTRA S with
the main switch and the ON/OFF button.
- Enter Service mode.
- Enter Diagnostics mode.
- Select BM, Others, BPM
9.2 BPM sub-tests
In the BPM service menu the following sub-
tests are included:
- Air leakage test: measures that the equip-
ment is airtight.
- Inflation speed test: measures the time to fill
the cuff with air.
- Static pressure: Check of pressure trans-
ducer calibration
Each of the tests can be carried out separately
but the above order for carrying out the sub-
tests is recommended.
Check that the results from the sub-tests not
exceed following limits:
- Air leakage: maximum 18 mmHg/ 3 min
- Inflation speed: 2 -11 s
- Static pressure: Maximum deviation from
reference to be within ± 3 mm Hg.
50 ± 3 mmHg
150 ± 3 mmHg
250 ± 3 mmHg
2:10
Base-kit
9.3 Check of air leakage
By entering this test mode the air leakage
for the BPM module, cuff hose and cuff
will be tested automatically.
Before entering the test mode cuff and cuff
hose to be connected to the AK 200 S /
AK 200 ULTRA S.
Cuff to be wrapped tight to the BPM test
equipment.
BPM test equipment is used to simulate
the patient arm circumference. The air
leakage is only tested for 90 sec but the
value is recalculated for 3 minutes.
If the displayed value is above 18 mm Hg /
3 minutes, this indicates that there is a
possible air leakage in the system.
It is of course also possible to perform this
test without the cuff and cuff hose con-
nected but then the test will only check
for air leakage within the
AK 200 S / AK 200 ULTRA S. In this case
replace the cuff and cuff hose by a tube,
which is closed.
9.4 Check of inflation speed
By entering this test mode the capacity for
the pump within the module will be tested
automatically. Before entering the test
mode cuff and cuff hose to be connected to
the AK 200 S / AK 200 ULTRA S.
Cuff to be wrapped tight to the BPM test
equipment. If the displayed time is above
11 seconds, this test indicates that the
pump is worn-out.
AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006
Base-kit Maintenance Manual

9.5 Check of pressure transducer calibration and
measured pressure
By entering this test mode it will be possible to
check the actual pressure value for the BPM
pressure on the AK 200 S /
AK 200 ULTRA S display.
10. Calibrate the Priming detector (BM 6).
10.1 Enter Service/Calibr/BM and set the
AK 200 S / AK 200 ULTRA S display to:
PRIMING DETECTOR
BM 6

Before entering the test mode, pressure trans- 10.2 Press to start calibration routine.
ducer calibration tube kit K13983002 to be
connected to the BPM connector on the rear of
the AK 200 S / AK 200 ULTRA S . No cuff and 10.3
cuff hose to be connected.
INSERT EMPTY REFERENCE TUBE
Press SET key when ready

Note! The pressure transducer calibration tube

kit must be drained before being connected, to
make sure that no fluids or particles enters the
BPM connector or tubing’s. This might otherwise
damage or destroy the sensitive BPM sensors.

When “Measured pressure” is displayed it is

possible to start applying the external reference
pressure.

Note! Pressures shall be applied very carefully

so that no overpressures occur.

To check the actual pressure value, external

pressure reference instrument to be connected
and external pressure of 250, 150, 50 mm Hg to
be applied. Check deviation from reference
pressure instrument for displayed value.
10.4 The calibration is now performed automati-
cally and the calibration factor is written into
the EEPROM.
10.5 The calibration value is now shown on the
information display:

READY BLOOD LEVEL

XX Confirm

10.6 Press the lit to confirm.

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Maintenance Manual Base-kit

11. Calibrate the Level detector
(Air detector) (BM 5).
11.1 Enter Service/Calibr/BM and set the
AK 200 S / AK 200 ULTRA S display to:
12. Measure the power on battery B1 on the
BM-CPU board, exchange if the value is
below 2,6 V (Note! The machine must be
switched on when measuring).

LEVEL DETECTOR
BM 5

11.2 Press to start calibration routine.

11.3 Insert a filled drip chamber. It is recom-

mended that both the water and the drip
chamber have a temperature of approx.
37 ºC. Make sure that the level detector and
drip chamber are dry and clean. If possible,
the drip chamber shall be from the same
type of bloodline as will be used during
treatment.

11.4 Press the lit .

11.5 The calibration is now performed automati-
cally and the calibration factor is written
into the EEPROM.

11.6 The calibration value is now shown on the

information display:

READY LEVEL TRANSMIT

XX YYY Confirm

The value under LEVEL is the new alarm

limit, it is recommended that this value is
between 30 and 40 for best performance.
The value under TRANSMIT is the trans-
mission level, which is normally 255 but can
also be 160, if the air detector transducers
are exceptionally good.

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Base-kit Maintenance Manual

13. Control of the blood pump occlusion
Check surface on the roller at the pump rotor, if
it is damaged exchange the unit. The roller unit
should easily go back to upper end position when
it has been pressed down to end position, ex-
change unit if it gets stuck in any position.
Note! If the blood lines/infusion lines have a
different wall thickness, the occlusion of the
blood pump must be adjusted to the right size.
Use the gauge pins (stop/go) available in the kit
K40158001. The kit includes following three
different gauge pins:
The GO pin should barely pass within the cali-
brating area.
The STOP pin is NOT allowed to pass in any
point within the calibrating area.
Note! Put grease on the GO and STOP pins
when not used and store gage in plastic bag to
prevent it from corroding.
Note! The gauge pins can also be ordered sepa-
rately:
T=1.1 (white) K40158002
T=1.6 mm (red) K40158003
T=2.0 mm (blue) K40158004

T = 1.1 (Stop pin = 1.1*2*0.7 = 1.5mm)

T = 1.6 (Stop pin = 1.6*2*0.7 = 2.2mm)
T = 2.0 (Stop pin = 2.0*2*0.7 = 2.8mm)

T = wall thickness of the blood tubing

Use following formula to calculate which gage

pin to use:
2 * wall thickness * 0,7 (mm)

Check the range between the blood pump rollers

and the path according to the picture below.
Adjust range between the blood pump rollers and
the path if it is necessary.

= Measuring

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Maintenance Manual Base-kit

14. Enter Service/Calibr/BM and set the 15. Enter Service/Calibr/BM and set the
AK 200 S / AK 200 ULTRA S display to: AK 200 S / AK 200 ULTRA S display to:

PRESSURE SYSTEM PRESSURE ARTERIAL

BM 1 BM 2

14.1 Press to start calibration routine.

14.2 Make sure that nothing is connected to the
transducer (zero pressure)
14.3 Check zero level of the System Pressure
Transducer.
Tolerance: ± 5 mmHg.
Calibrate if necessary (see chapter calibration
for details).
15.1 Press to start calibration routine.
15.2 Make sure that nothing is connected to the
transducer (zero pressure)
15.3 Check zero level of the Arterial Pressure
Transducer.
Tolerance: ± 5 mmHg.
Calibrate if necessary (see chapter calibration
for details).

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Base-kit Maintenance Manual

16. Enter Service/Calibr/BM and set the 17. Enter Diagnose/BM/Pumps and check that
AK 200 S / AK 200 ULTRA S display to: the blood pump(s) stops when the cover is
opened.
PRESSURE VENOUS
BM 3

16.1 Press to start calibration routine.

16.2 Make sure that nothing is connected to the

transducer (zero pressure).

16.3 Check zero level of the Venous Pressure

Transducer.
Tolerance: ± 5 mmHg.
Calibrate if necessary (see chapter calibration
for details).

18. Start the blood pump(s) and let it run at

lowest possible speed. Open the blood pump
cover and place a magnet (1) on the sensor
for the cover. Stop the blood pump rotor by
manually grabbing the handle (2).
Check that the power to the blood pump
motor is switched off within 2 seconds.

1 2

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:15

Maintenance Manual Base-kit

19. Enter Service/Calibr/FM and set the 20. Enter Service/Calibr/FM and set the
AK 200 S / AK 200 ULTRA S display to: AK 200 S / AK 200 ULTRA S display to:

DEGASSING PRESSURE FLOW OUTPUT PRESSURE

FM 7 FM 8

19.1 Press to start calibration routine. 20.1 Press to start calibration routine.

19.2 Disconnect a tube to achieve zero pressure 20.2 Disconnect a tube to achieve zero pressure
(see picture). (see picture).

19.3 Check zero level of the Degassing Pressure 20.3 Check zero level of the Flow Output Pres-
Transducer. sure Transducer.
Tolerance: ± 5 mmHg. Tolerance: ± 5 mmHg.
Calibrate if necessary (see chapter calibration Calibrate if necessary (see chapter calibration
for details). for details).

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Base-kit Maintenance Manual

21. Enter Service/Calibr/FM and set the 22. Enter Service/Calibr/FM and set the
AK 200 S / AK 200 ULTRA S display to: AK 200 S / AK 200 ULTRA S display to:

FLOW INPUT PRESSURE HIGH PRESSURE GUARD

FM 9 FM 10

21.1 Press to start calibration routine.

22.1 Press to start calibration routine.
21.2 Disconnect a tube to achieve zero pressure
(see picture). 22.2 Disconnect a tube to achieve zero pressure
(see picture).
21.3 Check zero level of the Flow Input Pressure
Transducer. 22.3 Check zero level of the High Pressure
Tolerance: ± 5 mmHg. Guard Transducer.
Calibrate if necessary (see chapter calibration Tolerance: ± 5 mmHg.
for details). Calibrate if necessary (see chapter calibration
for details).

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:17

Maintenance Manual Base-kit

23. Enter Service/Calibr/FM and set the 24. Enter Service/Calibr/FM and set the
AK 200 S / AK 200 ULTRA S display to: AK 200 S / AK 200 ULTRA S display to:

DIALYSIS FLUID PRESSURE SAFETY GUARD PRESSURE

FM 11 FM 12

23.1 Press to start calibration routine. 24.1 Press to start calibration routine.

23.2 Disconnect a tube to achieve zero pressure 24.2 Disconnect a tube to achieve zero pressure
(see picture). (see picture).

23.3 Check zero level of the Dialysis Fluid Pres- 24.3 Check zero level of the Safety Guard Pres-
sure Transducer. sure Transducer.
Tolerance: ± 5 mmHg. Tolerance: ± 5 mmHg.
Calibrate if necessary (see chapter calibration Calibrate if necessary (see chapter calibration
for details). for details).

OR

2:18 AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006

Base-kit
25. If installed: Calibrate the pH-sensor
(FM 13) with a buffer solution.
26. Remove the blood leak detector cover and
clean the inside of the blood leak housing.
Mount a blood leak calibration cover. Make
sure that the filter is in horisontal position,
start the AK 200 S / AK 200 ULTRA S.
Enter the Service menu, select calibration,
FM, intern and Blood Leak Detector
(FM24).
Place A-pickup tube in concentrate contai-
ner and let it stabilise for 15 minutes.
Note! Let the AK 200 S / AK 200 ULTRA S
stabilize at 37° C
Press to enter the blood leak calibra-
tion routine.
Check the blood leak detector limits 0 and
100 ±10.
Calibrate if necessary (see chapter
calibration for details).
27. Check the water level in the heating vessel,
should be approximately 1cm above the
centerline, adjust if necessary.
AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006
Maintenance Manual
28. Check the conductivity indications, at ap-
proximately 14 mS/cm.
Use GXL – fluid monitor screen and a refer-
ence instrument connected to the dialysis
fluid tubes.
The indicated conductivity values in GXL
should correspond to the indication on the
reference instrument. The maximum devia-
tion is ±0.1 mS/cm.
29. Check the temperature indications, at ap-
proximately 37 °C.
Use GXL – fluid monitor screen and a refer-
ence instrument connected to the dialysis
fluid tubes.
The indicated temperature value (at the
conductivity cell 2, guard) should correspond
to the indication on the reference instru-
ment. The maximum deviation is ±1.5 °C.
If the deviation is more than the stated
tolerance; the affected temperature trans-
ducer must be exchanged.
30. Place the B-pickup tube in the concentrate
container.
Perform an FRN calibration. Enter service
menu/Calibr/FM/Other/UF/Restr.
2:19
Maintenance Manual Base-kit

31. Let the machine pass Fch. Check the DC 38. If ULTRA: Calibration of internal pressure
leakage between TP 7 (Z0VL) on the Power regulator.
distribution board and the earth point on the
back plate. Measure in DC Voltage, should be
< 1 V. 38.1 Press and set the main flow to

32. Check the DC leakage between TP 7 (Z0VL) 500 ml/min.

on the Power distribution board and the
cover on the Degass pump motor. Measure in
DC Voltage, should be < 1 V. 38.2 Choose or .

33. Check the DC leakage between TP 7 (Z0VL)

on the Power distribution board and the 38.3 Press and switch to .
Degass pump head. Measure in DC Voltage,
should be < 1 V.
38.4 Connect the dialyzer coupling to the conduc-
34. Check the DC leakage between TP 7 (Z0VL) tivity cell on the reference instrument.
on the Power distribution board and the
cover on the Flow Out pump motor. Measure 38.5 Adjust venous pressure to +100 mmHg and
in DC Voltage, should be < 1 V. TMP to +400 mmHg.

35. Check the DC leakage between TP 7 (Z0VL) 38.6 Connect a tube between the infusion port
on the Power distribution board and the Flow and an external pressure reference instru-
Out pump head. Measure in DC Voltage, ment.
should be < 1 V.

36. Check the DC leakage between TP 7 (Z0VL) 38.7 Press to obtain main flow through the
on the Power distribution board and the
cover on the Flow In pump motor. Measure pressure regulator.
in DC Voltage, should be < 1 V.
38.8 Adjust the pressure regulator to
37. Check the DC leakage between TP 7 (Z0VL) +55 mmHg ±5 mmHg.
on the Power distribution board and the Flow
In pump head. Measure in DC Voltage,
should be < 1 V. 38.9 Press and remove the reference
instrument and tube.

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Base-kit Maintenance Manual

39. Perform a simulated treatment according to
following instruction:
· If the BVS is installed, switch it on.
· The machine must be in volume control.
· Insert a filled venous drip chamber in the
level detector.
· When the priming button is flashing, simulate
a venous pressure of approximately 50 mmHg.
· (Insert the BVS test tool, K22281001).
· Set the UF-volume to 0.9 and treatment TIME
to 1:00h.
· Connect a T-piece to the dialysis tubings. Put
the end of the tube in a measuring glass filled
with more than 1 liter of water, approx. 37 °C .
· Press fluid bypass. Check that the tube to the
meassuring glass is filled with water and all
air bubbles are evacuated.
· Set the blood pump speed to 200 ml/min, press
the priming button and start the blood pump.
· Press UF-rate and set priming UF rate and
minimum UF-rate to 0.0 l/h.
· Make sure the measuring glass is filled to 1.00
liter adjust if necessary.
· Check the residual volume at TIME=0:00
· Approved residual volume:
100 ml ±50 ml.
· Approved difference between actual
UF volume and UF Supervision
volume is 120 ml.
· The BVS test tool simulates a hemoglobin
value within the range 60 – 160 g/l.
When inserted into the BVS unit it is possible
to check the switch, that a reference value is
taken and that a graph is shown on the infor-
mation display when the BVS key is pressed.
The value for relative blood volume will be
approx. 0 % with some deviations. Do note
that the blood flow must be more than 180 ml/
min for 5 minutes before a reference value is
taken.

Note! It is very important to do the following

things (A,B and C) more or less simultaneously
i.e. within seconds.

A: Simulate blood in the priming detector.

B: Make sure (again) that the measuring glass is
filled to 1.0 liter.

C: Press .

D: Press TMP when UF rate is approximately at

set value (check bargraph).

Note! Make sure that the blood pump is not

stopped by any alarm during this test since this
may affect the accumulated UF volume.
All kind of fluid alarms (conductivity etc.) have to
be avoided.

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Maintenance Manual Base-kit

40. Check that the overload protection on the

heparin pump is working.

41. Check the arterial clamp by attaching the

calibration tube set into the arterial clamp.
Enter priming mode and create a level
detector alarm to get the clamp closed. Apply
a pressure of 600 mmHg. Check that the
pressure does not fall more than 30 mmHg in
15 seconds.

42. Check the venous clamp by attaching the

calibration tube set into the venous clamp.
Enter priming mode and create a level
detector alarm, by lowering the level in the
drip chamber, to get the clamp closed.
Apply a pressure of 600 mmHg.
Check that the pressure does not fall more
than 30 mmHg in 15 seconds.

43. If installed: Check the battery backup by

disconnecting the mains plug. Let the ma-
chine run for at least 1 minute.

Note! This is not a capacity test of the

backup batteries. Instructions how to per-
form a capacity test of the backup-batteries,
refer to chapter Calibration in AK 200 S /
AK 200 ULTRA S Service Manual.

44. Reconnect the mains plug to the outlet

supply of an electrical safety tester.

Perform the Earth Leakage Test (ELT) and

the Patient Earth Leakage Test (PLT) ac-
cording to instructions available in
HCEN12190, Electrical safety inspections for
AK-machines.

45. Perform heat/chemical disinfection.

2:22 AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006

A-kit Maintenance Manual

Preventive Maintenance: Supplementary A-kit

Parts
The A-kit is designed to be used as a complemen-
tary addition to the Base-kit for the preventive
maintenance procedures of AK 200 S and
AK 200 ULTRA S.

The A-kit (K40166001) includes following exterior

parts:

Step Monitor Denomination Part no. Qty

1 FM Pick-up tube (red) K13467002 1
2 FM Pick-up tube (blue-white) K13467001 1
3 FM Dialyser connector set (blue) K14082002 1
3,4 FM Locking ring (Dialyser connector) K22591001 2
4 FM Dialyser connector set (red) K14081002 1
4 FM Conical filter L50824001 1
4 FM O-ring for conical filter 100319046 1
4 FM Nipple K13736001 1
5 FM Non-return valve K17978001 1
6 FM Washer, blood pump rotor K07316001 4

Note!
All parts in the A-kit are possible to exchange
without opening the dialysis machine.

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:23

Maintenance Manual A-kit

How to exchange the exterior parts

included in the A-kit

1. Change the pick-up tube A (red). 4. Change the dialyser connector set red,
locking ring, nipple, conical filter and O-ring.

5 mm

2. Change the pick-up tube B (blue-white). 5. Change the non-return valve on the water
inlet tube.

3. Change the dialyser connector set blue and 6. Add/change the washers for the blood pump
the locking ring. rotors.

5 mm

2:24 AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006

A-kit
Actions to carry out after the parts have
been exchanged
1. First perform a heat disinfection program.
Refer to the AK 200 S or AK 200 ULTRA S
Operator’s Manual.
2. After the heat disinfection; re-tighten the nuts
of the dialyser connector set to the machine.
Nuts 5 mm
3. Let the machine pass FCH.
A leakage test of the dialyser connector set is
peformed in state 24.
4. Control of the blood pump occlusion
Check surface on the roller at the pump rotor, if
it is damaged exchange the unit. The roller unit
should easily go back to upper end position when
it has been pressed down to end position, ex-
change unit if it gets stuck in any position.
Note! If the blood lines/infusion lines have a
different wall thickness, the occlusion of the
blood pump must be adjusted to the right size.
Use the gauge pins (stop/go) available in the kit
K40158001. The kit includes following three
different gauge pins:
T = 1.1 (Stop pin = 1.1*2*0.7 = 1.5mm)
T = 1.6 (Stop pin = 1.6*2*0.7 = 2.2mm)
T = 2.0 (Stop pin = 2.0*2*0.7 = 2.8mm)
T = wall thickness of the blood tubing
AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006
Maintenance Manual
Use following formula to calculate which gage
pin to use:
2 * wall thickness * 0,7 (mm)
Check the range between the blood pump rollers
and the path according to the picture below.
= Measuring
Adjust range between the blood pump rollers and
the path if it is necessary.
The GO pin should barely pass within the cali-
brating area.
The STOP pin is NOT allowed to pass in any
point within the calibrating area.
Note! Put grease on the GO and STOP pins
when not used and store gage in plastic bag to
prevent it from corroding.
Note! The gauge pins can also be ordered sepa-
rately:
T=1.1 (white) K40158002
T=1.6 mm (red) K40158003
T=2.0 mm (blue) K40158004
2:25
Maintenance Manual B-kit

Preventive Maintenance: Supplementary B-kit

Parts
The B-kit is designed to be used as a complemen-
tary addition to the Base-kit for the preventive
maintenance procedures of AK 200 S and
AK 200 ULTRA S.

The B-kit (K40167001) includes following

overhaul parts:

Step Monitor Denomination Part no. Qty

Spike kit BiCart- and SelectCart holder
1 FM K21557006 2
(PEEK lower)
Complete valves:
2 FM FOVA, DIVA, TAVA, BYVA, DRVA K15235A 8
BCVA, TPVA, PBVA
3 FM Recirculation valve (complete) K15514002 1
4 FM Silicon tube (3x2mm) 100312032 7m
4 FM Silicone tube 2x1,5 100312166 1m
5 FM Santoprene tube 100312141 2m
6 BM Venous pressure line (complete) K21353A 1
7 BM Arterial pressure line (complete) K15145001 1
8 BM System pressure line (complete) K21358A 1
9 BM Pump tube (air pumps) K22114001 3
9 BM Strap (air pumps) 100314015 3

2:26 AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006

B-kit Maintenance Manual

How to exchange the parts included in

the B-kit
1. Change the lower complete spike house and 4. Change all the Silicone tubes in the fluid
O-rings in the BiCart and SelectCart holder. monitor.
Assemble according to machine configuration.

2. Change following complete valves: 5. Change all the Santoprene tubes in the fluid
FOVA, DIVA, TAVA, BYVA, DRVA, BCVA,TPVA monitor.
and PBVA.

3. Change complete Recirculation valve. 6. Change the (complete) venous pressure line.

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:27

Maintenance Manual B-kit

7. Change the (complete) arterial pressure line.

8. Change the (complete) system pressure line.

9. Change the pump tubes for the air pumps.

Clean the rollers with ethanol (70 %).

2:28 AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006

B-kit Maintenance Manual

Actions to carry out after the parts have

been exchanged

1. First perform a heat disinfection program.

Refer to the AK 200 S or AK 200 ULTRA S
Operator’s Manual.

2. Let the machine pass FCH.

3. Perform a BiCart / SelectCart priming

according to the Operator’s Manual.

AK 200 S /AK 200 ULTRA S HCEN12088 Rev. 05. 2006 2:29

 HCEN12088 © Gambro Lundia AB,2001. Revision 05.2006

Gambro Lundia AB, Monitor Division

Box 10101
SE-220 10 Lund
Sweden

Tel: +46 46 16 90 00
Fax: +46 46 16 96 96
www.gambro.com