Gambro AK 95 User manual

AK 95 / AK 95 S

Service Manual

A better way to better care

AK 95 / AK 95 S - Service manual

Contents:

Chapter 1 Installation guide

Chapter 2 Technical description

Chapter 3 Technical data

Chapter 4 Service technician’s guide

Chapter 5 Maintenance manual

Chapter 6 Calibrations

Chapter 7 Spare parts list

Chapter 8 Cable survey

Chapter 9 Symbol description

Chapter 10 Replacements

Chapter 11 Electrical safety inspections

Preface

About this manual

This service manual provides the information

needed to install the AK 95 or AK 95 S

monitor and how to carry out maintenance

and calibrations.

It is a guidance how to identify and repair

faults that may occur.

All information, texts and figures, are valid

for AK 95 S. If the information is specific for

AK 95 only, it is stated in the corresponding

text.

Installation

Installation of the machine should be done in

accordance with the recommended procedures

in the Installation Guide.

When installing a new monitor kindly

remember to fill out the Installation / Out of

Box report and return it to:

Gambro Lundia AB

Monitor Division

Magistratsvägen 16

PO Box 10101

SE-220 10 Lund

Sweden

This is an important information and it will

assist us to improve the product for you. The

Out of Box system is not valid for products,

components or printed circuit boards that

isn't in its original delivered condition.

Complaint

If a complaint is raised it shall be

communicated to the relevant Gambro Sales

Company. In order for the Sales Company to

be able to determine the relevance of a

complaint, it is of vital importance that the

deviation is communicated to them as

comprehensive as the issue requires.

Complaints are important information and it

will assist Gambro to improve the product for

you. The Complaint system is not valid for

products, components or printed circuit

boards that isn't in its original delivered

condition.

Disclaimer

The manufacturer accepts responsibility for

the safety, reliability, and performance of this

equipment only if installation, operational

procedures, maintenance, calibrations, and

repairs are carried out by appropriately

trained and suitable qualified people; if all

equipment modifications are authorized in

writing by the manufacturer and carried out

by appropriately trained and suitable

qualified people; if the electrical installation

of the relevant room complies with all

applicable local electrical codes and, if

applicable, IEC requirements; and if the

equipment is used in accordance with the

published Operator’s Manual.

Maintenance

To ensure proper operation of the AK 95 /

AK 95 S, a qualified service technician must

perform a complete series of maintenance

procedures at regular intervals.

The maintenance and calibration information

that you need to use is provided in this

Service Manual.

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.

Competence of Service Engineers

There is a certain minimum level of

competence required for Service Engineers

who are to maintain and repair Gambro

products, summarized as follows.

A Service Engineer is considered suitable

qualified if he/she has:

1. Practical experience of the AK 95 S

monitor.

2. Attended AK 95 S technical service course

and has been given a certificate stating

that the technician has passed the course.

3. Access to the recommended test

equipment and special tools detailed in

this Service Manual.

4. Access to the recommended spare parts,

see section Spare Parts List.

5. Access to and understanding of the

AK 95 S Operator's Manual, HCEN9794

or AK 95 Operator's Manual, HCEN9542.

In general, this policy implies that training

will be carried out by Gambro Lundia AB:

Monitor Division, while local markets are

responsible for their own service

organization.

Repair

Parts which are sent for repair shall be sent to the

following address:

Gambro Lundia AB

Monitor Division

Workshop

Magistratsvägen 16

PO Box 10101

SE-220 10 Lund

Sweden

Technical support

For technical support please contact your local

Gambro Service representative.

Valid revision

Publication no

. Denomination

HCEN9095, Rev. 10.2006 AK 95 / AK 95 S -

Service Manual

The complete AK 95 / AK 95 S - Service Manual,

HCEN9095, consists of the following separate

chapters:

HCEN9133 Rev. 01. 2004 Installation Guide

HCEN9134 Rev. 10. 2005 Technical Description

HCEN9369 Rev. 10. 2005 Technical Data, AK 95S

HCEN9135 Rev. 10. 2005 Technical Data, AK 95

HCEN9136 Rev. 10. 2005 Service Technicians

Guide

HCEN12189 Rev. 10. 2006 Maintenance Manual

HCEN9138 Rev. 10. 2005 Calibrations

HCEN9094 Rev. 10. 2005 Spare Parts List

K16756 CO 25702 Cable Survey

HCEN9160 Rev. 10. 2005 Symbol Description

HCEN12078 Rev.10. 2005 Replacements

HCEN12190 Rev. 05. 2006 Electrical safety

inspections

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

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Installation Guide

AK 95 / AK 95 S

January 2004

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

Installation Guide

1:1

1. Installation Guide

Contents

Installation

Unpacking and inspection .......................... 1:2

Environment and ........................................ 1:2

Physical Data .............................................. 1:2

Operating Environment ........................ 1:2

Transport and Storage Environment .... 1:2

Physical Data ......................................... 1:2

Mains Voltage and Power ...................... 1:3

Consumption .......................................... 1:3

Service Outlets ....................................... 1:3

Line Fuses .............................................. 1:3

Mains Water Supply .............................. 1:3

Tools............................................................. 1:3

Top Tray....................................................... 1:3

Connection to the Water Supply ................ 1:4

Connection to the Power Supply ................ 1:4

Connection of the battery ........................... 1:4

How to remove the cover to

connect the battery ..................................... 1:5

Installation of RP 95 S ................................ 1:6

Back-up battery ........................................... 1:8

Turn on the AK 95 S.................................... 1:9

Functional check - Fch............................... 1:9

Recommended start-up procedure .............. 1:9

Checklist .....................................................1:11

Note!

This installation Guide provides the information needed to

install both AK 95 and AK 95 S.

The text from this point forward only states AK 95 S.

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

1:2

Installation Guide

Figure 1. AK 95 S Units.

Ensure that the specified equipment has been

delivered. Do the packages contain the specified

monitor and options? Are there any units/

components missing? Check the additional

packing list (inside the additional package box).

If in doubt, please contact your Gambro Serv-

ice representative.

Ensure that the voltage specified on the voltage

tag matches the mains voltage. If in doubt,

please contact your Gambro Service

representative.

The AK 95 S can be installed in most environ-

ments if certain conditions as the temperature,

relative humidity, mains voltage etc. are met.

Operating Environment

AK 95 S:

Ambient temperature: +18 °C to + 35 °C

Relative humidity: 15 % - 85 %

Air pressure: 70 - 106 kPa

AK 95:

Ambient temperature: +10°C to + 35 °C

Relative humidity: 30% - 85 %

Air pressure: 70 - 106 kPa

Transport and Storage Environment

Units being transported or stored must be kept

in their original packaging. Units must be

handled en route in accordance with special

instructions. Units can be transported or stored

in the following environment for up to 15 weeks:

Ambient temperature: -20 °C to +70 °C

Relative humidity: 10 % - 96 %

Air pressure: 50 - 106 kPa

Note!Units to be transported and/or stored for

more than 15 weeks may only be subjected to

the conditions specified under Operating Envi-

ronment.

Environment and

Physical Data

Unpacking and

inspection

When unpacking, the equipment should be

checked. If the equipment is in any way dam-

aged, proper operation cannot be guaranteed.

Please contact your Gambro Service

representative.

The packages contain the units and components

shown in Figure 1.

Installation

Physical Data

AK 95 S:

Depth Width Height Weight

mm mm mm kg

Machine 600 480 1270 78

Stand 625 580 (all options

included)

AK 95:

Depth Width Height Weight

mm mm mm kg

Machine 420 350 1270 62

Stand 680 625

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

Installation Guide

1:3

A

B

Acetate

EN1075

Lift points

Tools

The tools listed below are needed during the

installation procedure.

• Tube cutter, 113 500 084

• Adjustable wrench, 113 003 009

• Hexagon spanner set

• Screwdriver, 1,2 x 8,0 - 175mm,

113 002 006

Top Tray

To avoid leakage into the machine, the top tray

must always be placed on the top of the ma-

chine, except during technical service.

Mains Voltage and Power

Consumption

The AK 95 S must be plugged into a grounded

power point not more than 3 metres distant.

Mains voltage:

100 V(at 50 Hz or 60 Hz)

110 V(at 50 Hz or 60 Hz)

230 V(at 50 Hz or 60 Hz) (±12%)

Power consumption:

2025 W at 230 V

1575 W at 110 V

1275 W at 100 V

Service Outlets

One extra grounded power socket should be

available close to the AK 95 S, for troubleshoot-

ing and maintenance purposes.

Line Fuses

Never overload the line fuses and do not supply

too many systems via a single line fuse.

Mains Water Supply

Required quality:

Level of purity according to ASAIO and AAMI

recommended standards on feed water for

dialysis monitors.

Water for the dialysis unit has to be supplied

from a Reverse Osmosis purification system.

Pressure:

1.2 - 6 bar to the pressure regulator mounted in

the MM 95.

Note! The pressure should be measured with

the flow from the water supply.

Temperature:+5 °C to +30 °C (treatment)

Consumption in treatment:

AK 95 S: 500 ml/min

AK 95: 550 ml/min

Drain: Open type. Not more than 1.2 metres

above outlet from fluid monitor.

Note! Local ordanances may require the use of

special measures to protect against the possibil-

ity of back-siphonage from dialysis equipment

into the water supply. When installing the

AK 95 S, such ordanance should be observed.

Figure 2. AK 95 S

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

1:4

Installation Guide

Connection to the Water

Supply

The water must fulfil all requirements set out

under Environment and Physical Data.

Connection to the Power

Supply

Main switch,

ON/OFF

Mains power,

connected to a

grounded

power socket

Water in

Drain

Fuses

Connection of the Battery

The rechargeable 9V battery (100 224 006) is

used to drive the buzzer alarm during main’s

power failure. The battery is not connected at

delivery.

NOTE! The battery must be connected during

the installation according to the instruction on

next page.

A discharged battery will be charged with

maximum 10 mA and it must be charged for at

least 50 hours to get completely charged. An all-

up charged battery will receive a maintaining

current of approximately 1,5 mA. The AK 95 S

charge the battery as long as the AC/DC con-

verter is switched on, i.e. AK 95 S itself does not

need to be switched on.

The battery is tested during every functional

check to ensure that the capacity is enough in

the battery, otherwise an attention will be

given:

BATTERY FAILURE

Change battery or press SELECT

NOTE! Jumper J200 on the Protective Driver

board must be mounted for the rechargeable

battery.

If use of an alkaline non-chargeable battery,

jumper J200 must be removed, if not, the

battery will be damaged.

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

Installation Guide

1:5

A

B

Acetate

1070

A

How to remove the cover to connect

the battery.

1. Loosen the three cover bolts, accessible

underneath the fluid part.

2. Move the cover upwards and then back-

wards.

3. Pull the cover to the right just 10 mm (if you

are positioned in front of the AK 95 S).

4. Turn the cover backwards counter-clockwise

to pass the circuit boards and the cover can

be removed.

5. Connect the rechargeable battery to board

connector P205 on the Protective Driver

board.

A

Cover

Front

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

1:6

Installation Guide

GAMBRO

Step 2

1. Put the RP 95 S unit into the front hole

of the stand. Fasten it with the attached

spacer and screw (∅ M4, 16mm)

2. Fasten the screw (with black plastic

knob).

GAM

BRO

1

GAMBRO

2

3

MB

RO

4

5

6

NOTE! This instruction is for AK 95 S equipped with RP 95 S at delivery.

RP 95 S can also be ordered and installed as a kit, K23054. Refer to rebuilding instruction K23055.

Installation of RP 95 S

Step 1

1. Loosen the two screws (with

black plastic knobs) under the

service tray holder.

2. Pull out the service tray holder

to its end position.

3. Loosen the two hexagonal

socket screws.

4. Remove the service tray holder

complete.

5. Fasten the hexagonal socket

screws again.

6. Attach the plug to the rear hole

of the stand and fasten the

screw (with black plastic knob).

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

Installation Guide

1:7

G

AM

BRO

GAM

BRO

180°

90°

Step 3

1. Turn the RP 95 S 180° in counter

clockwise direction.

2. Rotate the RP 95 S 90° to be

parallel with the AK 95 S front.

2

1

Step 4

1. Fasten the cable on the right upper

part of the stand with the enclosed

cable holder and screw.

2. Fasten the cable even on the back

part of machine with the enclosed

cable holder - use an existing screw.

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

1:8

Installation Guide

Back-up Battery

The optional back-up battery is pre-assembled

under the monitor stand at delivery.

Let the machine stay with the ACDC-unit in

power on mode over night in order to charge

the batteries.

Replacement of the lead acid batteries must be

done according to following electrical diagram.

Both lead acid batteries must be changed at the

same time and only batteries approved or

supplied by Gambro Lundia AB may be used.

Changed batteries must be recycled or disposed

of properly.

Fuse: T15 A

Running time: 30 minutes

The charge indicator on the power supply is lit

when the AK 95 S is equipped with the back-up

battery. The machine must be connected to

mains voltage and the mains switch must be on.

In a mains failure situation following attention

will be given.

POWER FAILURE, BATTERY OPERATION

Battery operated for x minutes

Before the battery is empty following attention

will be given.

LOW BATTERY POWER

Machine turnes off in one minute

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

Installation Guide

1:9

Turn on the AK 95 S

The ON/OFF button on the Operators Panel is

used to turn the machine on and off.

The ON/OFF button must be pressed at least 3

sec. in order to switch the machine on and off.

The main switch on the power supply should

always be in ON position, even when the

machine is not in use. This “Stand by” mode is

indicated by a lit segment on the TIME display

on the operators panel.

If a power failure occurs when AK 95 S is work-

ing, the same segment in the TIME display is

flashing.

For further information about operating

instructions, please see:

AK 95 S Operator's Manual, HCEN 9794

or

AK 95 Operator's Manual, HCEN 9542.

Functional check - Fch

Each time the AK 95 is started, the automatic

functional check, Fch, is carried out.

The functional check will be aborted if Rinse/

Drain or any of the disinfection modes are

selected.

h.min

Time

h.min

Time

Recommended start-up

procedure

First check:

• That the 9V battery is connected.

• That the mains cable is connected to power.

• That the main switch on the rear of the

monitor is turned on.

• That the machine is connected to the water

supply.

• That the drain tube is properly connected to

the machine and placed with an air gap between

the drain tube and the drain.

• That the dialysis fluid tubes are connected to

the safety couplings.

Start the machine

1. Press the ON/OFF button for 3 seconds.

2. Perform a Heat disinfection procedure accord-

ing to the Operator’s Manual.

3. Perform a complete functional check accord-

ing to the Operator’s Manual.

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

1:10

Installation Guide

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AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

Installation Guide

1:11

Checklist - Check if applicable

Yes

Checklist - filed by the Sevice Engi-

neer responsible for the installation.

Unpacking and inspection

Ensure that the specified equipment

has been delivered.

Check that the additional package box

contains the specified components.

Check, by visual inspection that the

machine shows no sign of damage.

Environment and Physical Data

Ensure that the Operating Environment

is according to the specifications.

Interconnection

Ensure that the monitors are intercon-

nected correctly.

Top Tray

Ensure that the top tray is placed at

the top of the machine.

Connection to the Water Supply

Ensure that the machine is correctly

connected to the Water Supply.

Ensure that the water fulfils all require-

ments set out under Environment and

Physical Data.

Ensure that the machine is correctly

connected to the drain.

Connection to the Power Supply

Ensure that the voltage specified on the

voltage tag matches the mainsvoltage.

Ensure that the machine is correctly

connected to the Power Supply.

Mains power must be connected to a

grounded power socket.

Connection of the Battery

Ensure that the rechargeable 9V battery is

correctly connected according to the instruc-

tions.

Connection of the dialysis fluid tubes

Ensure that the dialysis fluid tubes are

connected to the safety couplings.

Start-up procedure

Note! If you have any remarks during installa-

tion, please contact your Gambro Service

representative.

This record is to be signed and filed by the Service Engineer responsible for the installation.

Date............................Signature........................................................................

Serial number: ..................................

Ensure that the recommended

start-up procedure is followed.

Out of box report

Fill out the Installation / Out of

Box report and return it to:

Gambro Lundia AB

Monitor Division

Magistratsvägen 16

PO Box 10101

SE-220 10 Lund

Sweden

AK 95 / AK 95 S Service Manual

HCEN 9133 Rev. 01. 2004

1:12

Installation Guide

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