Ch03 HCEN12088 02 2010 10

Chapter 3
Maintenance manual
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:2
Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:3
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:4
Base-kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:4
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:4
How to exchange the parts included in the Base-kit . . . . . . . . . 3:5
Actions to carry out after the parts have been exchanged . . . . . 3:9
Supplementary A-kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:34
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:34
How to exchange the exterior parts included in the A-kit . . . . . 3:35
Supplementary B-kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:38
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:38
How to exchange the overhaul parts included in the B-kit . . . . . 3:39
HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:1

Program version 10.xx
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 procedures 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 specifications are met.
It is mandatory to perform at least one 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 unauthorized repair.
To fulfil the preventive maintenance procedures for

AK 200 S / AK 200 ULTRA S some parts must be exchanged. The
necessary parts to be exchanged are available in one 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
components 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 performed.
Note
3:2 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

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.
Test equipment
Test equipment needed to perform maintenance.
Test equipment Tolerance Manufacturer Order

number
Conductivity ±0.1 mS/cm MESA, IBP
measurement
Pressure measurement ±2 mmHg to ±200 mmHg MESA, IBP, Druck

±1% beyond ±200 mmHg
If BPM is installed:
±0.8 mmHg
Temperature ±0.2 ºC MESA, IBP
measurement:
Digital Voltmeter ±0.5% Fluke
Measuring glass ±5 ml
Blood leakage N/A Gambro K40169001
calibration cover
Gauge pin kit for blood T = 1.1 (Stop pin = 1.1 x 2 x 0.7 = 1.5 mm) Gambro K40158001
pump rollers (including T = 1.6 (Stop pin = 1.6 x 2 x 0.7 = 2.2 mm)
three different pins) T = 2.0 (Stop pin = 2.0 x 2 x 0.7 = 2.8 mm)
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 (if N/A Gambro K22151001
installed)
BPM Cuff (if installed) N/A Gambro 110350
pH buffers (if installed) ±0.07 pH units pH 7 –

100810001
pH 9 –
100810002
BVS test tool Gambro K22281001
Magnet for blood pump Gambro
cover K19049002

Preventive Maintenance
Base-kit
Parts
The Base-kit (K40165001) includes all parts necessary to
fulfil 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
5, 6 FM 100319008 4
holder, upper and lower.
7 FM O-ring for ultrafilter holders 100319029 4
7 FM Square-ring for ultrafilter holders K14920001 2
Filter BiCart holder, upper and lower
8 FM K16538C 2
(50µm)
9 FM Filter SelectCart holder, lower (50µm) K16538C 1
Filter after the SelectBag holder
10 FM K16538C 1
(50µm)
11 FM Filter heating vessel (250µm) K14944001 1
12 FM V-ring heating vessel 100318086 2
Membrane for internal pressure
13 FM K40153001 1
regulator
14 FM Membrane for non-return valve K17989001 1
15 FM Sample port for 6 mm tube K20219002 1
Sealing ring (Inlet unit - heating
16 FM
vessel) K07994001 1
16 FM Ring (Inlet unit - heating vessel) K08227001 1
17 FM Sealing for substitution fluid 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.
Note

How to exchange the parts included in the Base-kit
1. First perform a combined heat disinfection
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
hypochlorite. Refer to the AK 200 S or
AK 200 ULTRA S Operator’s Manual.
2. Change air filters in the Blood Monitor.
3. Change air filter in the Fluid Monitor.
4. Change air filters in the AC/DC unit.
5. Change the upper and lower O-rings in the

2
BiCart holder.
3
1
o-ring

2 6. Change the upper and lower O-rings in the
3
SelectCart holder.
1
o-ring
7. Change the O-rings and square-rings in the

ultrafilter holders. (Only for AK 200 S with
o-ring UFD-kit and AK 200 ULTRA S)
o-ring
square-
ring
Note
Outlet - higher position This information is for step 8 to 10:
To prevent that air is getting trapped
inside the particle filters (50 μm), it is
important that the particle filters are correct
positioned according to this figure.
Note
Inlet - lower position
8. Change the upper and lower filters on the

BiCart holder (50 μm).

9. Change the lower filter on the SelectCart
holder (50 μm).
10. Change the particle filter after the SelectBag

holder (50 μm).
11. Change the filter at the heating vessel

(250 μm).
12. Change the V-rings in the heating vessel.
A B
13. If ULTRA: Change the membrane for the

internal pressure regulator.

14. If ULTRA: Change the membrane for the
non-return valve.
15. Change the sample port.
16. Change the sealing ring and the ring on the

inlet unit inside the heating vessel.
• It is important that the sealing ring is

reassembled with its flat side according to
this illustration.
17. If ULTRA: Change the sealing for the

substitution fluid port on the FM front.
18. Mark month and year for the next scheduled

preventive maintenance. Attach the label to
the rear cover of the machine.
Year
08 2008 - 2013 13
09 12
10 11

Actions to carry out after the parts have been exchanged
1. Check that the screws for the blood pump(s)
are tightened.
2. Check that the screws for the hose clamps on

the water inlet and drain tube are tightened.
3. Check that the wheels are tightened.
4. Check that the screw for the infusion stand

is tightened.

5. Perform the Protective Earth Test (PET)
according to instructions available in Electrical
safety inspections for AK-machines.
TP4
6. Check the protective earth resistance in BM.
TP5
TP7
TP9
TP10 Measure between TP 8 (Z0VL) on the BM
TP11
TP17
CPU board and the earth point on the bottom
TP14
TP12
TP18
TP22 plate. Measure in MΩ, should be > 1 MΩ.
The machine must be empty and switched off
TP13
TP6
TP8
TP15
TP16
during measurement.
TP21
• The BM must be connected to the FM.

TP3 E01342007
TP19
TP2 TP20
1074
7. Check the protective earth resistance in FM.
Measure between TP 7 (Z0VL) on the Power
TP1
TP2
TP4
TP3 distribution board and the earth point on
the back plate. Measure in MΩ, should be
TP7 > 1 MΩ. The machine must be empty and
switched off during measurement.
TP8
TP5
TP6
E01345009
8. Erase the error code buffers. Enter service

menu > Diagnose > System > Errors >
Erase

9. BPM-test
Test method
• Attach BPM cuff, 110350, 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, Diagnose / BM / Others and BPM
BPM sub-tests
Following sub-tests are included:
• Air leakage test: measures that the equipment is airtight.
• Inflation speed test: measures the time to fill the cuff with air.
• Static pressure: Check of pressure transducer 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 mmHg.
50 ±3 mmHg
150 ±3 mmHg
250 ±3 mmHg

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 connected 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.
Check of inflation speed

By entering this test mode the capacity of 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.
Check of pressure transducer calibration and measured

pressure
By entering this test mode it will be possible to check the actual pressure
value of the BPM pressure on the AK 200 S / AK 200 ULTRA S display.
Before entering the test mode, pressure transducer calibration tube

from kit K13983002 to be connected to the BPM connector on the
AK 200 S / AK 200 ULTRA S. No cuff and cuff hose to be connected.
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.
Note
When “Measured pressure” is displayed it is possible to start applying

the external reference pressure.
Note
• The BPM is equipped with an over pressure protection. It is
activated for pressures above 300 mmHg.
• The pressure transducer test is to be performed within approx.
2 minutes. Then the pressure is automatically released.
Note

To check the actual pressure value, external pressure reference
instrument to be connected and external pressure of 250, 150,
50 mmHg to be applied. Check deviation from reference pressure
instrument for displayed value.

10. Calibrate the Priming detector (BM 6).
Equipment needed: Reference tube
10.1. Start the AK 200 S / AK 200 ULTRA S and enter the service
menu, Calibr / BM.
10.2. Set the display to:

PRIMING DETECTOR
BM 6
10.3. Press the Start UF Stop button to enter calibration routine.
10.4. The display shows:

INSERT EMPTY REFERENCE TUBE
Press SET key when ready
10.5. Insert an empty reference tube in the priming detector. The

reference tube shall be from the same type of blood line as
used during treatment.
10.6. Press the lit Arrow button
10.7. The calibration is now performed automatically and the

calibration factor is written into the EEPROM.
10.8. The calibration result is displayed:

READY BLOOD LEVEL
XX Confirm
10.9. Press the lit Arrow button to confirm.

11. Calibrate the Level detector (Air detector) (BM 5).
Equipment needed: Drip chamber, Pressure meter, Calibration tube set.
11.1. Start the AK 200 S / AK 200 ULTRA S and enter the service
menu, Calibr / BM.
11.2. Set the display to:
11.3. Press the Start UF Stop button to enter calibration routine.
11.4. Insert a filled drip chamber. It is recommended that both the

water and the drip chamber have a temperature of
37 °C. Make sure that the level detector (Air detector) and
drip chamber are dry and clean. The drip chamber shall be
from the same type of blood line as used during treatment.
11.5. Apply a pressure of 100 mmHg (± 10 mmHg), to the venous

drip chamber.
Use the pressure meter as reference.
Note
When creating a positive pressure in the venous drip chamber,
a more treatment like condition is simulated as the pressure
inside the drip chamber becomes approximately the same as the
venous pressure during treatment.
The purpose is to get a better contact between the chamber and
the air detector head, which results in a higher calibration value.
Note
11.6. Wait for 2 minutes and then press the lit Arrow button
11.7. The calibration is now performed automatically and the

calibration factor is written into the EEPROM.
11.8. The calibration result is displayed:
The value under LEVEL is the new alarm limit, which shall
be 50 or higher.
The value under TRANSMIT is the transmission level,
which is normally 255 but can also be 160, if the air detector
is exceptionally good.

12. Measure the voltage between TP 23 and TP 24 on the
BM CPU board. (See figure below.)
Exchange battery B1 if the value is below 2.6 V.
Note! The machine must be switched on when measuring.
TP23 TP24
B1
BM CPU board

13. Control of the blood pump/substitution flow 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. Exchange unit if it gets
stuck in any position.
Note
If the pump segment has a different wall thickness, the occlusion
of the pump must be adjusted to the correct wall thickness.
Note
Use the gauge pins (stop/go) available in the kit K40158001. The kit
includes following three different gauge pins:
T = 1.1 (Stop pin = 1.1x2x0.7 = 1.5mm)
T = 1.6 (Stop pin = 1.6x2x0.7 = 2.2mm)
T = 2.0 (Stop pin = 2.0x2x0.7 = 2.8mm)
T = wall thickness of the tubing
Use following formula to calculate which gauge pin to use:

2 x wall thickness x 0,7 (mm)
Adjustment instruction
Check the range between the pump rollers and the path according to
the picture below. Adjust range between the pump rollers and the path
if it is necessary.
= Calibrating area
• The GO pin should barely pass within the calibrating 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
the pins in a plastic bag to prevent it from corroding.
Note

14. Enter Service / Calibr / BM and set the
AK 200 S / AK 200 ULTRA S display to:
14.1. Press the Start UF Stop button 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 manual for
details).


pressure)
15.3. Check zero level of the Arterial Pressure Transducer.

details).


pressure)
16.3. Check zero level of the Venous Pressure Transducer.

details).

17. Enter Diagnose / BM / Pumps and check that the blood pump(s)
stops when the cover is opened.
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

19. Enter Service / Calibr / FM and set the
19.2. Disconnect a tube to achieve zero pressure (see picture).
19.3. Check zero level of the Degassing Pressure Transducer.

details).

20.3. Check zero level of the Flow Output Pressure Transducer.

details).

21.3. Check zero level of the Flow Input Pressure Transducer.

details).

22.3. Check zero level of the High Pressure Guard Transducer.

details).

23.3. Check zero level of the Dialysis Fluid Pressure Transducer.

details).
OR

24.3. Check zero level of the Safety Guard Pressure Transducer.

details).

25. If installed: Calibrate the pH-sensor (FM 13) with a buffer
solution. (see chapter Calibration manual for details).
26. Check the blood leak detector limits: 0 and 100 ±10.
26.1. Remove the blood leakage detector cover and clean the
inside of the blood leakage detector housing.
26.2. Mount a blood leakage calibration cover (K40169001).

Make sure that the filter is in horizontal position.
26.3. Enter the Service menu.
26.4. In service mode, select calibration, FM, intern and Blood

Leakage Detector (FM 24).
26.5. Let the machine stabilize at 37 °C. No concentrate shall be

used.
26.6. Press the Start UF Stop button to enter the blood leakage
calibration routine.
26.7. Check the blood leak detector limits 0 and 100 ±10.
details).
26.8. Drain the AK 200 S / AK 200 ULTRA S and remount the

standard blood leakage cover.
26.9. Enter the Service menu.
26.10. In service mode, select calibration, FM, intern.
27. Check the water level in the heating vessel, should be

approximately 1 cm above the centre line (at the centre of the
vessel according to the figure below), adjust if necessary.
Heating
vessel
1 cm above
centerline
28. Check the conductivity indications, at approximately 14 mS/cm.
Place A-pick up tube in concentrate container and let it stabilise

for 15 minutes.
Use GXL – fluid monitor screen and a reference instrument

connected to the dialysis fluid tubes.

The indicated conductivity values in GXL should correspond
to the indication on the reference instrument. The maximum
deviation is ±0.1 mS/cm.
29. Check the temperature indications, at approximately 37 °C.
Use GXL – fluid monitor screen and a reference 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 instrument.
The maximum deviation is ±1.5 °C.
If the deviation is more than the stated tolerance; the affected

temperature transducer must be exchanged.
30. Place A-pick up tube back into the heating vessel and wait for 5
minutes. Place the B-pick up tube in the concentrate container.
Enter Service menu, Calibr / FM / Other / UF / Restr.
Perform an FRN calibration.
31. Let the machine pass Fch. Check the DC leakage between TP 7
(Z0VL) on the Power distribution board and the earth point on the
back plate. Measure in DC Voltage, should be < 1 V.
32. Check the DC leakage between TP 7 (Z0VL) on the Power

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

distribution board and the Degass pump head. Measure in DC
Voltage, should be < 1 V.

distribution board and the cover on the Flow Out pump motor.

distribution board and the Flow Out pump head. Measure in DC

distribution board and the cover on the Flow In pump motor.

distribution board and the Flow In pump head. Measure in DC

38. If ULTRA: Calibration of internal pressure regulator.
Equipment needed: Pressure reference instrument, Calibration tube set.
38.1. Let the machine pass the functional check.
38.2. Press the Fluid flow button and set the main flow to
500 ml/min.
38.3. Activate HDF or HF.
38.4. Press the Pressure control button for 3 seconds until lit.
38.5. Connect the dialyzer coupling to the conductivity cell on the

pressure reference instrument.
38.6. Adjust venous pressure to +100 mmHg. Check that TMP is

approximately +150 mmHg.
38.7. Connect a tube between the substitution fluid port and the
external pressure reference instrument.
38.8. Press the Fluid Bypass button to obtain main flow through
the pressure regulator.
38.9. Adjust the pressure regulator to +55 mmHg ±5 mmHg. To

get a correct reading, the reference instrument and the test
tube must be at same height as the substitution fluid port.
38.10. Press the Fluid Bypass button and remove the pressure
reference instrument and tube.

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 1:00 h.
• Connect a T-piece to the dialysis tubings. Put the end of the

tube in a measuring glass filled with more than 1 l of water,
approx. 37 °C .
• Press the Fluid bypass button. Check that the tube to the
measuring 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 the UF-rate button and set priming UF rate and minimum
UF-rate to 0.0 l/h.
• Make sure the measuring glass is filled to 1.00 l adjust if

necessary.
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 l.
C: Press the Start UF Stop button.
D: Press the flashing TMP button when UF rate is
approximately at set value (check bargraph).
• 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.
Note
• 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
information display when the BVS button 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.
40. If installed: Back-up battery Capacity-test
Conditions for the test:
• The back-up batteries must be fully charged, e.g. the mains plug
must have been connected to mains and the mains switch on the
power supply must have been on, for at least 24 h before this
test is to be done. The charge indicator on the power supply is
lit when the AK 200 S / AK 200 ULTRA S is equipped with
back-up batteries.
• Continue the simulated treatment from step 39. The blood pump
must be running during this test.
• Fill the measuring cylinder with 1 l of water.
40.1. Disconnect the mains plug.
40.2. Let the machine run in simulated treatment for at least 15

minutes.
Following attention will be given.
POWER FAILURE BATTERY OPERATION

Battery operated for x minutes
40.3. After 15 minutes, re-connect the mains plug.
Note
• After the Capacity-test the machine has to be re-charged. After
24 h the back-up batteries are fully re-charged.
Note
If the machine stops within 15 minutes, re-connect the mains plug

and the backup-batteries must be exchanged. Before the machine
turns off following attention will be given.
LOW BATTERY POWER

Machine turns off in one minute

41. Check that the overload protection on the heparin pump is working.
42. 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.
43. 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.
44. Connect 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) according to instructions available in
Electrical safety inspections for AK-machines.
45. Perform heat/chemical disinfection.

Supplementary A-kit
Parts
The A-kit is designed to be used as a complementary addition
to the Base-kit for the preventive maintenance procedures of
The A-kit (K40166001) includes following exterior parts:

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.
Note

How to exchange the exterior parts included in the A-kit
1. Change the pick-up tube A (red).
2. Change the pick-up tube B (blue-white).
3. Change the dialyser connector set blue and

the locking ring.
5 mm
4. Change the dialyser connector set red, locking

ring, nipple, conical filter and O-ring.
5 mm
5. Change the non-return valve on the water inlet

tube.

6. Add/change the washers for the blood pump
rotors.

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.
3. Let the machine pass Fch.

A leakage test of the dialyser connector set is performed in state 24.
4. Control of the blood pump/substitution flow 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. Exchange unit if it
gets stuck in any position.
Note
If the pump segment has a different wall thickness, the occlusion
of the pump must be adjusted to the correct wall thickness.
Note
Use the gauge pins (stop/go) available in the kit K40158001. The kit
includes following three different gauge pins:
T = 1.1 (Stop pin = 1.1x2x0.7 = 1.5mm)
T = 1.6 (Stop pin = 1.6x2x0.7 = 2.2mm)
T = 2.0 (Stop pin = 2.0x2x0.7 = 2.8mm)
T = wall thickness of the tubing
Use following formula to calculate which gauge pin to use:

2 x wall thickness x 0,7 (mm)

Adjustment instruction
Check the range between the pump rollers and the path according to
the picture below. Adjust range between the pump rollers and the path
if it is necessary.
= Calibrating area
• The GO pin should barely pass within the calibrating 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
the pins in a plastic bag to prevent it from corroding.
Note

Supplementary B-kit
Parts
The B-kit is designed to be used as a complementary addition
to the Base-kit for the preventive maintenance procedures of
The B-kit (K40167001) includes following overhaul parts:

Spike kit BiCart- and SelectCart
1 FM K21557006 2
holder (PEEK lower)
Complete valves: FOVA, DIVA, TAVA,
2 FM K15235A 8
BYVA, DRVA BCVA, TPVA, PBVA
3 FM Recirculation valve (complete) K15514002 1
4 FM Silicon tube (3 x 2 mm) 100312032 7 m
4 FM Silicone tube 2 x 1.5 100312166 1 m
5 FM Santoprene tube 100312141 2 m
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

How to exchange the overhaul parts included in the B-kit
1. Change the lower complete spike house and
O-rings in the BiCart and SelectCart holder.
Assemble according to machine configuration.
2. Change following complete valves: FOVA,

DIVA, TAVA, BYVA, DRVA, BCVA,TPVA
and PBVA.
3. Change complete Recirculation valve.
4. Change all the Silicone tubes in the fluid

monitor.
5. Change all the Santoprene tubes in the fluid

monitor.

6. Change the (complete) venous pressure line.
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%).

1. 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 with BiCart Select concentrate.

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Chapter 3

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:1

The preventive maintenance procedures have been devised to require

Included in the preventive maintenance procedures are checks to verify

It is mandatory to perform at least one preventive maintenance every

A yearly maintenance is recommended. The rate of preventive

The AK 200 S / AK 200 ULTRA S will perform as designed only if it

To fulfil the preventive maintenance procedures for

• A-kit (K40166001): Includes exterior parts

• B-kit (K40167001): Overhauling service-kit

When performing preventive maintenance procedures or calibrations,

3:2 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

Test equipment Tolerance Manufacturer Order

Pressure measurement ±2 mmHg to ±200 mmHg MESA, IBP, Druck

pH buffers (if installed) ±0.07 pH units pH 7 –

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:3

Step Monitor Denomination Part no. Qty

3:4 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

2. Change air filters in the Blood Monitor.

3. Change air filter in the Fluid Monitor.

4. Change air filters in the AC/DC unit.

5. Change the upper and lower O-rings in the

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:5

7. Change the O-rings and square-rings in the

Inlet - lower position

8. Change the upper and lower filters on the

3:6 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

10. Change the particle filter after the SelectBag

11. Change the filter at the heating vessel

12. Change the V-rings in the heating vessel.

13. If ULTRA: Change the membrane for the

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:7

15. Change the sample port.

16. Change the sealing ring and the ring on the

• It is important that the sealing ring is

17. If ULTRA: Change the sealing for the

18. Mark month and year for the next scheduled

3:8 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

2. Check that the screws for the hose clamps on

3. Check that the wheels are tightened.

4. Check that the screw for the infusion stand

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:9

• The BM must be connected to the FM.

8. Erase the error code buffers. Enter service

3:10 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

• Enter Service mode, Diagnose / BM / Others and BPM

• Air leakage test: measures that the equipment is airtight.

• Static pressure: Check of pressure transducer calibration

• Air leakage: maximum 18 mmHg / 3 min.

• Static pressure: Maximum deviation from reference to be within

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:11

BPM test equipment is used to simulate the patient arm circumference.

Check of inflation speed

Cuff to be wrapped tight to the BPM test equipment. If the displayed

Check of pressure transducer calibration and measured

Before entering the test mode, pressure transducer calibration tube

When “Measured pressure” is displayed it is possible to start applying

3:12 AK 200 S / AK 200 ULTRA S Maintenance manual HCEN12088 Revision 02.2010

HCEN12088 Revision 02.2010 AK 200 S / AK 200 ULTRA S Maintenance manual 3:13

Equipment needed: Reference tube

10.2. Set the display to:

10.3. Press the Start UF Stop button to enter calibration routine.

10.4. The display shows: