Page 1 SERVICE MANUAL SINGLE PATIENT DIALYSIS MACHINE SURDIAL NIPRO CORPORATION Manufacturer 3-9-3, Honjo-Nishi, Kita-Ku, OSAKA 531-8510, JAPAN PHONE +81-6-6372-2331 / FAX +81-6-6371-7422 Version No.0R2135-1105...
Page 3 (although some chapters contain technical information) and this Service Manual describes information about maintenance of the equipment, replacement of parts and setting of each item. There are two types, Type I and Type II, of SURDIAL. When using this Service Manual, check the type of installed SURDIAL first.
Page 4 PREFACE-2...
Page 5: Safety Precautions
SAFETY PRECAUTIONS Proper operation and regular maintenance are essential for safe operation. Thoroughly read and understand the safety precautions listed in this instruction manual before use. Operation and safety precautions listed in this manual are specific intended for the use of this unit. If this unit is used for other purposes, which are not listed in this instruction manual, the user will be responsible for the consequential safety issues.
Page 6 DANGER Read this instruction manual before using the unit. • When this machine is operated and maintained in a proper way, a safe and reliable treatment is warranted. • Before operating the unit, thoroughly read and understand this manual. Improper operation can lead to injury or abnormal operation.
Page 7 WARNING Electronic equipment producing radio waves should not be used in the same room or building as where this unit is used. • Avoid the use of electronic equipment that produces radio waves including cellular phones, transceivers, and radio-controlled toys. Use of this equipment inside of a hospital building can lead to malfunction of the machine.
Page 8 CAUTION Before installing the unit, thoroughly read and understand the installation section of this manual. • Only trained professionals may install the unit. • Install the unit in accordance with the installation instructions. The connection of optional parts should be performed after reading and thoroughly understanding the corresponding manuals.
Page 9 CONTENTS PREFACE SAFETY PRECAUTIONS 1. APPLICATION ································································································ 1-1 2. CONTRAINDICATION ···················································································· 2-1 3. PRECAUTIONS ······························································································ 3-1 4. SYMBOL FOR SAFETY·················································································· 4-1 5. FLOW CHART 5.1. Fluid and blood lines··············································································· 5-1 5.1.1. Flow chart······················································································· 5-1 5.1.2. List of input components ································································ 5-3 5.1.3.
Page 10 6.2. Output components ················································································ 6.2.1-1 6.2.1. Two way electromagnetic valve: AV-3200-318-SC (V2 / V3 / V12 / V13 / V14 (V17))··················································· 6.2.1-1 6.2.2. Two way electromagnetic valve (V4 / V11) ···································· 6.2.2-1 6.2.2.1. TYPE I: AV-3202-63-S ······················································· 6.2.2-1 6.2.2.2. TYPE II: SVB-2B ·································································· 6.2.2-2 6.2.2.3.
Page 11 6.3.7.1. A Type·················································································· 6.3.7-1 6.3.7.2. B Type·················································································· 6.3.7-2 6.3.7.3. C Type·················································································· 6.3.7-3 6.3.8. Reducing valve Assy (PR)······························································ 6.3.8-1 6.3.8.1. ER0883ZSS8/RW83 ···························································· 6.3.8-1 6.3.8.2. ER0884ZBS8 ······································································· 6.3.8-2 6.3.9. Relief valve (RV1/RV2/RV3/RV4)··················································· 6.3.9-1 6.3.9.1. Relief valve 1 / Relief valve 2 ··············································· 6.3.9-1 6.3.9.2.
Page 12 8.4. Bubble sensor board··············································································· 8.4-1 8.4.1. SBY0160 board ·············································································· 8.4-1 8.4.2. SBY0205 board ·············································································· 8.4-2 8.5. Dialysate pressure sensor board ···························································· 8.5-1 8.5.1. TYPE I···························································································· 8.5-1 8.5.2. TYPE II: A Type·············································································· 8.5-3 8.5.3. TYPE II: B Type·············································································· 8.5-4 8.6. Main board······························································································ 8.6-1 8.7.
Page 13 9.10. Maintenance mode 7 screen ································································ 9.10-1 9.10.1. ROM before Ver.2.40 ··································································· 9.10-2 9.10.2. ROM after Ver.3.00 ······································································ 9.10-3 9.11. Maintenance mode 8 screen ································································ 9.11-1 9.11.1. ROM before Ver.2.40 ··································································· 9.11-2 9.11.2. ROM after Ver.3.00 ······································································ 9.11-3 9.11.2.1. Monitor screen ······································································· 9.11-3 9.11.2.2.
Page 14 10.20.2. Adjustment of priming volume ···················································· 10.20-2 10.21. Adjustment of syringe pump infusion flow··········································· 10.21-1 10.22. Adjustment of overload detection on Syringe pump Assy, when other than Nipro syringe used ··················································· 10.22-1 10.23. Adjustment of conductivity sensor ······················································ 10.23-1 11. DIP SWITCHES 11.1 Operation of dip SW’s············································································...
Page 15 12.2.4. C Type·························································································· 12.2-5 12.2.5. D Type·························································································· 12.2-6 12.3. Record sheet of setting value ······························································· 12.3-1 12.3.1. ROM before Ver.2.40 ··································································· 12.3-2 12.3.2. ROM after Ver.3.00 ······································································ 12.3-4 12.3.3. ROM after Ver.3.30 ······································································ 12.3-6 12.3.4. ROM after Ver.3.84 ······································································ 12.3-8 12.3.5.
Page 16 CONTENTS-8...
Page 17 1. APPLICATION (a) Single patient dialysis machine, SURDIAL is applied to treatment of patients with acute or chronic renal failure by dialysis when the application is instructed by doctor. (b) SURDIAL can be used at both hospital and home.
Page 19 2. CONTRAINDICATION Any application other than dialysis using SURDIAL is contraindicated.
Page 21 3. PRECAUTIONS The following precautions should be noted when using this unit: 1. This unit should be operated by skilled personnel only. 2. Important notes concerning the installation of the machine: (1) Keep the unit out of water. (2) Only use the machine in normal conditions. Normal air pressure, temperature, humidity, wind, sunlight.
Page 23 4. SYMBOL FOR SAFETY (a) The symbol shown below means that user of SURDIAL must read and understand this Service Manual before starting operation of the machine for safe and effective use of it. (b) The symbol shown below means that electric shock is caused by contact with high voltage...
Page 25 5. FLOW CHART...
Page 27 5.1. Fluid and blood lines 5.1.1. Flow chart NOTE • Show the following flow chart that C2 is installed between NV1 to H. • The machine can be separated two type, which is installed R3 or not. Confirm to install R3 or not before operating machine ACID DISINFECTANT or ACID...
Page 28 NOTE • Show the following flow chart that C2 is installed between BTW and P1 or RV4 is installed in the machine. ACID DISINFECTANT or ACID B_concentrate A_concentrate or Acetate DRAIN RO WATER Fig. 5-2 Flow chart...
Page 29 5.1.2. List of input components Symbol Component Function Temperature sensor 1 Supply water temp. measurement Temperature sensor 2 Heater outlet water temp. measurement Temperature sensor 3 Dialysate temp. measurement Conductivity cell Dialysate conductivity measurement Dialysate pressure sensor Dialysate line pressure measurement <PA>...
Page 30 5.1.3. List of output components EMV: electromagnetic valve Symbol Component Function EMV for priming Open/close of priming line EMV for drainage Open/close of drainage line EMV for AS2 Open/close of upper line of AS2 Line changeover of fresh fluid side of A EMV for fresh fluid in VCa chamber Line changeover of drainage side of A...
Page 31 5.1.4. List of other components Symbol Component Function Deaeration bath 1 Deaeration from supply water Deaeration bath 2 Deaeration from dialysate Buffer tank W Deaeration acceleration BTD1 Buffer tank D1 Dialysate mixing 1 BTD2 Buffer tank D2 Dialysate mixing 2 Dialysate check valve Dialysate back flow prevention Negative pressure maintenance in Bellow-...
Page 33 6. DISASSEMBLING AND REPLACEMENT...
Page 35 6.1. Input components 6.1.1. Conductivity cell Assy CD 6.1.1.1. A Type Fig. 6.1.1-1 Conductivity cell Assy (A Type) № Component Requirement Note Sensor holder 93153811104 O-ring Silicone rubber 93153812104 Pan head Phillips screw M3×8 With spring/flat washers (small) Hose port 93742611001 CD harness 93447132102...
Page 36 6.1.1.2. B Type Fig. 6.1.1-2 Conductivity cell Assy (B Type) № Component Requirement Note Sensor holder 93153811104 O-ring Silicone rubber 93153812104 Pan head Phillips screw M3×8 With spring/flat washers (small) Hose port P1/8B SUS316 CD harness 93447132102 Serial numbers installed 03T2610 03T2720 03V0437...
Page 37 6.1.1.3. C Type Fig. 6.1.1-3 Conductivity cell Assy (C Type) № Component Requirement Note Sensor holder 93613811002 O-ring Silicone rubber 93153812104 Pan head Phillips screw M3×8 With spring/flat washers (small) CD harness 93447132102 Serial numbers installed 04T2721 05T3840 04V0471 05V0725 04W0952 05W1368 Refer 6.1.1-5 also.
Page 38 6.1.1.4. D Type Fig. 6.1.1-4 Conductivity cell Assy (D Type) № Component Requirement Note Holder A 01930500027 For M3 O-ring 01930400224 Conductivity sensor harness Screw M3×10 With spring/flat washers Screw M3×25 With spring/flat washers O-ring Holder B 01930500026 Conductivity sensor Assy 93613800 Serial numbers installed 05T3841...
Page 39 Please read this section carefully and understand the information because there is the specific combination between Conductivity cell Assy and Temperature sensor Assy. There are 4 types of Conductivity cell Assy installed in SURDIAL. [Conductivity cell Assy] • A Type •...
Page 40 6.1.1-6...
Page 41 6.1.2. Dialysate pressure sensor Assy (PD) 6.1.2.1. TYPE I Sensor Sensor Fig. 6.1.2-1 Dialysate pressure sensor Assy (TYPE I) № Component Requirement Note Sensor BKT 93442911100 Cover 93442915100 Dialysate pressure sensor board SBY-0159 Spacer BSB-310 Brass Spring washer For M3 Small pan head Phillips screw M3×6 With spring/flat washers...
Page 42 6.1.2.2. TYPE II: A Type Fig. 6.1.2-2 Dialysate pressure Assy (TYPE II: A Type) № Component Requirement Note Screw M3×18 With spring/flat washers Manifold 01930200055 Packing 93532934001 O-ring AS568-016 Pressure sensor 19C015G3/SZ75582 Old type 19C015PV3K New type Base plate 93532932100 １...
Page 43 6.1.2.3. TYPE II: B Type Fig. 6.1.2-3 Dialysate pressure Assy (TYPE II: B Type) № Component Requirement Note Manifold 93882911 O-ring S-16 Pressure sensor P-8505-102G-012 Base plate 93882912 Spacer 93882913 Dialysate Pressure sensor SSM-05025 board Screw M3×12 With spring/flat washers Cover 93882814 Dialysate...
Page 44 6.1.2-4...
Page 45 6.1.3. Blood leak sensor Assy (BLD) 6.1.3.1. TYPE I: RK-GR1 Fig. 6.1.3-1 Blood leak sensor Assy (TYPE I: RK-GR1) № Component Requirement Note Upper body cover TM-0005-02 Body casing TM-0006-02 Light receiver holder TM-0007-02 Light emitter holder TM-0008-02 Condensing lens TM-0009-01 Rear body cover TM-0010-02...
Page 46 6.1.3.2. TYPE II: RK-GR2 Fig. 6.1.3-2 Blood leak sensor Assy (TYPE II: RK-GR2) № Component Requirement Note Base Heat-resistant ABS Cartridge Small pan head Phillips screw M4×12 Serial numbers installed 99T0374 ～ 03T2083 99U0033 ～ 02U0176 99V0086 ～ 02V0310 99W0049 ～ 03W0599 6.1.3-2...
Page 47 6.1.3.3. TYPE II: BLD-01 Fig. 6.1.3-3 Blood leak sensor Assy (TYPE II: BLD-01) № Component Requirement Note Body Cover 93444814100 BLD cartridge O-ring Hexagon headed Phillips bolt M4×10 With spring/flat washers Serial numbers installed 03T2084 02U0177 02V0311 03W0600 6.1.3-3...
Page 48 6.1.3-4...
Page 49 6.1.4. Pressure SW: AW-3200-63-A (PS) Fig. 6.1.4-1 Pressure SW № Component Requirement Note Screw M3×35 With spring/flat washers Bonnet D3C150 Spring holder D3H390 Spring D3K370 Shaft D3I1200 Casing D3D140 Diaphragm D3A090 Valve body D3B1181 Screw M3×30 With spring/flat washers 6.1.4-1...
Page 50 6.1.4-2...
Page 51 6.1.5. Temperature sensor Assy (T) 6.1.5.1. PT-HST-1000 Fig. 6.1.5-1 Temperature sensor Assy (PH-HST-1000) № Component Requirement Note T-tube 93613911100 Silicone tube 5× 11×40L Temperature sensor PT-HST-1000 Serial numbers installed 99T0001 03T2609 99U0001 02U0176 99V0001 03V0436 99W0001 03W0872 98R0001 99R0160 6.1.5-1...
Page 52 6.1.5.2. PT100-HSTA-900 Fig. 6.1.5-2 Temperature sensor Assy (PT100-HSTA-900) № Component Requirement Note Teflon tube TF185 n=1 when attaching to Conductivity cell Assy Hose port 01930600070 Sensor holder 93742513100 Temperature sensor PT100-HSTA-900 Serial numbers installed 03T2610 06U0177 03V0437 03W0873 No1 hose port is installed in the following serial number. 06T4448 06U0244 06V1011...
Page 53 6.1.6. Air bubble detector Assy (BD) Fig. 6.1.6-1 Air bubble detector Assy № Name Type Note Cover 93446313100 Pusher 93446312100 Base 93446311100 Screw M3×8 Screw M3×12 To install Spring No.5601 Packing 93446315100 Air bubble ditector Assy comes with a substitute screw as Screw . So please exchange it to a screw(M3×12) when installation.
Page 54 6.1.6-2...
Page 55 6.2. Output components 6.2.1. Two way electromagnetic valve: AV-3202-318-SC (V2/V3/V12/V13/V14 (V17)) Fig. 6.2.1-1 Two way electromagnetic valve (AV-3202-318-SC) № Component Requirement Note Actuator Assy Spring D3K430 Diaphragm holder Plunger Diaphragm D3Y180 Plunger Assy Seat Spacer Valve body D3B1161 Screw 6.2.1-1...
Page 56 6.2.1-2...
Page 57 6.2.2. Two way electromagnetic valve 6.2.2.1. TYPE I: AV-3202-63-S (V4/V11) Fig. 6.2.2-1 Two way electromagnetic valve (TYPE I: AV-3202-63-S) № Component Requirement Note Actuator Assy D3Y080 Back-less pipe D3I170 Spring D3K340 Plunger D3I630 Diaphragm D3A090 Valve body D3B1181 Screw M3×25 With spring/flat washers Serial numbers installed 99T0001...
Page 58 6.2.2.2. TYPE II: SVB-2B (V4/V11) Fig. 6.2.2-2 Two way electromagnetic valve (TYPE II: SVB-2B) № Component Requirement Note Screw With spring/flat washers Actuator Assy Plate M. Tube Spring 98-A54 Plunger 159-A511 Retainer ring 65-A10 Valve diaphragm 95-A011 Body 5-A520 Serial numbers installed 99T0374 07T4854 99U0033...
Page 59 6.2.2.3. TYPE II: SV2-322-S (V4/V11) Fig. 6.2.2-3 Two way valve (TYPE II: SV2-322-S) № Component Requirement Note Actuator Assy D3Y570 Core D3E370 Spring D3K680 Plunger Assy D3I2430 With pipe Plunger D3H370 Valve diaphragm D3A540 Valve body D3B1810 Screw M3×45 Serial numbers installed 07T4855 07U0325 07V1108...
Page 60 6.2.2-4...
Page 61 6.2.3. Two way electromagnetic valve 6.2.3.1. A type: AV-3202-63-SH (V10) Fig. 6.2.3-1 High vacuum electromagnetic valve (A type: AV-3202-63-SH) № Component Requirement Note Actuator Assy D3Y110 Back-less pipe D3I990 Spring D3K040 Plunger D3I1000 Diaphragm D3A090 Valve body D3B1181 With spring flat washers Screw M3×25 Serial numbers installed...
Page 62 6.2.3.2. B type: SAV-3202-33-SB (V10) Fig. 6.2.3-2 Two way electromagnetic valve (B type: SAV-3202-33-SB) № Component Requirement Note Actuator Assy D3Y460 Spring D3K500 Plunger D3I2120 Diaphragm D3A240 Valve body D3Y290 Fixed base D3F410 Spring flat washers Screw M3×22 Serial numbers installed 03T2204 07T4854 06U0177...
Page 63 6.2.3.3. C type: SV2-322-S (V10) Fig. 6.2.3-3 Two way valve (C type: SV2-322-S) № Component Requirement Note Actuator Assy D3Y570 Core D3E370 Spring D3K680 Plunger Assy D3I2430 With pipe Diaphragm pusher D3H370 Diaphragm D3A540 Valve body D3B1810 Screw M3×45 Serial numbers installed 07T4855 07U0325 07V1108...
Page 64 6.2.3-4...
Page 65 6.2.4. Three way electromagnetic valve: AV-3302-63-S (V5/V6/V7/V8/V9) Fig.6.2.4-1 Three way electromagnetic valve (AV-3302-63-S) № Component Requirement Note Actuator Assy D3Y170 Push rod D3I660 Diaphragm D3A090 Valve body D3B990 Stem D3I670 Diaphragm D3A090 Spring holder D3H110 Spring D3K150 Base D3F120 Screw M3×50 With spring washer 6.2.4-1...
Page 66 6.2.4-2...
Page 67 6.2.5. Bellowphragm pump: VCP-60 (VPa/VPb) 6.2.5.1. Sensor guide rod: Pin type 1 Fig. 6.2.5-1 Bellowphragm pump Assy № Component Requirement Note Upper part of cylinder Middle part of cylinder Lower part of cylinder BF diaphragm Piston BF diaphragm Sensor guide rod Rotation detection plate Applicable grease: Drive shaft...
Page 68 6.2.5.2. Sensor guide rod: Plane type Fig. 6.2.5-2 Bellowphragm pump Assy № Component Requirement Note Upper part of cylinder Middle part of cylinder Lower part of cylinder BF diaphragm Piston BF diaphragm 7-1 Sensor dog #0193 01 00 068 1 7-2 Pin #0193 01 00 064 1 Rotation detection plate...
Page 69 6.2.5.3. Sensor guide rod: Pin type 2 Fig. 6.2.5-3 Bellowphragm pump Assy № Component Requirement Note Upper part of cylinder Middle part of cylinder Lower part of cylinder BF diaphragm Piston BF diaphragm Sensor guide rod Rotation detection plate Applicable grease: Drive shaft Made by NOK.
Page 70 6.2.5.4. Sensor guide rod: Pin type 3 Fig. 6.2.5-4 Bellowphragm pump Assy № Component Requirement Note Upper part of cylinder Middle part of cylinder Lower part of cylinder BF diaphragm Piston BF diaphragm Sensor guide rod Rotation detection plate Applicable grease: Drive shaft Made by NOK.
Page 71 6.2.5.5. Reference for Bellowphragm Pump Bellowphragm pump (hereinafter referred to as “VP ) which install in SURDIAL machine can be separated 4 types. 1. Distinction of VP type Distinguish VP type by sensor guide rod as follows, Pin type 1: Install sensor guide rod which shape pin.
Page 72 6.2.5-6...
Page 73 6.2.6. Blood pump Assy (BP/BPC) Fig. 6.2.6-1 Blood pump Assy 6.2.6-1...
Page 74 6.2.6.1. M3 Type № Component Requirement Note Cover 93146123114 Install receiver metal Hinge shaft 91936116010 Shaft A 93146117185 Shaft B 93146119102 BP rotor 93146116287 No23 M3 set screw Roller 01930100175 Housing 93446111100 Attached to No24(2pieces) Rubber cap 93146127100 Packing 93146128197 Rubber sheet cover 93146112001 Magnet BKT (2)
Page 75 6.2.6.2. M4 Type № Component Requirement Note Cover 93146123114 Install receiver metal Hinge shaft 91936116010 Shaft A 93146117185 Shaft B 93146119102 BP rotor 93146116287 No23 M4 set screw Roller 01930100175 Housing 93446111100 Attached to No24(2pieces) Rubber cap 93146127100 Packing 93146128197 Rubber sheet cover 93146112001 Magnet BKT (2)
Page 76 6.2.6-4...
Page 77 6.2.7. Gear pump Assy (P1/P2) 6.2.7.1. TYPE I: Micro gear pump Fig. 6.2.7-1 Micro gear pump Assy (TYPE I) 6.2.7-1...
Page 78 № Component Requirement Note Gear casing Mounting disk End disk Back casing Inner magnet Outer magnet Mounting plate Drive gear shaft Counter gear shaft Drive gear Counter gear Spring Teflon seal Gasket Motor flange Set screw with hexagonal cavity Small pan head Phillips screw M3×8 Small pan head Phillips screw M2.5×4...
Page 79 6.2.7.2. TYPE II: Magnet gear pump (Normal Type) Fig. 6.2.7-2 Magnet gear pump Assy (TYPE II: Normal Type) 6.2.7-3...
Page 80 № Component Requirement Note Motor 1430089800 For 230V 1430089900 For 110V Magnet ring MDG0519 Rear casing Magnet can Mounting plate Bracket Drive gear Slave gear Gear case Flat pin MDG0528 Stepped Front bearing Rear bearing Front plate Rear plate Pump head Gasket A Gasket B Packing B...
Page 81 6.2.7.3. TYPE II: Magnet gear pump (A Type) Fig. 6.2.7-3 Magnet gear pump Assy (TYPE II: A Type) 6.2.7-5...
Page 82 № Component Requirement Note Motor 1430089800 For 230V 1430089900 For 110V Magnet ring MDG0519 Rear casing Magnet can Mounting plate Bracket Drive gear Name: Spare kit Slave gear Name: Spare kit Gear case Flat pin 4A400104 Not stepped Front bearing Name: Spare kit Rear bearing Name: Spare kit...
Page 83 6.2.7.4. Reference for Gear Pump There are two types of Magnet Gear Pumps used for SURDIAL. Read following information carefully and take appropriate action when necessary. (1) How to verify the type of Magnet Gear Pump For Magnet Gear Pump A Type, black marking (4mm diameter) is shown on the pump head.
Page 84 6.2.7-8...
Page 85 6.2.8. Venous clamp Assy (CLV) Fig. 6.2.8-1 Venous clamp Assy 6.2.8-1...
Page 86 № Component Requirement Note Solenoid BKT 93446211002 Solenoid base 93446212100 Head guide 93146223232 Clamp guide 93446214002 Head 93446215002 Solenoid RGY-AC0505DNP O-ring Spring №1112 Hexagon headed bolt M3×8 With spring/flat washers Small pan head Phillips screw M3×6 With spring/flat washers Small pan head Phillips screw M4×6 With spring washer Hexagon nut...
Page 87 6.2.9. Syringe pump Assy (SP) Fig. 6.2.9-1 Syringe pump Assy 6.2.9-1...
Page 88 № Component Requirement Note Pusher 93146511002 Frame 93449014100 Plate 93536520144 Plate2 91936527010 Shaft 93449019002 Housing 93536516100 Syringe clamp 93536513100 Rubber plate 93536525100 Syringe receiver 93146538001 Packing 93146537197 Clamp spring 93146528001 Feed screw 93146517001 Guide shaft 91936515010 Crunch spring 91936523010 Spring case 93146521251 Half nut 91936519010...
Page 89 6.3. Other components 6.3.1. Deaeration tank Assy (AS1) 6.3.1.1. A Type Fig. 6.3.1-1 Deaeration tank Assy (A Type) № Component Requirement Note Casing(1) 91933411006 Casing(2)-L 91933412006 Float 93442313115 Metal mesh 91933015002 O-ring Byton With spring Flat washer Small pan head Phillips screw M4×15 Hexagon nut Flat washer For M4...
Page 90 6.3.1.2. B Type Fig. 6.3.1-2 Deaeration tank Assy (B Type) № Component Requirement Note Casing(1) 91933411006 Casing(2)-L 91933412006 Float 93442313115 Metal mesh 91933015002 O-ring Byton With spring Flat washer Small pan head Phillips screw M4×30 Hexagon nut Flat washer For M4 Small truss Phillips screw M4×8 With Nylon washer...
Page 91 6.3.2. Deaeration tank Assy (AS2) Fig. 6.3.2-1 Deaeration tank Assy № Component Requirement Note Casing 93312412134 Casing(1) 91933411006 Packing 01930200088 Mesh 01930200089 Metal mesh 91933015002 Plate 01939700069 O-ring Byton Float switch OLV-2P-1(special) With spring Flat washer Small pan head Phillips screw M4×20 Hexagon nut Small truss Phillips screw M4×8...
Page 92 6.3.2-2...
Page 93 6.3.3. Buffer tank W Assy (BTW) Fig. 6.3.3-1 Buffer tank W Assy № Component Requirement Note Lower tank 91936937004 Upper tank (B) 91936955004 BTW bracket 93443513100 O-ring Byton With spring Flat washer Small pan head Phillips screw M4×15 Hexagon nut With spring Flat washer Hexagon head Phillips screw M4×10...
Page 94 6.3.3-2...
Page 95 6.3.4. Buffer tank D Assy (BTD1/BTD2) Fig. 6.3.4-1 Buffer tank D Assy № Name Type Note Lower tank 91936937004 Upper tank (A) 91936936004 BTD bracket 93444514100 O-ring Byton Small pan head Phillips screw M4×15 With spring/flat washers Hexagon nut Hexagon head Phillips screw M4×10 With spring/flat washers Small truss Phillips screw...
Page 96 6.3.4-2...
Page 97 6.3.5. Check valve 6.3.5.1. Dialysate check valve: #919342300041(AC-2200-55-S) (C1) Fig. 6.3.5-1 Dialysate check valve № Component Requirement Note Body ACB060 Seat holder/ Seat ACY040 Check valve seat Assy Spring ACK290 Lock nut ACH080 O-ring P9DC Sub-body ACB070 6.3.5-1...
Page 98 6.3.5.2. Bellowphragm check valve: AC-2200-53-S (C2) Fig. 6.3.5-2 Bellowphragm check valve (AC-2200-53-S ) № Component Requirement Note Casing ACC050 Diaphragm D2A181 Spring receiver ACH130 Spring ACK220 Valve body ACB140 Hose port 93742611001 Serial numbers installed 99T0001 01T1375 99U0001 01U0151 99V0001 01V0225 99W0001 01W0253...
Page 99 AC-4200-53-A (C2) From VP Fig. 6.3.5-3 Bellowphragm check valve (AC-4200-53-A) № Component Requirement Note Body ACB260 Seat ACY040 Check valve seat Assy Seat holder Spring ACK160 O-ring P9DC ACY050 Sub-body Assy Sub-body Name plate Serial numbers installed 01T1376 01U0152 01V0226 01W0254 6.3.5-3...
Page 100 6.3.5-4...
Page 101 6.3.6. Filter 6.3.6.1. Supply water filter (F) PP body type Serial numbers installed 99T0001 ～ 02T1867 99U0001 ～ 02U0176 99V0001 ～ 02V0300 99W0001 ～ 02W0400 Fig. 6.3.6-1 PP body type 98R0001 ～ 99R0160 № Component Requirement Note 91934220002 Mesh 91934222002 Packing 93142017002 Filter...
Page 102 6.3.6.2. Coupler line filter (F7) GVS filter Serial numbers installed 02T1868 ～ 03T2263 02V0301 ～ 02V0310 Fig. 6.3.6-3 GVS filter 02W0401 ～ 03W0672 № Component Requirement Note 93619318100 Hose port 93619319100 Packing 01939900124 Filter FI116ATERP265A00 Body 93619320100 CL filter Serial numbers installed 03T2264 ～...
Page 103 6.3.7. Flow meter Assy (FM/FS) 6.3.7.1. A Type Fig. 6.3.7-1 Flow meter Assy Component Requirement Note Flow meter SI-1AB SI-1AC FM, Improvement type L-shaped hose port 93283912001 Hose port 93742611001 Bracket 93443113100 Small pan head Phillips screw M3×6 With spring/flat washers Photo-micro sensor EE-SPY-412 Hexagon headed Phillips screw...
Page 104 6.3.7.2. B Type Fig. 6.3.7-2 Flow meter Assy Component Requirement Note Flow meter SI-6 (FS:Photo-micro sensor EE-SPX303) SESI-700 FM, Improvement type (FS:Photo-micro sensor EE-SPX303) FM bracket 93443114100 Hexagon head Phillips screw M4×10 Serial numbers installed SI-6 SESI-700 06T4409 ～ 10T7669 10T7670 ～...
Page 105 6.3.7.3. C Type Fig. 6.3.7-3 Flow meter Assy Component Requirement Note Flow meter SESI-701 (FS:Photo-micro sensor EE-SPX303N) FM bracket 93443114100 Hexagon head Phillips screw M4×10 Serial numbers installed 11T8861 ～ 11U0484 ～ 11V2552 ～ 11W3390 ～ 6.3.7-3...
Page 106 6.3.7-4...
Page 107 6.3.8. Reducing valve Assy (PR) 6.3.8.1. ER0883ZSS8/RW83 Fig. 6.3.8-1 Reducing valve Assy (ER0883ZSS8/RW83) № Component Requirement Note Reducing valve ER0883ZSS8 RW83 Flange 93442113002 PR hose port 93282116113 Hose port 93312116129 Small truss Phillips screw M4×8 With Nylon washers Serial numbers installed 99T0001 03T2399 99U0001...
Page 108 6.3.8.2. ER0884ZBS8 Fig. 6.3.8-2 Reducing valve Assy (ER0884ZBS8) № Component Requirement Note Reducing valve ER0884ZBS8 Flange 93442113002 PR Hose port 93282116113 Hose port 93312116129 Small truss Phillips screw M4×8 With Nylon washers Both reducing valve has compatibility each other. Serial numbers installed 03T2340 02U0177 03V0361...
Page 109 6.3.9. Relief valve 6.3.9.1. Relief valve 1/2: Type I AC-2200-55-TA / AC-2200-55-P (RV1/RV2) Type II AC-2200-55B (RV1/RV2) Fig. 6.3.9-1 Relief valve 1/ Relief valve 2 № Component Requirement Note Body ACB060 Seat holder/Seat ACY044 Check valve seat Assy Spring ACK330 For AC-2200-55-TA ACK160 For AC-2200-55-P...
Page 110 6.3.9.2. Relief valve 3: AC-3200-63H-T (RV3) Fig. 6.3.9-2 Relief valve 3 (AC-3200-63H-T) № Component Requirement Note Valve body Seat Packing Seat holder Spring Lock nut Casing Name plate 6.3.9-2...
Page 111 6.3.9.3. Relief valve AC-4200-53-S (RV4) From V2 Fig. 6.3.9-3 Relief valve 4 (AC-4200-53-S) To Chamber № Component Requirement Note Body ACB250 Sheet ACY040 Check sheet Assy Sheet holder Spring ACK160 O-ring P9DC ACY050 Sub-body Assy Sub-body Hose port 93742611001 PT1/8 Serial numbers installed 01T0992 ～...
Page 112 AC-4200-53-SA (RV4) From V2 From Chamber Fig. 6.3.9-4 Relief valve 4 (AC-4200-53-SA) Component Requirement Note Body ACB260 Sheet ACY040 Check sheet Assy Sheet holder Spring ACK160 O-ring P9DC ACY050 Sub-body Assy Sub-body Name plate Serial numbers installed 01T1228 ～ 01U0099 ～ 01V0216 ～...
Page 113 6.3.10. Sampling port Assy (SL) Sampling port Sampling port Fig. 6.3.10-1 Sampling port Assy Component Requirement Note Packing 93313418100 Bracket 93443416100 Small pan head Phillips screw M3×6 With spring/flat washers Syringe holder 01930400085 Packing (B) 01939800472 Valve 90403411001 Spring 91938867004 Body 01930400069 6.3.10-1...
Page 114 6.3.10-2...
Page 115 6.3.11. Chamber Assy (VCa / VCb) 6.3.11.1. Chamber Assy (Overall) Chamber Fig. 6.3.11-1 Chamber Assy (Overall) 6.3.11-1...
Page 116 № Component Requirement Note Chamber frame 93441011100 Rubber sheet 93141036001 Sheet 93311028002 Bellowphragm pump VCP-60 T-pipe 93613911100 Viscous plug 91931111010 Polyurethane tube US code 15-10 Yellow Polyurethane tube US code 25-10 Clear Shapper SNP-4 White Hose band Size 26 Blue Hexagon head Phillips bolt M4×12 With spring/flat washers...
Page 117 6.3.11.2. Chamber Assy (Viscous chamber) Fig. 6.3.11-2 Chamber Assy (Viscous chamber) 6.3.11-3...
Page 118 № Component Requirement Note Diaphragm 01939900035 Inner spacer 93141013001 Outer spacer 93141014001 Chamber T1 93611015001 1 slit (Fresh dialysate side) Chamber T3 93611016001 3 slit (Used dialysate side) Silicone oil THF450-100* Clamp 93141015102 Clamp fitting 93141039105 Shaft 93141038002 E-ring Thrust bolt M8-43 T-pipe 93441025100...
Page 119 6.3.12. Concentrate tank connectors As for the Tank Connectors, Surdial has for A concentrate, B concentrate and disinfectant concentrate. For A and B concentrate connectors, there are 3 types. 6.3.12.1. Concentrate Tank Connector (for A and B concentrates) Black socket type Fig.
Page 120 Red/ Blue Socket Type (Separated Hose Port Type) Fig. 6.3.12-1b Concentrate tank connector (for A and B concentrates) №. Component Requirement Note Socket QJ-2PNPT1/8, Red silicone For A concentrate rubber (Sleeve color: Red) QJ-2PNPT1/8, Red silicone For B concentrate rubber (Sleeve color: Blue) Silicone tube 5×...
Page 121 Red/ Blue Socket Type (One-piece Hose Port Type) Fig. 6.3.12-1c Concentrate tank connector (for A and B concentrates) №. Component Requirement Note Socket QJ-2P-H-2, Red silicone For A concentrate rubber (Sleeve color: Red) QJ-2P-H-3, Red silicone For B concentrate rubber (Sleeve color: Blue) Silicone tube 5×...
Page 122 6.3.12.2. Concentrate Tank Connector (for disinfectant concentrate) Fig. 6.3.12-2 Concentrate tank connector (for disinfectant concentrate) №. Component Requirement Note Connector holder 91936940004 Packing A 91936944004 Holder base 91936941004 91933311010 Silicone tube 5× 11×50L FEP tube TF185 6× 8×330L Color seal 91935931010 Green 6.3.12-4...
Page 123 6.3.13. Rinse port As for the Tank Connectors, Surdial has for A concentrate, B concentrate and disinfectant concentrate. For A and B concentrate connectors, there are 3 types. 6.3.13.1. Rinse Port No.1 (for A and B concentrates) Fig. 6.3.13-1 Rinse port No.1 (for A and B concentrates) №...
Page 124 6.3.13.2. Rinse Port No.2 (for A and B concentrates) Fig. 6.3.13-2 Rinse port No.2 (for A and B concentrates) № Component Requirement Note Body O-ring QJR22 Red silicone rubber Washer Gasket QJR21 Red silicone rubber Valve QJT24 Valve spring QJS23 Adapter Adapter nut Hose port...
Page 125 6.3.13.3. Rinse Port No.3 (for A and B concentrates) Fig. 6.3.13-3 Rinse port No.3 (for A and B concentrates) № Component Requirement Note QJ-2P-H-2, Red silicone for A concentrate rubber (Sleeve color: Red) Socket QJ-2P-H-3, Red silicone for B concentrate rubber (Sleeve color: Blue) Body O-ring...
Page 126 6.3.13.4. Rinse port (for disinfectant concentrate) Fig. 6.3.13-4 Rinse port (for disinfectant concentrate № Component Code No./Requirement Note Connector holder 91936940004 Packing (A) 91936944004 Holder base 91936941004 Holder bracket 93313318100 Small truss Phillips screw M4×8 With nylon washer Grommet 91936945004 Tube connector 91936939004 Color seal...
Page 127 6.3.14. Coupler Assy 6.3.14.1. A Type Fig. 6.3.14-1 Coupler Assy (A Type) № Components Requirement Note Body C00149 L slider D00143 V442500 Red: For (Red)R- 6 D00143 V881700 Blue: For (Blue)B- 6 Stop ring D00136 Coil spring D00399 Ball O-ring P12.5 Serial numbers installed 99T0001...
Page 128 6.3.14.2. B Type Fig. 6.3.14-2 Coupler Assy (B Type) № Components Requirement Note Socket 90363011001 Packing 90363014001 Slider R 90363013001 Slider B 90363012001 Blue Spring 91933314001 Ball MDM-3006 Stop ring 91933312001 Coupler Assy SAS-08033 SAS-08034 Blue Serial numbers installed 09T7151 09U0484 09V1838 09W2418...
Page 129 6.3.15. Needle valve 6.3.15.1. AM-1200-55A (#9315 27 13 120) (NV1/NV2) Fig. 6.3.15-1 Needle valve (AM-1200-55A) № Components Requirement Note Body O-ring Stem Guide Case Lock nut Serial numbers installed 99T0001 09T6673 99U0001 09U0483 99V0001 09V1748 99W0001 09W2311 98R0001 99R0160 6.3.15-1...
Page 130 6.3.15.2. SAS-08001 (NV1/NV2) Fig. 6.3.15-2 Needle valve (SAS-08001) № Components Requirement Note Body 01930700103 O-ring Shaft 01930500275 Collar 01930700106 Holder 01930700104 01930700105 Serial numbers installed 09T6674 09U0484 09V1749 09W2312 6.3.15-2...
Page 131 6.3.16. Piping parts Fig. 6.3.16 Piping parts № Components Requirement Note Hose connector 01930500296 Silicon tube 1× 3×150 T-tube 93613911100 Silicon tube 5× 11 Silicon tube 3× 6 6.3.16-1...
Page 132 6.3.16-2...
Page 133 7. CONSTRUCTION OF ELECTRICAL PART...
Page 135 7.1. Components of electrical part Upper part Lower part Fig. 7.1-1 Electrical part 7.1.1. Components at upper part of electrical part Operation panel Operation panel board LCD module Bubble sensor board Electrical POWER BOX 7.1.2. Component at lower part of electrical part Dialysate pressure sensor board 7.1-1...
Page 136 7.1.3. Placement of electrical part at machine 7.1.3.1. TYPE I Operation Operation panel board (rear side of machine) LCD module Electrical POWER BOX Bubble sensor board (right side in machine) Dialysate pressure sensor board. Fig. 7.1-2a TYPE I Placement of electrical part 7.1-2...
Page 137 7.1.3.2. TYPE II Operation Operation panel board (rear side of machine) LCD module Electrical POWER BOX Dialysate pressure sensor board. Bubble sensor board The air bubble sensor board is mounted either on the right in the equipment front side or above the electrical power box on the right side plane of the equipment.
Page 138 7.1.4. Components at left side in electrical POWER BOX Only the D type differs from the other types in arrangement of components in the left side of the electrical power box. Breaker Power SW Noise filter Terminal bed 1 DC+24V switching power source DC+5V,DC+12V,DC-12V switching power source or DC+5V,DC+12V,DC-12V power supply Terminal bed 2...
Page 139 7.1.5. Components at right side in electrical POWER BOX There are two types of electrical power boxes that differ in arrangement of the air bubble sensor board and optional battery. Main board Venous pressure sensor board Arterial pressure sensor board (option) DSUB board Buzzer board Battery (option)
Page 140 Main board Venous pressure sensor board Arterial pressure sensor board (option) VR board Buzzer board Battery (option) (*) Bubble sensor board POWER BOX of sub-board side (left side) * This type of electrical power box has a battery cover as an optional attachment of the battery.
Page 141 8. CONNECTION REPLACEMENT AND ADJUSTMENT...
Page 143 8.1. Operation panel sheet Flexible cable Panel sheet Fig. 8.1-1 Operation panel General description and application Key SW’s are encased in sheet of the operation panel. Adhesive tape placed at rear side of the panel sheet is applied to front side of upper part of machine.
Page 144 Replacement CAUTION Replace operation panel sheet after turning off power SW under care not to be charged with static electricity. Handle flexible cable carefully so that it is not folded and/or damaged. Otherwise malfunction may be caused. DO NOT apply excess external force to operation panel because key SW’s and patterns encased in the panel may be folded and/or damaged, resulting in malfunctioning of them, in particular when the panel itself is stored or handled.
Page 145 8.2. Operation panel board RESISTOR SER. LOT. Fig. 8.2-1 Operation panel board General description and functions Operation panel board is positioned at rear side of operation panel placed at upper part of machine. Contrast of LCD is adjusted by VR1 of the board. Flow rate of blood pump is set by VR2 of the board.
Page 146 Replacement CAUTION Replace operation panel board after turning off power SW under care not to be charged with static electricity. It is recommended to replace the board after cooling to room temperature because temperature of resistors placed on the board immediately tuning off power is high, potentially causing burn. Handle flexible cable carefully so that it is not folded and/or damaged.
Page 147 8.3. LCD module "UP" mark Fig. 8.3-1 LCD module General description and construction LCD module is constructed by LCD, back-light and board. LCD is STN type and can indicate 40 letters in each of 4 lines. Back-light is constructed by LED’s. CN1 is connector for back-light and is soldered to board.
Page 148 Replacement CAUTION DO NOT apply excess mechanical impact to LCD because it is constructed by glass. If broken, take care not to be injured by the glass fragments. If liquid crystal is leaked from damaged LCD and your skin or cloth is contaminated with the crystal, rinse out using soap immediately.
Page 149 8.4. Bubble sensor board 8.4.1. SBY0160 board VR601 SBY0160 CN601 CN602 Fig. 8.4-1 Bubble sensor board (SBY0160) General description and function Bubble sensor board is placed at upper part of machine. The board is used to detect bubble in blood line in cooperation with bubble sensor. Connection CN601 Connect to connector of [bubble sensor].
Page 150 8.4.2. SBY0205 board VR1(A) SBY0205 CN601 CN602 VR1(B) Fig. 8.4-2 Bubble sensor board (SBY0205) General description and function Bubble sensor board is placed at upper part of machine. The board is used to detect bubble in blood line in cooperation with bubble sensor. Connection CN601 Connect to connector of [bubble sensor].
Page 151 8.5. Dialysate pressure sensor board 8.5.1. TYPE I CN701 VR701 VR702 CN702 Fig. 8.5-1 Dialysate pressure sensor board (TYPE I) General description and function Dialysate pressure sensor board is placed at top of lower part of machine. The board is used to measure pressure in dialysate line in cooperation with dialysate pressure sensor.
Page 152 Replacement CAUTION Replace dialysate pressure sensor board after turning off power SW of machine under care not to be charged with static electricity. (1) Turn off power SW of machine. (2) Remove left cover from upper part of machine and left cover from lower part of it. (3) Remove dialysate pressure sensor ASSY as per the procedure specified in “6.1.2 Dialysate pressure sensor ASSY-TYPE I”.
Page 153 8.5.2. TYPE II: A Type Fig. 8.5-2 Dialysate pressure sensor board (TYPE II: A Type) General description and function Dialysate pressure sensor board is placed at top of lower part of machine. The board is used to measure pressure in dialysate line in cooperation with dialysate pressure sensor.
Page 154 8.5.3. TYPE II: B Type Fig. 8.5-3 Dialysate pressure sensor board (TYPE II: B Type) General description and function Dialysate pressure sensor board is placed at top of lower part of machine. The board is used to measure pressure in dialysate line in cooperation with dialysate pressure sensor.
Page 155 8.6. Main board CN1 CN18 CN16 CN22 DIPSW CN10 CN19 CN15 CN17 CN14 CN20 CN21 CN12 CN11 CN13 V.PRESS A.PRESS Fig. 8.6-1 Main board General description and functions Main board is attached to right side of DENSO box. Machine operation is controlled by microprocessor contained in the board. Various set values are back-upped by RAM and EEROM.
Page 156 Connection CN1 Connect to CN413 of [sub-board] through harness. CN2 Connect to [blood leak sensor] through harness. CN3 Connect to CN602 of [bubble sensor board] through harness. CN4 Not connected. CN5 Connect to CN408 of [sub-board] through harness. CN6 Not connected. CN7 Connect to [photo-sensor board of Bellowphragm pump A] through harness.
Page 157 Replacement Main board CAUTION Main board TYPE II (SBY0164) needs to place ROM after Ver.3.00. This board does not work properly if ROM before Ver.2.40 is placed. There are two types of main boards (SBY0164) for Type II. For details, refer to 8.13 Operation panel board, main board and sub-board .
Page 158 CAUTION Replace main board or ROM after turning off power SW of machine under care not to be charged with static electricity. After the board replacement, re-input set values. It should be noted that the values found in maintenance modes 5 and 6 are specific to machine. (Refer and use 12.3) (1) Turn on power SW of machine and record all set values.
Page 159 8.7. Venous and arterial pressure sensor boards CN701 VR701 VR702 PSD701 Pressure inlet port Fig. 8.7-1 Venous/arterial pressure sensor board General description and function Venous or arterial pressure sensor board is mounted on main board placed at right side of DENSO box.
Page 160 Replacement CAUTION Replace venous or arterial pressure sensor board after turning off power SW of machine under care not to be charged with static electricity. Connect tube to left side of sensor and expose right side of it to atmosphere. If connected to the right side, measured pressure is incorrect.
Page 161 8.8. DSUB board VR501 CN502 CN503 SPACER CN501 SPACER CN504 Fig. 8.8-1 DSUB board General description and functions DSUB board is placed at right side of DENSO box. The board is used to control blood pump flow rate at power failure when battery (VR501) as option is provided.
Page 162 Connection CN501 Connect to external monitor (option). CN502 Connect to CN9 of [main board] through harness. CN503 Connect to CN402 of [sub-board] through harness. CN504 Connect to CN810 of [buzzer board] through harness. Adjustment Not required Replacement CAUTION Replace DSUB board after turning off power SW of machine under care not to be charged with static electricity.
Page 163 8.9. Buzzer board SBY0162 board / SBY0267 board CN801 BZ801 Fig. 8.9-1 Buzzer board General description and function Buzzer board is placed at right side of DENSO box. The board is used to alert by buzzing (BZ801). SBY0162 and SBY0267 are the same boards. Connection CN801 Electrical power box A/B/C Type: Connect to CN504 of [DSUB board] through harness.
Page 164 Replacement CAUTION Replace buzzer board after turning off power SW of machine under care not to be charged with static electricity. (1) Turn off power SW of machine. (2) Remove right cover from upper part of machine and right cover from DENSO box. (3) Disconnect all connectors.
Page 165 8.10. Sub-board 8.10.1. SBY0157 board / SBY0163 board TAB401 CN406 CN407 FUSE403 CN414 TAB402 TAB403 CN405 RY402 CN404 VPb PCB SP PCB FUSE404 FUSE402 CN401 VPa PCB BP PCB CN416 FUSE405 CN408 CN413 CN402 CN403 CN409 CN415 CN412 CN411 CN410 Fig.
Page 166 Connection CN401 Connect to P1 and P2 through harnesses. CN402 Connect to CN503 of [DSUB board] through harness. CN403 Connect to harness of BPC. CN404 Used to connect AC power supply to sub-board through harness. CN405 Used to connect AC power supply to sub-board through harness. CN406 Connect to FAN.
Page 167 Replacement Sub-board CAUTION There are two types of sub board (SBY0157) and sub board (SBY0163) each. For details, refer 8.13 Operation Panel Board, Main Board and Sub Board . (1) Turn off power SW of machine. (2) Disconnect power plug from receptacle. (3) Remove left cover from upper part of machine and left cover from DENSO box.
Page 168 Fuse CAUTION Replace sub-board or fuse after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Handle sub-board under care not to be charged with static electricity. Power rating of sub-board should conform to that of power source of machine.
Page 169 8.10.2. SBY0270 board CN406 CN407 CN414 FUSE404 FUSE402 CN404 VPb PCB SP PCB CN401 CN416 VPa PCB BP PCB FUSE405 SUB PCB NCUX0266 0270 CN402 0266 CN411 CN417 CN403 CN409 CN413 CN408 CN410 CN415 Fig. 8.10-4 Sub-board General description and function Sub-board is placed at left side of DENSO box.
Page 170 Connection CN401 Connect to P1 and P2 through harnesses. CN402 Connect to CN503 of [DSUB board] through harness. CN403 Connect to harness of BPC. CN404 Used to connect AC power supply to sub-board through harness. CN406 Connect to FAN. CN407 Connect to SSR and relay for heater control through harnesses. CN408 Connect to CN5 of [main board] through harness.
Page 171 Replacement Sub-board CAUTION Handle Sub board carefully against static electricity. Though the location of connecters on Sub board in SBY0266 and SBY0270 are same, the components on the board are different. Explanation in this section is applied for SBY0270 only. Connect the specific connector to CN416 for AC110V model.
Page 172 Fuse CAUTION Replace sub-board or fuse after disconnecting power plug from the socket. Handle sub-board under care not to be charged with static electricity. Power rating of sub-board should conform to that of power source of machine. Otherwise, fire and/or machine failure may be caused. Use fuse of correct rating.
Page 173 8.11. DC+5V, ±12V Power supply 8.11.1. DC+5V, ±12V switching regulator SWT30-522 SWT30-522kai Fig. 8.11-1 DC+5V, ±12V switching regulator (SWT30-522/SWT30-522kai) General description and function DC+5V, ±12V switching regulator is placed at left side of DENSO box. The board is provided for DC+5V, DC+12V, DC-12V from AC voltage. The board is separated AC110V type into AC230V type.
Page 174 Replacement CAUTION Replace switching regulator after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Handle switching regulator under care not to be charged with static electricity. Power rating of switching should confirm to that power source of machine.
Page 175 8.11.2. DC+5V, ±12V switching regulator LDC30F-1-G LDC30F-1-Gkai Fig. 8.11-3 DC+5V, ±12V switching regulator (LDC30F-1-G/LDC30F-1-Gkai) General description and function DC+5V, ±12V switching regulator is placed at left side of DENSO box. The board is provided for DC+5V, DC+12V, DC-12V from AC voltage. The board is separated AC110V type into AC230V type.
Page 176 Replacement CAUTION Replace switching regulator after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Handle switching regulator under care not to be charged with static electricity. Power rating of switching should confirm to that power source of machine.
Page 177 8.11.3. DC+5V, ±12V converter board SBY0254 Fig. 8.11-5 DC+5V, ±12V converter board (SBY0254) General description and function DC+5V, ±12V converter board is placed at left side of DENSO box. The DC-DC converter board outputs DC+5V, DC+12V and DC-12V from DC+24. Specifications for the types for 110Vac and 230Vac are the same.
Page 178 Replacement CAUTION Replace switching regulator after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Handle switching regulator under care not to be charged with static electricity. Power rating of switching should confirm to that power source of machine.
Page 179 8.12. DC+24V switching regulator 8.12.1. PLEY24HSZ-C Terminal SELECT connector Fig. 8.12-1 DC+24V switching regulator (PLEY24HSZ-C) General description and function DC+24V switching regulator is placed at left side of DENSO box. The board is provided for DC-24V from AC voltage. Switch input voltage (AC110V/AC230V) by SELECT connector on the board. Connection Terminal Connect to TERMINAL BLOCK1 and CN411 of SUB-board through harnesses.
Page 180 Replacement DC+24V switching regulator CAUTION Replace switching regulator after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Handle switching regulator under care not to be charged with static electricity.
Page 181 Switching input voltage CAUTION Replace switching regulator after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Power rating of switching should confirm to that power source of machine. Otherwise, fire and/or machine failure may be caused.
Page 182 8.12.2. ZWS150PAF-24/J CN51 CN52 Fig. 8.12-3 DC+24V switching regulator (ZWS150PAF-24/J) General description and function DC+24V switching regulator is placed at left side of DENSO box. The board is provided for DC-24V from AC voltage. This is a switching power with the rated input voltage range of 100 240V.
Page 183 Replacement DC+24V switching regulator CAUTION Replace switching regulator after disconnecting power plug from receptacle. Only power SW OFF is insufficient to avoid danger because AC supply placed at left side in DENSO box is not disconnected, potentially causing electric shock. Handle switching regulator under care not to be charged with static electricity.
Page 184 8.12.3. CME150-24 CN51 Fig. 8.12-4 DC+24V switching regulator (CME150-24) General description and function DC+24V switching regulator is placed at left side of DENSO box. The board is provided for DC-24V from AC voltage. This is a switching power with the rated input voltage range of 100 240V.
Page 185 Replacement DC+24V switching regulator CAUTION Replace switching regulator after disconnecting power plug from receptacle. Handle switching regulator under care not to be charged with static electricity. Inside of switching regulator has heat parts when power turns on. DO NOT touch the part. Otherwise, a burn may be caused. (1) Disconnect power plug from receptacle.
Page 186 8.12-8...
Page 187 There are two types of flat cable connectors for the operation panel board, main board and sub board used in SURDIAL. One is a MOLEX product and one is an OMRON product. Use these connectors correctly, referring to the table below:...
Page 188 (2) Distinction among operation panel boards A connector for flat cable is used for CN2. Distinction is possible through a serial number of operation panel board in addition to the connector shape and marking. Connector Serial number of operation panel board MOLEX type SER.00001 SER.09603 OMRON type...
Page 189 (4) Distinction among sub boards A connector for flat cable is used for CN408. Distinction is possible through a silk print on the board in addition to the connector shape and marking. VPb PCB SP PCB VPa PCB BP PCB CN408 Board with MOLEX connector Board with OMRON connector...
Page 190 (5) Connection of Harness and Board Connection with the board by using an OMRON connector and connection with the harness by using a MOLEX connector is possible in addition to connection by using the same maker’s connectors. Connection is not possible, however, when a MOLEX connector is used on the board side and an OMRON connector is used on the harness side.
Page 191 8.14. VR board SBY0268 board CN503 VR501 CN502 Fig. 8.14-1 VR board General description and functions VR board is placed at right side of DENSO box. The board is used to control blood pump flow rate at power failure when battery (VR501) as option is provided.
Page 192 Replacement CAUTION Replace VR board after turning off power SW of machine under care not to be charged with static electricity. After the replacement, set BP BACKUP volume to OFF position. (1) Turn off power SW of machine. (2) Remove right cover from upper part of machine and right cover from DENSO box. (3) If battery (option) is provided, disconnect its connector.
Page 193 8.15. FUSE This section explains the fuses in the fuse holder of Power box. The fuses on the sub-board is explained in “8.10. Sub-board: SBY0266”. General description and function Sub-board is placed at left side of Power box. This fuse holder protects the wiring for switching power supply, transformer and sub-board. Serial numbers installed 09T7158 09U0484...
Page 194 Replacement CAUTION Replace sub-board or fuse after disconnecting power plug from the socket. Power rating of sub-board should conform to that of power source of machine. Otherwise, fire and/or machine failure may be caused. Use slow blow fuse. (1) Turn off power SW of machine. (2) Disconnect power plug from socket.
Page 195 9. MAINTENANCE MODES...
Page 197 9.1. Display LCD is used to display various dialysis related information and setting screens by 40 letters in each of 4 lines. Many information and setting screens are available and desired screen can be displayed by SW operation on operation panel. [F 5]SW(DISP.) [F 5]SW(DISP.) Rinse operation screen...
Page 198 9.1-2...
Page 199 9.2. Maintenance modes Dialysis related data indication, alarm setting, alarm release, machine function monitoring or concentration calibration can be executed in selected maintenance mode. 10 maintenance modes are available. There are mode to indicate information only, mode enabling setting at any time required and mode enabling setting under specified condition only . 9.2.1.
Page 200 (2) Press [F 3] or [F 4] SW to display "20. MAINTENANCE MODE FREE". (3) Press [F 1] SW to set to "ON". (4) Operation SW’s [ ]/[ ] are displayed above [F 1][F 2] and items enabled to be set blink.
Page 201 9.2.2. ROM after Ver.3.00 MODE TITLE SETTING DATA Indication only ALARM SETTING Enabled setting at any time required ALARM FORCED OFF Enabled setting at any time required FUNCTION MONITOR Enabled setting under specified condition CONCENTRATE DATA Enabled setting under specified condition CHARACTERISTICS Enabled setting under specified condition SYSTEM...
Page 202 (3) Press [F 1] SW to set to "ON". (4) Operation SW’s [ ]/[ ] are displayed above [F 1][F 2] and items enabled to be set blink. DANGER Setting or setting change of item to be maintained during dialysis is danger. DO NOT set or change item to be maintained under the condition that patient is connected to machine.
Page 203 9.3. Maintenance mode menu screen In maintenance mode screen, selection and registration of desired maintenance mode are enabled. Press [F 3] or [F 4] SW to changeover screen and press [F 1] or [F 2] SW to select maintenance mode as desired. Press [F 5] SW to display rinse operation or dialysis operation screen.
Page 204 9.3-2...
Page 205 9.4. Maintenance mode 1 screen In maintenance mode 1 screen, real time indication of various data during dialysis operation is executed. In the mode, only data indication is enabled and setting is disabled. Press [F 3] or [F 4] SW to check data. Press [F 5] SW to display maintenance mode menu screen.
Page 206 9.4.2. ROM after Ver.3.00 INDICATION DESCRIPTION 1.TREATED BLOOD VOLUME Treated blood volume indication 2.TREATMENT TIME Executed dialysis time indication 3.SN AVG.BLOOD FLOW Mean SN blood flow rate indication 4.SN STROKE VOLUME One stroke SN1 blood volume indication 5.BLD REAL VALUE Leaked blood level indication 6.BLD AUTO ZERO Blood leak auto zero value indication...
Page 207 9.5. Maintenance mode 2 screen In maintenance mode 2 screen, alarm value can be set. When setting is protected, indication only is enabled and setting is disabled. Press [F 3] or [F 4] SW to check data. If setting is not protected, press [F 1]or [F 2] SW to change set value.
Page 208 INDICATION DESCRIPTION 24.DETECTION FOR E22 Setting of blood leak alarm condition (NORMAL / SKIP) NORMAL : Alarm can be detected preparation/preparation end/dialysis/rinse back mode SKIP : Alarm can be detected dialysis/rinse back mode This function is installed in EPROM after Ver.3.30. 25.V.P MIN LIMIT IN HD Setting of lower limit for the setting range of venous pressure alarm at Dialysis process.
Page 209 9.6. Maintenance mode 3 screen In maintenance mode 3 screen, alarm can be released and resumed at any time required. Press [F 3] or [F 4] SW to shift blink and press [F 1] or [F 2] SW to change setting. By selecting “ON”, alarm is released and by selecting “OFF”, alarm is resumed.
Page 210 DANGER DO NOT release blood leak alarm during dilaysis. WARNING DO NOT release any alarm during dialysis. Otherwise, machine failure may be caused. CAUTION Monitor machine functions continuously during release of any alarm. 9.6-2...
Page 211 9.7. Maintenance mode 4 screen In maintenance mode 4 screen, functions of components such as those assembled in fluid (dialysate) line can be monitored and valves, pumps, clamp and fan can be operated manually. If setting is protected, indication only is enabled and setting is disabled. Press [F 3] or [F 4] SW to check data.
Page 212 FUNCTION WHEN Enabled SYMBOL IS MARKED SYMBOL COMPONENT Monitor control NOTE WITH IN DRAWING -ing Heater During power supply Blood pump During power supply Syringe pump During power supply Viscous pump position sensor Shaded photo-sensor Original point detection Viscous pump position sensor Shaded photo-sensor Rotation signal...
Page 213 9.8. Maintenance mode 5 screen In maintenance 5 screen, dialysate concentration can be set and information related to dialysate preparation in dialysis mode selected in setting screen can be indicated. 9.8.1. When dialysis mode BC1 or BC2 is set Currently set dialysis mode is found in screen title. If setting is protected, indication only is enabled and setting is disabled.
Page 214 9.8.2. When dialysis mode AC is set Currently set dialysis mode is found in screen title. If setting is protected, indication only is enabled and setting is disabled. Press [F 3] or [F 4] SW to check data. If not protected, press [F 1] or [F 2] SW to change setting. Press [F 5] SW to display maintenance mode menu screen.
Page 215 9.9. Maintenance mode 6 screen In maintenance mode 6 screen, data specific to instrument and the like can be set. If setting is protected, Indication only is enabled and setting is disabled. Press [F 3] or [F 4] SW to check data. If not protected, press [F 1] or [F 2] SW to change setting. Press [F 5] SW to display maintenance mode menu screen.
Page 216 9.9.1. ROM before Ver.3.70 INDICATION DESCRIPTION 1.YEAR Setting of calendar year 2.MONTH Setting of calendar month 3.DATE Setting of calendar day 4.HOUR Setting of clock hour 5.MINUTE Setting of clock minute 6.V.PRESS OFFSET Indication of venous pressure determined by input value added venous pressure sensor value 7.A.PRESS OFFSET Indication of arterial pressure determined by input value...
Page 217 BP flow rate calibration (GAIN and OFFSET) values are those determined using standard NIPRO blood line. When blood line of smaller sized or other manufacturer is used, adjustment is required. Also when blood line of smaller sized is used, adjust gap between BP rotors and housing.
Page 218 9.9.2. ROM after Ver.3.84 INDICATION DESCRIPTION 1.YEAR Setting of calendar year 2.MONTH Setting of calendar month 3.DATE Setting of calendar day 4.HOUR Setting of clock hour 5.MINUTE Setting of clock minute 6.V.PRESS OFFSET Indication of venous pressure determined by input value added venous pressure sensor value 7.A.PRESS OFFSET Indication of arterial pressure determined by input value...
Page 219 BP flow rate calibration (GAIN and OFFSET) values are those determined using standard NIPRO blood line. When blood line of smaller sized or other manufacturer is used, adjustment is required. Also when blood line of smaller sized is used, adjust gap between BP rotors and housing.
Page 220 9.9-6...
Page 221 9.10. Maintenance mode 7 screen In maintenance mode 7 screen, system and option settings can be performed. If setting is protected, Indication only is enabled and setting is disabled. Press [F 3] or [F 4] SW to check data. If not protected, press [F 1] or [F 2] SW to change setting. Press [F 5] SW to display maintenance mode menu screen.
Page 222 DESCRIPTION 1.SYRINGE RATE Setting of cross-sectional area ratio of syringe intended to be used to NIPRO syringe as 100%. When the ratio is 50%, infusion rate is doubled. 2.BP STOP AFTER POWER FAIL Setting to ON when blood pump SW is turned off at return to normal after power failure 3.V,A,DP ALARM RESETTING...
Page 223 DESCRIPTION 1.SYRINGE RATE Setting of cross-sectional area ratio of syringe intended to be used to NIPRO syringe as 100%. When the ratio is 50%, infusion rate is doubled. 2.BP STOP AFTER POWER FAIL Setting to ON when blood pump SW is turned off at return to normal after power failure 3.V,A,DP ALARM RESETTING...
Page 224 WARNING Connection of each option should conform to its setting. Otherwise, disabled function of the option or malfunction of machine may be caused. CAUTION Set each item value after full understanding its function. 9.10-4...
Page 225 9.11. Maintenance mode 8 screen In maintenance mode 8 screen, service frequency of each component is indicated by operation time or operation frequency. Press [F 3] or [F 4] SW to check data. Press [F 5] SW to display maintenance mode menu screen. 9.11-1...
Page 226 9.11.1. ROM before Ver.2.40 Fig. 9.11-1 Maintenance mode 8 screen INDICATION DESCRIPTION 1.POWER Indication of power connection time of machine 2.FAN Indication of fan operation time 3.P1 Indication of deaeration pump P1 operation time 4.P2 Indication of dialysate pump P2 operation time 5.CLV Indication of clamp operation frequency 6.V2...
Page 227 9.11.2. ROM after Ver. 3.00 9.11.2.1. Monitor screen Monitor screen is indicated by selecting OFF/ON DIPSW2 and OFF DIPSW3 on main board. Operation time or frequency of each component is indicated. Fig. 9.11-2 Monitor screen in maintenance mode 8 9.11.2.2. Input screen Input screen is indicated by selecting OFF DIPSW2 and ON DIPSW3 on main board.
Page 228 INDICATION DESCRIPTION 1.POWER Indication of power connection time of machine 2.FAN Indication of fan operation time 3.P1 Indication of deaeration pump P1 operation time 4.P2 Indication of dialysate pump P2 operation time 5.CLV Indication of clamp operation frequency 6.V2 Indication of two way electromagnetic valve (EMV) V2 operation frequency 7.V3 Indication of two way EMV V3 operation frequency...
Page 229 9.12. Maintenance mode 9 screen In maintenance mode 9 screen, air purge process can be executed according to instruction indicated in the screen. Press [F 1] SW to execute air purge process. Repress [F 1] SW to forcibly stop the process. Press [F 5] SW to display maintenance mode menu screen though the display is disabled during air purgeing.
Page 230 9.12-2...
Page 231 9.13. Maintenance mode 10 screen In maintenance mode 10 screen, history of up to 20 latest alarms is displayed. Press [F 3] or [F 4] SW to check data. Press [F 1] SW to clear the history. Press [F 5] SW to display maintenance mode menu screen. Fig.
Page 232 9.13-2...
Page 233 10. ADJUSTMENT CAUTION TYPE II is changed following points. 7:19. CONSOLE MODE 24. CONSOLE MODE in maintenance mode 7 7:20. MAINTENANCE MODE FREE 25. MAINTENANCE MODE FREE in maintenance mode 7...
Page 235 10.1. Measurement of chamber capacity and adjustment of silicone volume 10.1.1. Measurement of chamber capacity In the cases such as replacement of viscous chamber or viscous pump, silicone oil volume in the chamber may be changed. Measure the chamber capacity based on the below procedures and input the measured result into machine.
Page 236 (9) Measure RO water weight discharged from each of A and B chambers when each of [V5 and V6]and [V7 and V8] are ON using electronic balance under referring to data displayed in maintenance mode 4 screen to derive each of the A and B chamber capacities respectively. Calculate mean value of 3 measurements for each of the chambers.
Page 237 10.1.2. Adjustment of silicone oil volume Add silicone oil to the chamber when the capacity is larger than specified volume and aspirate it from the chamber when smaller than the volume based on the following procedures: (1) Required devices: Silicone tube (ID: 6mm, length: 200 300mm) Syringe (applicable to the silicone tube) Silicone oil (when added) Forceps (2 or more)
Page 238 (11) Remove the silicone tube and re-attach the plug . (12) Fix the plug securely with the snapper and remove the forceps. (13) Turn off “V4” manually in maintenance mode 4 screen. (14) Operate machine to measure the chamber capacity and input the measured result in maintenance mode 6 screen.
Page 239 10.2. Adjustment of venous and arterial pressure sensors 10.2.1. Adjustment of venous pressure sensor (1) Required devices Manometer (calibrated) Syringe Three way stopcock Air tube (ID: about 4mm) Precision screwdriver (2) Remove right cover from upper operation part and right cover from DENSO box to expose venous pressure sensor board.
Page 240 (8) Connect syringe and manometer to venous pressure inlet port as shown in the below Fig. Fig. 10.2-2 Adjustment of venous pressure sensor (9) Expose manometer to atmosphere and try to indicate venous pressure of 0mmHg in the screen by turning VR701. (10) Pressurize manometer to 300mmHg by advancing syringe plunger and try to indicate venous pressure of 300mmHg in the screen by turning VR702.
Page 241 10.3. Adjustment dialysate pressure sensor 10.3.1. TYPE I (1) Required devices Manometer (calibrated) Syringe Three way stopcock Air tube (ID: about 4mm) Silicone tube (ID: about 5mm) Precision screwdriver Forceps (2) Remove left cover from upper part of machine and left cover from lower part of it to expose dialysate pressure sensor Assy.
Page 242 (8) Clamp tube connected to one side of dialysate pressure sensor using forceps and connect syringe and manometer to tube connected to other side of the sensor as shown in the below Fig. Fig. 10.3-2 Adjustment of dialysate pressure sensor (9) Expose manometer to atmosphere and try to indicate dialysate pressure of 0mmHg in the screen by turning VR701.
Page 243 10.3.2. TYPE II 10.3.2.1. Adjustment dialysate pressure sensor (1) Required devices Manometer (calibrated) Syringe Three way stopcock Air tube ID: about 4mm Silicone tube ID: about 5mm Precision screwdriver Forceps (2) Remove left cover from lower part of machine to expose dialysate pressure sensor Assy.
Page 244 (9) Clamp tube connected to one side of dialysis pressure sensor using forceps and connect syringe and manometer to tube connected to other side of the sensor as shown in the below Fig. Fig.10.3-4 Adjustment of dialysate pressure sensor (10) Expose manometer to atmosphere and try to indicate dialysate pressure of 0mmHg in the screen by turning VR701.
Page 245 10.3.2.2. Adjustment of PD offset (1) Required devices Container (Volume: 2000mL with water) Forceps (2) Turn on [Dialysis] SW to shift to dialysis wait process. (3) Release setting protection by selecting ON of “20.MAINTENANCE MODE FREE” in maintenance mode 7 screen. (4) Connect the concentrate to concentrate connector.
Page 246 10.3-6...
Page 247 10.4. Adjustment of temperature sensor Connect resistor for calibration to terminal bed on main board and adjust temperature sensor by input from operation panel. (1) Required device Resistor for calibration (115.54 at 40.0 1/16W over) (2) Remove right cover from upper operation part and right cover from POWER box to expose terminal bed TM1 on main board.
Page 248 (8) Adjust by checking indicated value when the resistor is connected. Check the value in maintenance mode 6 screen and input offset value. 31.T1 OFFSET 40.1c: 0.0 32.T2 OFFSET 40.1c: 0.0 33.T3 OFFSET 40.2c: 0.0 :Item name :Currently recognized temperature :Set offset value (9) Remove the resistor from terminal bed and attach temperature sensor followed by connecting it as shown in Fig.
Page 249 10.5. Adjustment of pressure SW Apply pressure to pressure SW to adjust pressure when the SW is ON by turning adjusting screw based on the following procedures. (1) Required devices Manometer (calibrated) Syringe Three way stopcock Air tube (ID: about 4mm) Silicone tube (ID: about 5mm) Forceps Spanner (8mm)
Page 250 (7) Apply pressure to pressure SW by gradual advancement of syringe plunger. (8) Adjust pressure SW so that it is ON at a pressure between 0.06865 and 0.07845 MPa (514.5 to 588mmHg / 0.7 to 0.8kgf/cm ) by loosening set nut using spanner followed by turning adjusting screw.
Page 251 10.6. Adjustment of blood leak sensor 10.6.1. TYPE I: RK-GR1 Turn volume of blood leak sensor under checking value indicated in screen based on the following procedures. CAUTION Perform acid and chemical rinse and then clean the window inside blood leak detector, before you calibrate it.
Page 252 (11) Repeat the above steps (9) and (10) until each of 0±55 and 800±55 is set. Adjust R41 (rough adjustment) and R47 (fine adjustment) if each value can not be adjusted only R47. Fig. 10.6-1(b) Blood leak detector PCB NOTE R41 has large sensitivity because it is used for rough adjustment.
Page 253 10.6.2. TYPE II: RK-GR2 10.6.2.1. Zero revision of blood leak detector Adjust the zero revision of blood leak detector when “6.BLD AUTO ZERO” value less than -150ppm in maintenance mode 1 screen during preparation process. Press [Prep.] SW to shift to preparation process. Remove BLD cover of rear side of machine as shown in Fig.10.6-2.
Page 254 10.6.2.2. Check of accuracy of blood leak sensor using pseudo filter Press [Prep.] SW to shift to preparation process. (2) Check preparation time pass over 5 minutes and then check ”6. BLD AUTO ZERO” value more –80ppm in maintenance mode 1 screen. (3) Remove cartridge of blood leak detector as shown in Fig.10.6-4.
Page 255 10.6.3. TYPE II: BLD-01 10.6.3.1. Zero Offset of Blood Leak Sensor The blood leak sensor needs to be offset to zero when the value of “6. BLD AUTO ZERO” on the maintenance mode 1 screen becomes less than -150ppm in the standby process. CAUTION Check the value after removing stains fully by water rinsing and chemical rinsing.
Page 256 10.6.3.2. Checking through Pseudo Blood Leak Filter (1) Turn ON the power to the equipment and leave it for more than 5 minutes. (2) Dismount the cartridge of the blood leak sensor as shown below: Loosen one of the screws dismount the cartridge.
Page 257 10.6.3.3. Adjustment of Blood Leak Sensor If the value of “6. BLD AUTO ZERO” is out of a designated range when the cartridge with a pseudo blood leak filter is mounted in “Checking through Psuedo Blood Leak Filter”, adjustment is required again.
Page 258 (5) Repeat the steps (1) through (4) until each value described in “(1) – (2) Adjustment through the cartridge for zero offset” and “(3) – (4) Adjustment through the cartridge with pseudo blood leak filter” becomes within a designated range. (Adjustment 1) Adjustment Value Adjustment Section...
Page 259 10.7 Adjustment of reducing valve Adjust actuating pressure of reducing valve by turning adjusting screw of the valve by measuring manometer pressure after priming completion based on the following procedures. (1) Required devices Manometer (calibrated) Connection means (tubes and T-pipe) Forceps (2) Remove right cover form lower part of machine to expose reducing valve.
Page 260 (10) Tighten the set nut. This may cause small change of the set value. Check the value again. Adjusting value 0.0333 0.0363MPa (250 270mmHg 0.34 0.37kgf/cm Reducing valve (11) Remove the manometer and the connection means to return to the original condition. (12) Return the removed cover to the original position.
Page 261 10.8. Adjustment of priming end pressure Adjust priming end pressure by checking pressure at priming end by turning relief valve 1 based on the following procedures. (1) Required devices Manometer (calibrated) Connection means (tubes and T-pipe) Forceps Monkey wrench (2) Remove right cover from lower part of machine to expose relief valve 1. (3) Turn on power SW of machine.
Page 262 10.8-2...
Page 263 10.9. Adjustment of closed circuit pressure Adjust closed circuit pressure based on the following procedures. (1) Required devices Blood line Dialyzer (2) Remove left cover from lower part of machine to expose relief valve 2. (3) Turn on power SW of machine. (4) Turn on [DIALYSIS] SW to shift to dialysis wait process.
Page 264 10.9-2...
Page 265 10.10. Adjustment of priming flow rate 10.10.1. Adjustment by Flow meter Adjust priming flow rate of water by turning control valve NV1 by measuring discharge flow rate which is substantially same as priming flow rate. Follow the below procedures. (1) Required device Flow meter (2) Remove right cover from lower part of machine to expose NV1.
Page 266 10.10.2. Adjustment by Discharge Flow Time Adjust priming flow rate of water by turning control valve NV1 by measuring discharge flow time which is substantially same as priming flow rate. Follow the below procedures. (1) Required device Stopwatch (2) Remove right cover from lower part of machine to expose NV1. (3) Turn on power SW of machine.
Page 267 (11) Turn on [DIALYSIS] SW to shift to dialysis wait process. (12) Release console mode by selecting OFF of “19.CONSOLE MODE” in maintenance mode 7 screen. (13) Protect setting by selecting OFF of “20.MAINTENANCE MODE FREE” in maintenance mode 7 screen.
Page 268 10.10-4...
Page 269 10.11. Adjustment of bypass flow rate During V9 is OFF (that is, dialysate line is bypassed), adjust dialysate flow rate by turning adjusting screw of pinch cock 1 (PC1) under monitoring flow rate indication of flow meter based on the following procedures.
Page 270 10.11-2...
Page 271 10.12. Adjustment of gaps between housing and rotor rollers of blood pump 10.12.1. Adjustment by water head pressure Adjust the gaps by application of water head pressure to blood line set to blood pump based on the following procedures. (1) Required devices Blood line Water receiver Water bottle...
Page 272 10.12.2. Adjustment using syringe and manometer Adjust the gaps by application of water pressure to blood line set to blood pump by syringe based on the following procedures. (1) Required devices Blood line Water receiver Syringe Manometer Hexagon wrench (1.5mm) (2) Turn off power SW of machine.
Page 273 10.13. Adjustment of blood pump flow rate 10.13.1 In case of you use Standard Rolling Tube( 8× 12mm) Adjust blood pump flow rate by setting blood line to blood pump to input GAIN and OFFSET values of blood pump flow rate by referring to actually measured flow rate (discharged water weight or volume/min) in maintenance mode 6 screen based on the following procedures.
Page 274 (10) Set blood pump flow rate to 400mL/min and operate the pump. (11) Measure actually discharged water weight or volume/minute (mL/min). (12) Input “17.BPF(GAIN)” value of blood pump flow rate in maintenance mode 6 screen value to try to adjust the actual flow rate to about 400mL/min. Decrease (increase) the value if the actual flow rate is higher (lower) than the set flow rate.
Page 275 10.14. Leak test and gap adjustment of clamp 10.14.1. Leak test of clamp Leak test of clamp is performed to find whether gap adjustment of the clamp is required based on the following procedures. (1) Required devices Manometer Connection means Forceps Syringe Stopwatch...
Page 276 10.14.2. Gap adjustment of clamp If leak from the clamp is detected, adjust the clamp gap based on the following procedures. (1) Required devices Spanner (×2) (2) Remove left cover from upper part of machine to expose clamp. (3) Turn off power SW of machine. (4) Push rear side of the clamp by finger to check the gap.
Page 277 10.15. Adjustment of bubble sensor 10.15.1. SBY0160 board Adjust bubble sensor by setting water filled blood line to bubble detector followed by turning volume of bubble sensor board based on the following procedures. (1) Required devices Blood line Tester Precision screwdriver Micro-syringe (2) Remove left cover from upper part of machine to expose bubble sensor board as SBY0160.
Page 278 10.15.2. SBY0205 board Adjust bubble sensor by setting water filled blood line to bubble detector followed by turning volume of bubble sensor board based on the following procedures as step 1 and step 2. Step1: Adjustment of reference voltage (1) Required devices Tester Precision screwdriver (2) Remove left cover from upper part of machine to expose bubble sensor board as SBY0205.
Page 279 Step2: Adjustment of output level (1) Required devices Tester Precision screwdriver Blood line Micro-syringe (2) Remove left cover from upper part of machine to expose bubble sensor board as SBY0205. (3) Set tester to DC range and connect test TP3 of bubble sensor board to (+) probe of the tester and WJ1 of the board to (-) probe of it.
Page 280 10.15-4...
Page 281 10.16 Adjustment of conductivity and concentration Adjust dilution ratio of dialysate concentrate intended to be used to input the adjusted ratio and calibrate indicated dialysate conductivity and concentration by manipulation of operation panel based on the following procedures. Start of adjustment Selection of dialysis mode to be adjusted Bicarbonate dialysis 1 or 2 Acetate dialysis...
Page 282 10.16.1. Selection of dialysis mode to be adjusted Select dialysis mode: bicarbonate 1 (BC1), bicarbonate 2 (BC2) or acetate (AC) to be adjusted in setting II screen. Concentrate data of the selected mode is displayed in maintenance mode 5 screen. (1) Turn on power SW of machine.
Page 283 10.16.2. Input of concentration data Input basic concentrate data in maintenance mode 5 screen. When bicarbonate dialysis mode (BC1or BC2) is selected in setting II screen, input A and B concentrate data. When acetate dialysis mode (AC) is selected, input acetate concentrate data. See the data specified in the operation manual.
Page 284 Input of data of acetate concentrate (1) Check that current process is dialysis wait. (2) Press [F 5] SW to display maintenance mode 5 screen. (3) Press [F 3] or [F 4] SW to blink item to be inputted. (4) Press [F 1] or [F 2] SW to input data. (5) Input the following values by referring to concentrate data specified in the operation manual.
Page 285 10.16.3. Adjustment of dilution ratio Adjustment of dilution ratio of bicarbonate A concentrate Adjust the dilution ratio when bicarbonate dialysis mode is selected. Set dialysate preparation components to water and A concentrate only in maintenance mode 5 screen and operate machine in preparation or preparation end process. Measure concentration of prepared dialysate specimen after prepared dialysate conductivity is stabilized.
Page 286 Adjustment of dilution ratio of bicarbonate B concentrate Adjust the dilution ratio when bicarbonate dialysis mode is selected. Set dialysate preparation components to water and A and B concentrates in maintenance mode 5 screen and operate machine in preparation or preparation end process. Measure concentration of prepared dialysate specimen after the conductivity is stabilized.
Page 287 Adjustment of dilution ratio of acetate concentrate Adjust the dilution ratio when acetate dialysis mode is selected. Set dialysate preparation components to water and acetate concentrate in maintenance mode 5 screen and operate machine in preparation or preparation end process. Measure concentration of prepared dialysate specimen after prepared dialysate conductivity is stabilized.
Page 288 (4) Take dialysate specimen from sampling port. (5) Measure the specimen conductivity (mS/cm) using conductivity meter not assembled in SURDIAL. (6) Press [F 1] or [F 2] SW to input the measured conductivity into "9.COND. W+A+B". (7) Convert the measured conductivity to concentration (mmol/L) by referring to conversion Table when available.
Page 289 10.17. Adjustment of contrast Adjust contrast of LCD by turning volume of operation panel board under observing the LCD based on the following procedures. (1) Required device Precision screwdriver (2) Remove left cover from upper part of machine to expose operation panel board. (3) Turn on power SW of machine.
Page 290 10.17-2...
Page 291 10.18. Adjustment of gas purge pressure Adjust pressure during gas purge. Adjust pressure by turning adjusting screw of pinch cock 2 (PC2) under monitoring dialysate pressure in dialysis screen based on the following procedures. (1) Remove left cover from under part of machine to expose PC2. (2) Turn on power SW of machine.
Page 292 10.18-2...
Page 293 10.19. Adjustment of flushing volume in concentrate line CAUTION The flushing volume between V17 line for acid rinse (optional unit) and V12 line is same. The length of each line must be same. Concentrate line <V17> ACID DISINFECTANT Adjust flushing volume when the length of concentrate line is changed. Initialized value of flushing volume is different between after ROM ver.3.84 and ver.3.70.
Page 294 (7) Skip chemical rinse process by pressing [RINSE] SW after confirmation of opening V12. (8) Perform flushing after skipping chemical rinse process. Confirm concentrate is flowed to the middle of FEP tube. The range of flushing Adjustment range Flushing volume The middle of FEP tube (9) Turn off DIPSW1and then return the removed covers to the original position.
Page 295 10.20. Adjustment of priming volume in concentrate line CAUTION The priming volume between V17 line for acid rinse (optional unit) and V12 line is same. The length of each line must be same. Concentrate line <V17> ACID DISINFECTANT Adjust priming volume when the length of concentrate line is changed. Initialized value of priming volume is different between after ROM ver.3.84 and ver.3.70.
Page 296 (6) Turn on [RINSE] SW to shift to chemical rinse process. (7) Concentrate is aspirated after chemical rinse is started. First aspiration of concentrate is priming. Confirm concentrate is flowed over V12. The range of priming Adjustment range Priming volume From concentrate tank to after V12 (8) Turn off DIPSW1and then return the removed covers to the original position.
Page 297 Adjust infusion flow of syringe pump by setting syringe ratio. Default value is 100% based on the surface area (292.5mm ) of NIPRO 20mL syringes. When syringe ratio is set 50%, this means the cross area of syringe is smaller +100%(=×1/2).
Page 298 10.21-2...
Page 299 10.22. Adjustment of overload detection on Syringe pump Assy, when other than Nipro syringe used (1) Required devices Syringe used for treatment Syringe Manometer T-tube, tube (2) Put one syringe on the syringe pump. (3) Connect manometer and other syringe, then conform that machine gives overload alarm when applying pressure at 0.086MPa (500 800mmHg).
Page 300 10.22-2...
Page 301 10.23. Adjustment of conductivity sensor Connect resistor for calibration to terminal bed on main board and adjust conductivity sensor by volume of main board. (1) Required device Resistor for calibration(240 1/16W over, 360 1/16W over) (2) Remove right cover from upper operation part and right cover from POWER box to expose terminal bed TM1 on main board.
Page 302 (7) Prepare a tester and adjust the voltage within the range shown below. To measure the AC value correctly, use a true execution value type . For each measurement point and adjustment point, refer to Fig. 10.23-3. Adjust value Test point Adjust point Adjustment range 5VREF...
Page 303 11. DIP SWITCHES...
Page 305 11.1. Operation of dip SW’s Special functions are enabled by operating dip SW’s. (1) Remove right cover from upper part of machine and right cover from DENSO box to expose dip SW’s placed on main board. MAIN PCB MAIN PCB Main board DIPSW Dip SW DIPSW Fig.
Page 306 11.1-2...
Page 307 11.2. Functions of dip SW’s 11.2.1. ROM before Ver.2.40 11.2.1.1. Function of dip SW1 By turning on dip SW1, skip of rinse mode is enabled. By pressing [RINSE] SW during execution of rinsing operation, currently executed rinsing mode is skipped. Keep dip SW1 OFF during any process other than execution of maintenance.
Page 308 11.2.2. ROM after Ver.3.00 11.2.2.1. Function of dip SW1 By turning on dip SW1, skip of rinse mode is enabled. By pressing [RINSE] SW during execution of rinsing operation, currently executed rinsing mode is skipped. Keep dip SW1 OFF during any process other than execution of maintenance. 11.2.2.2.
Page 309 11.2.3. ROM after Ver.3.93 11.2.3.1. Function of dip SW1 By turning on dip SW1, skip of rinse mode is enabled. By pressing [RINSE] SW during execution of rinsing operation, currently executed rinsing mode is skipped. Keep dip SW1 OFF during any process other than execution of maintenance. 11.2.3.2.
Page 310 11.2.4. ROM after Ver.4.41 11.2.4.1. Function of dip SW1 By turning on dip SW1, skip of rinse mode is enabled. By pressing [RINSE] SW during execution of rinsing operation, currently executed rinsing mode is skipped. By turning on dip SW1, releasing of alarm at Dialysis process is enabled. Displaying maintenance mode menu 3 screen and release of the alarm.
Page 311 CAUTION Usable functions are limited to those operated by “skip of rinse mode/ releasing of alarm at dialysis process”, ”Changed service frequency”, “Cleared service frequency”. DO NOT operate “skip of rinse mode/releasing of alarm at dialysis process” at the state of connecting patients. DO NOT operate SW2 because it is intended to be used by manufacturer only.
Page 312 11.2-6...
Page 313 12. VARIOUS DATA...
Page 315 12.1. Loaded CPU and ROM Symbol Designation CPU type ROM type ROM indication Type name Main board µPD784031 HN27C4096AG-10 Version No. Registered date The last letter of version No. indicates language (E: ENGLISH; S: SPANISH). Fig. 12.1-1 ROM CAUTION Type machine need ROM after Ver.3.00.
Page 316 12.1-2...
Page 317 12.2. Wiring in POWER box 12.2.1. Electrical power box There are four types of electrical power boxes to be used for SURDIAL. When ordering parts, place the correct order suited to the type of used electrical power box. Distinction among electrical power boxes Check the label attached to the upper part of the right side of the electrical power box.
Page 318 Electrical power box (C type) Electrical power box (D type) The serial number below SURDIAL contains The serial number below SURDIAL contains alphabets and ends with “-E”. alphabets and ends with “-H20”. Serial numbers installed: Serial numbers installed: 08T6062 09T7157...
Page 319 12.2.2. A Type CN15 CN18 CN16 CN408 CN413 CN402 CN411 CN412 CN406 CN414 Fig.12.2-1 Wiring in POWER BOX A Type 12.2-3...
Page 320 12.2.3. B Type CN15 CN18 CN16 CN408 CN413 CN402 CN411 CN412 CN406 CN414 Fig.12.2-2 Wiring in POWER BOX B Type 12.2-4...
Page 321 12.2.4. C Type CN15 CN18 CN16 CN408 CN413 CN402 CN411 CN412 CN406 CN414 Fig.12.2-3 Wiring in POWER BOX C Type 12.2-5...
Page 322 12.2.5. D Type CN15 CN18 CN16 CN408 CN413 CN402 CN411 CN406 CN414 FUSE 6.3A FUSE 6.3A Fig.12.2-4 Wiring in POWER BOX D Type 12.2-6...
Page 323 12.3. Record sheet of setting value Record following setting value before operating machine. Record following setting value before replacing ROM. It is possible that previous data is erased when ROM replaces. (Refer “8.6 Main board - ROM ” ) 12.3-1...
Page 324 12.3.1. ROM before Ver.2.40 Hospital name Installation date : Machine serial NO : Machine type :SURDIAL ROM Ver. Maintenance mode 2 screen Maintenance mode 5 screen(BC1) Setting Setting Indication Unit Indication Unit value value 1.V.PRESS MAX RANGE mmHg 1.VCa W+A RATIO 2.V.PRESS MIN RANGE...
Page 325 Maintenance mode 6 screen Maintenance mode 7 screen Setting Setting Indication Unit Indication Unit value value 1.YEAR 1.SYRINGE RATE 2.BP STOP AFTER 2.MONTH POWER FAIL 3.DATE 3.V,A,DP ALARM 4.HOUR RESETTING 5.MINUTE 4.DISINFECTION RATIO 6.V.PRESS OFFSET mmHg 5.ACID RATIO 7.A.PRESS OFFSET mmHg 6.VP MAX ALARM LIMIT mmHg...
Page 326 12.3.2. ROM after Ver.3.00 Hospital name Installation date : Machine serial NO : Machine type :SURDIAL ROM Ver. Maintenance mode 2 screen Maintenance mode 5 screen(BC1) Setting Setting Indication Unit Indication Unit value value 1.V.PRESS MAX RANGE MmHg 1.VCa W+A RATIO 2.V.PRESS MIN RANGE...
Page 327 Maintenance mode 6 screen Maintenance mode 7 screen Setting Setting Indication Unit Indication Unit value value 1.YEAR 1.SYRINGE RATE 2.BP STOP AFTER 2.MONTH POWER FAIL 3.DATE 3.V,A,DP ALARM 4.HOUR RESETTING 5.MINUTE 4.DISINFECTION RATIO 6.V.PRESS OFFSET mmHg 5.ACID RATIO 7.A.PRESS OFFSET mmHg 6.HOT DISINFECTION 8.D.PRESS OFFSET...
Page 328 12.3.3. ROM after Ver.3.30 Hospital name Installation date : Machine serial NO : Machine type :SURDIAL ROM Ver. Maintenance mode 2 screen Maintenance mode 5 screen(BC1) Setting Setting Indication Unit Indication Unit value value 1.V.PRESS MAX RANGE MmHg 1.VCa W+A RATIO 2.V.PRESS MIN RANGE...
Page 329 Maintenance mode 6 screen Maintenance mode 7 screen Setting Setting Indication Unit Indication Unit value value 1.YEAR 1.SYRINGE RATE 2.BP STOP AFTER 2.MONTH POWER FAIL 3.DATE 3.V,A,DP ALARM 4.HOUR RESETTING 5.MINUTE 4.DISINFECTION RATIO 6.V.PRESS OFFSET mmHg 5.ACID RATIO 7.A.PRESS OFFSET mmHg 6.HOT DISINFECTION 8.D.PRESS OFFSET...
Page 330 12.3.4. ROM after Ver.3.84 Hospital name Installation date : Machine serial NO : Machine type :SURDIAL ROM Ver. Maintenance mode 2 screen Maintenance mode 5 screen(BC1) Seting Setting Indication Unit Indication Unit value value 1.V.PRESS MAX RANGE MmHg 1.VCa W+A RATIO 2.V.PRESS MIN RANGE...
Page 331 Maintenance mode 6 screen Maintenance mode 7 screen Setting Setting Indication Unit Indication Unit value value 1.YEAR 1.SYRINGE RATE 2.BP STOP AFTER 2.MONTH POWER FAIL 3.DATE 3.V,A,DP ALARM 4.HOUR RESETTING 5.MINUTE 4.DISINFECTION RATIO 6.V.PRESS OFFSET mmHg 5.ACID RATIO 7.A.PRESS OFFSET mmHg 6.HOT DISINFECTION 8.D.PRESS OFFSET...
Page 332 12.3.5. ROM after Ver.4.41 Hospital name Installation date : Machine serial NO : Machine type :SURDIAL ROM Ver. Maintenance mode 2 screen Maintenance mode 5 screen(BC1) Seting Setting Indication Unit Indication Unit value value 1.V.PRESS MAX RANGE MmHg 1.VCa W+A RATIO 2.V.PRESS MIN RANGE...
Page 333 Maintenance mode 6 screen Maintenance mode 7 screen Setting Setting Indication Unit Indication Unit value value 1.YEAR 1.SYRINGE RATE 2.BP STOP AFTER 2.MONTH POWER FAIL 3.DATE 3.V,A,DP ALARM 4.HOUR RESETTING 5.MINUTE 4.DISINFECTION RATIO 6.V.PRESS OFFSET mmHg 5.ACID RATIO 7.A.PRESS OFFSET mmHg 6.HOT DISINFECTION 8.D.PRESS OFFSET...
Page 334 12.3-12...

Nipro SURDIAL Service Manual

1 Application

2 Contraindication

3 Precautions

4 Symbol for Safety

5 Flow Chart

6 Disassembling and Replacement

7 Construction of Electrical Part

9 Maintenance Modes

10 Adjustment

11 Dip Switches

12 Various Data

Quick Links

Need help?

Questions and answers

Summary of Contents for Nipro SURDIAL

Page 5: Safety Precautions

Nipro SURDIAL Service Manual

1 Application

2 Contraindication

3 Precautions

4 Symbol for Safety

5 Flow Chart

6 Disassembling and Replacement

7 Construction of Electrical Part

9 Maintenance Modes

10 Adjustment

11 Dip Switches

12 Various Data

Quick Links

Need help?

Questions and answers

Related Manuals for Nipro SURDIAL

Summary of Contents for Nipro SURDIAL

Page 5: Safety Precautions

Table of Contents