Ch07EN Calibrations

Chapter 7
Calibrations
General information about the calibrations . . . . . . . . . . . . . . . . . . . . . 7: 2
The I2C-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 2
New pressure transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 3
I2C Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 3
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 4
Why is calibration needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 4
Calibrating the AD-systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 5
Calibration errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 5
Calibration errors - Pressure transducers . . . . . . . . . . . . . . . . . . 7: 5
Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 6
Calibration of AD-converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7: 8
Location of testpoints for AD converter calibration . . . . . . . . . 7: 9
Calibration of linear transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:10
Selection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:11
Venous pressure transducer calibration . . . . . . . . . . . . . . . . . . . . . . 7:12
Arterial pressure transducer calibration . . . . . . . . . . . . . . . . . . . . . . 7:14
Priming detector calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:16
Occlusion adjustment, blood pump . . . . . . . . . . . . . . . . . . . . . . . . 7:17
Adjustment instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:17
Blood leak detector calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:18
Variable flow calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:20
Conductivity transducer calibration . . . . . . . . . . . . . . . . . . . . . . . . . 7:22
Dialysis pressure transducer calibration . . . . . . . . . . . . . . . . . . . . . 7:24
Degassing pressure transducer calibration . . . . . . . . . . . . . . . . . . . 7:26
HPG pressure transducer calibration . . . . . . . . . . . . . . . . . . . . . . . 7:28
pH transducer calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:30
Pressure regulator calibration, PR 1 . . . . . . . . . . . . . . . . . . . . . . . . 7:32
Pressure regulator calibration, PR 2 . . . . . . . . . . . . . . . . . . . . . . . . 7:33
UF cell calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:34
Prerequisite for the complete UF cell calibration . . . . . . . . . . . . 7:35
UF cell calibration: Complete mode . . . . . . . . . . . . . . . . . . . . . . . . 7:36
During the UF cell calibration: . . . . . . . . . . . . . . . . . . . . . . . . . 7:37
When the automatic UF cell calibration is finished: . . . . . . . . . . 7:38
If the calibration is out of limits . . . . . . . . . . . . . . . . . . . . . . . . . 7:38
UF cell calibration: Intern mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:39
When the internal UF cell calibration is ready: . . . . . . . . . . . . . 7:39
UF cell calibration: Verify mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:40
During the verification of the UF cell calibration: . . . . . . . . . . . 7:41
When the verification of the UF cell calibration is finished: . . . 7:42
BPM test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:43
Test method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:43
BPM sub-tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:43
Check of air leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:43
Check of inflation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:44
Check of pressure transducer calibration and measured
pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:44
HCEN12212 Revision.05.2008 AK 96 - Calibrations 7:1

General information about the calibrations
During the calibration the compensation values (offset and coefficient)
are calculated by AK 96 dialysis machine and stored in a small (128 bytes)
E2PROM (Electrically Erasable Programmable Read-Only Memory)
placed on the actual transducer’s board.
In the beginning of the functional check the AK 96 dialysis machine will

check and read all transducer E2PROMs, and place the values in RAM
to be used for the compensation.
The I2C-bus
The AK 96 dialysis machine uses a separate bus – the I2C-bus – to
communicate with the transducers. The E2PROM on a transducer board
contains an address – information about the board’s physical position on
the transducer motherboard (FM I/O board), physically placed on top
of the UF-measuring cell:
Transducer board
FM I/O board
UF-measuring cell
The arrangement ensures that transducers can not be interchanged

without a complaint (= a technical error) from the machine. The address
– the ID-number – for a given transducer must correspond to its physical
position (the “slot”) on the transducer motherboard (FM I/O board).
The communication between a CPU and a set of transducers takes place

through the I2Cbus. One I2C-bus can handle eight E2PROMs (also
called I2C-PROMs):
Transducer Transducer Transducer

board board board
2 2 2
E PROM E PROM E PROM
I2C bus CPU
7:2 AK 96 - Calibrations HCEN12212 Revision.05.2008

There are four I2c buses, three of them are connected to transducers
and the fourth is for communication between CPU P and CPU W. Here
is an overview:
CPU C:
RTM Not Used Regulator Cond A HPG Not Used Degassing Not Used
Run Time temp. Temp A Pressure
Meter PT-100 at
heater.
E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM
Address 0 1 2 3 4 5 6 7 CPU C
I2C bus A (I2CCA)
Not Used Venous UF-cell Cond B Not Used A/D Conv Not Used Not Used
Pressure Channel 1 Temp B MM 95
CPU C Channel 2 ref. volt.
Address 0 1 2 3 4 5 6 7 CPU C
I2C bus B (I2CCB)
CPU P:
I2C bus A (I2CPA) not used!
Blood Not Used pH Cond P Diascan Dialysis Venous Arterial

leak Temp P pressure pressure pressure
Address 0 1 2 3 4 5 6 7 CPU P
I2C bus B (I2CPB)
CPU P I2C bus CPU W
New pressure transducers

Since a new pressure transducer has an ID from it’s calibration in
production, a technical error will appear when it is installed.
Therefore always perform an I2C scanning when a new transducer has

been installed.
I2C Errors
The error codes for the I2C buses are found as C CC 008 xxx for CPU C
(I2CCA and I2CCB) and as P PTRA for CPU P (I2CPB).
If all error codes for one bus are issued it is most likely that one of the
transducer has an error that takes “down” the whole bus. The best
solution to the problem is to disconnect one transducer at the time until
only one error code is issued. Then the disconnected transducer is the
faulty one and should be exchanged for a new one. If error codes for
more than one I2C bus is issued the error is probably due to some defect
on the FM I/O board.

Calibrations
The different transducer are calibrated in different ways. The pressure
transducers are calibrated in three steps (0 mmHg, -500 mmHg and
+500 mmHg) while e.g. the conductivity cells are calibrated in two steps
(0.0 mS and 14.0 mS)
The calibration of the UF-cell differs radically from the rest, and requires
a so called calibration station.
Why is calibration needed?

No transducer is ideal – all transducers have two basic errors: a sensitivity
error and an offset error:
Output signal (+)
Ideal
Offset error
Real
Input (-) Input (+)
Sensitivy
error
Output signal (-)
To compensate for these two, the machine must calculate an offset value
which will bring the line to cross through the zero point, and a calibration
coefficient – a factor, typically between 0.90 – 1.10 which will correct the
slope of the line so it matches the ideal.
2
No pressure E PROM
-500mmHg
+500mmHg
Note
Never try to fit a another transducer board to a transducer since there
is an analog trimming made with a resistor (laser trimmed) during
manufacturing.
Note

Calibrating the AD-systems
Since all transducers are read by an AD-system (MUX + AD-converter),
it is necessary to calibrate these before calibration of any transducer.
There are four different AD-converters in the AK 96 dialysis machine
according to page 7: 8
An AD calibration is very simple: It involves measuring the voltage

across a resistor (a reference voltage), and entering the reading in the
respective calibration menus.
Calibration errors
If the machine finds that one of the calculations generated an offset or a
coefficient which is outside its limits, it will generate a calibration error.
There are several possibilities:
Calibration error Reason for the error

Set value and measured value are too If a value, far away from the reading on the reference
separated instrument is entered. Typically, entering a positive
pressure, when the actual pressure is negative.
Set value is too near values entered The calibration achieves highest accuracy, if the
earlier measuring points are far apart.
A three-point calibration with zero, -15mm Hg and

+18 mmHg will generate a poor result.
Calibration errors - Pressure transducers

If the AK 96 dialysis machine finds, during the pressure transducer
calibration procedure, that a calculated offset or calibration coefficient is
outside certain limits, a calibration error appears. These limits are:
• Offset: ±20 mmHg
• Calibration Coefficient: 0.9 – 1.1
• Correlation Coefficient: Low limit 0.95

Test equipment
Following calibration instructions are based on the availability of some
test equipment, listed below:
Test equipment Tolerance Manufacturer Order no

Conductivity ±0.1 mS/cm MESA, IBP
measurement
Pressure measurement ±2 mmHg to ±200 mmHg ±1% beyond MESA, IBP,
±200 mmHg Druck
If BPM is installed: ±0.8 mmHg"
UF calibration box Gambro K21908002
Temperature ±0.2 ºC MESA, IBP

measurement:
Digital Voltmeter ±0.5% Fluke
Blood leak Calibration N/A Gambro K40169001
Cover
Gauge pin kit for blood T = 1.1 (Stop pin = 1.1x2x0.7 = 1.5 mm) Gambro K40158001
pump rollers (including T = 1.6 (Stop pin = 1.6x2x0.7 = 2.2 mm)
three different pins) T = 2.0 (Stop pin = 2.0x2x0.7 = 2.8 mm)
T = wall thickness of the blood tubing
Gauge pin kit for blood T = 1.1 (Stop pin = 1.1x2x0.7 = 1.5 mm) Gambro K40158002
pump rollers (to be T = 1.6 (Stop pin = 1.6x2x0.7 = 2.2 mm) K40158003
ordered separately) T = 2.0 (Stop pin = 2.0x2x0.7 = 2.8 mm) K40158004
Calibration tube kit N/A Gambro K13983002
Tube for calibration of N/A
priming detector
BPM test equipment N/A Gambro K22151001
BPM Cuff N/A Gambro 110350

pH buffers ± 0.07 pH units pH 7- 100810001
pH 9 - 100810002
Special tool For silicone tube connectors Gambro K12755001

This page is intentionally left blank

Calibration of AD-converters
1. Start the AK 96 dialysis machine, enter the Service menu and select
Calibrations.
2. Choose AD-converter.
When selecting “AD-converter” following display appears:
SELECT AD-CONVERTER
CPU-C CPU-P CPU-W MM95
3. Select AD-converter to calibrate with the Cursor keys and press the
Select key to enter the calibration.
CPU X AD LOW REF SET HIGH

xx.xx mV xx.xx xx.xx xx.xx
4. Measure the voltage (using a 4.5 digit voltmeter), between following

testpoints or across the resistor:
CPU Testpoint Tetspoint Circuit board Limits

Ref (mV)
CPU-C TP 6 TP 5 Control Driver 45.00 - 55.00
board
CPU-P TP 1 TP 2 Protective Driver 45.00 - 55.00
board
CPU-W TP 3 TP 4 Protective CPU 4500 - 5500
board
MM 95 R 24 R 24 MM I/O board 45.00 - 55.00
5. Set the “AD REF VOLTAGE” on the display to the value shown on
the voltmeter and press the Select key.
6. Press the lit UF Start/Stop button to load the value into the E2PROM.
CPU X AD-REF VOLTAGE STORED
7. Press the Back key to exit.

Location of testpoints for AD converter calibration
AD ref voltage range:

AD ref voltage range: 45.00 to 55.00 mV
45.00 to 55.00 mV
PVREF
TP1
TP 5 TP2
Z0VAD
CPU C A/D ref
TP 6
Control driver board Protective driver board
AD ref voltage range:

4.500 to 5.500 V
MM I/O AD ref voltage range:
TP3 45.00 to 55.00 mV
WREF
(TP1)
(TP2)
CPU W PROM
TP4 R24
Z0VRW
CPU W
SafeRAM
pH plug
Protective CPU board MM I/O board

Calibration of linear transducers
Calibrations.
2. Choose Transducers.
3. Select Extern or Internal flow support.
Note
• Select Extern for no flow (pumps stopped).
• Select Internal and the AK 96 maintains a flow during the calibration.
Note
Support condition for different calibrations
Calibration Flow support condition

Venous pressure transducer CPU P Internal or External
Venous pressure transducer CPU C Internal or External
Arterial pressure transducer Internal or External
Priming detector Internal or External
Blood leak detector Internal
Conductivity cell Internal
Dialysis pressure transducer External
Degassing pressure transducer External
HPG pressure transducer External
pH transducer External
Run time meter Internal or External
The machine enters the Selection diagram. Refer to page 7:11.
4. Select transducer to calibrate with the Cursor keys and press the
Select key to enter the calibration.
5. Follow the instructions for each calibration.
Note
If the calibration is to be aborted without saving the new calibration
values: Press Back key.
Note

Selection diagram
VENOUS PRESSURE TRANSDUCER (P) RUN TIME METER
VENOUS PRESSURE TRANSDUCER (C) pH TRANSDUCER
ARTERIAL PRESSURE TRANSDUCER HPG PRESSURE TRANSDUCER
PRIMING DETECTOR DEGASSING PRESSURE TRANSDUCER
BLOOD LEAK DETECTOR DIALYSIS PRESSURE TRANSDUCER
CONDUCTIVITY A TRANSDUCER CONDUCTIVITY A B P TRANSDUCER
CONDUCTIVITY B TRANSDUCER CONDUCTIVITY P TRANSDUCER

Venous pressure transducer calibration
1. Connect the Gambro reference instrument (together with a
calibration tube set) to the venous pressure transducer (blue) on the
front of the AK 96 dialysis machine, according to following figure.
DX A
2. Zero set the reference instrument, wait for stable reading.
Calibrations.
4. Select Transducers, External and VENOUS PRESSURE

TRANSDUCER CPU P from the selection diagram.
5. Press the Select key to confirm the selected transducer.
6. Apply zero pressure by opening the three clamps A, B and C on

the calibration tube set. Set the “REF SET” value on the AK 96
to 0 mmHg.
7. Press the Select key to enter the setting.
8. Close clamp A. Apply a pressure of approx. -500 mmHg, shown on

the reference instrument. Close clamp B.
VEN PR P LOW REF SET HIGH

-500 -550 -500 550
9. Set the “REF SET” value on the AK 96 to the reading on the

reference instrument.

11. The machine now enters the sensitivity calibration.
Press the Select key to continue.
12. Open clamp A and B, then close clamp A again. Apply a pressure
of approx. +500 mmHg, shown on the reference instrument. Close
clamp B.
VEN PR P LOW REF SET HIGH

500 -550 +500 550
15. Press the lit UF Start/Stop button to load the calibration values into
the E2PROM.
16. The calibration is completed when the information display shows:
EEPROM STORAGE COMPLETED

Press BACK to exit
18. Continue with the venous pressure transducer calibration for CPU C.
Follow this instruction except for paragraph 4, where VENOUS
PRESSURE TRANSDUCER CPU C shall be selected instead of
VENOUS PRESSURE TRANSDUCER CPU P.
Note
Note
Note
If a calibration error occurs:
• Try to do the calibration again.
• If the error occurs a second time: Change the transducer and the
transducer board. Report the error message on the error display to
your Gambro service representative.
Note

Arterial pressure transducer calibration
1. Connect the Gambro reference instrument (together with a
calibration tube set) to the arterial pressure transducer (red) on the
front of the AK 96 dialysis machine, according to following figure.
DX A
2. Zero set the reference instrument, wait for stable reading.
Calibrations.
4. Select Transducers, External and ARTERIAL PRESSURE

TRANSDUCER CPU P from the selection diagram.
6. Apply zero pressure by opening the three clamps A, B and C on

the calibration tube set. Set the “REF SET” value on the AK 96
to 0 mmHg.

ART PR LOW REF SET HIGH

-500 -550 -500 550


clamp B.
ART PR LOW REF SET HIGH

500 -550 +500 550
the E2PROM.

Press BACK to exit
Note
Note
Note
Note

Priming detector calibration
Calibrations.
2. Select Transducer, External and PRIMING DETECTOR from

the selection diagram.
3. Press the Select key to start calibration routine.
4. The display shows:
INSERT TUBE
Press SELECT to confirm
5. Insert an empty tube in the priming detector and press the Select key.
Use the normal tube from the blood line.
6. The calibration is now done automatically and the calibration factor

is written into the E2PROM.

Press BACK to exit
Note
Note
Note
If an technical error is detected, the calibration must be restarted,
or the priming detector replaced.
Note

Occlusion adjustment, blood pump
• 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 blood lines/infusion lines have a different wall thickness, the
occlusion of the blood pump must be adjusted to the right size.
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)
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 blood pump rollers and the path according
to the picture below. Adjust range between the blood pump rollers and
the path if it is necessary.
• 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 gage
in plastic bag to prevent it from corroding.
Note

Blood leak detector calibration
1. Make sure there is no fluid in the AK 96 monitor. If there is fluid in
the monitor, press Rinse/Disinfection-button to drain the machine.
2. Remove the blood leak detector cover and clean the inside of the
blood leak housing.
3. Mount a blood leak calibration cover (K40169001).
Calibrations.
5. Select Transducer, Intern and BLOOD LEAK DETECTOR

from the selection diagram.
6. Place the A-pickup tube in the concentrate container.
7. Press the Select key to enter the Blood leak calibration routine.
Let the machine stabilize in conductivity and temperature a few
minutes. Wait for green fluid path.
8. Make sure the filter is in horizontal position and set “REF SET” to 0.
9. Press the Select key when the BL LEAK value is stable.
10. Turn the calibration filter to vertical position and set “REF SET”
to 100.
11. When the BL LEAK value is stable, press the Select key to enter the
setting.

13. Press the lit UF Start/Stop button to store the calibration values.

Press BACK to exit

16. Drain the AK 96 dialysis machine and remount the standard blood
leak cover.
Note
Note

Variable flow calibration
The variable flow calibration will set the number of steps needed to
obtain a flow of 500 ml/min.
The value will then be used during functional check and when entering
service mode as the flow always should be 500 ml/min in functional
check and service mode.
Calibrations.
2. Place A-pickup tube in the concentrate container.
3. Select Other / Variable flow to initiate the calibration.
4. Following text will be displayed during the calibration:
STEPS: XXX FLOW: ---- ml/min

Please wait. Press BACK to abort
STEPS: the position of the stepper motor

FLOW: the average dialysis flow
5. When the AK 96 dialysis machine has found a new calibration value

it will automatically store the value in the Safe-RAM. Following text
will automatically appear:
ADJUSTING VARIABLE DIALYSIS FLOW

Please wait XX seconds
6. At the end of the calibration the new calibration data is displayed:
VAR. FLOW MOTOR POSITION STORED

NEW VALUE: XXX OLD VALUE: YYY
7. Press the Back key to finish the calibration.

Note
During the variable flow calibration it is possible to supervise the
conductivity and temperature.
If variable flow is not installed following attention will be displayed:
VARIABLE FLOW IS NOT INSTALLED

Check preset
Note
Note
Note

Conductivity transducer calibration
The calibration is a "two point calibration". The two points are
0.0 mS/cm (RO-water) and 14.0 mS/cm (with concentrate).
WARNING
After completing the conductivity calibrations, the conductivity value
must be confirmed by the hospital laboratory.
WARNING
Note
• Before conductivity calibration, Chemical cleaning must be
performed, one with Citric acid and one with Hypochlorite.
• For machines with variable flow: Make sure the variable flow is
calibrated before performing the conductivity cell calibration. Refer
to page: 7:20
Note
Calibrations.
2. Select Transducer, Intern.
3. Select the conductivity transducer to be calibrated from the selection

diagram. The possible cond. cell calibrations are:
• CONDUCTIVITY A TRANSDUCER
• CONDUCTIVITY B TRANSDUCER
• CONDUCTIVITY P TRANSDUCER
• CONDUCTIVITY ABP TRANSDUCERS
4. Press the Fluid bypass button.
5. Connect the Gambro reference instrument to the dialyzer connectors.
6. Press the Fluid bypass button.
7. Connect both A- and B-concentrate connectors to the AK 96.
8. Let the AK 96 and the reference instrument stabilize for at least

30 minutes. Make sure that the machine is not in bypass, i.e. the
Fluid bypass button is not lit.
Note
There must be flow through the measuring cell of the reference
instrument during the conductivity cell calibration.
Note
9. Press the Select key to enter the calibration routine.

10. Calibration with RO-water
10.a. Wait until the reading on the reference instrument has stabilized
at 0.0 mS/cm.
10.b. Check that the temperature on the reference instrument is

approx. 37 °C.
10.c. Set REF SET to 00.0.
10.d. Press the Select key to enter the value.
11. Calibration with concentrate
11.a. Place A-pickup tube in the concentrate container.
11.b. The AK 96 will now regulate conductivity to approx.

14 mS/cm. Let the conductivity stabilize for 20 minutes.
The green fluid path must be lit.
11.c. Check that the temperature on the reference instrument is

approx. 37 °C.
11.d. Set the “REF. SET” value on the AK 96 display to the same
value shown on the reference instrument.
11.e. Press the Select key to enter the value.

the E2PROM.

Press BACK to exit
Note
All the transducers A, B and P are all calibrated in this way.
Note
Note
Note

Dialysis pressure transducer calibration
1. Disconnect tube no. 24316.
Insert a plug (from the calibration kit) according to the figure below.
2. Disconnect the angled silicone connector from TAVA. Insert a plug

(from the calibration kit) according to the figure below.
3. Disconnect tube no. 24458 from the top of the deairating chamber.
Connect Gambro reference instrument to the silicone connector
according to the figure below.
DX
4. Zeroset the reference instrument, wait for stable reading.
Calibrations.
6. Select Transducer, External and DIALYSIS PRESSURE

TRANSDUCER from the selection diagram.
8. Apply zero pressure by opening the two clamps A, and B on the

calibration tube set. Set the “REF SET” value on the AK 96 to
0 mmHg.



clamp B.
15. Set the “REF SET” value on the AK 96 to the reading of the
the E2PROM.

Press BACK to exit

Note
Note
Note
• Reconnect the fluid path to its original design after the calibration.
• Always perform a Heat disinfection after the fluid path has been
opened.
Note

Degassing pressure transducer calibration
1. Replace the silicone T-connector to the degassing pressure transducer
with a straight silicone connector. Insert a plug (from the calibration
kit) according to the figure below.
2. Disconnect the degassing pressure transducer from the flow pump.

Connect Gambro reference instrument to the silicone connector
according to the figure below.
A
DX
Calibrations.
5. Select Transducer, External and DEGASSING PRESSURE


0 mmHg.


clamp B.
the E2PROM.

Press BACK to exit

Note
Note
Note
opened.
Note

HPG pressure transducer calibration
1. Replace the silicone T-connector from the HPG pressure transducer
with a straight silicone connector. Insert a plug (from the calibration
kit) according to the figure below.
2. Connect Gambro reference instrument to the angled silicone

connector according to the figure below.
A
DX
Calibrations.
5. Select Transducer, External and HPG PRESSURE


0 mmHg.


clamp B.
the E2PROM.

Press BACK to exit

Note
Note
Note
opened.
Note

pH transducer calibration
A complete calibration procedure consists of the following steps:
• Offset calibration, with a buffer solution (a solution with a very
accurate and stable pH-value) having a pH-value in the range of pH
6.5-7.5, followed by:
• Sensitivity calibration with a buffer solution having pH-value that

differs at least 2 pH units from the buffer used for offset calibration.
1. Make sure there is no flow or fluid in the AK 96. The inlet water
must be closed.
Calibrations.
3. Select Transducer, External and pH TRANSDUCER from the

selection diagram.
4. Press the Select key to start calibration routine.
5. Remove the pH sensor from the pH sensor housing by loosening the

nut holding the pH sensor and rinse the sensor in distilled water.
6. Check that the “REF SET” on the AK 96 displays pH 7.
7. Put the pH sensor in a cup with pH 7 buffer solution (ordering no.

100810001) which must cover the glass membrane i.e. the level in the
cup should be at least 30 mm from the bottom.
8. Stir in order to achieve balance in the buffer solution. Do not let the
pH sensor lean against the bottom of the cup. Wait for 2 minutes.
9. Press the Select key to set the “REF SET” value on the AK 96 and
wait until the calibration display returns.
Note
If an error message is shown after this step, check the buffer solutions,
level in the cup and repeat the procedure from step 1. If there still is
an error after 2nd try, replace the pH-sensor.
Note
10. Rinse the pH sensor in distilled water.
11. Check that the “REF SET” on the AK 96 displays pH 9.
12. Put the pH sensor in a cup with pH 9 buffer solution (ordering no.
100810002) which must cover the glass membrane i.e. the level in the
cup should be at least 30 mm from the bottom.
13. Stir in order to achieve balance in the buffer solution. The pH sensor
must not lean against the bottom of the cup. Wait for 2 minutes.

14. Press the Select key and wait. The display shows: Entering sensitivity
calibration.
Note
If an error message is shown after this step, check the buffer solutions,
level in the cup and repeat the procedure from step 1. If there still is
an error after 2nd try, replace the pH-sensor.
Note
15. Press the Select key to confirm that the calibration shall continue.
16. When the calibration display returns, press the lit UF Start/Stop button
to load the calibration values into the E2PROM.

Press BACK to exit
19. Remount the pH-sensor into the pH sensor housing.
Note
Note
Note
• pH calibration should be performed (according to the Maintenance
manual) on a regular basis to ensure optimum performance.
Note

Pressure regulator calibration, PR 1
1. Turn off the water supply.
2. Connect Gambro reference instrument just before the INPS pressure

switch, according to following figure.
PR 2
INPS Pressure regulator, PR 1
C
DX
3. Close clamp A, B and C.
4. Turn on the water supply.
5. Start the AK 96 dialysis machine.
6. Perform a functional check and wait until the conductivity and the
temperature are stable. The fluid path on the operator’s-panel must
be green before the calibration begins.
7. Open clamp C.
8. Adjust the pressure regulator, PR 1, until the pressure measured at

the reference instrument is 600 mmHg ±75 mmHg.
9. Perform a Drain.
10. Disconnect the Gambro reference instrument.
Note
opened.
Note

Pressure regulator calibration, PR 2
1. Turn off the water supply.
2. Disconnect tube no. 24304 from the angled silicone connector (after
the PR 2).
3. Insert a silicone T-connector according to the figure below. Use a

short tube from the calibration kit and connect the T-connector to
the angled silicone connector.
4. Connect the reference instrument to the T-connector according to

the figure below.
5. Close clamp A, B and C.
Pressure regulator, PR 2
INPS
DX
B
6. Zeroset the Reference instrument, wait for stable reading.
7. Turn on the water supply.
8. Start the AK 96 dialysis machine.
9. Perform a functional check and wait until the conductivity and the
temperature are stable. The fluid path on the OP-panel must be
green before the calibration begins.
10. Open clamp C.
11. Adjust the pressure regulator, PR 2, until the pressure measured at

the reference instrument is 130 mmHg ± 10 mmHg.
12. Perform a Drain.
Note
opened.
Note

UF cell calibration
General
This section describes the calibration routine of the UF-measuring unit.
The UF-measuring unit consists of two flow measurement channels called

channel 1 (Ch1) and channel 2 (Ch2).
Cond.
Cell P
T
P HPG
ZEVA
UF-measuring
2 1 cell
TAVA BYVA
DIVA
Ch1 is the channel used to measure the main flow to the dialyzer and Ch2
is used to measure the flow from the dialyzer, i.e. the sum of the main
flow and the UF flow. The UF flow is the difference between Ch2 and
Ch1 flows. UF flow is also called differential flow.
The UF cell calibration routine can be run in 3 different modes. The

modes are Complete, Intern and Verify.
• Select Complete for an automatic UF cell calibration.
• Select Intern for an internal calibration (taration but updating the

E2PROM instead of RAM). This is done without the external UF
calibration equipment connected to the AK 96 dialysis machine.
• Select Verify for a verification of the result from the latest calibration.

Prerequisite for the complete UF cell calibration
• Perform both a disinfection and a cleaning decalcification to remove
both organic and calcium precipitates, according to the AK 96
Operator’s Manual.
• For machines with variable flow: Make sure the variable flow is
calibrated before performing the UF cell calibration.
Refer to page: 7:20
• The Complete calibration routine requires that the external UF

calibration station (ordering no. K21908002) is connected to the
AK 96, see fig. below.
AK 96
High Level
V.ref.
Low Level
UFVA Flow in/out
Connection for the
UF calibration cable Dialysis fluid
24 V DC from nipples
power adapter Drain nipple
The equipment contains a reference volume, a flow directing valve

(UFVA) and electronics. The UF calibration station controls the directing
valve by measuring low level and high level of the reference volume and
depending on the selected UF mode the valve will become closed or
opened when low or high level is detected.
Low Level fill up. The reference is filled just over the first
level transducer.
Low Level drain. The reference is emptied just below the
first Level transducer.
High Level fill up. The reference is filled to just over the
second level transducer.
High level drain. The reference is emptied just below the
second Level transducer.

UF cell calibration: Complete mode
Note
• Make sure that the AK 96 dialysis machine is complete shut down.
All electrical connections must be done before the power for AK
96 is turned on.
• Be aware of that there is no main switch on the UF calibration box.

Note
1. Connect the UF calibration station to the AK 96 external

communication port. Use the UF calibration cable, K21876001.
2. Connect the UF calibration unit to the mains via the power adapter.
3. Start the AK 96 dialysis machine with the main switch and the
ON/OFF button.
4. Place B-pickup tube in the concentrate container.
Note
If the machine is equipped with a UFD-kit, let the AK 96 pass FCH
(wait for green fluid path) before entering Service mode.
Note
5. Enter the Service menu.
6. Select Calibrations/Transducers/UF/Complete.
7. Connect the dialysis fluid tubes to the UF calibration box.
8. Enter the Reference volume with the Display Up/Down keys (The
Reference volume is labelled on the UF Calibration unit)
9. Press the Select key to confirm.
10. After the Reference volume is confirmed the UF cell calibration runs
automatically, until the calibration is finished.

During the UF cell calibration:
The time display shows the time since the calibration was started.
The information displays also shows the different stages during the
calibration:
• E2PROM test:
The E2PROMS are tested incase there is a communication error with
the UF cell.
• Fluid preparation:
The AK 96 dialysis machine awaits that the fluid is correct in
temperature and conductivity (37 °C and 14.4 mS on the B Cell)
• Low and High level fill up:

During this period the reference volume is filled and emptied, this is
done to check that the tool is working properly.
• UF stabilization:
During this period the fluid path is heated up so there is no
temperature drift in the components.
• Main flow offset calibration:

During this period the offset on both channels is measured and saved
in RAM memory. The test is performed in the same way as during
taration.
• Ch1 flow calibration:

The valves are set so the flow will go through the Ch1 until the
reference volume is filled. Since the reference volume is known the
flow can be calculated. This value is used to calculate a new coefficient
for the Ch1 so the measured volume match the actual volume. The
new coefficient for Ch1 is saved in RAM and used in the next test.
• Differential flow calibration:

The new coefficient (Ch1) is used when the Ch2 coefficient is
calculated by running the same flow trough both channels. i.e. the
same as differential flow in taration.
• Verifying calibration of UF-cell:

The verification is done by draining the reference volume through the
Ch2. Since it is a known volume the accuracy of the UF measuring
system is measured.
• Verifying calibration of Isolated UF:

The reference volume is then filled through Ch2, the flow is
backwards through the cell, negative value on Ch2. When it is filled it
is emptied just through the Ch2 and the volume is measured by Ch2
only and the UF cell is checked for accuracy during Isolated UF.

When the automatic UF cell calibration is finished:
1. Press the Back key.
After the calibration AK 96 continues to store the calculated values.

When the storage is completed, the verification results are displayed.
First the display for UF Volume (for 3 seconds):
UF VOL REF VOL VOL DIFF

1006.5 1007.3 -0.28 %
Then the display for Isolated UF Volume (for 3 seconds):
ISO VOL REF VOL VOL DIFF

1007.5 1007.3 +0.28 %
Then the previous display is showed again for 3 seconds and so on.
When ready, press the Back key to exit the Complete UF cell calibration.
Note
Perform a Rinse before leaving the AK 96 dialysis machine.
Note
If the calibration is out of limits

If the calibration is out of limits then it will be displayed as calibration
failed.
The maximum limits are:

• UF volume deviation ±1.0 %
• Isolated UF volume ±1.0 %
Note
The other values such as offset and coefficients can be found in the
GXL menu for UF Calibration logging:
For Ch1 and Ch2 Offset ±500 Coefficient 0.92-1.02
Note
Note
The equipment is turned off in the following order:
1. Press AK 96 ON/OFF button.
2. Turn off the AK 96 main switch.
3. Disconnect the UF calibration box from the power socket.

Note

UF cell calibration: Intern mode
Note
Select Intern for an internal calibration (taration but updating the
E2PROM instead of RAM). This is done without the external UF
calibration equipment connected to the AK 96 dialysis machine.
Note
1. Start the AK 96 with the main switch and the ON/OFF button.
3. Enter the Service menu
4. Select Calibrations/Transducers/UF/Intern.
The internal UF cell calibration runs automatically, until the calibration

is finished.
When the internal UF cell calibration is ready:

After the calibration, AK 96 displays:
INTERNAL UF CALIBRATION READY

SELECT for info, BACK to save
Press the Select key to show more information.
Press the Back key to save the calibrations values.
When the storage is completed, AK 96 displays:

Press BACK to exit
When ready, press the Back key to exit the internal UF cell calibration.

UF cell calibration: Verify mode
Note
• Make sure that the AK 96 dialysis machine is complete shut down.
All electrical connections must be done before the power for AK
96 dialysis machine is turned on.
• Be aware of that there is no main switch on the UF calibration box.

Note
1. Connect the UF calibration box to the AK 96 external communication

port. Use the UF calibration cable, K21876001.
2. Connect the UF calibration unit to the mains via the power adapter.
3. Start the AK 96 with the main switch and the ON/OFF button.
Note
If the machine is equipped with a UFD-kit, let the AK 96 pass FCH
(wait for green fluid path) before entering Service mode.
Note
5. Enter the Service menu.
6. Select Calibrations/Transducers/UF/Verify.
7. Connect the dialysis fluid tubes to the UF calibration box.
8. Enter the Reference volume with the Display Up/Down keys (The
Reference volume is labelled on the UF Calibration unit)
9. Press the Select key to confirm.
10. After the Reference volume is confirmed the UF cell verification runs
automatically, until the it is finished.

During the verification of the UF cell calibration:
The time display shows the time since the calibration was started.
The information displays also shows the different stages during the
calibration:
• E2PROM test:
The E2PROMS are tested incase there is a communication error with
the UF cell.
• Fluid preparation:
The AK 96 awaits that the fluid is correct in temperature and
conductivity (37 °C and 14.4 mS on the B Cell)
• Low and High level fill up:

During this period the reference volume is filled and emptied, this is
done to check that the tool is working properly.
• UF stabilization:
During this period the fluid path is heated up so there is no
temperature drift in the components.
• Main flow offset calibration:

During this period the offset on both channels is measured and saved
in RAM memory. The test is performed in the same way as during
taration.
• Ch1 flow calibration:

The valves are set so the flow will go through the Ch1 until the
reference volume is filled. Since the reference volume is known the
flow can be calculated. This value is used to calculate a new coefficient
for the Ch1 so the measured volume match the actual volume. The
new coefficient for Ch1 is saved in RAM and used in the next test.
• Differential flow calibration:

The new coefficient (Ch1) is used when the Ch2 coefficient is
calculated by running the same flow trough both channels. i.e. the
same as differential flow in taration.
• Verifying calibration of UF-cell:

The verification is done by draining the reference volume through the
Ch2. Since it is a known volume the accuracy of the UF measuring
system is measured.
• Verifying calibration of Isolated UF:

The reference volume is then filled through Ch2, the flow is
backwards through the cell, negative value on Ch2. When it is filled it
is emptied just through the Ch2 and the volume is measured by
Ch2 only and the UF cell is checked for accuracy during Isolated UF.

When the verification of the UF cell calibration is finished:
When the verification is completed, AK 96 displays the results:
First the display for UF Volume (for 3 seconds):
UF VOL REF VOL VOL DIFF

1006.5 1007.3 -0.28 %
Then the display for Isolated UF Volume (for 3 seconds):
ISO VOL REF VOL VOL DIFF

1007.5 1007.3 +0.28 %
Then the previous display is showed again for 3 seconds and so on.
When ready, press the Back key to exit the verification of the UF cell
calibration.
Note
Perform a Rinse before leaving the AK 96 dialysis machine.
Note
Note
The equipment is turned off in the following order:
1. Press AK 96 ON/OFF button.
2. Turn off the AK 96 main switch.
3. Disconnect the UF calibration box from the power socket.

Note

BPM test
Test method
• Attach BPM cuff, 110350, tight to the BPM test equipment,
K22151001.
• Start the AK 96 dialysis machine with the main switch and the
ON/OFF button.
• Enter the Service menu.
• Select Diagnose/BM/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 mm Hg.
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 96. 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 96. 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 for the pump within the module
will be tested automatically. Before entering the test mode cuff and cuff
hose to be connected to the AK 96 dialysis machine.
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 for the BPM pressure on the AK 96 display.
Before entering the test mode, pressure transducer calibration tube from
kit K13983002 to be connected to the BPM connector on the AK 96. 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
Pressures shall be applied very carefully so that no over pressures
occur.
Note
To check the actual pressure value, external pressure reference instrument

to be connected and external pressure of 250, 150, 50 mm Hg to
be applied. Check deviation from reference pressure instrument for
displayed value.

Ch07EN Calibrations

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Chapter 7

HCEN12212 Revision.05.2008 AK 96 - Calibrations 7:1

In the beginning of the functional check the AK 96 dialysis machine will

The arrangement ensures that transducers can not be interchanged

The communication between a CPU and a set of transducers takes place

Transducer Transducer Transducer

I2C bus CPU

7:2 AK 96 - Calibrations HCEN12212 Revision.05.2008

E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM

E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM

Blood Not Used pH Cond P Diascan Dialysis Venous Arterial

E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM E2PROM

CPU P I2C bus CPU W

New pressure transducers

Therefore always perform an I2C scanning when a new transducer has

HCEN12212 Revision.05.2008 AK 96 - Calibrations 7:3

Why is calibration needed?

Input (-) Input (+)

Output signal (-)

7:4 AK 96 - Calibrations HCEN12212 Revision.05.2008

An AD calibration is very simple: It involves measuring the voltage

Calibration error Reason for the error

A three-point calibration with zero, -15mm Hg and

Calibration errors - Pressure transducers

• Calibration Coefficient: 0.9 – 1.1

• Correlation Coefficient: Low limit 0.95

HCEN12212 Revision.05.2008 AK 96 - Calibrations 7:5

Test equipment Tolerance Manufacturer Order no

Temperature ±0.2 ºC MESA, IBP

BPM test equipment N/A Gambro K22151001

BPM Cuff N/A Gambro 110350

7:6 AK 96 - Calibrations HCEN12212 Revision.05.2008

HCEN12212 Revision.05.2008 AK 96 - Calibrations 7:7

CPU X AD LOW REF SET HIGH

4. Measure the voltage (using a 4.5 digit voltmeter), between following

CPU Testpoint Tetspoint Circuit board Limits

CPU X AD-REF VOLTAGE STORED

7. Press the Back key to exit.

7:8 AK 96 - Calibrations HCEN12212 Revision.05.2008

AD ref voltage range:

Control driver board Protective driver board

AD ref voltage range:

Protective CPU board MM I/O board

HCEN12212 Revision.05.2008 AK 96 - Calibrations 7:9

3. Select Extern or Internal flow support.

Support condition for different calibrations

Calibration Flow support condition

Venous pressure transducer CPU C Internal or External

Arterial pressure transducer Internal or External

Priming detector Internal or External

Blood leak detector Internal

Conductivity cell Internal

Dialysis pressure transducer External

Degassing pressure transducer External

HPG pressure transducer External

Run time meter Internal or External

The machine enters the Selection diagram. Refer to page 7:11.

5. Follow the instructions for each calibration.

7:10 AK 96 - Calibrations HCEN12212 Revision.05.2008

VENOUS PRESSURE TRANSDUCER (P) RUN TIME METER

VENOUS PRESSURE TRANSDUCER (C) pH TRANSDUCER

ARTERIAL PRESSURE TRANSDUCER HPG PRESSURE TRANSDUCER

PRIMING DETECTOR DEGASSING PRESSURE TRANSDUCER