Nipro SURDIAL 55Plus Single Patient Dialysis Machine Maintenance Manual 2010

Description

Nipro SURDIAL 55Plus Single Patient Dialysis Machine Maintenance Manual 2010

This Nipro SURDIAL 55Plus Single Patient Dialysis Machine Maintenance Manual 2010 is the English instruction volume used to install, inspect, service, and recalibrate the SURDIAL 55Plus single-patient hemodialysis unit. The machine is intended for physician-prescribed hemodialysis in acute or chronic renal failure. The document is marked Original Instructions, printed as BH1211-1004-ENG0 dated 14 Apr. 2010, and published by Nipro Corporation, Osaka.

File Details

• Manual type: Instruction Manual — Maintenance Manual
• Brand / model: Nipro SURDIAL 55Plus single patient dialysis machine
• Language: English
• Page count: 126
• File format: PDF
• Document number: BH1211-1004-ENG0 (14 Apr. 2010)

Who May Work From This Manual

Maintenance is restricted to service technicians who received Nipro dialysis-machine technical training, or to personnel working under a trained technician. The machine must not be connected to a patient during any maintenance task. Replacement parts must be those specified by the manufacturer. Anyone who readjusts or repairs the unit is stated to be liable for consequential events. After storage longer than one month, a disinfection and water rinse of at least one hour is required before treatment resumes.

Installation, Power, and Water Limits

Operating ambient temperature is 15 to 35 °C with 35 to 80 % non-condensing humidity and air pressure 795 to 1062 hPa. Clearance of more than 5 cm above, 10 cm on each side, and 20 cm at the rear is required, plus a ventilation opening larger than φ20 cm or an unobstructed open side. Outside dimensions: top width 290 mm, wheel-part width 490 mm, wheel-part depth 440 mm, height 1365 mm excluding the infusion stand or 1930 mm including it.

The 230 V unit needs 230 V AC ±10 %, 50/60 Hz, a 10 A protective-earth outlet for the standard machine, or 15 A with the Hot Citric option. The 110 V unit needs 110 V AC ±10 %, 50/60 Hz, 15 A standard or 20 A with Hot Citric. Adaptors that remove protective earth are prohibited. Water supply pressure must stay between 0.05 and 0.74 MPa (0.5 to 7.5 kgf/cm²). Standard water flow is 700 mL/min or higher; Hot Citric, Variable Dialysate Flow, and Mass Flow assemblies need 900 mL/min or higher. Supply temperature is 17 to 30 °C on the standard specification (14 to 30 °C with those options; 4 to 30 °C with Heat Exchanger) and at least 5 °C below the preset dialysate temperature. Drainage must exceed 1500 mL/min, with the drain tube 3 m or shorter and tip height no more than 60 cm with a free outlet.

Inspection Rhythm and Log

Operators run a same-day checklist covering leakage, hose clamps, residual chemicals, disinfectant or acetic-acid volume, dialysate concentration, abnormal sound or heat, fan-filter blockage, exterior stains, start-up test result, overnight coupler seating, coupler-switch detection, and syringe fill. The fan air filter is cleaned monthly. Service technicians perform a periodical inspection every 5000 hours or every 6 months and maintain the hydraulic line and electrical board on the same interval. Items marked 6□ are six-month checks; items marked 6□+□ are twelve-month checks. Results are entered with √, ○, X, A, T, C, or L, using the highest-priority symbol when more than one action applies. Hydraulic lines must be rinsed before any part exchange because dialysate and body fluid can cause infection.

IMAGES PREVIEW

Chapters Covered

• Intended Use, Contraindications, Safety, and Safety Precautions (Class I, Type B, IPX1 drip-proof, no flammable atmospheres)
• 1. Installation Environment — surrounding environment; workspace; 230 V and 110 V electric power; water supply pressure, flow, and temperature; drainage
• 2. Precautions for Maintenance — service technician qualification; planned work; clothing; handling; specified parts; liability
• 3. Daily Inspection — operator daily list; monthly fan-filter cleaning; technician 5000-hour / 6-month inspection and hydraulic-electrical maintenance; post-storage disinfection
• 4. Maintenance and Inspection Instructions — log purpose; 6-month vs 12-month symbols; recording codes
• 5. Maintenance and Inspection Log — externals and cables; water/concentrate/drain; closed line; disinfectant feeder; blood pump; heparin pump; monitoring alarms; electric tests; other hydraulic items; Powder Bicarbonate option; variable / high-flow option
• 6. Maintenance and Inspection Manual — methods and pass/fail criteria for every log item (solenoid motion from MAINTE4, reducing-valve pressure, PO2, flow-meter drift, UF/concentrate pump motion, gas-purge pressure, BYPASS flow, residual chlorine, blood-pump volume accuracy, heparin infusion accuracy, temperature/concentration/pressure/blood-leak/air-bubble alarms, short-circuit breaker, backup battery, leakage current, earth resistance, filling flow and filling-complete pressure)
• 7. Parts Replacement — wear list with 2-year / ad-libitum intervals and Nipro code numbers; exploded replacement of F1 water filter, two-way solenoid valves, temperature / dialysate-pressure / conductivity sensors, degassing and air-elimination tanks, buffer tanks, magnet gear pumps P1/P2, heparin and blood pumps, sample and rinse ports, concentrate joints, flow sensors, couplers, BLD-01, chambers Ca/Cb, UFP, P3 and P4 concentrate pumps, relief valve, clamp; air filters; Powder Bicarbonate option; Hot disinfection with citric acid option
• 8. Terminology — 3P outlet, gas purge, filling line, filling complete pressure, filling flow rate, air elimination tank, chamber, concentrate pump, UF pump, closed line, MAINTE screen
• 9. Other Adjustments — BLD-01 zero compensation and simulated-filter check; heparin-pump overload sensitivity; water+A and water+A+B concentration offset/gain; CD1 / CD2 / CD3 conductivity calibration

Taken together, the Nipro SURDIAL 55Plus Single Patient Dialysis Machine Maintenance Manual 2010 gives a trained technician the site limits, the inspection pass bands, the part numbers and exploded sequences needed to change hydraulic assemblies, and the MAINTE / SET screen steps used to bring sensors back onto specification.

Inspection Pass Bands Used in the Shop

Reducing-valve pressure between V1 and the valve, after V1/V4/V10 (and V35) are held on then V4 is turned off, must read 0.037 to 0.041 MPa (280 to 310 mmHg). Flow-meter change during standby must stay under 20 mL/min. Gas-purge dialysate pressure is −100 to 0 mmHg. Blood-pump actual flow must fall in 126–154 mL/min at display 140 and 297–363 mL/min at display 330. Heparin infusion at 9.9 mL/hr for 60 min must stay within 10 % of the preset volume (adjust SYRINGE RATIO on MAINTE6 if not). Temperature indication must stay within ±0.5 °C; concentration within 2 mEq/L. REAL blood leak in preparation at 36.5 °C must be under 150; simulated-filter check is the labeled dummy value ±80 ppm. Residual chlorine after disinfection rinse must be under 0.1 ppm. Standard filling drainage flow is 660–680 mL/min and must not finish in under 40 s; filling-complete pressure on FS1-OUT is 0.093–0.098 MPa (0.95–1.0 kgf/cm²); max dialysate flow is 700 mL/min. Variable / high-flow option filling is 890–950 mL/min (not under 32 s), filling-complete pressure 0.113–0.118 MPa, max flow 800 mL/min. Earth leakage current under 0.5 mA; frame-to-ground resistance under 1 Ω. After a 48-hour charge, blood pump at 150 mL/min and heparin pump at 2.0 mL/h must run more than 20 minutes on backup (new Ni-Cd 20KR-CH 3AH pack about 30 minutes). Solenoid body screws torque to 0.69 N·m (7 kgf·cm); conductivity-sensor screws 0.39 N·m (4 kgf·cm); magnet-pump mounting-plate screws 0.59 N·m and pump-head screws 0.78 N·m in a diagonal sequence.

Wear Parts, Options, and Calibration Work

Chapter 7 lists assemblies against 2-year or ad-libitum change, including water-supply filter F1 (FI116ATERP265A00), solenoid diaphragms D3A540 / D4A350 (best yearly), magnet gear pumps MDG-R2RA24H-57 (spare kit SK-R2N-34A), blood pump MRP22-011, heparin pump 93896500, UFP V-10AUM-P1, A-concentrate pump V-07AUM-P2A, B-concentrate pump V-10AUM-P2B at 0.60 mL/r (0.30 mL/r on powder-B variants), BLD-01, CR2032 lithium cell, and the Ni-Cd backup pack. Option codes cover Hot disinfection with citric acid (<H>), Powder Bicarbonate (<P>), Acid-Rinsing Port (<A>), CF flashing (<C>), and Heat Exchanger (<HE>). Full-machine silicone tubing quantities are given as 30 m of ø5×ø11 and 6.5 m of ø3×ø6.

Chapter 9 walks BLD-01 zero compensation when REAL blood leak is 150 ppm or higher, simulated-filter verification, and two-volume REAL-value adjustment to 30–40 ppm in standby. Heparin overload is set so the alarm trips near 0.086 MPa (500–800 mmHg), about 3.0 N per nut turn. Concentration work uses MAINTE5 offsets and MAINTE6 P3/P4 FLOW gains until water+A and water+A+B stay within ±2 mEq/L. CD2/CD3 and CD1 conductivity are aligned on SET4 against a calibrated meter at stated mS/cm windows, with CD1 also using analog-board VR2; final difference must stay within ±2 %.

Use This Manual on the Bench

With the Nipro SURDIAL 55Plus Single Patient Dialysis Machine Maintenance Manual 2010 a trained technician can set the room, power, and water correctly, complete the 6- and 12-month log against published criteria, replace hydraulic and extracorporeal assemblies using the listed Nipro codes and torque values, and restore blood-leak, heparin-overload, concentrate, and conductivity calibration after parts work. Those limits and sequences are what keep alarms, mixing accuracy, and backup run-time inside the bands the inspection chapter requires. Instant PDF delivery after payment — no shipping wait — readable on any device and printable for the shop binder.