Infusion pumps

Baxter Flo-Gard 6201: troubleshooting and error codes

The ServiceForge knowledge base holds 165 documented symptoms for the Baxter Flo-Gard 6201, with 329 ranked causes, 259 diagnostic checks with test points and expected values, and 103 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Inaccurate delivery rate patient safety

Pump delivery does not match set rate or volume

Ranked causes

1. Wrong administration set type (common)
2. Tubing mispositioned or improperly seated (common)
3. Temperature out of range (occasional)
4. Cracks in door hinges (rare)
5. Deformed coil springs in backplate (rare)
6. Worn cams or pumping fingers (rare)
7. Damaged door latch (rare)

7 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Free flow occurs when door closed patient safety

Fluid flows without pump driving it when door is closed

Ranked causes

1. Wrong or incompatible administration set (common)
2. Tubing mispositioned or not properly seated (common)
4. Cracks in door hinges (rare)
5. Deformed coil springs in backplate (rare)
6. Worn cams or pumping fingers (rare)
7. Damaged door latch (rare)

7 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

OCCLUSION or UPSTREAM OCCLUSION alarm patient safety

Occlusion detected when door closed and START key pressed

Ranked causes

1. Tubing pinched, kinked, or mispositioned (common)
2. Obstruction in tubing path (common)
3. Incompatible administration set (occasional)
4. Temperature out of range (occasional)
5. Contamination in door or baseplate (occasional)
6. Damaged door latch or hinges (rare)

First check

Run Automatic Test Mode 1: Calibration Mode 1

6 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

OCCLUSION or UPSTREAM OCCLUSION alarm with door closed patient safety

Pump detects flow obstruction when door is closed and START key pressed

Ranked causes

1. Tubing mispositioned in sensor or safety clamp (common)
2. Pinched or kinked tubing in pump (common)
3. Obstructions upstream or downstream of pump (occasional)
4. Wrong administration set type or code (occasional)
5. Ambient or solution temperature below 60°F (rare)
6. Solution spills or residues affecting pressure sensing (common)

First check

Verify tubing positioned in sensor and safety clamp

Test point: Sensor and safety clamp area
Expected: Tubing properly seated in both sensor and clamp

5 more checks with pass and fail actions, 6 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

One or more front panel keys not accepted

Single key or multiple keys fail to respond

Ranked causes

1. Panel lock active (common)
2. Temporary software glitch (common)
3. Front panel ribbon cable disconnected or damaged (occasional)
4. Front panel film damaged (occasional)
5. Sensor board failure (rare)
6. Display board failure (rare)

6 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

AIR alarm continuously on

Air alarm remains triggered continuously

Ranked causes

1. Air present in tubing or wrong set type (common)
2. Tubing scratched or deformed (common)
3. Air sensor calibration out of spec (occasional)
4. Air sensor dirty or damaged (occasional)
5. Occlusion sensor failure (rare)

First check

Run Automatic Test Mode 2: Calibration Mode 2

5 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

AIR alarm with no air present

Air alarm triggers despite no visible air in tubing, or when door closed and START pressed

Ranked causes

1. Tubing improperly positioned in air sensor (common)
2. Tubing damage or deformation (common)
3. Wrong administration set type (occasional)
4. Air sensor contamination (occasional)
5. Solution spill on sensor (occasional)

5 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP alert or alarm constantly on

Alert/alarm persists even when slide clamp is properly inserted

Ranked causes

1. Dirty slide clamp sensor (common)
2. Loose or disconnected connections (common)
3. Sensor calibration error (occasional)
4. Sensor board failure (rare)
5. Safety/slide clamp assembly defective (rare)

5 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Low battery voltage caution

Pump displays code 6 with BATTERY LOW alarm and CHARGING LED off

Ranked causes

1. AC power not connected or insufficient (common)
2. Power fuse failed (occasional)
3. Battery fuse failed (occasional)
4. Loose battery terminal connections (occasional)
5. Battery failed (occasional)

First check

Check AC plug connection tightness

Expected: Plug firmly seated

3 more checks with pass and fail actions, 5 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump door does not open or close smoothly caution

Door movement restricted, stiff, or binding during opening or closing

Ranked causes

1. Administration set tubing or slide clamp mispositioned (common)
2. Wrong administration set type or code (occasional)
3. Solution spills or residues affecting movement (common)
4. Door latch roller pin binding or stiff (occasional)
5. Damage to door latch, latch pin roller, or door hinge (rare)

First check

Inspect administration set tubing and slide clamp positioning

Test point: Tubing guides and slide clamp slot
Expected: Tubing and clamp properly seated in guides

4 more checks with pass and fail actions, 7 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

AIR alarm with no air in tubing or door closed patient safety

AIR alarm triggered when there is no visible air in tubing or door is closed during START

Ranked causes

1. Tubing not fully positioned in air sensor (common)
2. Tubing surface scratches or flattened shape (occasional)
3. Wrong administration set type or code (occasional)
4. Solution spills or residues on air sensor (common)

First check

Inspect tubing positioning in air sensor

Test point: Air sensor area
Expected: Tubing fully inserted into air sensor

3 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air detected in administration set patient safety

Ultrasonic sensor detects air bubble; pump stops infusing, red ALARM LED illuminates, AIR displayed in Message Display, audible alarm sounds.

Ranked causes

1. Air bubble at sensor (common)
2. Empty fluid container (common)
3. Improper set loading (occasional)
4. START key pressed with no set in pump (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Plug icon not lit when plugged in or battery icon lit during AC power high voltage

Power indicator LED not illuminated when pump connected to AC outlet, or battery indicator displays despite AC connection

Ranked causes

1. Power plug not fully inserted (common)
2. Blown rear power fuse (common)
3. AC outlet providing incorrect voltage (occasional)
4. Power cord continuity broken (occasional)

First check

Verify power plug is fully inserted into AC outlet

Test point: Power plug connector
Expected: Plug seated firmly in grounded outlet

3 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump operation louder than normal

Equipment produces excessive noise during normal operation

Ranked causes

1. Improper set type or contamination (common)
2. Solution spill on pump mechanism (common)
3. Loose motor mounting bracket screws (common)
4. Internal component vibration (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Remote computer configuration option cannot be set

Configuration option fails to update when sent from external computer control software

Ranked causes

1. Cable connection issue between computer and pump (common)
2. User-generated software not properly loaded (common)
3. Connector issue (occasional)
4. CPU or Sensor board failure (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Safety clamp does not latch open

Safety clamp arm remains latched or fails to hold open position

Ranked causes

1. Slide clamp mispositioned or misseated (common)
2. Incompatible slide clamp design (common)
3. Safety clamp arm cover not fully open (occasional)
4. Contamination on clamp or slot (occasional)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air bubble detected in run mode caution

Pump displays code 1, indicating air detected in infusion line

Ranked causes

1. Air in tubing (common)
2. Dirty air sensor (occasional)
3. Air sensor out of calibration (occasional)

First check

Visual inspection for air in tubing

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

All front panel keys disabled except BACKLIGHT and TOT VOU STATUS

Most front panel keys are inactive; only BACKLIGHT and TOT VOU STATUS keys functional

Ranked causes

1. Panel lock active with no Lot indicator (common)
2. Front panel film failure (occasional)
3. CPU or Sensor board malfunction (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Audible alarm always on

Alarm sound continuously activates and cannot be silenced

Ranked causes

1. Battery or fuse issue (common)
2. Fuse F302 or ICP301 failure or connector issue (occasional)
3. CPU board malfunction (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Audible alarm does not sound

Alarm sound fails to activate when alert condition present

Ranked causes

1. Temporary malfunction or connector issue (common)
2. Speaker failure (occasional)
3. Sensor or CPU board failure (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Backup buzzer does not activate during self test

Backup alert buzzer fails to sound during power-on self test

Ranked causes

1. Buzzer wiring disconnected (common)
2. Battery fuse blown (occasional)
3. Backup buzzer defective (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery does not display or function on battery power

BATTERY message not shown when AC unplugged, or battery-powered operation fails during extended runtime

Ranked causes

1. Battery not charged or defective (common)
2. Charging voltage out of specification (occasional)
3. Power supply voltage out of specification (occasional)

First check

Battery runtime on battery power alone

Test point: Device unplugged from AC
Expected: Unit runs for at least 5 minutes or pumps 10 mL without AC power

3 more checks with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery icon lit during AC operation caution

Battery status indicator light illuminates while unit powered from AC mains

Ranked causes

1. AC fuse F2 failed (common)
2. Connector issue with AC power circuit (occasional)
3. CPU or Sensor board malfunction (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Communication alarm detected

Pump displays code 7 with framing/overrun/parity error from external computer

Ranked causes

1. Pump not in computer control mode (common)
2. Communication cable disconnected or miswired (common)
3. PC software incorrectly loaded (occasional)

First check

Verify pump operating mode

Expected: Pump in computer control mode

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

DOOR OPEN alarm absent or false trigger patient safety

Alarm does not sound when door opened, or triggers when door closed

Ranked causes

1. Magnet on door latch missing or misaligned (common)
2. Connector CN851 disconnected or damaged (occasional)
3. CPU board failure (rare)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Downstream occlusion detected caution

Pump displays code 2/3, indicating fluid line occluded after pump head

Ranked causes

1. Scratched or deformed tubing (common)
2. Temperature out of range (occasional)
3. Dirty occlusion sensors (occasional)

First check

Inspect tubing for damage

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Free flow occurs when door open patient safety

Fluid flows without pump driving it when door is open

Ranked causes

1. Wrong administration set type (common)
2. Solution spill on safety clamp (common)
3. Tubing mispositioned in safety clamp (common)

5 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Inconsistent or unauthorized motor speed patient safety

Motor speed changes unpredictably or does not match user-programmed rate; pump delivers incorrect infusion rate

Ranked causes

1. Motor rotation detector malfunction (occasional)
2. Memory corruption in rate storage locations (rare)
3. PWM circuit malfunction causing incorrect motor current (occasional)

First check

Verify motor rotation detector signal presence

Test point: Detector output to UPP/master CPU
Expected: Consistent signal pulses matching motor shaft rotation
Tools: Oscilloscope

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDE CLAMP alert or alarm constantly on

Slide clamp alert or alarm indicator displays and sounds continuously

Ranked causes

1. Dirty slide clamp sensor or connection issue (common)
2. Slide clamp sensor calibration issue (occasional)
3. Safety/slide clamp assembly failure (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP alert or alarm on door closure patient safety

Pump alerts or alarms when door is closed indicating slide clamp not properly inserted

Ranked causes

1. Slide clamp not fully inserted into slot (common)
2. Solution spills or residues on slide clamp or assembly (common)
3. Wrong administration set slide clamp design (occasional)

First check

Verify slide clamp fully inserted into slot

Test point: Slide clamp slot
Expected: Slide clamp pushed completely into slot

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

INSERT SLIDECLAMP alert or alarm when door closed

Alarm triggers when pump door is closed

Ranked causes

1. Slide clamp not fully inserted in slot (common)
2. Solution spill on slide clamp or assembly (common)
3. Incompatible slide clamp design (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

LCD display blank, irrational, or missing segments caution

Display shows no information, garbled text, or partial segments missing

Ranked causes

1. LCD cushion not installed or misaligned (common)
2. CPU board malfunction (occasional)
3. Sensor or Display board failure (occasional)

First check

Use Test Mode 5 to check ICP301 and CNDISP connections

Expected: Proper connection and continuity detected

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Motor overcurrent caution

Overcurrent detected to motor during operation

Ranked causes

1. Loose motor coupler (common)
2. Loose connector CN201 (occasional)
3. Faulty Sensor board or CPU board (rare)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Motor overinfusion - high rotation count patient safety

Motor rotation higher than expected based on revolution counter interrupts

Ranked causes

1. Pump head mechanical wear or blockage (common)
2. Motor coupling issue (occasional)
3. Encoder disk misalignment (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Motor revolution counter interrupt missing

Motor rotating but no pulse received from revolution counter

Ranked causes

1. Loose encoder disk (common)
2. Photointerrupter malfunction (occasional)
3. Sensor or CPU board fault (rare)

4 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

PANEL LOCK switch not accepted

Panel lock control switch does not respond or function

Ranked causes

1. Switch malfunction (common)
2. Connector issue (occasional)
3. Sensor board malfunction (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump cannot be turned off caution

Pump continues running and cannot be shut down by power switch

Ranked causes

1. Low backup battery voltage (common)
2. Front panel cable short circuit (occasional)
3. Connector issue (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump cannot be turned on caution

Pump fails to power on when power button is pressed

Ranked causes

1. Low backup battery voltage (common)
2. Front panel cable short circuit (occasional)
3. Connector issue with CNBUS1/CNBUS2, CN601, CN602 (occasional)

First check

Check backup battery voltage per Section 5.3.1

Expected: Battery voltage sufficient

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump continues to run after power-off command patient safety

Pump does not shut down when ON-OFF/CHARGE key is pressed; Vcpu, Vref, or Voth voltages remain active

Ranked causes

1. Master CPU failure or software malfunction (rare)
2. Power control circuit HIC302 malfunction (occasional)
3. ON-OFF/CHARGE key stuck or faulty (occasional)

First check

Verify ON-OFF/CHARGE key functionality

Test point: Key button and Vkey signal line
Expected: Key press interrupts Vkey signal to master CPU
Tools: Oscilloscope, multimeter

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump does not operate on AC power high voltage

Pump fails to function when connected to specified AC outlet; Plug Icon may not illuminate

Ranked causes

1. AC fuse blown (500 mA slow blow) (common)
2. DC power supply board failure or defect (occasional)
3. AC inlet or power cord damaged (occasional)

First check

Inspect AC input fuses for continuity

Test point: AC fuses (two 500 mA slow blow)
Expected: Continuity with no visible damage
Tools: Multimeter, fuse puller

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump does not operate on battery power

Pump fails to function when AC power is disconnected and running on internal battery; Plug Icon is not lit

Ranked causes

1. Internal battery discharged or defective (common)
2. Battery circuit fuse blown (2.0 A) (common)
3. Power control circuit HIC302 failure (occasional)

First check

Inspect battery circuit fuse for continuity

Test point: Battery circuit 2.0 A fuse
Expected: Continuity with no visible damage
Tools: Multimeter, fuse puller

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump does not run on AC but runs on battery

Unit operates only on internal battery; AC power not working

Ranked causes

1. AC power cord not firmly connected (common)
2. AC fuses blown (occasional)
3. Power supply voltage out of range (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Pump runs on battery but not on AC power caution

Equipment operates on internal battery but fails to run when connected to AC power

Ranked causes

1. AC power connector or cable issue (common)
2. CPU board malfunction (occasional)
3. Sensor board malfunction (occasional)

3 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Safety clamp will not latch open patient safety

Safety clamp arm does not hold in open position or cannot be opened

Ranked causes

1. Slide clamp not fully seated in slot (common)
2. Wrong administration set slide clamp design (occasional)
3. Safety clamp arm cover not in full open position (occasional)

First check

Verify slide clamp fully positioned and seated in slot

Test point: Slide clamp slot
Expected: Slide clamp seated fully in slot

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Slide clamp alarm caution

Pump displays code 9 (v1.09+), indicating slide clamp issue

Ranked causes

1. Slide clamp not inserted or improperly inserted (common)
2. Dirty slide clamp sensor (occasional)
3. Slide clamp sensor malfunction (rare)

First check

Verify slide clamp is properly inserted

Expected: Clamp fully inserted in slot

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Upstream occlusion alarm does not activate patient safety

Clamping tubing above pump does not trigger upstream occlusion detection within three minutes

Ranked causes

1. Upstream occlusion sensor calibration out of specification (common)
2. Occlusion sensor button stuck or not moving freely (occasional)
3. Upstream occlusion sensor reading out of specification after button free (occasional)

First check

Prime and load standard administration set at room temperature

Test point: Administration set tubing and pump mechanism
Expected: Baxter "s" suffix set properly seated per Section 7.3.2.1 steps 1-4

3 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Upstream occlusion detected caution

Pump displays code 4/5, indicating fluid line occluded before pump head

Ranked causes

1. Spilled solution in sensor region (common)
2. Incorrect tubing type or loading (occasional)
3. Temperature out of range (occasional)

First check

Inspect for spilled solution near sensor

2 more checks with pass and fail actions, 3 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air bubble detection fails patient safety

Air bubbles not detected in administration set during operation

Ranked causes

1. Air sensor calibration out of specification (common)
2. Air bubble size below detection threshold (occasional)

First check

Verify air sensor calibration

Test point: Air sensor calibration per Section 5.3.2
Expected: Calibration values within specification

3 more checks with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air bubble detection failure or excessive sensitivity patient safety

Pump fails to detect air bubbles at specified threshold or detects air when none present; air detection sensitivity misconfigured

Ranked causes

1. Air detection configuration set incorrectly (common)
2. Air detection sensor or electronics defective (occasional)

First check

Perform air alarm test with specified bubble volume

Test point: Administration set with Y-site
Expected: Pump detects air bubble at threshold volume (NORM: 110 µL alarm, 50 µL no alarm)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Air sensor alarm test patient safety

Verify air sensor detection and alarm activation when an intact air bubble reaches the sensor.

Ranked causes

1. Air bubble broken up before reaching sensor (occasional)
2. Air sensor miscalibrated for 25 or 50 microliter bubble detection (occasional)

First check

Position air bubble below pump fingers and above air sensor

Test point: Pump chamber
Expected: Intact air bubble positioned correctly

1 more check with pass and fail actions, 2 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

ALARM LED does not light

Alarm status indicator light does not illuminate when it should

Ranked causes

1. Connector issue or battery problem (common)
2. CPU or Display board failure (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

ALERT LED always lit

Alert status indicator light remains illuminated continuously

Ranked causes

1. Display board malfunction (common)
2. Sensor board malfunction (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

ALERT LED does not light

Alert status indicator light fails to illuminate

Ranked causes

1. Display board connection or malfunction (common)
2. Sensor board malfunction (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Backlight cannot be turned off

LCD backlight remains illuminated and cannot be disabled

Ranked causes

1. Sensor board malfunction (common)
2. Display board malfunction (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery icon lit while pump runs on AC

Display shows battery indicator even though connected to AC power

Ranked causes

1. AC power plug not firmly connected (common)
2. Rear power fuses blown (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery icon off during battery operation

Battery status indicator light not illuminated while unit running on internal battery

Ranked causes

1. Display board malfunction (common)
2. CPU board malfunction (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Battery low alarm on START key press caution

Pressing START key triggers BATTERY LOW alarm indication

Ranked causes

1. Low backup battery voltage (common)
2. Open fuse F2 or battery terminal continuity issue (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Beep does not sound when key pressed (non-BACKLIGHT/SILENCE)

No audible beep when pressing control buttons

Ranked causes

1. Connector disconnection or short circuit (common)
2. Speaker defective (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Beep does not sound when key pressed while pump stopped

Key press beep sound does not play when keys other than BACKLIGHT/SILENCE pressed while pump not running

Ranked causes

1. Temporary malfunction or connector issue (common)
2. Sensor or CPU board failure (occasional)

2 corrective actions and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Main and backup battery voltages

Verify main battery (MB) and backup battery (BB) calibration values in Test Mode 1.

Ranked causes

1. Main battery voltage out of specification (MB) (unknown)
2. Backup battery voltage out of specification (BB) (unknown)

First check

Verify main battery voltage (MB)

Test point: SEC RATE window of Main Display
Expected: 688-714 (Actual voltage = Displayed data × 0.01953) counts, 688-714

1 more check with pass and fail actions, 4 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

More symptoms

CHECK SET/LOADING alarm on door closure
Clicking noise from pump head
Communication timeout alarm
Communication timeout with computer
DOOR OPEN alarm incorrect activation
INSERT SLIDECLAMP message appearing when slide clamp not present
INSERT SLIDECLAMP message not appearing
Main voltage supply out of specification
Misloaded tubing detected
Motor overcurrent condition detected
Motor underinfusion - low rotation count
Occlusion downstream of pump
Occlusion upstream of pump
Optional nurse call always off
Optional nurse call always on
Pump does not switch to battery when AC unplugged
Pump fails to run on internal battery (no LCD display)
PUMPING LED always lit
PUMPING LED does not light
RATE, VTBI, or START key not accepted by pump
Rear clamp fails to hold on IV pole
Remote computer configuration cannot be set
Slide clamp not inserting or INSERT SLIDECLAMP message persists
Unit does not power off
Unit does not power on
Administration set loading error
Air sensor calibration out of specification
ALARM and ALERT LEDs lit but pump does not operate
ALARM and ALERT LEDs lit but pump not operating
ALARM LED always lit
Alarm volume control not responsive
All front panel keys disabled except BACKLIGHT and TOT VOL/STATUS
Audible alarm volume insufficient
Backlight does not light
Backlight not turning off on battery power
Backlight off during internal battery operation
Backlight off while pump runs on internal battery
Backup battery voltage out of specification
Battery does not hold charge
Battery does not maintain charge during operation
Battery does not provide backup power when AC unavailable
Battery icon off while pump runs on internal battery
Battery LOW BATTERY alert not functioning
BATTERY message does not clear when AC power restored
Battery power low
Calibration: Air sensor with primed tubing
Calibration: Air sensor with unprimed tubing
Calibration: Configuration reset after maintenance
Calibration: DC line voltage
Calibration: DC line voltages
Calibration: Output current limit by VR1
Calibration: Output voltage by VR2
Calibration: Power Supply Output Voltage by VR2
Calibration: Safety Slide Clamp Mechanical
Calibration: Slide shaft sensor (VR803)
Calibration: Upstream occlusion sensor
CHECK SET/LOADING alarm when door closed
CPU supply voltage out of specification
Door open alarm does not activate
Door open alarm test failure
Downstream occlusion alarm does not activate
Downstream occlusion not detected
Downstream occlusion sensor calibration out of specification
Excessive gravity flow when pump door closed
Exterior damage or contamination visible
External communication error
FLOW RATE or CHECK VTBI alarm when START pressed
FLOW RATE or CHECK VTBI alarm with START key pressed
Hi or Lo displayed during Volume-Time programming
Infusion pump flow rate accuracy out of specification
Interval between alarm tones too long
Interval between audible alarm tones too long
LCD displays blank, irrational, or missing segments
Leakage current or ground impedance out of specification
Microprocessor failure with code
Mounting clamp binding or loose
Panel Lock button not functioning
Panel Lock not functioning
Plug Icon not illuminated
Plug icon not lit when plugged into AC
Power cord damaged or defective
Power cord damaged or unsafe
Pre-calibration preparation
Pump does not stop and alarm does not activate on upstream occlusion
Pump stops with audible alarm for no apparent reason
Pump stops with audible alarm unexpectedly
Pump stops with BATTERY LOW alarm
RAMP PDP ENTER DATA alert displayed
RAMP PDP RATES HIGH alert displayed
Rear clamp fails to hold pump on IV pole
RESUME PDP Ramp Profile Phase alert displayed
Safety clamp allows free flow of fluid
Slide clamp feature alert or alarm not functioning
Slide clamp mechanism locking failure
Slide clamp not loaded
Slide clamp not loaded alert or alarm
Slide clamp sensor not detecting clamp insertion
START key causes BATTERY LOW alarm
Tube misloading sensor output out of specification
Tubing misload over left FSR not detected
Tubing misload over right FSR not detected
Tubing misloading not detected (left side)
Tubing misloading not detected (right side)
Upstream occlusion not detected
Upstream occlusion sensor calibration out of specification

105 more symptoms with ranked causes and checks are in ServiceForge. Connect ServiceForge to your AI

Error codes

Code	Meaning	Trigger	Severity
`0`	No alarms or failures recorded	Normal operation or log cleared fewer than 10 events ago	info
`1`	Air bubble detected in pump	Air detected in tubing during Run mode	warning
`10`	Misloaded tubing detected	Tubing not in correct position in pump mechanism	warning
`11`	Checksum error of ROM code	Master CPU or Slave CPU detects ROM data integrity failure	error
`11`	Upstream occlusion in Revolution Counter Interrupt	Upstream occlusion detected via counter interrupt mechanism	warning
`12`	Upstream occlusion in Revolution Counter	Upstream occlusion detected by revolution counter interrupt	warning
`12`	Door open detection circuit malfunction	Pin P54 of Master CPU remains active/not released	error
`2`	Downstream occlusion detected (sensor output threshold)	Fluid line after pump blocked; sensor threshold exceeded	warning
`20`	Door open detection malfunction	P54 of Master CPU remains low	critical
`20`	Frequency converter circuit malfunction (Master CPU)	Pin P20 of Master CPU remains high or low	error
`21`	Frequency converter malfunction for occlusion detection	P20 of master CPU remains high or low	critical
`22`	Frequency converter malfunction for occlusion detection	P20 of master CPU remains high or low	critical
`2-3`	Downstream occlusion detected	Tubing compressed or occluded downstream	warning
`23`	IRQ interrupt port remains high	P50 pin signal remains at high level (+5VDC)	error
`24`	UP and DOWN occlusion values agree	Occlusion sensor values identical when they should differ	critical
`25`	Failure in occlusion circuit	Occlusion circuit malfunction detected	critical
`27`	Slide clamp detection circuit malfunction	Slide clamp sensor not responding	error
`28`	Air sensor outputs cannot be selected	NORM and MIN air sensor modes not selectable	error
`29`	Occlusion sensors cannot be selected	UP and DOWN occlusion sensors not selectable	error
`3`	Downstream occlusion detected (sensor absolute value)	Fluid line severely blocked; sensor reached absolute threshold	warning
`30`	A/D converter malfunction for air detection	A/D conversion did not complete in 50 mS	critical
`31`	Malfunction in air MIN detection circuitry; input to A/D converter remains high	A/D converter input stuck high during air detection MIN test	error
`32`	Malfunction in air NORM detection circuitry; input to A/D converter remains high	A/D converter input stuck high during air detection NORM test	error
`33`	Air MIN detection input not 0V when transducer not oscillating	A/D input non-zero while MIN air transducer stationary	critical
`33`	Malfunction in air MIN detection circuitry; input to A/D converter not 0V	A/D input should be 0V when MIN air transducer not oscillating but is not	error
`34`	Air NORM detection input not 0V when transducer not oscillating	A/D input non-zero while NORM air transducer stationary	critical
`34`	Malfunction in air NORM detection circuitry; input to A/D converter not 0V	A/D input should be 0V when NORM air transducer not oscillating but is not	error
`35`	Front panel key pressed for more than 40 seconds	Key held for more than 40 seconds	warning
`36`	Master CPU received abnormal ON/OFF signal	Power control signal malfunction detected	critical
`37`	ON-OFF/CHARGE key pressed for more than 5 seconds when pump power was off	ON-OFF/CHARGE key held down more than 5 seconds with power off	warning
`38`	Tube misloading detection circuitry malfunction	Tube misload detector hardware failure	critical
`4`	Upstream occlusion detected (sensor output threshold)	Fluid line before pump blocked; sensor threshold exceeded	warning
`41`	Abnormal operation of master CPU	Master CPU malfunction detected	critical
`42`	Malfunction in alarm control circuit	Alarm control circuitry failure	critical
`4-5`	Upstream occlusion detected	Tubing compressed or occluded upstream	warning
`46`	PWRON1 signal is held low	PWRON1 signal stuck low	critical
`47`	PWRON1 signal is held high	PWRON1 signal stuck high	critical
`48`	Malfunction in real time clock; RTC does not count time correctly	RTC circuit not functioning properly	error
`49`	Malfunction in real time clock; abnormal RTC data	RTC detected data corruption	error
`5`	Upstream occlusion detected (sensor absolute value)	Fluid line severely blocked before pump; sensor at absolute minimum	warning
`50`	Master CPU received TRAP interrupt	TRAP interrupt signal to master CPU	critical
`51`	Master CPU received CMI interrupt	CMI interrupt signal detected	critical
`52`	Master CPU received SWI interrupt	SWI interrupt signal detected	critical
`53`	Master CPU received NMI interrupt	NMI interrupt signal detected	critical
`54`	Master CPU received OCI interrupt	OCI interrupt signal detected	critical
`55`	Master CPU received IRQ2 interrupt	IRQ2 interrupt signal detected	critical
`58`	TIMER 1 interrupt does not occur	TIMER 1 interrupt signal missing	critical
`59`	Program stuck in block 1 routine	Program execution halted in block 1	critical
`6`	Low battery voltage	Battery voltage 10.4V or less detected	warning
`60`	Battery voltage detection input to A/D remains high	A/D converter input stuck high	critical
`61`	Battery voltage detection input to A/D remains low	A/D converter input stuck low	critical
`62`	Backup battery voltage detection input to A/D remains high	Backup battery voltage detection A/D stuck high	critical
`63`	Lithium backup battery voltage too low	Backup battery voltage insufficient	critical
`64`	Malfunction in A/D converter circuitry; channels 0-3 conversion did not complete in 144 us	A/D conversion timeout on channels 0-3	error
`65`	Malfunction in A/D converter circuitry; channels 4-7 conversion did not complete in 144 us	A/D conversion timeout on channels 4-7	error
`66`	CPU supply voltage is too high	CPU supply voltage exceeds acceptable range	critical
`67`	CPU supply voltage is too low	CPU supply voltage below acceptable range	critical
`68`	Malfunction in A/D converter circuitry; channels 8-9 conversion did not complete in 72.6 us	A/D conversion timeout on channels 8-9	error
`69`	Abnormal battery recharging voltage	Battery charging voltage out of specification	critical
`7`	Communication alarm detected	Framing error, overrun error or parity error during PC communication	error
`70`	Data in duplicate memory areas does not agree	Memory check detects mismatch in duplicate storage	critical
`71`	Slave CPU received no data from Master CPU	Master CPU fails to send data to Slave	critical
`72`	Slave CPU received undefined data 4 times from Master CPU	Multiple reception of undefined data	critical
`73`	Overcurrent to motor (exceeds 1 A)	Motor current exceeds 1 A safe limit	critical
`74`	Motor slipped at maximum current	Motor unable to maintain engagement at max current	critical
`77`	No revolution interrupt while motor was rotating	Motor rotation not detected by encoder	critical
`78`	Drive defect - overinfusion	Motor speed exceeds expected revolution count	critical
`79`	Drive defect - underinfusion	Motor speed below expected revolution count	critical
`8`	Communication time out alarm	No communication between pump and external PC for given period	error
`82`	No acknowledgment from Slave CPU for three trials	Slave CPU fails to acknowledge after three attempts	critical
`83`	Undefined message type received from Slave CPU	Invalid message received from Slave CPU	critical
`83`	LVDT reading of downstream occlusion sensor is too high	Downstream occlusion sensor calibration drift	warning
`86`	LVDT reading of downstream occlusion sensor too low	Downstream occlusion sensor LVDT below threshold	warning
`87`	LVDT reading of downstream occlusion sensor too high	Downstream occlusion sensor LVDT above threshold	warning
`89`	Bank switching control circuit failure	Bank switching circuit malfunction detected	critical
`9`	Slide clamp alarm	Slide clamp not inserted or improperly inserted	warning
`90`	Checksum error of RATE, VTBI and VI data	Data checksum verification failed	critical
`91`	Checksum error of Programmed Delivery Profile stored data	PDP stored data checksum verification failed	critical
`92`	Checksum error of Programmed Delivery Profile working data	PDP working data checksum verification failed	critical
`93`	Write data and read data of M5M5165 do not agree	Memory write/read verification failure	error
`94`	Configuration option settings checksum is not 0	Configuration data corruption	error
`95`	Checksum error of alarm log data	Alarm log data corruption	error
`99`	Undefined failure code from Slave CPU	Slave CPU sends invalid or unrecognized failure code to Master CPU	error
`AIR`	Air bubble detected	Ultrasonic sensor detects air in the administration set	error
`AIR`	Air detected in administration set	Ultrasonic sensor detects air bubble in pump head	error
`BATTERY LOW`	Battery power critically low	During battery operation, approximately 15 minutes of running time remain	warning
`CHECK SET/LOADING`	Administration set loading error	Tubing pinched between pump head door and baseplate	error
`CHECK VTBI`	Set volume to be infused exceeds configured maximum	When user attempts to set VTBI above limit	warning
`COM TIMEOUT`	Communication timeout with controlling computer	No communication between device and computer for specified time period	warning
`DOOR OPEN`	Pump door opened during infusion	Pump door opened while pump is running	warning
`DOOR OPEN`	Pump door not fully closed	Door must be fully closed with tubing properly loaded for pump to operate	warning
`DOOR OPEN`	Door is open or door sensor malfunction	When door opens or sensor fails	warning
`EXT COMM ERROR`	External communication error from controlling computer	Controlling computer sends multiple queries or commands without waiting for device replies	warning
`F-78`	Drive defect alarm	Detected during high-speed drive test at 1999 mL/hr	error
`F-79`	Drive defect alarm	Detected during high-speed drive test at 1999 mL/hr	error
`FAILURE`	Microprocessor detected pump malfunction	When FAILURE does not clear after power cycle, microprocessor has detected malfunction	error
`FAILURE with code number`	Microprocessor has detected a pump malfunction	Microprocessor self-test or operational monitoring detects fault	critical
`FLOW RATE`	Set flow rate exceeds configured maximum	When user attempts to set rate above limit	warning
`INSERT SLIDECLAMP`	Slide clamp not detected in slide clamp slot	Pump door closed without slide clamp loaded into mechanism when feature is enabled	warning
`OCCLUSION`	Occlusion detected downstream of pump	Downstream occlusion sensor detects increased back-pressure	error
`OCCLUSION`	Downstream occlusion detected	Downstream occlusion sensor senses increased back-pressure between patient and pump	error
`UPSTREAM OCCLUSION`	Upstream blockage detected	Upstream occlusion sensor senses closed clamp or complete blockage upstream of pump	error
`UPSTREAM OCCLUSION`	Upstream occlusion detected	Upstream occlusion sensor senses closed clamp or complete blockage upstream of the pump	error

Likely causes and actions for each code are in ServiceForge. Connect ServiceForge to your AI

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ServiceForge knowledge base record. Field-unverified unless technicians confirmed it. A teaching summary of the record, not a service manual. Export 2026-10-14.