Surgical energy systems

Ethicon Total Energy: troubleshooting and error codes

The ServiceForge knowledge base holds 13 documented symptoms for the Ethicon Total Energy, with 13 ranked causes, 40 diagnostic checks with test points and expected values, and 62 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Alert notification displayed

Grey pop-up message shown on User Screen with designated alert; two quick audio tones emitted

Ranked causes

1. Non-hazardous condition affecting patient, equipment, or workflow (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Advanced Bipolar (ENSEAL) energy output high voltage

Verify ENSEAL Test 1, Test 2, and Test 3 output power at 10, 100, and 500 ohm loads through Advanced port; results recorded on Output Verification Check Form

Ranked causes

1. Energy module output out of specification (unknown)

First check

Insert ENSEAL test leads into Advanced port

Test point: Advanced port
Expected: Test leads fully inserted and connected

6 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Advanced Monopolar energy output high voltage

Verify output power at 120 watts in Coag 1 mode through Advanced port with 500 ohm load; results recorded on Output Verification Check Form

Ranked causes

1. Energy module output out of specification (unknown)

First check

Select Advanced Energy in Output Verification mode

Test point: ESU display
Expected: Advanced mode selected

3 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Contact Quality Monitoring (CQM) patient safety

Verify patient return electrode port light response at 50, 150, and threshold ohm loads using CQM Safety Leads; confirm threshold is between 63 and 77 ohms

Ranked causes

1. CQM system out of specification (unknown)

First check

Power on system and prepare for CQM test

Test point: Communications Module on/off button
Expected: System powered on; no patient return electrode attached to Energy Module

6 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Electrical safety – Earth Leakage Current high voltage

Verify earth leakage current under normal condition, reversed polarity, and single fault (neutral open) conditions does not exceed specification limits

Ranked causes

1. Leakage current out of specification (unknown)

First check

Measure earth leakage current at 264 V, 60 Hz normal condition

Test point: System leakage to earth/chassis
Expected: ≤0.5 mA, ≤0.5 mA
Tools: Electrical safety analyzer, 264 V 60 Hz source

3 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Electrical safety – Ground Bond test high voltage

Verify total system ground resistance without and with power cord attached meets specification of ≤0.100 ohms or ≤0.200 ohms respectively at 25 A, 60 Hz

Ranked causes

1. Ground resistance out of specification (unknown)

First check

Measure total system ground resistance without power cord

Test point: System frame to safety ground
Expected: ≤0.100 ohms at 25 A, 60 Hz, ≤0.100
Tools: Ground bond analyzer, 25 A 60 Hz source

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

Calibration: Electrical safety – Patient Leakage Current (optional) patient safety

Optional test: Verify patient leakage current under normal condition, reversed polarity, and single fault conditions does not exceed specification limits

Ranked causes

1. Patient leakage current out of specification (unknown)

First check

Measure patient leakage current at 264 V, 60 Hz normal condition

Test point: Patient circuit leakage to earth
Expected: ≤50 uA, ≤50 uA
Tools: Electrical safety analyzer, 264 V 60 Hz source

5 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Harmonic energy output high voltage

Verify Harmonic Test 1, Test 2, and Test 3 output power at 50, 200, and 800 ohm loads through Advanced port; results recorded on Output Verification Check Form

Ranked causes

1. Energy module output out of specification (unknown)

First check

Insert HARMONIC test leads into Advanced port

Test point: Advanced port
Expected: Test leads fully inserted and connected

6 more checks with pass and fail actions, 1 corrective action, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Calibration: Touch Screen test (optional)

Optional test to verify User Screen touch functionality; each cell should change to lighter shade when touched

Ranked causes

1. User Screen touch sensor defective (rare)

First check

Navigate to Touch Screen Test utility

Test point: User Screen display
Expected: Maintenance menu displayed; Touch Screen Test option visible

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

Contact Quality Monitoring alarm triggered patient safety

Flashing red pop-up message on User Screen; Patient Return Port light turns red; three-tone audio alarm sounds; Monopolar output disabled

Ranked causes

1. Patient return electrode resistance increased by 40% within 10-135 ohms range (unknown)

First check

Measure patient return electrode resistance

Test point: Patient Return Port
Expected: 10 to 135 ohms, within range; alarm at +40% increase

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Low priority alarm triggered

Yellow pop-up message displayed on User Screen with low priority alarm symbol; two-tone audio alarm sound emitted

Ranked causes

1. Issue requiring surgical staff attention for procedural progress (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Medium priority alarm triggered patient safety

Flashing yellow pop-up message displayed on User Screen with medium priority alarm symbol; three-tone audio alarm sound emitted

Ranked causes

1. Hazardous condition requiring prompt attention (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Notification not resolved after on-screen guidance

Alarm, alert, or other event persists despite following displayed prompts and recommended actions

Ranked causes

1. Unresolved system condition requiring technical support (unknown)

1 corrective action and part numbers are in ServiceForge. Connect ServiceForge to your AI

Error codes

Code	Meaning	Trigger	Severity
`ACCSY-FSW001`	Footswitch Port Error	Error detected on one or more Footswitch Ports	error
`ACCSY-IO001-A`	USB Port Error	System detected an error on one or more of the back panel USB ports	error
`ACCSY-IO001-B`	Ethernet Port Error	System detected an error on the back panel Ethernet port	error
`ACCSY-IO001-C`	Digital Accessory Port Error	System detected an error on the back panel Digital Accessory Port	error
`Factory reset error`	Error occurred during factory reset process	Failure during factory reset execution	error
`HEAD-CFG002`	Invalid Module(s) Detected	System detected an invalid configuration upon startup due to extra, invalid, or unidentified module	error
`HEAD-CFG003`	No Module(s) Detected	System detected an invalid configuration upon startup due to no modules connected	error
`HEAD-CFG007`	Software/Hardware Conflict Detected	During initial setup, system received user input indicating an issue with hardware configuration	error
`HEAD-CON001`	Software Update Error	System could not complete the software update process	error
`HEAD-CON002`	Data Upload Failure	System could not complete upload of software update confirmation	warning
`HEAD-TBL001`	System Restart Required	System detects error requiring restart	error
`HEAD-TBL002`	System Detected Module Error – System Unavailable for Use	Presence of faulty module detected	critical
`HEAD-TBL003`	System Power Loss	Power supply disruption	critical
`HEAD-TBL005`	System Error	System detected a fault that requires further troubleshooting	error
`HEAD-TBL006`	Maintenance Required Soon - Clock Battery Low	Upon startup, system detected a low clock battery	warning
`HEAD-TBL007`	Clock Battery Maintenance Required	Clock battery critically low	warning
`HEAD-TBL008`	Communication Module Error	Error detected in Communications Module	error
`INST-AE001`	Replace Instrument	Multiple instances detected requiring instrument replacement	warning
`INST-AE001-A`	Replace Instrument – Continuous Instrument Jaw Error	Open circuit condition detected on Advanced Energy instrument after several occurrences	warning
`INST-AE001-B`	Replace Instrument – Continuous Contact with Metal Error	Advanced Energy Instrument activated on metal (staples, clips, retractors, clamps)	warning
`INST-AE001-C`	Replace Instrument – Unable to Pass HARMONIC™ Instrument Attachment Test	Connected HARMONIC™ instrument fails attachment test	error
`INST-AE001-D`	Replace Instrument – HARMONIC™ Blade Error Detected	Error detected with blade of connected HARMONIC™ instrument	error
`INST-AE002`	Check Tissue Thickness and Reactivate	Open circuit condition detected on Advanced Energy instrument preventing energy delivery	info
`INST-AE003`	Reposition Instrument Jaws and Reactivate	Advanced Energy instrument activated on metal (staples, clips, retractors, clamps)	info
`INST-AE004`	Connect Compatible Instrument to HARMONIC™ Hand Piece	Incompatible HARMONIC™ instrument detected	warning
`INST-AE005`	Software Upgrade Required to Use This Instrument	Instrument not compatible with installed software version	warning
`INST-AE007`	Simultaneous Activation Not Available Over 150W	System detected two Energy Modules each with a Monopolar Instrument with power settings above 150 W allowable threshold	warning
`INST-AE008`	Simultaneous Activation Not Available	Advanced Energy instrument cannot be used simultaneously as power level exceeds allowable system limit or combination with second Advanced Energy instrument exceeds threshold	warning
`INST-AE009`	Connect Compatible Instrument to the HARMONIC Hand Piece	System detected a HARMONIC handpiece without an instrument connected	warning
`INST-AE010`	Remaining Uses on HARMONIC Hand Piece	System detected the number of uses remaining on a connected hand piece is between 1 and 10	info
`INST-AE011`	Replace HARMONIC™ Hand Piece	Issue detected with connected hand piece	error
`INST-AE012`	Replace HARMONIC™ Hand Piece	Hand piece has reached end of life	error
`INST-AE014`	No Uses Remaining	Instrument exceeded allowable usage or single-use reused	warning
`INST-AE015`	HARMONIC Hand Piece Test	User initiated HARMONIC hand piece diagnostic test	info
`INST-AE016`	Advanced Features Are Not Available in This Instrument	System detected an issue with the instrument that prevents use of advanced features	warning
`INST-AIT002`	Tighten HARMONIC™ Hand Piece Assembly	Issue with attachment between instrument and hand piece detected	warning
`INST-AIT003`	HARMONIC Instrument Attachment Test	User initiated HARMONIC instrument attachment diagnostic test	info
`INST-BASIC001`	Set Power Settings to Enable Energy Output	User attempted to activate an instrument without selecting power settings	warning
`MODU-CQM001`	Check Patient Return Electrode	Issue with quality of contact or connection with patient return electrode detected	warning
`MODU-GEN001`	Software Update Required to Use the Module	System detected one or more modules upon startup with module software version that does not match currently installed system software version	warning
`MODU-GEN004`	Energy Module Error	Error detected with connected Energy Module	critical
`MODU-GEN007`	Energy Module Error	Error detected with connected energy module	error
`Software update error`	Error occurred during software update process	Failure during Ethernet or USB software update execution	error
`SYST-CLNCL001`	Return to Main Screen to Activate Instrument	User attempting to activate instrument while viewing non-clinical screens	info
`SYST-LSE001`	System Error	System detects fault and stops activation	warning
`SYST-OVH001`	Cooling Fan Error	Loss of cooling fan operation detected	error
`SYST-OVH002`	Module Overheating	One or more modules overheating	warning
`USER-ACT002`	Footswitch Not Assigned to Instrument	System detected user depression of a footswitch assigned to a port without an instrument or where instrument is not properly connected	warning
`USER-ACT003`	Instrument Jaws Open	System detected HARMONIC instrument jaws are in an open state during activation mode that requires closed jaws	warning
`USER-ACT004`	Release Secondary Input	System detected activation request for second energy modality while another energy modality on same Energy Module is already active	warning
`USER-ACT005`	Reactivate to Continue Sealing	System detected an ENSEAL activation lasting longer than 2 minutes	info
`USER-ACT006-A`	Release Hand Switch	System detected a depressed activation button upon instrument connection or system startup	warning
`USER-ACT006-B`	Release Footswitch	System detected a depressed footswitch pedal upon instrument connection or system startup	warning
`USER-ACT007`	Simultaneous Activation Not Allowed	System detected an attempted activation on instrument(s) where simultaneous activation of two instruments has been disabled	warning
`USER-ACT008`	Current Threshold Exceeded	Accumulated current during monopolar activation exceeds allowable threshold	warning
`USER-ACT012-A`	Release All Activation Switches	System detected a depressed switch on an instrument or footswitch pedal when energy is not being delivered	warning
`USER-ACT013`	Open Jaws to Enable Auto Bipolar	Prior to delivering therapeutic output, system detected clamped tissue in jaws on a bipolar instrument while Auto Bipolar is enabled	warning
`USER-BIT001`	HARMONIC Blade Approaching Maximum Impedance	System detected excessive force against the blade on a HARMONIC instrument	warning
`USER-BIT002`	Maximum Impedance on HARMONIC™ Blade Detected	Instrument loaded to point where output stops	warning
`USER-BIT003`	HARMONIC™ Blade Error Detected	System detects need to diagnose blade	error
`USER-OV001`	Disconnect Instruments to Enter Energy Output Verification Mode	System detected the Output Verification Key while instruments or leads are connected to one or more Energy Module ports	warning
`USER-OV003`	Connect Energy Output Verification Key to Test This Energy Module	Energy Output Verification attempted without Output Verification Key connected	warning

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

Community

0 fixes logged by technicians through their AI, with outcomes, for this model.

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