Infusion pumps · MRidium family

IRadimed 3860+: troubleshooting and error codes

The ServiceForge knowledge base holds 121 documented symptoms for the IRadimed 3860+, with 150 ranked causes, 221 diagnostic checks with test points and expected values, and 61 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Pump does not start infusion or flow rate incorrect patient safety

Pump fails to begin infusion after Start button pressed, or measured flow rate does not match set rate

Ranked causes

1. IV administration set not installed correctly (common)
2. Pump rate or VTBI not set correctly (common)
3. Inlet or patient line occlusion preventing flow (occasional)
4. Pump mechanism failure or motor malfunction (rare)

First check

Verify IV set installed and door closed properly

Test point: Pump door and IV set seating
Expected: Door closes and latches, IV set seated flush in pump chamber

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

Display not functioning or degraded image caution

LCD display fails to show information or displays garbled or dim image

Ranked causes

1. Backlight failure or 5V supply issue (common)
2. RF shield mesh displacement or damage (occasional)
3. LCD controller (1330 type) failure (rare)

First check

Verify 5V supply voltage to display connector

Test point: Display power connector pin 1 (positive) and pin 2 (ground)
Expected: 5.0 V DC, +/-0.25 V
Tools: Digital multimeter

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

Flow rate outside acceptable tolerance patient safety

Measured infusion flow rate deviates more than 5% from set rate or specified tolerance

Ranked causes

1. IV solution viscosity or temperature different from test conditions (occasional)
2. Pump calibration drift or mechanical wear (occasional)
3. IV set or tubing restriction or diameter variation (occasional)

First check

Prepare IV set with water at room temperature

Test point: IV solution container and tubing
Expected: Water filled to 2/3 in drip chamber; tubing primed and air-free; water container hung 21 inches above pump

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

Pumping chamber door misalignment or improper fit caution

Door does not fit flush with case or has friction/resistance opening and closing

Ranked causes

1. Door hinge pin corrosion or wear (occasional)
2. Door latch axle screw loose (common)
3. Brass door axle corroded or obstructed (occasional)

First check

Inspect door flush fit and alignment

Test point: Pumping chamber door AS112 or AS113 top, bottom, and side edges
Expected: Door fits flush with case on all sides

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

Air in line detection failure patient safety

Pump does not detect air bubble or indicate Air In Line alarm within 50 seconds when running IV set without fluid

Ranked causes

1. Bubble detector (HE09/HE09A) dirty or blocked (common)
2. Bubble detector optical sensor malfunction (occasional)

First check

Test bubble detector air detection capability

Test point: Pump running at 10 mL/Hr with IV set containing no fluid
Expected: Air In Line alarm within 50 seconds

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

Alarm sound not functioning patient safety

Audible alarm does not sound during alarm conditions or alarm test

Ranked causes

1. Alarm sound disabled or muted in settings (occasional)
2. Speaker or audio circuit failure (rare)

First check

Momentarily press Off switch and listen for alarm audio

Test point: Pump speaker and audio circuit
Expected: Audible alarm sound heard; pump remains powered on

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

Battery pack mechanical damage or puncture patient safety

1133 Battery Pack damaged by impact, dropping, overheating, compression, or puncture to internal cells, potentially causing overheating, smoking, or catastrophic battery failure.

Ranked causes

1. Impact damage, dropping, compression, or mechanical shock (occasional)
2. Puncture to internal battery cells from sharp objects (occasional)

First check

Inspect battery pack for cracks, dents, or visible physical damage

Test point: 1133 Battery Pack case exterior
Expected: No cracks, dents, deformation, or damage visible

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

Bubble detection alarm not triggered or functioning patient safety

Pump fails to detect air bubbles in line or alarm does not activate when bubble passes through pump

Ranked causes

1. Bubble detector sensor malfunction or obstructed (rare)
2. Alarm display or LED circuit failure (rare)

First check

Set pump rate to 500 ml/hr and VTBI to 100 ml

Test point: Display settings
Expected: Display shows Rate: 500 ml and VTBI: 100 ml; Ready to Start flashing

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

Calibration: Pump flow accuracy

Factory calibration of 3860+ and 3861 pump flow rate using Sartorius GD603 scale and encoder wheel alignment to achieve accurate delivery profile at various flow rates.

Ranked causes

1. Encoder wheel misalignment relative to pumping finger position (occasional)
2. Offset adjustment needed for step size correction (occasional)

First check

Verify raw curve taper using SartoConnect data

Test point: Scale measurement during calibration
Expected: Ideal curve per Figure A with appropriate taper profile
Tools: Sartorius GD603 scale, SartoConnect software, Microsoft Excel

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

Check Door alarm on flow detection failure patient safety

Alarm raised when flow stop switch does not respond within 0.75 seconds after door opens

Ranked causes

1. Free-flow detector switch (IVPAB016) not responding properly (occasional)
2. Door switch not opening properly (occasional)

First check

Measure flow stop switch opening time after door open

Test point: Flow Stop Switch IVPAB016 signal
Expected: Switch opens within 0.75 second of door switch detecting open
Tools: Timer or oscilloscope

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

Display not clear or unreadable

Boot display appears but text is garbled, dim, or pixels not functioning

Ranked causes

1. Display window or overlay scratched or cracked (occasional)
2. Internal display module failure or LCD connection loose (rare)

First check

Inspect display window covering and overlay for physical damage

Test point: Front display area
Expected: No scratches, cracks, or damage to window or overlay

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

Door latch or clamp mechanism malfunction caution

Door handle/cam lock does not operate smoothly, does not latch securely, or does not release properly

Ranked causes

1. Latch cam worn or misaligned (occasional)
2. Door clamp latch paw worn or damaged (common)

First check

Verify door handle/cam lock ease of operation

Test point: Door latch handle/cam AS104
Expected: Smooth, easy operation without binding or resistance

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

Door open alarm during pumping patient safety

Alarm triggered and pump shuts down when door is detected open during infusion operation

Ranked causes

1. Door not fully latched in closed position (common)
2. Door switch or optic sensor malfunction (occasional)

First check

Verify door closure and latch engagement

Test point: Door clamp mechanism
Expected: Hard rubber pin fully contacts switch or optic sensor when latched

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

Fluid delivery rate inaccurate patient safety

Pump delivers less than 100 mL in measured time period when set to 100 mL/Hr; flow rate outside specification

Ranked causes

1. Motor speed out of specification (common)
2. Pumping gasket worn or leaking (occasional)

First check

Measure fluid delivery at 100 mL/Hr over calibrated time period

Test point: Graduated cylinder or Infutest system; pump outlet
Expected: Delivered volume matches 100 mL/Hr setting within manufacturer tolerance
Tools: 100 mL and/or 25 mL graduated cylinder, Infutest or calibrated fluid measurement system

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

Inlet occlusion alarm not triggered or functioning patient safety

Pump fails to detect inlet line obstruction or alarm does not activate when inlet tubing pinched

Ranked causes

1. Inlet occlusion detection sensor malfunction (rare)
2. Alarm display or LED circuit failure (rare)

First check

Start pump with water flowing

Test point: Display and LED indicators
Expected: Pulsing > symbol in upper display; Green flashing LED in door; water flowing

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

IV set not properly seated in Flo-Stop holder patient safety

IV set does not remain seated in Flo-Stop holder when door opened; 'Check Door' alarm occurs inappropriately

Ranked causes

1. Flo-Stop holder plastic damaged by drug degradation (occasional)
2. Flo-Stop holder recess clogged or obstructed (common)

First check

Inspect Flo-Stop holder for damage and obstruction

Test point: IVP1047 or AS120 Flo-Stop holder recess
Expected: No damage, obstructions, or fluid spillage; clean condition

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

Patient occlusion alarm not triggered or functioning patient safety

Pump fails to detect outlet line obstruction or alarm does not activate when distal tubing blocked

Ranked causes

1. Patient occlusion detection sensor malfunction (rare)
2. Alarm display or LED circuit failure (rare)

First check

Clear any inlet occlusion, start pump with water flowing

Test point: Display and LED indicators
Expected: Pulsing > symbol in upper display; Green flashing LED in door; water flowing through distal tubing

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

Power indicator LED not illuminated

LED below power on/off switches does not light when External DC Power/Charger connected or battery installed

Ranked causes

1. External DC Power/Charger not connected or connectors loose (common)
2. Battery pack not installed (common)

First check

Verify External DC Power/Charger connected and line power active

Test point: DC input connector on pump
Expected: Connectors screwed in tightly, line power connected

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

Prevent battery pack damage patient safety

Precautions to avoid internal damage to 1133 Battery Pack that could disable protective circuitry and cause catastrophic failure

Ranked causes

1. Physical damage from impact, dropping, overheating, compression, or mechanical abuse (common)
2. Disassembly or tool damage to battery pack (occasional)

First check

Inspect battery pack for damage

Test point: 1133 Battery Pack exterior surfaces
Expected: No cracks, dents, punctures, corrosion, or signs of impact or thermal damage

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

Pump does not initialize or start

Pump fails to power on or display initial boot sequence after pressing power button

Ranked causes

1. Battery not charged sufficiently (common)
2. Power button not pressed or held correctly (occasional)

First check

Verify battery has been charged for minimum 6 hours

Test point: Battery pack 1133
Expected: Battery fully charged

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

Pumping chamber door and latch mechanical inspection

Verify pumping chamber door (AS112AOP or AS113AOP) fits flush with case, latches securely, and operates freely without friction.

Ranked causes

1. Door misalignment, binding, or latch failure (occasional)
2. Worn or damaged upper door clamp latch paw (IVP1038) (occasional)

First check

Pumping chamber door flush fit inspection

Test point: Door edges at top, bottom, and sides
Expected: Door fits flush with case; no gaps

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

Pumping mechanism integrity test

Test pumping chamber door springs (HM10) and seal integrity by occluding IV set and verifying proper pinch-off and occlusion pressure maintenance.

Ranked causes

1. Worn or damaged pumping gasket/seal (IVP1070) (common)
2. Weak or broken extension springs (HM10) (occasional)

First check

Pumping mechanism occlusion pressure test

Test point: IV set tube occlusion by pump
Expected: Pump reaches 10 PSI maximum occlusion pressure without backflow or free flow leakage
Tools: iRadimed Series 1000 IV set, pressure gauge

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

Pumping mechanism weak or occlusion failure patient safety

IV set not pinched off or pump cannot build occlusion pressure when patient tubing clamp is closed

Ranked causes

1. Extension spring (HM10) worn or weak (common)
2. Pumping fingers worn or misaligned (occasional)

First check

Test pumping mechanism integrity and spring force

Test point: IV set loaded in pump during Pump mode operation
Expected: Pump achieves 10 PSI occlusion pressure with patient tube clamp closed

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

Swollen battery stuck in pump or remote patient safety

1133 Battery Pack expands excessively and becomes jammed or difficult to remove from 3860+ pump or 3865 remote display chassis

Ranked causes

1. Excessive battery expansion causing jamming (occasional)
2. Battery plastic case beginning to crack during removal attempts (rare)

First check

Assess degree of battery swelling and jamming

Test point: Battery fit in chassis
Expected: Battery moves slightly when pried with gentle screwdriver pressure

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

Air bubble detected in IV line patient safety

Unit measures air bubble of 100µL or larger in infusion line and triggers alarm when acoustic impedance increases due to air-liquid interface

Ranked causes

1. Air bolus in IV tubing (common)

First check

Verify acoustic sensor detects air bubble presence

Test point: Acoustic impedance detection element
Expected: Voltage signal reduced when air present compared to fluid-filled state

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

Battery cell voltage imbalance

Battery cells not within 0.2 V of each other or any cell outside 3.8 to 4.25 V range

Ranked causes

1. Battery cell imbalance or failure (occasional)

First check

Verify all battery cells within range and balanced

Test point: Service mode F2 Battery Status display; all 4 cell voltages
Expected: 3.8 to 4.25 V per cell, all within 0.2 V of each other, 3.8-4.25, delta 0.2

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

Battery discharge current abnormal

Battery discharge current significantly different from approximately -240 mA when charger disconnected

Ranked causes

1. Battery or discharge circuit fault (rare)

First check

Verify battery discharge current with charger disconnected

Test point: Service mode F2 Battery Status display; Current field
Expected: Approximately -240 mA, nominal -240

Battery pack protective circuit failure or damage patient safety

1133 Battery Pack integral safety circuit damaged or failed, unable to prevent catastrophic battery failure.

Ranked causes

1. Physical damage to battery pack compromising protective circuitry (occasional)

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

Battery pack swollen or expanded patient safety

1133 Battery Pack case expands or swells due to internal gas release from aging lithium-polymer cells, potentially causing case failure, cell failure, or safety circuit failure.

Ranked causes

1. Aged lithium-polymer cells releasing internal gas (common)

First check

Inspect battery pack for visible swelling or expansion of case

Test point: 1133 Battery Pack exterior
Expected: No visible swelling or case expansion

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

Battery pack swollen or expanded patient safety

1133 Battery Pack case visibly expands or swells due to internal gas release from aging lithium-polymer cells

Ranked causes

1. Battery pack aging and internal gas release (common)

First check

Inspect battery case for visible swelling or expansion

Test point: 1133 Battery Pack exterior
Expected: Smooth, flat battery case with no bulging

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

Battery shows swelling patient safety

Battery pack exhibits visible swelling or deformation indicating internal damage

Ranked causes

1. Internal battery degradation or short circuit (rare)

First check

Visual inspection for battery swelling

Test point: Battery pack physical appearance
Expected: No visible swelling or deformation

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

Battery state of charge low

Battery state of charge below 50% before testing

Ranked causes

1. Battery not pre-charged before test (common)

First check

Verify battery state of charge

Test point: Service mode F2 Battery Status display
Expected: 50 to 100 %, 50-100

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

Battery terminal voltage out of range

Battery terminal voltage outside 15.0 to 16.9 V range during service mode test

Ranked causes

1. Battery faulty or not fully charged (occasional)

First check

Verify battery terminal voltage

Test point: Service mode F2 Battery Status display with charger cable connected
Expected: 15 to 16.9 V, 15-16.9

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

Bubble detection not functioning

Bubble detection indicator (upper case B or lower case b) not displaying correctly on screen

Ranked causes

1. Bubble detection sensor malfunction or calibration issue (unknown)

First check

Verify bubble detection indicator with no IV Set installed

Test point: Screen bottom center, bubble indicator
Expected: Upper case B displayed

1 more check with pass and fail actions are in ServiceForge. Connect ServiceForge to your AI

Bubble detection not working correctly patient safety

Bubble detection indicator at bottom center of screen does not show uppercase B with no IV set or lowercase b with fluid-filled set installed

Ranked causes

1. Bubble detection sensor malfunction (unknown)

First check

Verify bubble detection with no IV set installed

Test point: Bottom center of screen indicator
Expected: uppercase B

1 more check with pass and fail actions are in ServiceForge. Connect ServiceForge to your AI

Bubble detector functional test patient safety

Verify bubble detector (HE09A) ability to detect air in line within specified time.

Ranked causes

1. Bubble detector failure or malfunction (occasional)

First check

Air in line detection time

Test point: Bubble detector response with empty IV set running at 10 mL/Hr
Expected: Air In Line alarm within 50 seconds
Tools: IV set, pump operation

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

Calibration: Backup battery replacement

Replace CR2032 coin cell memory/clock backup battery to ensure proper timekeeping and history record retention.

Ranked causes

1. CR2032 backup battery depleted or aged (common)

First check

Backup battery replacement interval

Test point: Battery age and condition record
Expected: Replace every two years or if 'Lost History' message appears

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

Calibration: Battery MRI environment

Verification of backup battery functionality during service mode

Ranked causes

1. Battery out of specification (unknown)

First check

Verify battery charge and functionality

Test point: Battery
Expected: Battery meets specification

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

Calibration: Battery status verification patient safety

Verify battery state of charge, terminal voltage, individual cell voltages, current draw, and cycle count meet specifications.

Ranked causes

1. Battery voltage or charge state out of specification (occasional)

First check

Battery state of charge with charger connected

Test point: F2 key display: State of Charge (%)
Expected: 50 to 100%

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

Calibration: Bubble detection MRI environment

Verification of bubble detection functionality during service mode

Ranked causes

1. Bubble detector out of specification (unknown)

First check

Verify bubble detection sensor response

Test point: Bubble detection sensor
Expected: Sensor detects bubbles correctly

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

Calibration: Flow preventer switch MRI environment

Verification of flow preventer switch operation during normal operating mode

Ranked causes

1. Flow preventer switch malfunction (unknown)

First check

Verify flow preventer switch operation

Test point: Flow preventer switch
Expected: Switch functions correctly

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

Calibration: Flow stop pull test MRI environment

Verification of flow stop mechanism under pull load during normal operating mode

Ranked causes

1. Flow stop mechanism failure (unknown)

First check

Apply pull force and verify flow stops

Test point: Flow stop mechanism
Expected: Flow stops under pull test load

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

Calibration: Flow stop pull test patient safety

Verify black pinch clamp full retraction and flow preventer housing retention

Ranked causes

1. IVP1068 Door Clamp Clip worn (occasional)

First check

Load IVP1056 IV set and close door

Test point: Door and flow stop carrier
Expected: Door closes fully

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

Calibration: Infusion pump flow rate patient safety

Verify pump delivers correct flow rates at multiple programmed settings with volume and rate tolerance bands

Ranked causes

1. Pump flow rate out of specification (unknown)

First check

Measure delivered volume at 1400 ml/hr

Test point: Pump output
Expected: 44.27 – 48.93 ml or 1330 – 1470 ml/hr, 44.27 – 48.93 ml

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

Calibration: Infusion rate accuracy at 125 ml/hr patient safety

Verification of pump accuracy at low-medium flow rate setting

Ranked causes

1. Flow rate out of tolerance at 125 ml/hr (unknown)

First check

Deliver fluid at 125 ml/hr and measure output

Test point: Pump output collection point
Expected: 10.4 ml, 9.88 – 10.92 ml or 118.75 – 131.25 ml/hr

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

Calibration: Infusion rate accuracy at 1400 ml/hr patient safety

Verification of pump accuracy at high flow rate setting

Ranked causes

1. Flow rate out of tolerance at 1400 ml/hr (unknown)

First check

Deliver fluid at 1400 ml/hr and measure output

Test point: Pump output collection point
Expected: 46.6 ml, 44.27 – 48.93 ml or 1330 – 1470 ml/hr

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

Calibration: Infusion rate accuracy at 25 ml/hr patient safety

Verification of pump accuracy at low flow rate setting

Ranked causes

1. Flow rate out of tolerance at 25 ml/hr (unknown)

First check

Deliver fluid at 25 ml/hr and measure output

Test point: Pump output collection point
Expected: 4.2 ml, 3.99 – 4.41 ml or 23.75 – 26.25 ml/hr

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

Calibration: Infusion rate accuracy at 500 ml/hr patient safety

Verification of pump accuracy at medium flow rate setting

Ranked causes

1. Flow rate out of tolerance at 500 ml/hr (unknown)

First check

Deliver fluid at 500 ml/hr and measure output

Test point: Pump output collection point
Expected: 16.6 ml, 15.77 – 17.43 ml or 475 – 525 ml/hr

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

Calibration: Infusion rate accuracy at 999 ml/hr patient safety

Verification of pump accuracy at medium-high flow rate setting

Ranked causes

1. Flow rate out of tolerance at 999 ml/hr (unknown)

First check

Deliver fluid at 999 ml/hr and measure output

Test point: Pump output collection point
Expected: 33.3 ml, 31.63 – 34.97 ml or 949.05 – 1048.95 ml/hr

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

Calibration: Keypad MRI environment

Verification of keypad functionality during normal operating mode

Ranked causes

1. Keypad malfunction (unknown)

First check

Verify all keys respond correctly

Test point: Keypad
Expected: All keys functional

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

Calibration: Motor speed MRI environment

Verification of motor speed performance during service mode

Ranked causes

1. Motor speed out of specification (unknown)

First check

Verify motor speed within specification

Test point: Motor operation
Expected: Motor operates at correct speed

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

Calibration: Motor speed verification

Verify pump motor speed is within specification during manual pump run in service mode.

Ranked causes

1. Motor speed outside specification (occasional)

First check

Motor speed measurement

Test point: Pump motor during MANUAL PUMP RUN
Expected: 180 +/- 30 RPM, +/- 30 RPM

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

Calibration: Occlusion detection patient safety

Verification of line occlusion detection capability during normal operating mode

Ranked causes

1. Occlusion detection out of specification (unknown)

First check

Verify system detects line occlusion

Test point: Occlusion detection sensor
Expected: System detects occlusion within specification

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

Calibration: Occlusion limit verification

Verification that pump detects patient line occlusion and triggers alarm within 40 seconds when pressure reaches 10 psi.

Ranked causes

1. Occlusion limit setting incorrect or detection timing delayed (occasional)

First check

Verify occlusion limit setting

Test point: MENU F3 soft key display
Expected: 10 psi
Tools: Pump display

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

Calibration: Pressure sensor MRI environment

Verification of pressure sensor accuracy during service mode

Ranked causes

1. Pressure sensor out of specification (unknown)

First check

Verify pressure sensor reading

Test point: Pressure sensor
Expected: Pressure reading within specification

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

Calibration: Pressure sensor tare and span

Verify and adjust pressure sensor P1 and P2 readings to ensure accurate occlusion pressure detection using tare offset and span calibration procedures in service mode.

Ranked causes

1. Pressure sensor calibration drift (common)

First check

Tare offset zero verification

Test point: P1 and P2 pressure displays
Expected: 0 +/- 0.5 PSI with hand bulb open
Tools: Pressure gauge with hand bulb, circular IV test set

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

Calibration: Pump accuracy verification at multiple flow rates

Verification of pump accuracy using Infutest 2000 device at 100 mL/hr, 10 mL/hr, 1 mL/hr, 1400 mL/hr, and 999 mL/hr rates to ensure flow output meets ±2-3% tolerance.

Ranked causes

1. Flow compensation adjustment needed at specific flow rates (occasional)

First check

Prepare IV set and Infutest 2000 connection

Test point: Patient end of IV set to Infutest 2000 channel A or B
Expected: IV set primed, all air bubbles removed, stop cock in test position
Tools: IV Set 1056, Infutest 2000, water container, syringe

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

Calibration: Pump flow rate 125 ml/hr

Verify infusion pump delivers correct volume at 125 ml/hr using Infusion Pump Analyzer or graduated cylinder with distilled water

Ranked causes

1. Pump flow rate out of specification (unknown)

First check

Measure output volume or flow rate at 125 ml/hr

Test point: IVP1056 infusion set output into graduated cylinder or Infusion Pump Analyzer
Expected: 9.88 – 10.92 ml or 118.75 – 131.25 ml/hr, ±5%
Tools: Graduated cylinder or Infusion Pump Analyzer

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

Calibration: Pump flow rate 1400 ml/hr

Verify infusion pump delivers correct volume at 1400 ml/hr using Infusion Pump Analyzer or graduated cylinder with distilled water

Ranked causes

1. Pump flow rate out of specification (unknown)

First check

Measure output volume or flow rate at 1400 ml/hr

Test point: IVP1056 infusion set output into graduated cylinder or Infusion Pump Analyzer
Expected: 44.27 – 48.93 ml or 1330 – 1470 ml/hr, ±5%
Tools: Graduated cylinder or Infusion Pump Analyzer

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

Calibration: Pump flow rate 25 ml/hr

Verify infusion pump delivers correct volume at 25 ml/hr using Infusion Pump Analyzer or graduated cylinder with distilled water

Ranked causes

1. Pump flow rate out of specification (unknown)

First check

Measure output volume or flow rate at 25 ml/hr

Test point: IVP1056 infusion set output into graduated cylinder or Infusion Pump Analyzer
Expected: 3.99 – 4.41 ml or 23.75 – 26.25 ml/hr, ±5%
Tools: Graduated cylinder or Infusion Pump Analyzer

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

More symptoms

Calibration: Pump flow rate 500 ml/hr
Calibration: Pump flow rate 999 ml/hr
Calibration: Pump flow rate linearization
Calibration: Sound, KVO rate, and occlusion limit
Calibration: SpO2 verification
Calibration: Time and date
Channel A door does not open properly
Channel B flow rate out of specification
Check Door B alarm verification
Coin cell battery low voltage
Coin cell battery voltage low
Determine current software version
Display readability inspection
Door handle/cam lock operation test
External case and chassis inspection
Flo-Stop holder inspection and assembly test
Flow preventer alarm not triggering when pinch clamp activated
Flow preventer does not trigger alarm on door open
Flow rate accuracy test at 125 ml/hr
Flow rate accuracy test at 1400 ml/hr
Flow rate accuracy test at 500 ml/hr
Flow rate accuracy test at 999 ml/hr
Flow stop does not fully retract after door open/close cycle
Flow stop does not fully retract on door close
Flow Stop Pull Test failure
Flow Stop Pull Test verification
Fluid delivery accuracy test
Inlet occlusion alarm does not trigger
Inlet Occlusion detection
Inlet occlusion not detected when tubing clamped above pump
IV set seating and flow control test
Keypad buttons not producing audible tones
Keypad control functional test
Keypad display not showing entered values
Keypad does not respond to input
Motor hinge pin misaligned
Motor speed out of specification
Motor speed outside specification
Motor speed verification
No probe alarm
No Probe alarm clears properly
No Probe alarm does not sound or display
Pole clamp mechanism freedom test
Pressure sensor reading incorrect
Pressure sensor readings incorrect
Pressure transducer offset error
Pressure transducer span error
Pressure transducer zero drift after adjustment
Preventive maintenance overdue
Probe off alarm
Probe Off alarm does not sound or display
PT occlusion alarm does not trigger
PT Occlusion detection
PT occlusion not detected when tubing clamped below pump
Pump does not start or infuse
Pump flow accuracy 1400 ml/hr test
Pump flow rate outside acceptable range
Pump motor speed out of specification
Service mode entry verification
Software update
SpO2 display not functioning

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

Error codes

Code	Meaning	Trigger	Severity
`1`	Master/Slave communications failure on Channel A	Processor communication loss between master and slave controllers on Channel A pump	critical
`1000`	Shaft revolution time too short on Channel A	Shaft completed revolution in less than minimum required time	critical
`1001`	Shaft revolution did not occur on Channel A	Expected shaft revolution during programmed operation did not occur	critical
`1002`	Shaft revolution timeout error on Channel A	Shaft revolution exceeded maximum allowed time on Channel A	critical
`1003`	Shaft rotating when it should not on Channel A	Encoder detects motor shaft rotation when motor command is off	critical
`101`	Master/Slave communications failure on Channel B	Processor communication loss between master and slave controllers on Channel B pump	critical
`103`	Motor control processor watchdog timeout on Channel B	Motor control processor failed to service watchdog timer on Channel B	critical
`1100`	Shaft revolution time too short on Channel B	Shaft completed revolution on Channel B in less than minimum required time	critical
`1101`	Shaft revolution did not occur on Channel B	Expected shaft revolution on Channel B during operation did not occur	critical
`1102`	Shaft revolution timeout on Channel B	Shaft revolution on Channel B exceeded maximum allowed time	critical
`1103`	Shaft rotating when it should not on Channel B	Encoder detects motor shaft rotation on Channel B when motor command is off	critical
`129`	Encoder index not found while seeking starting mark on Channel A	Slave processor did not detect encoder index pulse during initial position seek	critical
`130`	Motor rotating too slowly on Channel A	Measured motor speed during operation is below minimum threshold	critical
`132`	Starting index mark found in wrong position on Channel A	Encoder starting index located at position misaligned with minor index marks	critical
`134`	Minor index mark not detected on Channel A	Processor expected to detect minor index mark during operation but did not	critical
`135`	Minor index mark not detected while motor stopped on Channel A	Processor expected to detect minor index mark after motor stop but did not	critical
`136`	Encoder index not detected during normal operation on Channel A	Encoder index pulse missed during continuous pump operation	critical
`2`	Watchdog timeout error	System watchdog timer expired indicating processor hang or freeze	critical
`229`	Encoder index not found while seeking starting mark on Channel B	Slave processor did not detect encoder index pulse during initial position seek on Channel B	critical
`23`	Pump Malfunction - Multiple causes depending on alarm number	Various processor, motor, or communications errors in Channels A or B	critical
`23`	Pump Malfunction	Various motor control, processor, or encoder detection failures	critical
`230`	Motor rotating too slowly on Channel B	Measured motor speed on Channel B below minimum threshold during operation	critical
`232`	Starting index mark in wrong position on Channel B	Encoder starting index located misaligned with minor index marks on Channel B	critical
`234`	Minor index mark not detected on Channel B	Processor expected minor index mark during operation on Channel B but did not detect	critical
`235`	Minor index mark not detected while motor stopped on Channel B	Processor expected minor index mark detection after motor stop on Channel B but did not	critical
`236`	Encoder index not detected during normal operation on Channel B	Encoder index pulse missed during continuous operation on Channel B	critical
`23 (Alarm 1)`	Pump Malfunction - Master/Slave communications failure (Channel A)	Master and slave processor communication breakdown on channel A	critical
`23 (Alarm 1000)`	Pump Malfunction - Shaft revolution occurred too quickly (Channel A)	Shaft completes revolution in less than required minimum time on channel A	critical
`23 (Alarm 1001)`	Pump Malfunction - Shaft revolution did not occur (Channel A)	Shaft did not complete expected revolution on channel A	critical
`23 (Alarm 1002)`	Pump Malfunction - Shaft revolution timeout error (Channel A)	Shaft revolution took longer than timeout threshold on channel A	critical
`23 (Alarm 1003)`	Pump Malfunction - Shaft should not be turning but it is (Channel A)	Shaft rotation detected when motor should be stopped on channel A	critical
`23 (Alarm 101)`	Pump Malfunction - Master/Slave communications failure (Channel B)	Master and slave processor communication breakdown on channel B	critical
`23 (Alarm 103)`	Pump Malfunction - Motor control processor watchdog timeout (Channel B)	Motor controller watchdog timer expired on channel B	critical
`23 (Alarm 1100)`	Pump Malfunction - Shaft revolution occurred too quickly (Channel B)	Shaft completes revolution in less than required minimum time on channel B	critical
`23 (Alarm 1101)`	Pump Malfunction - Shaft revolution did not occur (Channel B)	Shaft did not complete expected revolution on channel B	critical
`23 (Alarm 1102)`	Pump Malfunction - Shaft revolution timeout error (Channel B)	Shaft revolution took longer than timeout threshold on channel B	critical
`23 (Alarm 1103)`	Pump Malfunction - Shaft should not be turning but it is (Channel B)	Shaft rotation detected when motor should be stopped on channel B	critical
`23 (Alarm 129)`	Pump Malfunction - Slave processor did not see encoder index while seeking (Channel A)	Encoder index pulse not detected during starting index mark search on channel A	critical
`23 (Alarm 130)`	Pump Malfunction - Motor is rotating too slow (Channel A)	Motor speed falls below minimum threshold on channel A	critical
`23 (Alarm 132)`	Pump Malfunction - Starting index mark in wrong position (Channel A)	Starting index mark detected at incorrect position relative to minor marks on channel A	critical
`23 (Alarm 134)`	Pump Malfunction - Minor index mark not detected (Channel A)	Expected minor index mark not seen during motor operation on channel A	critical
`23 (Alarm 135)`	Pump Malfunction - Minor index mark not seen while motor stopped (Channel A)	Minor index mark expected but not detected when motor is stationary on channel A	critical
`23 (Alarm 136)`	Pump Malfunction - Encoder index not detected during normal operation (Channel A)	Encoder index pulse missing during normal pump operation on channel A	critical
`23 (Alarm 2)`	Pump Malfunction - Watchdog timeout	Master processor watchdog timer expired	critical
`23 (Alarm 229)`	Pump Malfunction - Slave processor did not see encoder index while seeking (Channel B)	Encoder index pulse not detected during starting index mark search on channel B	critical
`23 (Alarm 230)`	Pump Malfunction - Motor is rotating too slow (Channel B)	Motor speed falls below minimum threshold on channel B	critical
`23 (Alarm 232)`	Pump Malfunction - Starting index mark in wrong position (Channel B)	Starting index mark detected at incorrect position relative to minor marks on channel B	critical
`23 (Alarm 234)`	Pump Malfunction - Minor index mark not detected (Channel B)	Expected minor index mark not seen during motor operation on channel B	critical
`23 (Alarm 235)`	Pump Malfunction - Minor index mark not seen while motor stopped (Channel B)	Minor index mark expected but not detected when motor is stationary on channel B	critical
`23 (Alarm 236)`	Pump Malfunction - Encoder index not detected during normal operation (Channel B)	Encoder index pulse missing during normal pump operation on channel B	critical
`23 (Alarm 3)`	Pump Malfunction - Motor control processor watchdog timeout (Channel A)	Motor controller watchdog timer expired on channel A	critical
`23 (Alarm 4)`	Pump Malfunction - Nonmaskable interrupt	Nonmaskable interrupt triggered on master processor	critical
`23 (Alarm 5)`	Pump Malfunction - ROM checksum error	Firmware ROM checksum validation failure on startup or runtime	critical
`3`	Motor control processor watchdog timeout on Channel A	Motor control processor failed to service watchdog timer within timeout period	critical
`4`	Nonmaskable interrupt error	Nonmaskable interrupt generated by processor	critical
`5`	ROM checksum error	Calculated ROM checksum does not match stored value during boot	critical
`Check Door B`	Door opened while pump running	Door opened during active infusion	warning
`Inlet Occlusion`	Blockage detected in inlet (supply) line	Tubing above pump is pinched or kinked	error
`Inlet Occlusion`	Input line obstruction detected	Tubing clamped, kinked or blocked above pump inlet	warning
`PT Occlusion`	Output line obstruction detected	Tubing clamped, kinked or blocked below pump outlet	warning
`PT Occlusion`	Blockage detected in outlet (patient) line	Tubing below pump is pinched or kinked	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.