Chest compression systems · LUCAS family

Physio-Control LUCAS 3: troubleshooting and error codes

The ServiceForge knowledge base holds 102 documented symptoms for the Physio-Control LUCAS 3, with 119 ranked causes, 140 diagnostic checks with test points and expected values, and 73 error codes. Each symptom below shows its causes and the first check; the rest is one connection away. Connect ServiceForge to your AI

Symptoms

Linear sensor calibration failed patient safety

POT CAL value for Control exceeds 6% or Protective exceeds 3.1%, alarm sounds and error code displayed in Control CPU window

Ranked causes

1. Suction cup obstruction or interference (common)
2. Device not in upright position (common)
3. Suction cup not at correct starting position (occasional)
4. Compression module defect (rare)

First check

Verify suction cup movement is unobstructed

Test point: suction cup
Expected: free movement without interference

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

30:2 compression mode malfunction patient safety

Device does not operate correctly in 30:2 mode; sound is unusual, LED does not confirm mode, or alerts do not function

Ranked causes

1. Software or mode configuration issue (occasional)
2. Sound generation or speaker malfunction (occasional)
3. LED or indicator malfunction (occasional)

First check

Activate 30:2 mode; listen for compression cycles

Test point: Device speakers and compression mechanism
Expected: Compression sound is normal; no unusual noise

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

Bellows leaking or not sealing properly

Air leakage from bellows assembly or loss of pressure during compression cycles

Ranked causes

1. Bellows ring misaligned or improperly seated (common)
2. Bellows clamp bolts loose or undertightened (occasional)

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

Bluetooth connection to PC not working

Device fails to establish or maintain Bluetooth connection with PC during Transmit mode

Ranked causes

1. Bluetooth module malfunction or firmware issue (unknown)
2. COM Board App not properly updated or configured (unknown)

First check

Initiate Transmit mode and attempt Bluetooth connection to PC

Test point: Bluetooth module communication
Expected: Device successfully pairs and connects to PC via Bluetooth

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

Bluetooth connectivity failure in transmit mode

Device cannot establish Bluetooth connection to PC or connection is unstable in transmit mode

Ranked causes

1. Bluetooth module or driver issue (occasional)
2. Software version mismatch or compatibility issue (occasional)

First check

Activate transmit mode; attempt Bluetooth connection to PC

Test point: Device Bluetooth module and PC Bluetooth interface
Expected: Device successfully pairs and connects to PC

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

Charging sequence does not start high voltage

Device fails to initiate charging sequence when PSU is connected

Ranked causes

1. Power supply not properly connected or faulty (unknown)
2. Device charging electronics malfunction (unknown)

First check

Connect PSU to device and observe charging sequence initiation

Test point: Power supply connection and charging LED
Expected: Charging sequence starts; appropriate LED indicator illuminates

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

Claw Mechanism does not lock securely patient safety

Release Ring exhibits play or Claw Mechanism does not remain locked when pressure is applied

Ranked causes

1. Claw Lock Mechanism requires lubrication or adjustment (unknown)
2. Release Ring has excessive play or wear (unknown)

First check

Check Release Ring play with Claw Mechanism unlocked

Test point: Release Ring
Expected: Minimal or no play

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

Claw mechanism unlocks under pressure patient safety

Claw mechanism does not remain locked when pressure is applied during compression

Ranked causes

1. Claw lock mechanism wear or lubrication issue (occasional)
2. Claw mechanism internal damage or misalignment (rare)

First check

Engage claw mechanism; apply manual downward pressure on compressor

Test point: Claw mechanism lock
Expected: Claw remains locked without disengagement

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

Compression module misaligned or making noise

Grinding, squealing, or knocking sounds during compression; module may be loose or out of position

Ranked causes

1. Compression module mounting screws loose or undertightened (common)
2. PCB bracket fasteners loose (occasional)

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

Decompression Spring does not move smoothly

Decompression Spring exhibits stiffness, grinding, or unusual noise during operation

Ranked causes

1. Decompression Spring requires lubrication or maintenance (unknown)
2. Decompression Spring mechanism fouled or damaged (unknown)

First check

Manually operate Decompression Spring

Test point: Decompression Spring mechanism
Expected: Smooth motion without unusual noise

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

Drive belt slipping or not driving motor

Motor does not turn or compression cycles are weak; belt may be slipping or misaligned

Ranked causes

1. Drive belt worn, damaged, or broken (occasional)
2. Belt cover screws loose (occasional)

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

Electric motor not running or running poorly high voltage

Motor fails to start, runs intermittently, or produces weak output; compression cycles may be weak or absent

Ranked causes

1. Motor mounting screws loose or undertightened (common)
2. Motor terminal connector loose or corroded (occasional)

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

Hood cover cables disconnected or damaged patient safety

Hood not powering up, no audio output, or communication issues; loose cable connections visible

Ranked causes

1. Cable connectors loose or not fully seated (common)
2. Cable damaged or pinched during hood installation (occasional)

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

Internal function test LED not green or test fails

Internal function test does not complete successfully or LED does not show green status

Ranked causes

1. Software or firmware issue (occasional)
2. LED module malfunction (occasional)

First check

Run internal function test via device interface

Test point: Device control panel or software interface
Expected: LED displays green; test completes without error

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

30:2 mode active LED not green

Active 30:2 LED does not display green during 30:2 mode operation

Ranked causes

1. LED failure or 30:2 mode not functioning (unknown)

First check

30:2 mode active LED

Test point: LED indicator
Expected: Green

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

30:2 mode does not function correctly patient safety

Device produces unusual sound, LED indicators not illuminated correctly, or audible alert not functioning in 30:2 mode

Ranked causes

1. Electronics malfunction or LED/audio failure (unknown)

First check

Operate device in 30:2 mode and listen for unusual sound

Test point: Device operation in 30:2 mode
Expected: Runs without unusual sound

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

30:2 mode does not operate correctly patient safety

Device produces unusual sound, active 30:2 LED does not illuminate green, or audible alert prior to ventilation pause is missing

Ranked causes

1. Electronic malfunction or software issue in 30:2 mode (unknown)

First check

Listen for unusual sound during 30:2 mode operation

Test point: Device audio output
Expected: Device runs without unusual sound

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

30:2 mode LED not active or green

30:2 active LED fails to illuminate green during 30:2 mode operation

Ranked causes

1. LED failure or electronics malfunction (unknown)

First check

30:2 active LED status

Test point: 30:2 active LED
Expected: Green

30:2 mode LED not green or audible alert missing patient safety

30:2 LED fails to illuminate green or audible alert does not sound prior to ventilation pause

Ranked causes

1. Electronics or firmware issue affecting 30:2 mode operation (unknown)

First check

Run device in 30:2 mode and verify 30:2 LED illuminates green

Test point: 30:2 mode LED
Expected: LED illuminates green during compression cycles

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

30:2 mode malfunction patient safety

Device runs with unusual sound, 30:2 LED not green, or audible alert and intermittent LED before ventilation pause not working

Ranked causes

1. Software or electronic control issue in 30:2 mode (rare)

First check

Test device operation in 30:2 mode

Test point: Device audio, compression rhythm, LED indicator
Expected: Runs without unusual sound; active 30:2 LED is green

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

30:2 mode operation abnormal patient safety

Device produces unusual sound, active 30:2 LED not green, or audible alert/LED missing before ventilation pause

Ranked causes

1. Electronics or mode control malfunction (unknown)

First check

Run device in 30:2 mode and listen for unusual sounds

Test point: 30:2 mode operation
Expected: Device runs without unusual sound

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

30:2 mode produces unusual sound

Device produces unusual sound during 30:2 compression/ventilation mode operation

Ranked causes

1. Mechanical wear or lubrication issue (unknown)

First check

30:2 mode audio inspection

Test point: Device audio output during 30:2 mode
Expected: No unusual sound

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

Adjust mode suction cup operation abnormal

Suction cup does not run smoothly in adjust mode

Ranked causes

1. Suction cup wear or mechanism misalignment (unknown)

First check

Enter adjust mode and observe suction cup operation

Test point: Suction cup
Expected: Suction cup runs smoothly

Audible alert absent before ventilation pause

Device does not produce audible alert prior to ventilation pause in 30:2 mode

Ranked causes

1. Buzzer failure or alert function disabled (unknown)

First check

Audible alert before ventilation pause

Test point: Device speaker or buzzer
Expected: Audible alert and intermittent LED

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

Audible alert or intermittent LED absent before ventilation pause patient safety

Device fails to produce audible alert or intermittent LED prior to ventilation pause in 30:2 mode

Ranked causes

1. Electronics or audio circuit malfunction (unknown)

First check

Audible alert and intermittent LED prior to ventilation pause

Test point: Audio and LED output
Expected: Audible alert and intermittent LED active before ventilation pause

Bellows or Suction Cup damaged caution

Bellows or Suction Cup exhibit damage, cracks, or deterioration

Ranked causes

1. Wear, impact damage, or material degradation (unknown)

First check

Bellows and Suction Cup physical inspection

Test point: Bellows and Suction Cup
Expected: No damage or deterioration

Bellows or Suction Cup malfunction caution

Bellows or Suction Cup not functioning properly

Ranked causes

1. Wear, damage, or contamination of Bellows or Suction Cup (common)

First check

Visually inspect Bellows and Suction Cup

Test point: Bellows and Suction Cup components
Expected: No cracks, deformation, or contamination

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

Bluetooth connection setup

Device must be placed in Bluetooth mode before wireless connection with Program Loader

Ranked causes

1. Device not in Bluetooth mode (common)

First check

Device powered off

Test point: Device
Expected: No LEDs illuminated

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

Bluetooth connection to PC does not work in transmit mode

Device fails to establish Bluetooth connection to personal computer in transmit mode

Ranked causes

1. Bluetooth module malfunction or connection issue (unknown)

First check

Enable transmit mode and attempt Bluetooth pairing with PC

Test point: Bluetooth module connection
Expected: Bluetooth connection to PC is established and working

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

Bluetooth connection to PC fails

Device cannot establish or maintain Bluetooth connection to personal computer in Transmit mode

Ranked causes

1. Bluetooth module malfunction or configuration issue (occasional)

First check

Test Bluetooth connection in Transmit mode

Test point: Bluetooth radio and PC interface
Expected: Connection established and working

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

Calibration: Linear Sensor (POT CAL)

Procedure to calibrate the linear sensor potentiometer after software update or when POT CAL recalibration is needed

Ranked causes

1. Routine calibration after software update (common)

First check

Device position setup

Test point: device
Expected: upright, suction cup ~20mm from top

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

Carry ball nut does not move smoothly

Carry ball nut produces unusual noise or moves with resistance during operation

Ranked causes

1. Carry ball nut requires lubrication (unknown)

First check

Observe carry ball nut movement

Test point: Carry ball nut
Expected: Smooth movement without unusual noise

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

Carry Ball Nut does not run smoothly

Carry Ball Nut exhibits stiffness, grinding, or unusual noise during operation

Ranked causes

1. Carry Ball Screw requires lubrication (unknown)

First check

Operate Carry Ball Nut through full range

Test point: Carry Ball Nut assembly
Expected: Smooth motion without unusual noise

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

Carry ball nut movement abnormal

Carry ball nut does not run smoothly or produces unusual noise

Ranked causes

1. Carry ball nut wear or insufficient lubrication (common)

First check

Observe carry ball nut operation for smoothness and noise

Test point: Carry ball nut
Expected: Smooth operation without unusual noise

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

Carry ball nut moves with unusual noise

Carry ball nut operation is noisy or not smooth during mechanics test

Ranked causes

1. Carry ball nut mechanical wear or inadequate lubrication (unknown)

First check

Carry ball nut operation

Test point: Carry ball nut
Expected: Runs smoothly without unusual noise

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

Carry Ball Nut moves with unusual noise or stiffness

Carry Ball Nut does not run smoothly or produces unusual noise during operation

Ranked causes

1. Carry Ball Screw requires lubrication (unknown)

First check

Inspect and listen to Carry Ball Nut movement

Test point: Carry Ball Nut assembly
Expected: Runs smoothly without unusual noise

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

Carry Ball Nut noise or binding caution

Carry Ball Nut does not run smoothly or produces unusual noise

Ranked causes

1. Wear or contamination of ball nut bearing surfaces (occasional)

First check

Test Carry Ball Nut movement

Test point: Carry Ball Nut on Ball Screw
Expected: Runs smoothly without unusual noise

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

Carry ball nut operation rough or noisy

Carry ball nut does not run smoothly or produces unusual sound during compression cycles

Ranked causes

1. Carry ball nut requires lubrication (common)

First check

Manually cycle carry ball nut and listen for smooth operation

Test point: Carry ball nut on ball screw
Expected: Runs smoothly without unusual noise

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

Carry Ball Nut runs with noise or stiffness

Carry Ball Nut does not run smoothly or produces unusual noise during device operation

Ranked causes

1. Carry Ball Nut requires lubrication or maintenance (unknown)

First check

Carry Ball Nut movement inspection

Test point: Carry Ball Nut
Expected: Runs smoothly without unusual noise

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

Charge mode does not initiate charging sequence high voltage

Device does not begin charging when PSU is connected in charge mode

Ranked causes

1. PSU connection issue or faulty charging circuit (occasional)

First check

Connect PSU to device in charge mode; observe charging indication

Test point: PSU connector and charging indicator
Expected: Charging sequence initiates; indicator shows charging status

Claw mechanism binding or not moving smoothly

Claw lock does not open/close smoothly or feels stiff during operation

Ranked causes

1. Insufficient lubrication on claw moving parts (common)

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

Claw Mechanism does not remain locked patient safety

Claw Mechanism fails to stay locked when pressure is applied

Ranked causes

1. Claw Lock Mechanism requires lubrication or adjustment (unknown)

First check

Claw Mechanism lock test

Test point: Claw Mechanism
Expected: Remains locked when pressure is applied

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

Claw mechanism does not remain locked under pressure patient safety

Claw mechanism unlocks or moves when pressure is applied during mechanics test

Ranked causes

1. Claw lock mechanism worn or inadequately lubricated (common)

First check

Claw mechanism lock under pressure

Test point: Claw mechanism
Expected: Remains locked when pressure applied

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

Claw mechanism release ring play excessive

Release ring exhibits excessive play when claw mechanism is unlocked

Ranked causes

1. Release ring wear or claw mechanism wear (unknown)

First check

Inspect release ring for excessive play with claw mechanism unlocked

Test point: Release ring
Expected: No excessive play

Communication PCB replacement caution

Communication PCB on Controller PCB requires replacement; device needs reprogramming after installation.

Ranked causes

1. Communication PCB failure or degradation (unknown)

First check

Visual inspection of Communication PCB for damage or corrosion

Test point: Communication PCB surface
Expected: No visible damage, corrosion, or component failure

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

Continuous compression mode malfunction patient safety

Device does not operate correctly in continuous mode; LED does not confirm mode or does not blink at correct interval

Ranked causes

1. Software or mode timing issue (occasional)

First check

Activate continuous compression mode; observe LED indicator

Test point: Continuous mode LED
Expected: LED is green during continuous operation

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

Continuous mode does not function correctly patient safety

Continuous mode LED not illuminated or LED does not blink at correct interval

Ranked causes

1. Electronics malfunction or LED failure (unknown)

First check

Activate continuous mode and verify LED illumination

Test point: Continuous mode LED indicator
Expected: LED is green

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

Continuous mode does not operate correctly

Continuous mode LED does not illuminate green or does not blink every 10 strokes

Ranked causes

1. Electronic or software malfunction in continuous mode (unknown)

First check

Verify continuous mode LED illumination

Test point: Continuous mode LED
Expected: LED is green

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

Continuous mode LED blink pattern incorrect

LED fails to blink every 10 strokes during continuous mode operation

Ranked causes

1. Electronics or timing circuit malfunction (unknown)

First check

Continuous mode LED blink frequency

Test point: LED blink pattern
Expected: Blinks every 10 strokes

Continuous mode LED not active or green

Continuous mode LED fails to illuminate green during continuous mode operation

Ranked causes

1. LED failure or electronics malfunction (unknown)

First check

Continuous mode LED status

Test point: Continuous LED
Expected: Green

Continuous mode LED not green

Continuous mode LED does not display green during continuous mode operation

Ranked causes

1. LED failure or continuous mode not functioning (unknown)

First check

Continuous mode LED

Test point: LED indicator
Expected: Green

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

Continuous mode LED not illuminating or blink rate incorrect

Continuous mode LED fails to illuminate green or does not blink at correct 10-stroke interval

Ranked causes

1. Electronics or firmware issue affecting Continuous mode operation (unknown)

First check

Run device in Continuous mode and verify LED illuminates green

Test point: Continuous mode LED
Expected: LED illuminates green during continuous compression

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

Continuous mode malfunction patient safety

Continuous mode LED not green or LED does not blink every 10 strokes

Ranked causes

1. Software or electronic issue in continuous compression mode (rare)

First check

Verify continuous mode LED status

Test point: Continuous mode LED
Expected: Green

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

Continuous mode operation abnormal

Continuous mode LED not green or LED does not blink every 10 strokes

Ranked causes

1. Electronics or mode control malfunction (unknown)

First check

Verify continuous LED indicator in continuous mode

Test point: Continuous LED
Expected: LED is green

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

Decompression spring movement abnormal

Spring does not move smoothly or produces unusual noise during operation

Ranked causes

1. Decompression spring wear or misalignment (unknown)

First check

Observe decompression spring movement for smoothness and noise

Test point: Decompression spring
Expected: Smooth movement without unusual noise

Decompression spring moves with noise or resistance

Spring movement is not smooth or produces unusual sound during operation

Ranked causes

1. Decompression spring requires maintenance or lubrication (common)

First check

Manually operate decompression spring and listen for noise

Test point: Decompression spring assembly
Expected: Moves smoothly without unusual noise

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

Decompression Spring moves with noise or stiffness

Decompression Spring does not move smoothly or produces unusual noise during operation

Ranked causes

1. Decompression Spring requires lubrication or maintenance (unknown)

First check

Decompression Spring movement inspection

Test point: Decompression Spring
Expected: Moves smoothly without unusual noise

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

Decompression spring moves with unusual noise

Decompression spring operation is noisy or not smooth during mechanics test

Ranked causes

1. Decompression spring mechanical wear or misalignment (unknown)

First check

Decompression spring operation

Test point: Decompression spring
Expected: Moves smoothly without unusual noise

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

Decompression spring moves with unusual noise or stiffness

Decompression spring does not move smoothly or produces unusual noise during operation

Ranked causes

1. Decompression spring requires lubrication or has mechanical wear (unknown)

First check

Observe decompression spring movement

Test point: Decompression spring
Expected: Smooth movement without unusual noise

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

Decompression Spring stiffness or noise caution

Decompression Spring does not move smoothly or produces unusual noise

Ranked causes

1. Wear, dirt, or lack of lubrication in spring mechanism (occasional)

First check

Test Decompression Spring movement

Test point: Decompression Spring
Expected: Moves smoothly without unusual noise

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

More symptoms

Device does not charge when PSU is connected
Device exterior condition is damaged or dirty
Device exterior damage or bellows condition issues
Device exterior damage or contamination
Device exterior damaged or dirty
Device exterior damaged or soiled
Device produces unusual sound during 30:2 mode
Device runs with unusual sound during 30:2 mode
Electric fan and mesh grill require cleaning
Electric Fan or Mesh Grill contaminated
Fabric condition issues with straps or carrying bag
Fabric straps or carrying bag damaged
Fabrics are damaged or worn
Fabrics worn or damaged
Hood cannot be opened or removed
Internal function test LED does not show green
Internal function test LED not green
Last service date not recorded on PC
Last Service Date not set to current date
Last service date not set to PC date
Last Service Date not synchronized with PC Date
LED does not blink at correct interval in continuous mode
Main Body/Frame Assembly replacement
Patient straps or carrying bag damage or deterioration
Patient straps or stabilization strap degraded
PAUSE LED does not illuminate green
PAUSE LED not green
PAUSE mode LED not green
Power Inlet replacement
Program Loader Bluetooth initialization
Release ring has excessive play
Release Ring play detected in Claw Mechanism
Release ring play detected when claw unlocked
Service date not set correctly
Software installation required
Software version and checksum not verified
Software version mismatch or checksum error
Software version requires verification or update
Suction Cup does not run smoothly in Adjust mode
Suction Cup operation rough in Adjust mode
USB connection setup
View device error codes and warnings

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

Error codes

Code	Meaning	Trigger	Severity
`ALARM TYPE ROM TEST`	Protective CPU internal ROM test failure at startup	ROM self-test fails during power-on	critical
`BATT_10_MIN_ALARM`	Battery voltage drops below 25.3V	Battery voltage indicates low charge state	warning
`BATT_EMPTY_ALARM`	Battery voltage drops below 25V	Battery depleted during operation	critical
`BATT_HIGH_TEMP_ALARM`	Battery temperature exceeds 70°C	Battery temperature sensor detects >70°C	critical
`CHARGER_STOP`	Charger fault detected with motor disabled	Charger system malfunction during operation	critical
`COM_B_TIMEOUT (0x55)`	I2C battery charger communication timeout	No I2C communication with Charger system for >100 seconds	critical
`COM_I2C (0x56)`	I2C communication faults excessive	I2C bus communication errors above threshold	warning
`COM_P_TIMEOUT (0x50)`	I2C protective system communication timeout	No I2C communication with Protective system for >100 seconds	critical
`COM_RTC (0x53)`	Real-time clock fault	RTC read failure at startup or SPI communication fault	warning
`COM_SD_MEM (0x54)`	SD card communication fault	SD card not inserted or broken	warning
`CONTROL_LIFETICK`	I2C communication fault with Control CPU (warning)	I2C communication failure at mode change	warning
`CONTROL_STOP`	Control fault detected with motor disabled	Control system malfunction during operation	critical
`INT_1msCODE (0x3A)`	1ms code access timeout	Halted or disturbed Control CPU response	error
`INT_C_24V (0x32)`	Control 24V supply less than 18V	Main power supply drops below 18V	error
`INT_C_5V (0x31)`	Control 5V supply out of range	Control 5V less than 4.5V or greater than 5.5V	error
`INT_C_HALL (0x3C)`	Motor Hall sensor fault	Hall sensor signal failure detected	warning
`INT_CODE (0x36)`	Access of vital function code fault (10ms)	Control CPU hangs or timing violation detected	critical
`INT_C_POTCAL (0x3D)`	Control potentiometer linearity fault	Control potentiometer response is too non-linear	critical
`INT_C_REF (0x33)`	Control 2.5V reference out of range	Control 2.5V reference less than 2V or greater than 3V	error
`INT_C_TEMP (0x34)`	Too high internal board temperature (>85°C)	Control board temperature exceeds 85°C limit	critical
`INT_CURRENT (0x38)`	Motor current fault exceeds 20A	Mean current to motor greater than 20A	error
`INTERNAL TEMPERATURE`	Protective board temperature exceeds 85°C	Temperature sensor on Protective board detects >85°C	critical
`INT_P_5V (0x30)`	Protective 5V supply out of range	Protective 5V less than 4.5V or greater than 5.5V	error
`INT_POTHALL (0x37)`	Potentiometer position and Hall sensor mismatch	Mismatch between potentiometer and Hall sensor readings after correct start	warning
`INT_P_POTCAL (0x3E)`	Protective potentiometer linearity fault	Protective potentiometer response is too non-linear	critical
`INT_P_REBOOT (0x39)`	Protective CPU reboot in active mode	Protective board resets during active operation	error
`PISTON_TIME_OUT`	Protective potentiometer detects no 50% stroke movement for 10 seconds	Piston does not move 50% of stroke within 10 second window	critical
`RUN_13N (0x49)`	13N release spring force high (>10mm)	Release force displacement exceeds 10mm	warning
`RUN_ADJUST (0x46)`	Incorrect motor power at adjust mode	Motor power greater than 25W during adjust servo operation	warning
`RUN_NO_POTCAL (0x4B)`	Potentiometer not calibrated	System detects potentiometer has not been calibrated	critical
`RUN_POTCAL (0x4A)`	Potentiometer calibration fault	Potentiometer not moved during calibration or read error detected	critical
`RUN_PROTECTIVE (0x45)`	Halt or reverse by protective system during active moving mode (>1s)	Protective system disables active mode during operation	critical
`RUN_P_STOP (0x4C)`	Protective system has stopped operation	Protective system error detected	critical
`RUN_RATIO (0x44)`	Piston ratio fault (50 consecutive strokes)	Compression ratio deviates from preset ratio +/- 20% over 50 strokes	critical
`RUN_TIMEDOWN (0x48)`	Compression stroke time too long or too shallow	50 consecutive strokes with timing or depth out of range	critical
`RUN_TIMEOUT (0x40)`	Piston not moved during active moving mode (>1s)	No motor movement detected during >1 second of active mode	critical
`RUN_TIMEUP (0x47)`	Time up too long >0.15s (50 consecutive strokes)	Release phase exceeds 0.15 seconds during 50 strokes	critical
`RUN_TOO_DEEP (0x41)`	Piston too deep (compression depth excessive)	Piston depth exceeds normal range during operation	critical
`RUN_TOO_SHALLOW (0x42)`	Piston too shallow (50 consecutive strokes @ 100 bpm)	50 consecutive strokes measure <target depth minus 10mm at 100bpm	critical
`T1_BATT_COM_ALARM`	Battery communication fault	Battery communication error detected at startup	warning
`T1_BATT_COPYRIGHT_ALARM`	Incorrect copyright string in battery	Battery copyright verification fails at startup	warning
`T1_BATT_CS_ALARM`	Battery communication checksum fault	Battery communication checksum validation failure	warning
`T1_B_OFF (0x2A)`	Battery charger did not respond to startup test	Charger CPU does not complete startup test	warning
`T1_CAL_EE (0x15)`	Control potentiometer calibration data checksum fault	Calibration data corruption detected	critical
`T1_C_DOWN (0x2D)`	Control not moving down before reverse test at startup	Motor does not move down during startup reverse test sequence	warning
`T1_C_EE (0x10)`	Control EE-Prom checksum data error	CPU fault detected during initialization	critical
`T1_C_INITCURR (0x20)`	High current detected at startup	High current read during initial startup	warning
`T1_C_LOWCURR (0x24)`	Too low current detected at first current test	Motor current below expected value during startup test	warning
`T1_C_POT (0x28)`	POT value incorrect or mismatch at start or no change during moving	Control/protective POT divergence >10mm at start or non-linear response	critical
`T1_C_POT (0x28)`	Potentiometer value mismatch at warm start	Control and Protective potentiometer divergence >10mm at warm start	warning
`T1_C_RAM (0x11)`	Control preset checksum data error	CPU or communication fault during startup	critical
`T1_C_RELEASE (0x22)`	Current detected at release/disable test by control	Unexpected current during release phase	critical
`T1_C_TOTOP (0x2F)`	Control timeout at move to top at startup	Motor cannot move to top position within timeout	warning
`T1_E2_PROM`	Protective CPU internal E2PROM test failure at startup	EEPROM self-test fails during power-on	critical
`T1_E2_PROM_ALARM`	Charger CPU internal E2PROM test failure at startup	EEPROM self-test fails during Charger power-on	critical
`T1_PB_FLASH (0x14)`	Incompatible programs in protective board	Program mismatch detected after board change	critical
`T1_P_DISABLE (0x25)`	Protective disable failure at current test startup	Protective system fails to disable at expected point	warning
`T1 PISTON RELEASE ERROR`	Protective release line operation fault at startup	Current detected during disable test or moved too low during enable test	critical
`T1 PISTON REVERSE ERROR`	Reverse test failure at startup	Motor reverse movement incorrect or fault current read at startup	critical
`T1_POWER_OFF_ALARM`	Charger startup test incomplete	T1 test does not end correctly	critical
`T1_P_POT (0x27)`	Read Protective potentiometer timeout at startup	Protective potentiometer read operation times out	warning
`T1_P_REW (0x2E)`	Protective timeout at reverse test at startup	Motor reverse test does not complete within timeout	warning
`T1_P_STATE_1 (0x21)`	Start of release test timeout from protective board	Protective board fails to complete release test	critical
`T1_P_STATE_3 (0x23)`	Start of current test timeout or current detected by protective	Protective fails current test or detects unexpected current	critical
`T1_P_STATE_5 (0x29)`	No end of Protective current test at startup	Protective current test does not complete within timeout	warning
`T1_RAM`	Protective CPU internal RAM test failure at startup	RAM self-test fails during power-on	critical
`T1_RAM_ALARM`	Charger CPU internal RAM test failure at startup	RAM self-test fails during Charger power-on	critical
`T1_ROM_ALARM`	Charger CPU internal ROM test failure at startup	ROM self-test fails during Charger power-on	critical
`T1_START_COM (0x13)`	No communication from Protective or Battery-Charger CPUs at startup	I2C communication failure at device startup	warning
`TOO_DEEP_COMPRESSION`	Compression depth exceeds safe limits	Excessive compression depth detected during active mode	critical
`TOO_MANY_USES`	Battery cycle count exceeds 200 uses	Battery use counter reaches threshold	warning
`TOO_OLD_BATTERY`	Battery age exceeds recommended service life	Battery exceeds maximum age specification	warning
`TOO_SHALLOW_COMPRESSION`	Compression depth below minimum after 50 strokes	Insufficient compression depth for 50 consecutive strokes	critical

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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.