Infusion pumps · Medfusion family

Smiths Medical Medfusion 3000: troubleshooting and error codes

The ServiceForge knowledge base holds 74 documented symptoms for the Smiths Medical Medfusion 3000, with 108 ranked causes, 152 diagnostic checks with test points and expected values, and 139 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 power on

Pump fails to turn on or respond to power button

Ranked causes

1. Dead battery (common)
2. Main board to interconnect cable disconnected (occasional)
3. AC power connection issue (occasional)
4. Battery connection issue (occasional)
5. Keypad cable disconnected (occasional)

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

Pump will not turn on or power up

Pump does not respond to power button; no display, no LED indicators, no startup sequence

Ranked causes

1. Dead or fully discharged battery; must charge before power-on (common)
2. Main PCB to Interconnect PCB ribbon cable loose or disconnected (occasional)
3. AC power supply connections loose or missing (occasional)
4. Battery connections loose or disconnected (occasional)
5. Keypad cable loose or disconnected (occasional)

First check

Connect AC power and charge battery

Test point: AC power connection; battery charge status (if readable)
Expected: AC power connected; allow 2+ minutes charge time

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

Battery does not hold charge

Battery drains quickly when pump disconnected from AC power; pump shuts down during operation or cannot sustain operation on battery alone

Ranked causes

1. Battery ribbon cable disconnected or loose (common)
2. Battery charging circuit failure (occasional)
3. Battery chemistry degraded or cell failure (occasional)
4. Battery calibration required (occasional)

First check

Inspect and reseat battery ribbon cable

Test point: Battery ribbon cable connector on Interconnect PCB
Expected: Connector fully seated, no looseness

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

Learn Error - Remote Not in Teach Mode

Learning pump displays error message 'Learn Error - Remote Not in Teach mode' when attempting configuration cloning from Teacher pump. Communication fails during infrared data transfer.

Ranked causes

1. Teacher pump not in Teach Mode or infrared ports misaligned (common)
2. Teacher and Learning pumps have different software versions (occasional)
3. Learning pump not properly configured in Learn Mode (occasional)
4. Pump hardware malfunction or damaged Interconnect PCB (rare)

First check

Verify Teacher pump in Teach Mode

Test point: Profile Settings menu
Expected: Teach Mode selected and active

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

Alarms do not sound or sound faintly patient safety

Speaker produces no sound or very low volume for alarms; audio may be inaudible in clinical environment

Ranked causes

1. Alarm volume configured to lowest level (common)
2. Speaker grid holes obstructed (occasional)
3. Speaker failure (rare)

First check

Review alarm volume setting (V3 pumps)

Test point: Custom Program audio settings menu
Expected: Alarm volume set to medium or high level

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

LCD has poor contrast or is unreadable

Display text is dim, hard to read, or has low contrast; visibility impaired regardless of ambient lighting

Ranked causes

1. LCD contrast setting at minimum or too low (common)
2. LCD negative supply voltage fault (rare)
3. LCD or Main PCB hardware failure (rare)

First check

Run Adjust Contrast utility

Test point: Biomed > Calibration > Adjust Contrast menu
Expected: Contrast adjustment slider available and responsive; display improves with slider adjustment

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

No charge light illuminated

Battery charge indicator LED does not light when pump connected to AC power; may indicate battery not charging or power supply problem

Ranked causes

1. AC power not connected or pump not powered on (common)
2. Both AC and charge indicators off; indicator light or display issue (occasional)
3. Battery not charging or charger failure (occasional)

First check

Verify AC power connection

Test point: AC power inlet on pump rear
Expected: AC cord plugged into power outlet; AC indicator LED lit

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

Occlusion alarms occur too frequently patient safety

Pump triggers occlusion alarm repeatedly during normal infusion; false alarms without actual line blockage

Ranked causes

1. Occlusion alarm limit set too low in Configuration (common)
2. High infusion line backpressure due to setup or medication (common)
3. Force sensor miscalibration or drift (occasional)

First check

Review occlusion alarm limit setting

Test point: Pump Configuration occlusion limit value
Expected: Occlusion limit set to appropriate level for line setup and medication

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

Alarms do not sound audibly caution

Alarms either do not sound or sound very faintly

Ranked causes

1. Alarm volume configured to lowest level (common)
2. Speaker failure (occasional)

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

Battery not working message

Pump displays battery failure message or no battery response

Ranked causes

1. Battery ribbon cable disconnected (common)
2. Battery pack failure (occasional)

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

Battery not working message displayed

Pump displays 'Battery Problem: Battery not working' message; battery pack is not communicating with pump electronics

Ranked causes

1. Battery ribbon cable disconnected or loose (common)
2. Battery pack defective (common)

First check

Inspect battery ribbon cable connection

Test point: Battery ribbon cable connector on Interconnect PCB (inside case bottom)
Expected: Connector fully seated and locked

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

Calibration: AC line leakage (Medfusion 3500BC) high voltage

Verify enclosure and earth leakage current on 3500BC model with functional earth ground

Ranked causes

1. Enclosure leakage exceeds 100 micro-amps (rare)
2. Earth leakage exceeds 100 micro-amps through AC power cord earth conductor (rare)

First check

Connect pump to Safety Analyzer

Test point: AC power inlet
Expected: Analyzer configured in Line Leakage mode

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

Calibration: Syringe size sensor

Load calibration slugs into barrel clamp and adjust position to find lowest size reading for both small and large standards, recording count values.

Ranked causes

1. Syringe size sensor requires calibration (common)
2. Large standard calibration needed (common)

First check

Verify small standard size reading

Test point: Barrel clamp with small slug
Expected: Lowest size reading achieved when clamp perpendicular and adjusted back/forth

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

General inspection caution

Annual maintenance visual and physical inspection of pump components, power cord, labels, and housing

Ranked causes

1. Physical damage or wear on pump components (occasional)
2. Loose internal or external parts detected during inspection (occasional)

First check

Inspect for physical damage to housing and keypads

Test point: Pump housing and keypad surfaces
Expected: No cracked housings or torn keypads

9 more checks with pass and fail actions, 9 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Indicator lights do not flash

Status indicator lights do not illuminate during startup or function

Ranked causes

1. Keypad connection loose (common)
2. Keypad failure (occasional)

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

Indicator lights do not flash during startup or with alarms

LED indicator lights on pump do not illuminate during power-up or in response to alarms and function activation; display may be dark or unresponsive

Ranked causes

1. Keypad cable loose or disconnected from Main PCB (common)
2. Keypad or LED circuit failure (rare)

First check

Inspect keypad cable connection to Main PCB

Test point: Keypad ribbon cable connector on Main PCB
Expected: Connector fully seated and locked; no movement or looseness

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

Keypad key does not respond to presses

One or more keypad buttons do not register when pressed; no response or stuck key condition

Ranked causes

1. Keypad connection loose or disconnected (common)
2. Keypad hardware failure (rare)

First check

Run Keypad Test in Biomed diagnostics

Test point: Biomed > Diagnostics > Keypad Test menu
Expected: All keys pass diagnostic test; no failed keys reported

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

LCD display poor contrast

Liquid Crystal Display text or graphics not clearly visible

Ranked causes

1. LCD contrast setting too low (common)
2. LCD negative supply or display failure (occasional)

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

Maximum infusion rate not available or set too low patient safety

Pump maximum delivery rate setting is lower than desired; maximum rate option in menu unavailable or locked

Ranked causes

1. Maximum rate configured low in pump Configuration (common)
2. Individual profile has lower maximum rate than global setting (occasional)

First check

Review global Max Delivery Rate setting

Test point: Profile Settings > View Settings > Max Delivery Rate
Expected: Max Delivery Rate set to desired value or higher

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

No charge light indicator

Charge indicator light does not illuminate when battery charging or AC powered

Ranked causes

1. AC power not connected (common)
2. Battery charging issue (occasional)

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

AC power indicator test high voltage

Verify AC power indicator LED lights when pump plugged into AC source and extinguishes when unplugged

Ranked causes

1. AC power indicator LED malfunction or power supply issue (rare)

First check

Verify AC indicator LED lights when connected to AC power

Test point: AC indicator LED on pump
Expected: AC indicator LED is lit

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

Adjust LCD contrast voltage

LCD display contrast is too light or too dark. Factory default is 00BF but may vary by display manufacturer.

Ranked causes

1. LCD contrast voltage requires adjustment (occasional)

First check

Set contrast voltage

Test point: CONTRAST VOLTAGE
Expected: 00BF (or adjusted value per lighting conditions)

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

Annual maintenance: General inspection caution

Visual and functional inspection of pump housing, mechanical components, power cord, labels, and rubber feet for damage, wear, or loose parts.

Ranked causes

1. Physical damage or normal wear (unknown)

First check

Inspect for obvious physical damage

Test point: pump housing, keypads, flippers, clamps
Expected: no cracked housings, torn keypads, or visible damage

8 more checks with pass and fail actions, 10 corrective actions, and part numbers are in ServiceForge. Connect ServiceForge to your AI

Annual maintenance: Power-up test caution

Functional verification of alarm sounds, LED indicators, battery capacity, self-tests, display legibility, and AC/battery switching upon power-on.

Ranked causes

1. Power supply or display malfunction (unknown)

First check

Plug AC power cord and verify AC/battery indicators light

Test point: AC power receptacle, AC indicator LED, battery charge indicator LED
Expected: both AC and battery indicators are lit

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

Battery calibration required

CPI (Capacity Inaccurate) counter exceeds threshold; pump requires recalibration cycle

Ranked causes

1. Shallow discharge cycles accumulated since last calibration (common)

First check

Monitor CPI value in Biomed > Diagnostics > Monitor Battery Status

Test point: Biomed > Diagnostics > Monitor Battery Status
Expected: CPI <= 80 Hex

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

Battery depleted, pump loses calibration patient safety

Battery Depleted alarm occurs; pump loses all calibration information; approximately 5 minutes of operation remain before full disconnect; audible alarm continues from super-capacitor

Ranked causes

1. Battery capacity below 1600 mA-hours (common)

First check

Recharge pump and monitor battery status

Test point: Biomed > Diagnostics > Monitor Battery Status
Expected: After several minutes of recharging, gauge shows learned capacity; LMD value greater than 1600 mA-hours

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

Calibration: AC input assembly replacement high voltage

Steps to remove and install AC input module assembly with verification of AC power indicator function.

Ranked causes

1. AC Input Module Assembly failure or replacement required (unknown)

First check

Verify AC power indicator lights after replacement

Test point: AC power indicator light
Expected: AC power indicator lights on

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

Calibration: AC line leakage (Standard Medfusion 3000) high voltage

Verify enclosure leakage current and optional CF-rated patient contact leakage are within specification

Ranked causes

1. Leakage current exceeds Class II BF limit of 100 micro-amps (rare)

First check

Connect pump to Safety Analyzer

Test point: AC power inlet
Expected: Analyzer configured in Line Leakage mode

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

Calibration: AC line leakage (standard) high voltage

Verify electrical leakage current within acceptable limits for patient safety (BF or CF rating compliance)

Ranked causes

1. AC leakage current out of specification (unknown)

First check

Measure enclosure leakage current (BF rating)

Test point: Plunger driver tube or center post of DC input jack
Expected: Less than 100 micro-amps in normal setting, <100
Tools: Safety Analyzer in Line Leakage mode

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

Calibration: AC power supply replacement high voltage

Steps to remove and install AC power supply PCB with verification of AC power indicator light function.

Ranked causes

1. AC Power Supply PCB failure or replacement required (unknown)

First check

Verify AC power indicator lights after replacement

Test point: AC power indicator light
Expected: AC power indicator lights on

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

Calibration: Adjust contrast (voltage)

Adjust LCD display contrast voltage setting using up/down keys. Factory default is 00BF; adjust higher or lower based on lighting conditions.

Ranked causes

1. Display contrast requires adjustment for lighting conditions (occasional)

First check

Adjust contrast voltage setting

Test point: LCD display
Expected: Visual clarity appropriate for ambient lighting conditions

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

Calibration: All sensors

Recalibration required after replacing case top to ensure proper sensor operation and pump accuracy.

Ranked causes

1. Case top replacement affects sensor alignment (common)

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

Calibration: Battery charge and performance status

Monitor battery NiMH/NiCad cell capacity, charge level gauge accuracy, and shallow discharge cycle count to maintain performance

Ranked causes

1. Battery gauge accuracy degraded or capacity low (occasional)

First check

Monitor battery LMD (Last Measured Discharge) capacity

Test point: Biomed > Diagnostics > Monitor Battery Status menu
Expected: LMD ≥ 1600 mA-hours, ≥1600
Tools: Pump Biomed diagnostics menu

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

Calibration: Battery full discharge-recharge cycle

Execute complete battery discharge to depleted alarm, then recharge to recalibrate gauge and relearn true battery capacity

Ranked causes

1. Battery calibration required (CPI threshold exceeded or new battery installed) (occasional)

First check

Verify pump connected to AC and charge level reaches 99-100%

Test point: Biomed > Diagnostics > Monitor Battery Status gauge
Expected: Charge Level 99-100%

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

Calibration: Battery monitor accuracy

Battery gauge recalibration to ensure correct capacity reading and low battery alarm accuracy

Ranked causes

1. CPI (Capacity Inaccurate) exceeds threshold after shallow discharge cycles (common)

First check

Connect pump to AC power

Test point: AC power inlet
Expected: Pump powered from AC mains

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

Calibration: Bottom housing replacement

Steps to remove and install bottom housing assembly with serial number label configuration based on installed Interconnect PCB model.

Ranked causes

1. Bottom housing damage or replacement required (unknown)

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

Calibration: Flow delivery accuracy

Verify syringe plunger travel distance matches expected range for infusion rate accuracy at 300 ml/hr with 50 ml volume limit

Ranked causes

1. Flow calibration out of specification (unknown)

First check

Measure syringe plunger travel distance for flow accuracy

Test point: Syringe flange to plunger distance
Expected: B-D 60cc: 3.473" to 3.615"; B Braun Perfusor/Omnifix 50cc: 3.146" to 3.275"; Fresenius 50cc: 2.904" to 3.023"; Monoject 60cc: 3.473" to 3.615"; Terumo 60cc: 2.901" to 3.020" inches, ±0.071" (B-D), ±0.065" (B Braun), ±0.060" (Fresenius), ±0.07
Tools: Calipers, 50/60 cc Luer-lock syringe, Safety Analyzer

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

Calibration: Force sensor verification caution

Verify force sensor readings are within acceptable range using calibration kit with force gauge; check at no load, 5 pounds, and 15 pounds applied force.

Ranked causes

1. Force sensor calibration drift or error (unknown)

First check

Verify force reading with no syringe loaded

Test point: screen force display
Expected: between –0.7 and +0.7 pounds, ±0.7 pounds

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

Calibration: Main PCB replacement

Steps to remove and install Main PCB with reconnection of all cable and sensor connections. Requires serial number and Configuration version for P.A.S.S. pumps.

Ranked causes

1. Main PCB failure or replacement required (unknown)

First check

Reconnect all cable connections on Main PCB

Test point: J10, J3, J6, J12, J2, J4, J11 connectors
Expected: All cables connected and secured per procedure

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

Calibration: Plunger position sensor

Plunger position sensor drift or misalignment. Requires calibration of position sensor reference points.

Ranked causes

1. Plunger position sensor requires recalibration (common)

First check

Verify plunger position sensor minimum and maximum values

Test point: PLUNGER POS DATA
Expected: 151 to 901 COUNTS, to 901 COUNTS

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

Calibration: Plunger position sensor verification

Annual maintenance check to verify plunger position sensor readings are within specification using small and large calibration slugs

Ranked causes

1. Plunger position sensor out of calibration (unknown)

First check

Verify small calibration slug position reading with ~0.1 lbs force

Test point: Position reading on screen
Expected: between 0.680" and 0.720", inclusive inches, ±0.02

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

Calibration: Position and size

Sensor recalibration needed after case handle replacement to maintain accurate syringe position and size detection.

Ranked causes

1. Case handle replacement affects position/size sensor calibration (common)

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

Calibration: Pressure sensor

Pressure sensor calibration or offset adjustment after repair or drift detection.

Ranked causes

1. Pressure sensor requires recalibration (common)

First check

Verify pressure sensor values

Test point: PRESSURE DATA
Expected: 0 COUNTS

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

Calibration: Save changes and exit

Save new calibration values and exit Biomed Calibration menu. Option to exit without saving if calibration error occurred.

Ranked causes

1. Need to save calibration changes after adjustment (common)

First check

Confirm calibration changes ready to save

Test point: Calibration menu
Expected: All required calibrations completed

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

Calibration: Size and position sensor combined

Combined recalibration of both syringe size and plunger position sensors when both require adjustment.

Ranked causes

1. Size and position sensors require recalibration (common)

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

Calibration: Small syringe size and position sensor check caution

Verify position sensor reading is within acceptable range when plunger driver is loaded on calibration slug with light force applied.

Ranked causes

1. Position sensor calibration drift or error (unknown)

First check

Verify position sensor reading with calibration slug loaded

Test point: screen position display
Expected: between 0.660" and 0.740", inclusive inches, ±0.04 inches
Tools: Small calibration slug, calipers with 0.001" resolution

Calibration: Syringe size sensor verification

Annual maintenance check to verify syringe size sensor readings are within specification using small and large calibration slugs

Ranked causes

1. Syringe size sensor out of calibration (unknown)

First check

Verify small calibration slug size reading

Test point: Size reading on screen
Expected: between 0.256" and 0.272", inclusive inches, ±0.008

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

Calibration: Tubing holder size

Recalibration of size sensor needed after tubing holder replacement to maintain accurate syringe size detection.

Ranked causes

1. Tubing holder replacement affects size sensor calibration (common)

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

Calibration: View calibration data

Display pump calibration data on screen for factory service or troubleshooting. Shows Force, Plunger Position, Pressure, and Syringe Size count values.

Ranked causes

1. Need to verify calibration data for troubleshooting (occasional)

First check

Review Force calibration data

Test point: Calibration data screen
Expected: Force counts display (reference: 42-475 COUNTS range)

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

Clutch or clutch cam replacement caution

Clutch halves or cam gear requires removal and reinstallation in carriage assembly during service.

Ranked causes

1. Worn or damaged clutch or cam requiring replacement (unknown)

First check

Remove e-ring from cam in carriage plate

Test point: Cam in carriage plate
Expected: E-ring removed
Tools: Needle nose pliers or hemostats

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

Flow delivery rate outside acceptable tolerance patient safety

Measured syringe plunger travel does not fall within specified range for selected syringe type

Ranked causes

1. Pump delivery mechanism calibration error (unknown)

First check

Configure pump for flow delivery accuracy test

Test point: Begin Infusion screen
Expected: Rate of 300 ml/hr selected with volume limit of 50 ml

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

Installation/Quick check-out: Force sensor verification with no load caution

Verify force reading is within nominal range when pump is powered on with no syringe loaded.

Ranked causes

1. Force sensor zero offset error (unknown)

First check

Verify force reading with no syringe loaded

Test point: screen force display
Expected: between –0.7 and +0.7 pounds, ±0.7 pounds

Keyclick beep is faint or absent

Button click sounds from keypad are faint or not heard

Ranked causes

1. Keyclick audio configured to lowest level or disabled (common)

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

Keyclick beeps are faint or absent

Key press feedback sounds (beeps) are inaudible or very quiet; audio feedback disabled or configured to low level

Ranked causes

1. Keyclick volume configured to lowest level or disabled (common)

First check

Check keyclick loudness setting (V3 pumps)

Test point: Custom Program audio settings menu
Expected: Keyclick loudness set to medium or high level; not at minimum

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

Keypad button does not respond

Pressing keypad button does not register or control pump function

Ranked causes

1. Keypad mechanical or connection failure (common)

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

Keypad replacement

Keypad requires removal from top housing and disconnection of interconnect and backlight cables; removal of ground tab.

Ranked causes

1. Damaged keypad or membrane switch requiring replacement (unknown)

First check

Disconnect Interconnect ribbon cable from Main PCB

Test point: J9 connector on Main PCB
Expected: Interconnect cable unplugged

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

LCD and backlight assembly replacement

Old-style or new-style LCD display with backlight requires removal and reinstallation; backlight orientation critical for function.

Ranked causes

1. Damaged LCD display or backlight assembly requiring replacement (unknown)

First check

Disconnect display cable from Main PCB

Test point: J12 connector on Main PCB
Expected: Display cable disconnected

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

Libraries not available in configuration

Drug infusion libraries do not appear in pump configuration menu

Ranked causes

1. Libraries disabled or cleared in configuration (common)

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

Low battery capacity detected

LMD (Last Measured Discharge) below threshold; battery replacement needed

Ranked causes

1. Battery capacity degraded below 1600 mA-hours (common)

First check

Monitor LMD value in Biomed > Diagnostics > Monitor Battery Status

Test point: Biomed > Diagnostics > Monitor Battery Status
Expected: LMD >= 1600 mA-hours

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

Maximum infusion rate not available

Maximum flow rate setting option does not appear or is limited

Ranked causes

1. Maximum rate configured too low (common)

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

More symptoms

No drug libraries, profiles, or categories available
Occlusion alarm does not occur during test
Occlusion alarms occur frequently
Plunger cable replacement
Power-up test
Pump activation before manual procedures
Pump cleaning and disinfection
Pump option or feature is not available
Pump requires annual maintenance
Syringe manufacturer not available
Syringe manufacturer not available in pump Configuration
System Fault alarm activated
Watchdog Fail-Safe alarm triggered
Watchdog or system failure alarm

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

Error codes

Code	Meaning	Trigger	Severity
`A2D Reference Voltage BGND Test`	Analog-to-digital converter reference voltage invalid during background self-test	Background self-test measured invalid range on ADC reference voltage	critical
`A2D Reference Voltage BGND Test`	Invalid range on ADC reference voltage	Background self-test execution	error
`ACU Power Strobe Failure`	Auxiliary Control Unit processor not maintaining power strobe signal	Self-test found ACU processor not maintaining power strobe	critical
`ACU Watchdog Failure`	Auxiliary Control Unit watchdog alarm signal active	Self-test found ACU watchdog alarm signal active, processor failed to pet watchdog	critical
`Analog Supply BGND Test`	Analog power supply voltage outside valid range during background self-test	Background self-test measured invalid range on analog supply voltage	critical
`Aux Controller Unit Post`	ACU processor failed motor current shutdown during watchdog alarm test	Power-up self-test found ACU processor failed to shut down motor current during watchdog test	critical
`Background CRC Test Timeout`	Software timing failure in cyclic redundancy check during background test	Software timing failure during background CRC test	critical
`Background Self Test Timeout`	Software timing failure in background self-test	Background self-test execution	error
`Background Self Test Timeout`	Software timing failure during background self-test operation	Software timing failure during background self-test	critical
`Backup Audible Alarm Post`	Backup audible alarm not working at correct power or frequency	Power-up self-test	warning
`Backup Critical Data Corrupted`	Backup configuration data lost, primary data used to restore	Backup critical data in non-volatile EEPROM is lost	info
`Battery Communication Timeout`	Battery gauge not communicating with pump	Battery current detected but gauge not responding	warning
`Battery Depleted alarm`	Battery is completely discharged and pump cannot operate	Battery voltage drops to minimum usable level during unplugged operation	critical
`Battery Not Charging`	Battery is not charging despite external power present	AC or DC external power detected but battery not charging	warning
`Battery Not Working`	Battery very low while pump connected to external power	Very low battery signal detected during AC/DC power connection	warning
`Calculated Rate Out of Range`	Pump calculated a rate that is not valid based on physical limits	Invalid combination of entered infusion parameters or syringe parameters	unknown
`Calibration Required`	Sensor calibration data test failed	Power-up or calibration Save operation showed calibration data failure	error
`Calibration Required`	Calibration values in non-volatile memory invalid or missing	Calibration values stored in EEPROM are invalid, typically after new main board installation	critical
`Check Clutch / Plunger Lever`	Plunger driver motion is not correct	Position potentiometer senses plunger driver not moving correctly	unknown
`Check Syringe Barrel Clamp`	Syringe barrel clamp sensor has difficulty verifying clamp position	Certain syringe models/sizes; barrel clamp lifted during power-up	unknown
`Check Syringe Flange Sensor`	Syringe not loaded correctly as sensed by flange sensor	Syringe flange sensor detects improper loading or sensor failure	unknown
`Check Syringe Plunger Sensor`	Syringe not loaded correctly as sensed by plunger sensor	Plunger sensor detects incorrect loading or Syringe Plunger Driver moved during startup	unknown
`Check Syringe Plunger Sensor`	Pump detected plunger loaded when no syringe present	At power-up when barrel clamp sensor indicates no syringe	critical
`Clear TVD to Start Infusion`	Total volume delivered exceeds programmed limit and must be cleared	TVD or TDD exceeds volume limit setting	info
`Completing System Initialization`	User pressed start before background self-tests completed	User presses start button before pump self-testing completes at power-up	info
`Completing System Initialization`	Self-tests still running when user attempted to start infusion	User presses Enter before background self-tests complete after power-up	info
`Control Key Switch BGND Test`	Keypad key detected stuck on during continuous background self-test	Continuous background self-test found key stuck on	critical
`Control Key Switch Post`	Keypad key detected stuck on during power-on self-test	Power-on self-test found key stuck on keypad	critical
`Control Key Switch Post`	Single keypad key pressed for extended duration	Key pressed for longer than 7 seconds; or locked keypad key pressed longer than 1 minute	error
`Critical Data Block BGND Test`	Critical delivery settings RAM corrupted as detected by background CRC test	Background self-test showed critical data block RAM corrupted via CRC test failure	critical
`Critical Data Block Post`	Configuration data backup and primary CRC mismatch	Backup and primary configuration data fail CRC agreement	critical
`Critical Data Block Post`	Primary and backup configuration data in EEPROM do not agree	Power-up self-test found primary and backup configuration/library data both good but not matching	critical
`Critical Data Failure`	Settings reverse calculation verification failed or critical flags invalid	After programming settings, pump verification calculation failed or critical software flags invalid	critical
`Critical Data Failure`	Settings validation or critical flag failure	After programming settings	error
`D2A Offset Voltage BGND Test`	Force sensor offset signal failure in DAC	Background self-test found failure in force sensor offset signal	critical
`Data Does Not Match Previous Entry`	User confirmation value does not match original entry	When confirmation of user-entered data is required but values don't match	info
`Default Configuration Restored`	All configuration settings returned to factory defaults	Both primary and backup configuration lost in EEPROM	warning
`Depleted Battery`	Battery fully discharged below low voltage threshold	Battery voltage measured by gauge falls below low voltage threshold	warning
`Depleted Battery (System Failure)`	Battery voltage critically low, delivery stopped	Battery voltage measured by pump gauge is too low	critical
`Depleted Battery (System Failure)`	Battery fully discharged below low voltage threshold	Battery voltage drops below fully depleted threshold	critical
`Display Controller Post`	LCD display test failure detected during power-up self-test	Power-up self-test failure in LCD display controller	critical
`External COM Task Timeout`	External device sending commands too quickly or too many invalid commands	External computer/device sending excessive/invalid commands to pump	error
`Flash Memory BGND Test`	Program memory CRC failure detected during background self-test	CRC failure found in program memory during background self-tests	critical
`Flash Memory Post`	Program memory CRC failure detected during power-up self-test	CRC failure found in program memory during power-up self-tests	critical
`Force Sensor BGND Test`	Force sensor signal out-of-range or not responding to bridge test during background test	Background self-test found force sensor signal out-of-range or no response to bridge test signal	critical
`Force Sensor Bgnd Test`	Force sensor self-test failed	Self-test performed on force sensor and failed; plunger driver moved or received hard bump during startup	unknown
`Force Sensor Bridge Test`	Force sensor bridge shows no voltage change during test	Background self-test execution	error
`Force Sensor Bridge Test`	Force sensor bridge strain gauge no voltage change when test signal asserted	Software sensed no voltage change when sensor test signal was asserted	critical
`Force Sensor Test`	Force sensor output did not change when DAC offset voltage changed	Power-up self-test found force sensor output not responding to DAC offset change	critical
`History Data Corrupted`	Infusion history log is corrupted	Software unable to retrieve history data in 6 consecutive attempts	info
`Improper Shutdown`	Previous power-down did not occur through normal power key press	Pump powered on; last shutdown was not via power button (e.g., power loss, crash)	warning
`Improper Shutdown`	Pump powered off without proper shutdown procedure	Power-down did not occur through pressing power button	info
`Infusion Complete`	Programmed infusion volume delivered successfully	Infusion reached the set volume limit	warning
`Infusion Complete`	Infusion has reached programmed volume limit	Delivered volume reaches set volume limit	info
`Input Out of Range - Greater Than Max Value`	User-entered value exceeds maximum allowable limit	User attempts to enter number greater than maximum value allowed	info
`Input Out of Range - Less Than Min Value`	User-entered value below minimum allowable limit	User attempts to enter number less than minimum value allowed	info
`Input Task Timeout`	Software timing failure in input processing task	Software timing failure in input task	critical
`Internal A2D Failure`	10-bit analog-to-digital converter internal failure detected	Software self-test identified failure in 10-bit ADC	critical
`Invalid Infusion Parameter Combination`	Parameter combination does not allow valid flow rate calculation	User entered invalid parameter combination or wrong syringe size for Drug Program	warning
`Invalid Interrupt`	Software attempted to execute invalid interrupt vector	Software/hardware detected invalid interrupt execution	critical
`Invalid Interrupt & System Advisory: Improper Shutdown`	Critical interrupt error coinciding with improper shutdown	Invalid interrupt detected along with improper shutdown event	critical
`Invalid Interrupt & System Advisory: Improper Shutdown`	Improper shutdown alarm combined with invalid interrupt condition	Simultaneous improper shutdown and system interrupt detected	error
`Invalid Library Entry`	Library entry was not defined correctly when created	Pump attempts to use improperly configured library entry	info
`Invalid Library Entry`	Drug Program selected is invalid; pump cannot deliver it	Problem detected with selected Drug Program	error
`Invalid Rate for Syringe Size (V3 pumps only)`	Programmed infusion rate incompatible with selected syringe type	When using E-plates library entries, changing syringe size causes mismatch	warning
`Invalid Syringe Size`	Syringe size not recognized or improperly handled during delivery	Unrecognized syringe for model; barrel clamp lifted during delivery	unknown
`Invalid Syringe Size`	Syringe size sensor reading does not match selected syringe manufacturer	Barrel clamp potentiometer sensor mismatch or barrel clamp lifted during delivery	critical
`KVO in Progress`	Delivery switched to KVO (keep vein open) rate after volume limit reached	Infusion reached set volume limit and automatically changed to KVO rate	warning
`Learn Error - Remote Not in Teach Mode`	Configuration cloning failed due to Teacher pump not ready or not communicating	Learning pump initiates learn process but cannot detect Teacher pump in active Teach Mode via infrared	error
`LED Task Timeout`	Software timing failure in LED control task	Software timing failure in LED task	critical
`Limits Adjusted - Cannot Delivery All Doses`	Soft limits adjusted to keep rate within allowable limits	PharmGuard soft limits and syringe parameters would result in rate outside allowable limits	warning
`Logic Supply Voltage BGND Test`	Logic power supply voltage outside valid range during background self-test	Background self-test measured invalid range on logic supply voltage	critical
`Low Battery (1% drop incremental)`	Battery capacity continues to drop below 10%	Each 1% drop in battery capacity after initial signal when power cord unplugged	warning
`Low Battery alarm`	Battery charge level is low	Battery voltage drops below low threshold during unplugged operation	warning
`Low Battery (each 1% drop in capacity following initial sign`	Battery capacity drops below 10%; percentage alerts continue if unplugged	Battery capacity measured at each percent below 10%; continues while on battery power	info
`Low Battery (initial signal)`	Battery capacity fallen below 10% threshold	Initial low battery detection when capacity drops below 10%	warning
`Maintenance Is Recommended`	Periodic maintenance reminder for annual maintenance testing	Maintenance interval has elapsed since last scheduled preventive maintenance	info
`MCU Power Strobe Failure`	Main processor power strobe output signal test failure	Self-test of power strobe output port signal from main processor failed	critical
`Monitor Task Timeout`	Software timing failure in monitoring task	Software timing failure in monitor task	critical
`Motor Failed to Stop Error`	Stepper motor continues rotating after stop command issued	Software sensed motor rotation after stop pump motor command executed	critical
`Motor Not Running`	Motor is not running	Erroneous sensor signal or mechanical/electrical failure	unknown
`Motor Not Running Error`	Stepper motor does not rotate when rotation expected	Motor sensor did not detect stepper motor rotation	critical
`Motor Not Running Error`	Motor sensor did not detect stepper motor rotation	Motor sensor failed to detect stepper motor rotation	critical
`Motor Rate Error`	Stepper motor operating at incorrect speed	Stepper motor moving at wrong speed during operation	critical
`Motor Rate Error`	Motor is not running at programmed rate	Motor speed not matching programmed rate	unknown
`Motor Rate Error`	Motor rotation rate not matching expected value	Motor sensor did not measure correct stepper motor rotation rate	critical
`Motor Supply Voltage BGND Test`	Motor power supply voltage outside valid range during background self-test	Background self-test measured invalid range on motor supply voltage	critical
`Motor Volume Limit Error`	Motor has exceeded expected step count for programmed volume delivery	Motor runs more steps than required to deliver set volume limit	critical
`Neglected Pump (User Call-back)`	Pump left in user input screen and inactive for extended time	Pump remains in user input screen (e.g., set rate, titrate rate) for more than 30 seconds	warning
`Non Critical Data Corrupted`	Non-critical settings data in EEPROM lost or corrupted	Non-critical settings stored in EEPROM is lost	info
`Occlusion alarm`	Line occlusion detected during infusion	Pressure rise in infusion tubing indicates blocked line	error
`Occlusion - Check Infusion Line`	Infusion line is occluded	Force sensor in plunger driver senses occlusion when force exceeds set limit	unknown
`Occlusion - Check Infusion Line`	High backpressure detected in infusion line due to blockage	Force sensor in plunger driver sensed occlusion when force exceeds set limit	critical
`Outside Range Limit - Silence Alarm to Continue`	User-entered infusion rate outside established library safety limits	User enters rate which is outside of library limits	warning
`Periodic Callback - Silence Alarm to Continue`	User-programmed periodic callback alarm activated	Periodic alarm set by user reaches scheduled time	warning
`PharmGuard Data Corrupted`	PharmGuard Safety Data in EEPROM lost or unreadable	PharmGuard Safety Data stored in EEPROM is lost or corrupted	info
`PharmGuard Data Transfer is Recommended`	PharmGuard Safety Data storage nearly full	PharmGuard Safety Data approaches storage capacity	warning
`Plunger Sensor Failure`	Plunger position sensor voltage out of range	Software sensed plunger sensor voltage out of range	critical
`Positive Supply BGND Test`	Power supply malfunction detected	Background self-test execution	error
`Positive Supply BGND Test`	Positive power supply voltage out of valid range	Background self-test measured invalid positive supply voltage	critical
`Pressure Increasing - Check Infusion Line`	Backpressure in infusion line is gradually increasing	Force sensor detects increasing pressure during infusion	warning
`Primary Audible Alarm BGND Test`	No current detected in primary speaker	Background self-test execution	error
`Primary Audible Alarm Post`	No current detected in primary speaker during power-up test	Power-up self-test	error
`Primary Critical Data Corrupted`	Primary configuration data lost, backup data used to restore	Primary critical configuration data in EEPROM is lost	info
`Profile Does Not Match Last Settings Profile`	Current pump profile does not match profile used for recalled settings	Recall Last Settings feature invoked for different profile than settings were programmed under	info
`Profile Does Not Match Last Settings Profile`	Recall Last Settings incompatible with current delivery profile	User attempts Recall Last Settings but currently selected profile differs from saved profile	info
`Pump is Locked`	Pump settings locked during active delivery	Pump in delivery mode with settings locked	info
`Pump Motor Drive Off Post`	No current detected in stepper motor at power-up	Power-up self-test sensed no current in stepper motor	critical
`Pump Motor Drive Phase A Post`	Stepper motor winding A open at power-up	Power-up self-test found stepper motor phase A winding open	critical
`Pump Motor Drive Phase B Post`	Stepper motor winding B open at power-up	Power-up self-test found stepper motor phase B winding open	critical
`RAM BGND Test`	RAM failure on Main PCB	Software test showed failure of RAM on Main PCB	critical
`Rate Below Recommended Min for Syringe Size`	Programmed infusion rate below minimum recommended for syringe type	User programs rate lower than manufacturer recommendation for selected syringe	info
`Restricted Flow - Bolus Cancelled`	Bolus dose delivery cancelled due to flow restrictions	During bolus rate reduction, rate fell below main infusion rate or time extended past 59 minutes maximum	warning
`Restricted Flow - Bolus Cancelled`	Bolus rate reduction resulted in rate below main rate or max time exceeded; bolus cancelled	During bolus dose rate reduction, calculated rate fell below main infusion rate or total time exceeded 59 minutes	warning
`Restricted Flow - Loading Cancelled`	Loading dose rate reduction resulted in rate below main rate or max time exceeded; loading dose cancelled	During loading dose rate reduction, calculated rate fell below main rate or total time exceeded 59 minutes	warning
`Restricted Flow - Loading Cancelled`	Loading dose delivery cancelled due to flow restrictions	During loading dose rate reduction, rate fell below main infusion rate or time extended past 59 minutes	warning
`Restricted Flow - Rate Reduced`	Pump reduced infusion rate to overcome high backpressure during bolus or loading dose	High backpressure detected during bolus or loading dose delivery on Medfusion 3500	warning
`Serial EEPROM Timeout`	Serial EEPROM communication timeout on main board	Software test execution	error
`Set Time and Date`	Real-time clock reset to default	Real-time clock reset when battery depleted or main board supply discharged	warning
`Set Volume Limit Before KVO`	Volume limit must be set before KVO rate can be programmed	User attempts to set KVO rate without first setting volume limit	warning
`SPI BUS Timeout`	SPI bus component failure timeout	Software test execution	error
`Supercap Post`	Super-capacitor insufficient charge at power-up	Power-up self-test sensed insufficient charge in super-capacitor	warning
`Syringe Does Not Match Library Entry`	Loaded syringe size does not match library entry specification	When using E-plates library entries, loaded syringe does not match stored syringe size	info
`Syringe Empty`	Plunger driven to end of syringe barrel, no fluid remains	Plunger driver position potentiometer senses syringe empty position	critical
`Syringe Empty`	Syringe has been completely emptied	Plunger driver position potentiometer reaches empty position for loaded syringe size	error
`Syringe Empty - Manual`	Syringe reached empty position; user can resume to deliver residual fluid until occlusion limit reached	After Syringe Empty alert, user presses resume to extract remaining fluid in syringe barrel	error
`Syringe Empty - Manual`	After reaching empty position, manual continuation option available	After Syringe Empty alarm, user presses Enter to resume	critical
`Syringe Flange Not in Place`	Syringe flange is not properly inserted	Syringe not loaded correctly or flange sensor failure	unknown
`Syringe Flange Not in Place`	Plunger flange not detected in pump when syringe loaded	When syringe is loaded but pump does not detect flange via barrel clamp sensor	critical
`Syringe Flange Sensor Failure`	Syringe flange sensor voltage out of range	Software sensed syringe sensor voltage out of range	critical
`Syringe Near Empty`	Syringe has only a few minutes of fluid remaining	Plunger position indicates low fluid volume	warning
`Syringe Plunger Not in Place`	Pump does not detect plunger in barrel when syringe loaded	When syringe is loaded but pump does not detect plunger via barrel clamp sensor	critical
`Syringe Plunger Not in Place`	Syringe plunger is not properly positioned	Syringe not loaded correctly as sensed by barrel clamp size sensor or plunger sensor failure	unknown
`SYSTEM ADVISORY – BATTERY NOT WORKING`	Battery malfunction or disconnection detected	Battery gauge detects failure or absence of battery power	warning
`System Advisory - Description`	Generic system advisory alert with additional description	Various system-level advisory conditions	info
`System Failure - Description`	Generic system failure alert with additional description	Various critical system failure conditions	critical
`Time Base BGND Test`	System time base does not agree with time of day clock	Background self-test found MCU time base did not match clock tick	error
`Time of Day Clock Post`	System time base does not agree with time of day clock at power-up	Power-up self-test found MCU time base did not match clock tick	error
`Time of Day Clock Timeout`	Time of day clock failed to communicate	Time of day clock failed to communicate during software test	error

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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.