Infusion pumps · Medfusion family

Smiths Medical Medfusion 4000: troubleshooting and error codes

The ServiceForge knowledge base holds 100 documented symptoms for the Smiths Medical Medfusion 4000, with 141 ranked causes, 111 diagnostic checks with test points and expected values, and 99 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 won't turn on

Pump fails to power on even after pressing power button

Ranked causes

1. Battery depleted (common)
2. Loose Main PCB to Interconnect PCB ribbon cable (occasional)
3. AC power connection issue (occasional)
4. Battery connections loose or defective (occasional)
5. Keypad cable loose or disconnected (occasional)

First check

Verify AC power connection

Test point: AC outlet and pump inlet
Expected: Pump plugged into live AC outlet

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

Alarms do not sound

Alarms sound faintly or not at all during operation

Ranked causes

1. Alarm loudness configured to lowest level (common)
2. Speaker grid holes obstructed (occasional)
3. Speaker malfunction (occasional)

First check

Verify alarm loudness setting

Test point: Profile Settings > View Settings > Alarm Loudness
Expected: Setting should not be at lowest level

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

Alarms do not sound or sound faintly

Alarm audio output is absent or at very low volume during alarm conditions

Ranked causes

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

First check

Verify alarm loudness setting

Test point: Profile Settings > View Settings > Alarm Loudness
Expected: Check current loudness level setting

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

Battery does not hold charge

Battery charge capacity low or pump shuts down immediately when unplugged from AC power

Ranked causes

1. Battery ribbon cable disconnected (occasional)
2. Battery not charging adequately (occasional)
3. Battery pack defective (occasional)

First check

Check battery ribbon cable connection

Test point: Battery door interior, Interconnect PCB connector
Expected: Battery ribbon cable firmly seated and fully connected

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

Force sensor not responding to test signal

Force sensor does not change output voltage when test signal applied. Strain gauge may be unplugged or bridge open.

Ranked causes

1. Force sensor bridge unplugged or open connection (common)
2. Syringe loaded during power-up self-test (occasional)
3. Main PCB offset circuit, Plunger PCB, or cable failure (occasional)

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

Motor does not rotate or stalls

Motor sensor detects no rotation of stepper motor. Pump cannot deliver medication.

Ranked causes

1. Motor sensor failure on Main PCB (common)
2. Worm/gear/leadscrew jamming or mechanical wear (occasional)
3. Drive train mechanical wear (occasional)

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

Motor rotates at incorrect speed

Motor sensor measures incorrect rotation rate for stepper motor. Delivery rate inaccurate.

Ranked causes

1. Motor sensor failure on Main PCB (common)
2. Force sensor inoperative causing motor stall on occlusion (occasional)
3. Drive train mechanical wear (occasional)

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

Occlusion detected in infusion line patient safety

Force sensor sensed force exceeding occlusion threshold, indicating potential line blockage or tubing issue

Ranked causes

1. Actual occlusion in infusion line (common)
2. Infusion set tubing too small for rate or fluid viscosity (occasional)
3. Force sensor requires calibration (occasional)

First check

Visually inspect infusion line for occlusion

Expected: No kinks, blockages, or disconnections visible
Tools: Visual inspection

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

Plunger driver not moving correctly patient safety

Position potentiometer detects plunger driver motion anomaly during delivery, may be caused by slack in drive system, lever issues, clutch problems, or hardware failure

Ranked causes

1. Prime function not used before starting delivery (common)
2. Plunger levers moved or clutch not engaged (common)
3. Position potentiometer not calibrated or contaminated (occasional)

First check

Verify plunger lever moves freely and captures syringe plunger

Expected: Lever moves without restriction and grips plunger
Tools: Visual/tactile inspection

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

Backup audible alarm not functioning

Power-up self-testing found backup audible alarm not working at correct power or frequency. Alarm buzzer malfunction.

Ranked causes

1. Alarm buzzer failure on Main PCB (rare)
2. Main PCB ACU controller failure (rare)

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

Battery fully depleted and pump non-functional

Battery voltage dropped below low voltage threshold. Pump stops delivery and watchdog generates alarm. May occur on battery power only.

Ranked causes

1. Battery fully discharged (common)
2. Chronic battery function issue (occasional)

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

Battery not working message

Pump displays battery error message or battery status unavailable

Ranked causes

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

First check

Check battery ribbon cable connection

Test point: Battery door interior, Interconnect PCB connector
Expected: Battery ribbon cable firmly seated and fully connected

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

Battery problem: Battery not working message

System displays battery fault or no battery detected error

Ranked causes

1. Battery ribbon cable disconnected or loose at Interconnect PCB (common)
2. Battery pack failure (occasional)

First check

Inspect battery ribbon cable connection

Test point: Battery door, Interconnect PCB connector
Expected: Battery ribbon cable firmly seated and undamaged

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

Calibration: Main PCB replacement software installation

Load and verify correct software version on Main PCB after replacement; restore configuration from Interconnect PCB base board

Ranked causes

1. Main PCB replaced; software and configuration must be restored (common)
2. Configuration not loaded to Main PCB (common)

First check

Verify software version after installation

Test point: Power-on screen
Expected: Software version matches expected pump software version

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

Clock calendar not initialized

System date and time not set; clock defaults to incorrect date/time on startup or during operation

Ranked causes

1. Clock not initialized at startup (occasional)
2. Clock not initialized during operation (occasional)

First check

Verify system date and time

Test point: Biomed > Utilities > View time and date
Expected: Correct date and time displayed

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

External device communication timeout

External computer or device connected to pump is sending too many commands rapidly or many invalid commands. Software cannot process requests within timeout window.

Ranked causes

1. External device command rate too high (common)
2. External device sending invalid commands (common)

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

Force sensor self-test failed patient safety

Self-test performed on force sensor failed, indicating sensor malfunction or plunger driver movement during startup

Ranked causes

1. Force sensor malfunction (common)
2. Plunger driver moved during pump startup (occasional)

First check

Monitor force sensor operation using diagnostics

Test point: Biomed > Diagnostics > Monitor Analog Sensors
Expected: Force sensor responds to test signals
Tools: Biomed menu

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

LCD display not responding or image corrupted

Display self-test failed. Display shows no image or incorrect display output.

Ranked causes

1. Display cable disconnected or loose (common)
2. LCD display hardware failure (occasional)

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

LCD has poor contrast

Liquid crystal display is difficult to read due to low or high contrast level

Ranked causes

1. LCD contrast requires adjustment (common)
2. LCD negative supply voltage out of range (rare)

First check

Run LCD contrast adjustment

Test point: Biomed > Calibration > Adjust Contrast
Expected: Display contrast optimized and visible

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

Liquid Crystal Display has poor contrast

LCD display has low contrast or is difficult to read

Ranked causes

1. LCD contrast setting too low (common)
2. LCD negative supply voltage issue (rare)

First check

Adjust LCD contrast

Test point: Biomed > Calibration > Adjust Contrast
Expected: Contrast adjusted to acceptable level

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

Motor unit assembly and drive train installation caution

Reassembly of motor, worm, worm gear, and drive train after disassembly; includes lubrication and torque specifications.

Ranked causes

1. Motor unit disassembly requires reassembly with correct lubrication and torque (common)
2. Drive train assembly requires careful handling during installation (common)

First check

Worm lubrication before motor installation

Test point: Worm hole
Expected: Filled with Dow 111 Silicone Grease Compound

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

No charge light

Battery charge indicator light does not illuminate

Ranked causes

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

First check

Verify AC power connection

Test point: AC power outlet
Expected: Pump connected and AC indicator light on

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

Occlusion alarms occur frequently

Pump generates occlusion alarms more often than expected during normal operation

Ranked causes

1. Occlusion alarm limit set too low (common)
2. High backpressure in infusion line (common)

First check

Review occlusion alarm limit setting

Test point: Profile Settings or Biomed Configuration
Expected: Occlusion limit appropriate for infusion setup

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

Primary speaker not producing audio alarm caution

Background or power-up self-test detects no current flowing in primary speaker. Alarm buzzer silent.

Ranked causes

1. Speaker disconnected or wire loose (common)
2. Speaker failure (occasional)

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

Program flash memory CRC failure

Flash memory contains program code with failed cyclic redundancy check. Program data corrupted.

Ranked causes

1. Flash memory corruption during software re-programming (occasional)
2. Flash memory chip failure on Main PCB (rare)

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

Pump base not responding or shutdown failed

Pump base experienced failure during power down sequence. Base does not respond to commands.

Ranked causes

1. Power down sequence failure (occasional)
2. EEPROM read failure or disconnected Interconnect PCB (rare)

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

Stepper motor not energized at startup

Power-up self-test senses no current in stepper motor drive circuit. Motor cannot operate.

Ranked causes

1. Pump operating on depleted battery power (common)
2. Motor supply or driver circuit failure (occasional)

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

Stepper motor phase A winding open circuit

Power-up self-test detected stepper motor phase A winding has opened connection. Motor cannot generate torque.

Ranked causes

1. Pump on depleted battery power during startup (common)
2. Motor winding disconnected or wire loose (occasional)

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

Stepper motor phase B winding open circuit

Power-up self-test detected stepper motor phase B winding has opened connection. Motor cannot generate torque.

Ranked causes

1. Pump on depleted battery power during startup (common)
2. Motor winding disconnected or wire loose (occasional)

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

Super-capacitor insufficient charge at startup

Power-up self-test detected super-capacitor voltage too low. Backup power supply insufficient.

Ranked causes

1. Super-capacitor low charge from new Main PCB or dead battery (common)
2. Super-capacitor hardware failure (rare)

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

A/D converter internal failure

Software self-test identified failure in 10-bit analog to digital converter. Sensor readings unreliable.

Ranked causes

1. A/D converter chip failure on Main PCB (rare)

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

A2D reference voltage out of range

Background self-test measured invalid range on analog-to-digital converter reference voltage. Voltage reading out of specification.

Ranked causes

1. A/D converter reference voltage regulator failure (rare)

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

AC power supply not functioning after installation high voltage

AC power indicator does not light after AC power supply replacement

Ranked causes

1. AC power supply not properly installed or defective (unknown)

First check

Verify AC power indicator

Test point: AC power indicator LED
Expected: Indicator light illuminated

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

ACU power strobe not maintained

Self-test found ACU processor not maintaining its power strobe signal during test.

Ranked causes

1. ACU processor power strobe malfunction (rare)

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

ACU watchdog alarm active

Self-test found ACU watchdog alarm signal is active. Processor may have failed to service watchdog within allotted time.

Ranked causes

1. Processor software failure or watchdog timeout (rare)

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

Adjust display contrast voltage

Varies onscreen contrast of LCD display. Factory default is 00BF (may vary by LCD manufacturer). Adjustable higher or lower for comfortable viewing in different lighting conditions.

Ranked causes

1. Display contrast requires adjustment for optimal viewing (occasional)

First check

Access contrast adjustment menu

Test point: Calibration menu
Expected: Adjust Contrast option selected

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

Analog supply voltage invalid

Background self-test measured invalid range on analog supply voltage. Voltage reading out of specification.

Ranked causes

1. Analog supply voltage regulator failure (rare)

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

Background CRC test timeout

Software CRC test failed to complete within allotted time. CRC calculation took too long.

Ranked causes

1. Software transient timing failure (rare)

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

Background self-test timeout

Background self-test took longer than 8 seconds to complete, exceeding timeout threshold. Timing failure occurred.

Ranked causes

1. Software transient failure or timing issue (rare)

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

Backlight connector polarity verification

Verify backlight wires are correctly connected to Main PCB; if reversed, backlight will not illuminate

Ranked causes

1. Backlight leads reversed during installation (occasional)

First check

Verify backlight illuminates after power-up

Test point: LCD backlight
Expected: Backlight illuminated during power-up sequence

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

Battery not communicating or low

Battery gauge not communicating with pump, or very low battery signal detected while connected to AC power. Battery capacity shows as zero.

Ranked causes

1. Loose or disconnected battery connections (common)

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

Battery pack not charging caution

Battery charge indicator does not light when connected to AC power, or battery information absent from Monitor Battery Status screen

Ranked causes

1. Battery not properly connected to Interconnect PCB (common)

First check

Verify battery charge indicator lights

Test point: Battery charge indicator LED
Expected: Indicator lights when AC power connected

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

Battery pack replacement needed caution

Battery requires replacement or is not functioning after installation

Ranked causes

1. Exhausted or damaged battery pack (common)

First check

Verify battery charge indicator lights after connecting pump to AC power

Test point: Battery charge indicator LED
Expected: Indicator lights

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

Battery replacement needed - charge cycle limit reached patient safety

Battery charge cycle counter reaches or exceeds 400 cycles limit during Biomed diagnostics monitoring

Ranked causes

1. Battery at end-of-life charge cycle limit (common)

First check

Access Biomed > Diagnostics > Monitor Battery Status and view Charge Cycles value

Test point: Charge Cycles field
Expected: Value below 400 cycles, maximum

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

Battery replacement needed - low full capacity patient safety

Battery full-capacity indicator falls below minimum threshold during monitoring via Biomed diagnostics

Ranked causes

1. Battery aging or degradation reducing full capacity (common)

First check

Access Biomed > Diagnostics > Monitor Battery Status and view Full-Capacity value

Test point: Full-Capacity field
Expected: Value above 3024 mAh for 22-4050-51 or above 4550 mAh for 22-4051-01, minimum threshold

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

Calibration: AC power supply function verification high voltage

Verification that AC power supply is functioning correctly after replacement or service

Ranked causes

1. AC power supply replaced or serviced (unknown)

First check

Verify AC power indicator lights when plugged in

Test point: AC power indicator LED
Expected: AC power indicator lights

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

Calibration: Battery function verification

Verify new battery is functioning nominally before returning pump to service

Ranked causes

1. New battery installation completed (common)

First check

Connect pump to AC mains and observe battery charge indicator

Test point: Battery charge indicator light
Expected: Indicator lights on

3 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 caution

Installation and verification of replacement bottom housing assembly with all subcomponents

Ranked causes

1. Bottom housing replacement required (unknown)

First check

Verify soft silicone gasket around lower housing lip is continuous and intact

Test point: Lower housing lip perimeter
Expected: Gasket continuous and intact with no damage

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

Calibration: Clutch or clutch cam replacement

After replacing clutch halves or cam, recalibrate and verify pump functionality per guidelines before returning to use.

Ranked causes

1. Clutch halves or cam replaced (common)

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

Calibration: Display contrast adjustment

Procedure to adjust LCD display contrast within Biomed Calibration menu

Ranked causes

1. Display contrast requires adjustment for visibility (unknown)

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

Calibration: Force sensor

Adjustment of force sensor settings. Sensor measures plunger force to ensure proper operation and safety limits.

Ranked causes

1. Initial force sensor calibration or recalibration required (common)

First check

Access force sensor calibration

Test point: Calibration menu
Expected: Cal Force Sensor option selected

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

Calibration: Interconnect PCB reinstallation and verification

Procedure to reinstall Interconnect PCB with antenna, radio module, and clear shield; verify serial number and pump functionality before return to use.

Ranked causes

1. PCB reinstallation and verification procedure (common)

First check

Verify serial number is correct following installation

Test point: pump startup screen and bottom serial number label
Expected: Serial number on startup screen matches label on pump bottom

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

Calibration: Leadscrew replacement

After replacing leadscrew, recalibrate and verify pump functionality per guidelines before returning to use.

Ranked causes

1. Leadscrew replaced (common)

First check

Verify leadscrew Nylock nut torque

Test point: Nylock nut holding leadscrew on right end plate
Expected: 60 in.-oz (0.42 Nm) then loosen 1/4 turn, loosen 1/4 turn after initial torque
Tools: Torque wrench, 1/4 inch wrench

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

Calibration: Main PCB replacement and pump function verification

After replacing Main PCB, pump signals Configuration Required alarm and requires full recalibration, reconfiguration, and function verification before return to service.

Ranked causes

1. Main PCB replaced without configuration (common)

First check

Verify Configuration correctly installed on Main PCB

Test point: Pump display after configuration load
Expected: Configuration matches facility-validated version

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

Calibration: Motor unit replacement

After replacing motor, worm, or worm gear, recalibrate and verify pump functionality per guidelines before returning to use.

Ranked causes

1. Motor, worm, or worm gear replaced (common)

First check

Verify motor mounting screws are torqued correctly

Test point: 2 pan head screws holding motor
Expected: 100 in oz (0.71 Nm), as specified
Tools: Torque screwdriver with Phillips head

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

Calibration: Plunger position

Adjustment of plunger position sensor settings to establish empty position and plunger head travel limits.

Ranked causes

1. Initial plunger position calibration or recalibration required (common)

First check

Access plunger position calibration menu

Test point: Calibration menu
Expected: Cal Plunger Position option selected

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

Calibration: Plunger position sensor

Calibration procedure to check or adjust plunger position sensor values within Biomed Calibration menu

Ranked causes

1. Plunger position sensor requires recalibration after maintenance or drift (unknown)

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

Calibration: Position potentiometer replacement

After replacing position potentiometer, recalibrate and verify pump functionality per guidelines before returning to use.

Ranked causes

1. Position potentiometer replaced (common)

First check

Verify position potentiometer mounting screw torque

Test point: Small flat head screw at right end plate
Expected: 16 in.-oz. (0.11 Nm), as specified
Tools: Torque screwdriver

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

Calibration: Size and position sensor

Calibration procedure to check or adjust syringe size and position sensor values within Biomed Calibration menu

Ranked causes

1. Sensor requires recalibration after maintenance or drift detected (unknown)

First check

Select Calibration menu in Biomed

Test point: Biomed > Calibration
Expected: Calibration submenu options displayed

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

Calibration: Syringe size and position

Concurrent adjustment of syringe size sensor (barrel clamp assembly, measures external diameter) and syringe position sensor (drive train assembly, measures plunger head position for empty position and travel determination).

Ranked causes

1. Initial calibration or recalibration required (common)

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

More symptoms

Calibration: Syringe size sensor
Clutch assembly replacement
Configuration settings lost or invalid
Critical data block RAM corrupted
Firmware version mismatch between pump head and base
Force sensor signal out of range
Force sensor voltage invalid
Indicator lights do not flash
Key click or beep is faint or not present
Keypad key does not work
Keypad stuck or unresponsive
Maximum rate not available
MCU power strobe signal failure
MCU time base synchronization failure
Monitor software task timing failure
Motor current not disabled during watchdog test
Motor exceeded volume delivery limit
Motor rotation sensor failure after stop command
Motor supply voltage out of specification
Network settings corrupted or missing
No Profiles available
OS timer failed during watchdog event
PCB firmware recovery error: Firmware mismatch
Plunger position sensor voltage out of range
Positive supply voltage out of specification
Pump fails to initialize sensors
Pump option or feature not available
Pump powers on with blank screen and buzzer sounds and will not power off after firmware upgrade
Radio PCB removal
Real time clock reset
Serial EEPROM communication timeout
Speaker does not produce power-on tones
Speaker not functioning after installation
SPI bus communication failure
Syringe barrel clamp sensor difficulty
Syringe flange sensor active
Syringe flange sensor voltage out of range
Syringe Manufacturer not available
Syringe plunger sensor active
System RAM memory corrupted

40 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`	ADC reference voltage invalid	Background self-test detects invalid voltage range	critical
`ACU POWER STROBE FAILURE`	ACU processor power strobe not maintained	ACU processor fails to maintain power strobe signal	critical
`ACU WATCHDOG FAILURE`	ACU watchdog alarm active	Processor failed to pet watchdog within allotted time	critical
`ANALOG SUPPLY BGND TEST`	Analog supply voltage invalid	Background self-test detects invalid voltage range	critical
`AUX CONTROLLER UNIT POST`	ACU POST motor current shutdown failure	ACU failed to shut down motor current during watchdog test	critical
`BACKGROUND CRC TEST TIMEOUT`	Background CRC test timeout	Software timing failure	warning
`BACKGROUND SELF TEST TIMEOUT`	Background self-test exceeds time limit	Background test takes more than 8 seconds	warning
`BACKUP AUDIBLE ALARM POST`	Backup alarm power or frequency invalid	POST detects incorrect alarm power/frequency	critical
`Backup Critical Data Corrupted`	Backup configuration data was lost; primary data restored backup	EEPROM redundancy check failed during initialization	warning
`BASE HARDWARE FAILURE`	Base hardware self-test failed	Non-zero hardware test result or interface initialization failure	critical
`BASE NOT RESPONDING`	Base power-down sequence failure	Failure during power down sequence	critical
`BASE UNKNOWN FAILURE`	Read EEPROM failure	EEPROM read operation fails	critical
`BATTERY COMMUNICATION TIMEOUT`	Battery gauge not communicating	Battery current detected but no gauge communication	warning
`BATTERY NOT WORKING`	Battery malfunction	Very low battery signal detected while on AC power	warning
`CALCULATED RATE OUT OF RANGE`	Pump calculated an invalid delivery rate based on entered values	Invalid combination of syringe parameters and desired rate	error
`CALIBRATION REQUIRED`	Sensor calibration failed	Calibration data test fails during power-up or save	warning
`CHECK CLUTCH / PLUNGER LEVER`	Plunger driver position not moving correctly during delivery	Position potentiometer detects abnormal plunger driver motion	error
`CHECK SYRINGE BARREL CLAMP`	Syringe barrel clamp sensor verification failure	Certain syringe models cause barrel clamp sensor difficulty; clamp lifted during power-up	warning
`CHECK SYRINGE FLANGE SENSOR`	Syringe not loaded correctly; flange sensor active	Syringe flange size sensor detects improper loading	error
`Check Syringe Plunger Sensor`	Syringe plunger sensor indicates incorrect loading or movement during startup	Syringe not loaded correctly or plunger moved during pump startup	error
`CHECK SYRINGE PLUNGER SENSOR`	Syringe not loaded correctly; plunger sensor active	Syringe not detected as properly loaded; plunger driver moved during startup	error
`Configuration Required`	No Configuration file present on Main PCB	Pump powered up after Main PCB replacement without existing configuration	warning
`Configuration Required`	Configuration file not present on Main PCB	Main PCB replaced or configuration lost; pump powered up without valid configuration	warning
`CONTROL KEY SWITCH BGND TEST`	Keypad key stuck on	Key found stuck during background self-test	critical
`CONTROL KEY SWITCH POST`	Keypad key pressed too long	Single key pressed >7sec or locked key >1min	critical
`CRITICAL DATA BLOCK BGND TEST`	Critical delivery data corrupted	Background self-test shows data block corruption	critical
`CRITICAL DATA BLOCK POST`	Critical configuration data CRC mismatch	Backup and primary data fail CRC check	critical
`CRITICAL DATA FAILURE`	Incompatible pump settings or software data failure	Incompatible setting ranges or critical flags found invalid	critical
`Critical Data Failure`	Programmed settings failed reverse-calculation validation	After settings programmed, pump verification failed or incompatible ranges detected	error
`D2A OFFSET VOLTAGE BGND TEST`	Force sensor offset signal failure in background self-test	Background self-test detects failure in force sensor offset signal	critical
`Depleted Battery`	Battery fully discharged below low voltage threshold	Battery voltage drops below minimum operating threshold	critical
`DISPLAY CONTROLLER POST`	LCD display failure detected in power-up self-test	Power-up self-test fails in LCD display testing	error
`Display Controller Post`	LCD display self-test failed during power-up	Power-up self-test detects display communication or response failure	error
`External COM Task Timeout`	External device communication timeout	External computer sending too many commands or invalid commands too rapidly	warning
`Firmware Mismatch`	Pump head and base firmware versions do not match	Active MCU and base ICB firmware versions or GUID are incompatible	error
`FIRMWARE MISMATCH`	Firmware version mismatch between pump head and base	Active software in pump head (MCU) and base ICB differ or invalid GUID	error
`FLASH MEMORY BGND TEST`	CRC failure in program memory during background self-test	Background self-tests detect CRC failure in program memory	critical
`FLASH MEMORY POST`	CRC failure in program memory during power-up self-test	Power-up self-tests detect CRC failure in program memory	critical
`FORCE SENSOR BGND TEST`	Force sensor signal out-of-range or bridge test signal not detected	Background self-test finds sensor out-of-range or no change with bridge-test signal	error
`Force Sensor Bgnd Test`	Force sensor self-test failed indicating malfunction or disturbance during startup	Force sensor self-test failure during pump initialization	error
`FORCE SENSOR BGND TEST`	Self-test failed on force sensor	Force sensor self-test failure during pump startup	error
`Force Sensor Bridge Test`	Force sensor bridge circuit test failure	Software sensed no voltage change when sensor test signal asserted	error
`FORCE SENSOR TEST`	Force sensor output unresponsive to DAC offset voltage change	Power-up self-test finds sensor output unchanged when DAC offset changed	error
`Force Sensor Test`	Force sensor power-up test failure	Force sensor output does not change when DAC offset voltage changed	error
`History Data Corrupted`	Infusion history log data lost	Software unable to retrieve history in 6 consecutive attempts	warning
`Improper Shutdown`	Pump did not shut down through proper procedure	Pump powered on after improper power-down sequence	warning
`IMPROPER SHUTDOWN`	Abnormal power-down detected	Last power-down not through proper shutdown procedure	info
`Infusion Complete`	Programmed infusion has been successfully delivered	Infusion reaches programmed volume or time	info
`Internal A2D Failure`	10-bit A/D converter self-test failure	Software self-test identifies A/D converter hardware failure	error
`Invalid Entry`	Problem with Drug Program selected; pump cannot deliver it	Invalid entry attempted on numerical entry screen	warning
`INVALID INFUSION PARAMETER COMBINATION`	Infusion parameters do not allow valid flow rate calculation	User entered invalid parameter combination or wrong syringe size	warning
`INVALID SYRINGE SIZE`	Syringe size not recognized or barrel clamp lifted during delivery	Unrecognized syringe size for selected model or barrel clamp lifted	error
`KB DATA INTEGRITY FAILURE`	Network settings corrupted	Network configuration data validation fails	warning
`LIMITS ADJUSTED - CANNOT DELIVER ALL DOSES`	Software adjusted limits to prevent out-of-range rates	Soft limits and syringe parameters conflict with allowable rate limits	warning
`Limits Adjusted - Cannot Deliver All Doses`	Soft limit values adjusted to keep rate within allowable limits	Drug Program parameters would result in rate exceeding limits	warning
`Maintenance Is Recommended`	Annual Maintenance Testing is due	Scheduled maintenance date reached	info
`MCU POWER STROBE FAILURE`	Power strobe output signal from main processor failed	Self-test detects failure in power strobe output port signal	error
`MONITOR TASK TIMEOUT`	Software timing failure in monitor task	Software timing failure in monitor task execution	error
`Motor Failed to Stop Error`	Motor continues rotating after stop command	Software detects motor rotation after stop motor command executed	error
`MOTOR NOT RUNNING`	Motor fails to operate during programmed infusion	Motor does not start when infusion programmed	error
`Motor Not Running Error`	Motor sensor detects no rotation	Motor sensor does not detect stepper motor rotation	error
`MOTOR NOT RUNNING ERROR`	Motor rotation not detected during operation	Motor sensor does not detect any rotation of stepper motor	error
`Motor Rate Error`	Motor rotation rate out of specification	Motor sensor measures incorrect rotation rate for stepper motor	error
`MOTOR RATE ERROR`	Motor running speed does not match programmed rate	Motor speed differs from programmed delivery rate	error
`Motor Supply Voltage BGND Test`	Motor supply voltage out of specification (should be 17V)	Background self-test measures invalid range on motor supply voltage	error
`MOTOR VOLUME LIMIT ERROR`	Motor exceeded step count for volume limit	Motor executes more steps than calculated for set volume limit	error
`NETWORK CONFIGURATION RESET`	Network configuration reset executed	Network reset command executed in Biomed menu	info
`NON CRITICAL DATA CORRUPTED`	Non-critical settings corrupted	Data corruption in non-volatile EEPROM	info
`Non Critical Data Corrupted`	Other settings stored in EEPROM were lost	EEPROM data corruption detected	info
`OCCLUSION - CHECK INFUSION LINE`	Infusion line occlusion detected; plunger force exceeds limit	Force sensor detects excessive pressure from occluded line	error
`OSTMR TASK TIMEOUT`	OS Timer failed to respond during Watchdog event	OS Timer does not respond within specified time during Watchdog tickle	critical
`PharmGuard Data Corrupted`	PharmGuard Safety Data buffer CRC error	CRC check failed when reading PharmGuard data	info
`Plunger Sensor Failure`	Plunger position sensor voltage out of range	Plunger position potentiometer reads voltage outside valid range	error
`POSITIVE SUPPLY BGND TEST`	Main PCB power supply malfunction detected	Power supply outputs incorrect voltage (should be 9.472V ±5%)	error
`Positive Supply BGND Test`	Positive supply voltage out of specification (should be 9.472V ±5%)	Power supply voltage measured outside valid range during background test	error
`Primary Audible Alarm BGND Test`	Primary speaker background self-test failure	Background self-test detects no current in primary speaker	unknown
`Primary Audible Alarm Post`	Primary speaker power-up self-test failure	Power-up self-test detects no current in primary speaker	unknown
`Primary Critical Data Corrupted`	Primary configuration data corrupted; backup restored	CRC mismatch between computed and saved values during startup	warning
`PUMP MOTOR DRIVE OFF POST`	No current in stepper motor during power-up	Power-up self-test detects no current in stepper motor	error
`Pump Motor Drive Off Post`	Motor not energized during power-up self-test	Power-up self-test detects no current in stepper motor	error
`PUMP MOTOR DRIVE PHASE A POST`	Stepper motor phase A winding open during power-up	Power-up self-test finds stepper motor winding open	error
`PUMP MOTOR DRIVE PHASE B POST`	Stepper motor phase B winding open during power-up	Power-up self-test finds stepper motor winding open	error
`RAM BGND Test`	RAM cyclic redundancy test failure	Software test shows RAM failure during background self-test	error
`RAM BGND TEST`	RAM failure on Main PCB during background test	Software test shows failure of RAM on Main PCB	critical
`SERIAL EEPROM TIMEOUT`	Serial EEPROM failure on Main PCB	Software test shows failure of serial EEPROM on Main PCB	critical
`SET TIME AND DATE`	Real time clock reset	Clock reset when battery depleted	info
`SPI BUS TIMEOUT`	SPI bus component failure	Software test shows failure of component on SPI bus	critical
`SUPERCAP POST`	Power-up self-test detected insufficient charge in super-capacitor	System power-up self-test	error
`SYRINGE FLANGE NOT IN PLACE`	Syringe flange not properly inserted; flange clip detection failure	Barrel clamp size sensor detects flange not inserted or sensor failure	error
`SYRINGE FLANGE SENSOR FAILURE`	Software detected syringe sensor voltage out of range	Syringe sensor electrical test during operation	error
`SYRINGE PLUNGER NOT IN PLACE`	Syringe plunger not properly seated; plunger detection failure	Barrel clamp size sensor detects plunger not in holder or sensor failure	error
`System Advisory`	System advisory alarm with specific condition description	System advisory condition detected	info
`System Failure`	System failure with specific condition description	System failure condition detected	critical
`System Fault`	System fault condition detected; fluid delivery stops immediately	One of system fault conditions occur	critical
`Task Stack Usage`	Task stack usage exceeds 90 percent	Software monitoring detected stack usage above threshold	warning
`TIME BASE BGND TEST`	Background self-test found system time base does not agree with time-of-day clock	Background diagnostic self-test	warning
`TIME OF DAY CLOCK POST`	Power-up self-test found system time base does not agree with time-of-day clock	Power-up self-test	warning
`TIME OF DAY CLOCK TIMEOUT`	Time of day clock failed to communicate	System attempts to communicate with time-of-day clock	error
`Watchdog Fail-Safe`	System error handler of last resort indicating power, electronics, hardware or software failure	System enters inconsistent state	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.