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What This Guide Helps With
Error 120.4520 indicates a failure in the battery precharge process, preventing the pump from recognizing or charging the battery. This results in loss of battery backup capability, which can interrupt therapy during transport or power loss.
Step-by-Step Troubleshooting
1. Ensure Patient Safety First
- Remove the pump from active patient use if battery operation is required
- Transfer infusion to a functioning pump
- Ensure therapy continues without interruption
2. Verify the Reported Error and Behavior
- Power on the pump and confirm Error 120.4520 appears
- Observe if the error occurs at startup or during AC connection changes
- Check if the pump operates normally on AC power
- Look for missing or faulted battery indicators
3. Check AC Power and Charging Behavior
- Connect the pump or PCU to a known working outlet or dock
- Verify stable operation on AC power
- Observe battery charging indicators
- Check for intermittent power interruptions
4. Reseat the Battery
- Power down the unit
- Remove and reinstall the battery
- Ensure proper alignment and full seating
- Confirm there is no looseness after installation
5. Inspect Battery and Contacts
- Check for dirty or corroded contacts
- Inspect for bent or recessed pins
- Look for battery damage or swelling
- Clean contacts if necessary
6. Swap with a Known Good Battery
- Install a known good, fully charged Alaris battery
- Power on the device
- Determine if the error clears or persists
7. Power Cycle the Device
- Remove AC power and battery
- Wait 30–60 seconds
- Reconnect AC power and reinstall battery
- Check if the error clears
If the Problem Persists
If Error 120.4520 continues after reseating the battery, inspecting contacts, and replacing with a known good battery, this indicates failure of the internal power management or battery precharge circuitry.
- Remove the device from service
- Label the device Out of Service
- Send for repair or bench evaluation
Clinical Use Tip
Never troubleshoot battery or power issues on an active patient. Always move the patient to a backup device before continuing troubleshooting.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"BD Alaris pump displaying Error 120.4520; battery not recognized or not charging."
Cause
What was observed during troubleshooting.
Example:
"Battery failed precharge response. Error persisted after reseating and replacement with known good battery, indicating internal power circuit issue."
Resolution
What action was taken.
Example:
"Removed from service, labeled out of service, and sent for repair of battery charging circuitry."
Helpful Details to Include (If Known)
- Alarm behavior
- Accessories swapped
- Power behavior
- Environmental factors
- Indicator lights
- Final device status
Final Thought
Battery-related errors directly affect safe infusion operation. Always rule out external causes first, but escalate quickly when internal circuitry failure is suspected.
That is successful troubleshooting.