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What This Guide Helps With
This guide assists Clinical Engineering in troubleshooting situations where a BD Alaris infusion pump fails its internal self-test during startup. The device may display a system error, fail to boot fully, repeatedly restart, or stop at the startup screen.
Many startup failures are related to external accessories, modules, battery issues, or power conditions rather than internal hardware failure. This guide focuses on simple external checks before assuming an internal system fault.
Step-by-Step Troubleshooting
Ensure Patient Safety First
- Verify the infusion pump is not connected to a patient before troubleshooting.
- If the device failed during use, move the patient to another functioning infusion pump.
- Ensure therapy continues safely before evaluating the device.
Verify AC Power Source
- Confirm the pump is connected to a known working hospital-grade outlet.
- Test the outlet with another device if needed.
- Ensure the AC power cord is firmly seated in both the pump and the wall outlet.
- Check for visible damage to the power cord.
- Why this matters: Low or unstable input power can interrupt the startup process and cause the self-test to fail.
Observe Startup Error Messages or Codes
- Power the pump on and carefully observe any error messages or codes displayed during the self-test.
- Document any message shown on the display.
- Note whether the failure occurs immediately or later in the boot sequence.
- Why this matters: Specific error codes may indicate issues with memory, modules, battery systems, or internal communication.
Remove All Attached Modules
- Disconnect any attached Channel Modules or specialty modules from the PC Unit.
- Remove all modules from the mounting rail.
- Power the PC Unit on by itself.
- Why this matters: A faulty module can cause the PC Unit to fail startup diagnostics or communication checks.
Perform a Power Cycle
- Completely power down the device.
- Disconnect AC power.
- Wait approximately 30 seconds.
- Reconnect power and attempt to start the device again.
- Why this matters: Temporary software or memory faults can sometimes clear after a full power reset.
Check the Battery Condition
- If the pump contains an internal battery:
- Verify the battery is installed properly.
- Look for battery warning indicators.
- Attempt startup while connected to AC power.
- Why this matters: A failing battery can sometimes interrupt power stabilization during the self-test process.
Inspect for External Damage or Contamination
- Perform a quick visual inspection of the unit.
- Check for:
- Liquid intrusion
- Cracked housing
- Burnt smell
- Unusual heat
- Debris in connectors
- Why this matters: Physical damage or contamination may interfere with internal components or connectors during system checks.
Test With a Different AC Power Cord
- Swap the AC power cord with a known working cord if available.
- Why this matters: A failing or intermittent power cord may supply inconsistent power during the startup sequence.
If the Problem Persists
If the pump continues to fail the self-test after completing these checks, common external causes have likely been ruled out. The issue may involve:
- Internal power supply faults
- Memory or firmware errors
- Main system board failure
- Internal communication errors
At this point the device should be:
- Removed from service
- Labeled Out of Service
- Sent for repair or bench evaluation
Knowing when to stop and escalate is part of proper troubleshooting.
Clinical Use Tip
Do not attempt troubleshooting on a pump that is actively connected to a patient. If the pump fails during use, immediately transition the patient to a functioning infusion pump before beginning evaluation.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
“Nursing reported the BD Alaris pump fails during startup and displays a system error during the self-test.”
Cause
What was observed during troubleshooting.
Example:
“Unit repeatedly failed power-on self-test with modules attached. After module removal and power cycle, the failure persisted, indicating likely internal system fault.”
Resolution
What action was taken.
Example:
“Removed pump from service, labeled Out of Service, and sent to Clinical Engineering shop/vendor for further diagnostic evaluation.”
Helpful Details to Include (If Known)
- Outlet tested
- AC power cord condition
- Error messages or codes observed
- Whether modules were attached
- Battery indicator status
- Any unusual sounds, smells, or heat
- Final device status (removed from service or repaired)
Final Thought
Startup self-test failures often appear serious, but beginning with basic checks—power, modules, and accessories—can quickly rule out simple causes. When these external checks do not resolve the issue, removing the device from service protects patient safety and allows for proper repair while maintaining accurate service documentation.
That is successful troubleshooting.