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What This Guide Helps With
This guide assists Clinical Engineering in troubleshooting occlusion or flow blockage alarms on an ICU Medical Plum 360 infusion pump. These alarms occur when the pump detects high pressure in the infusion line, which may indicate a kink, obstruction, or improper setup. Most issues are external and do not require internal repair.
Step-by-Step Troubleshooting
Ensure Patient Safety First
- Do not attempt troubleshooting while the pump is actively infusing a patient.
- Switch the patient to a backup pump or alternative infusion method if needed.
- This avoids interrupted therapy or patient harm.
Check the Infusion Set and Tubing
- Inspect tubing for kinks, bends, or pinch points.
- Verify that all connections (syringe, tubing, catheter) are secure.
- Replace tubing if there are visible blockages or damage.
- Reason: Occlusion alarms often trigger from mechanical obstruction.
Verify Syringe or Bag Placement
- Confirm the syringe is seated properly in the pump mechanism.
- Ensure the bag is hung correctly and the line is free-flowing.
- Reason: Misaligned or improperly loaded containers can cause false occlusion alarms.
Check Flow Path and Pressure Limits
- Inspect the entire line from pump to patient for resistance or clots.
- Ensure the infusion set matches the pump’s recommended specifications.
- Reason: Incorrect or incompatible sets may trigger pressure alarms.
Examine Pump Settings
- Review infusion rate and volume parameters.
- Check for programming errors or unexpected rate changes.
- Reason: Excessive rates may cause high pressure and occlusion alarms.
Power Cycle the Pump
- Turn off the pump, wait 10 seconds, then power it back on.
- Reload the infusion set after power-up.
- Reason: Resets the pump’s pressure sensors and clears transient errors.
Test with a Known Good Set
- If occlusion persists, replace the current tubing and syringe with a verified working set.
- Reason: Confirms whether the issue is with consumables or the pump itself.
If the Problem Persists
All external causes have been ruled out (tubing, syringe, bag placement, flow path).
The pump’s pressure sensor or internal mechanism may be faulty.
Action:
- Remove the device from service.
- Label it Out of Service.
- Send for bench evaluation or repair.
- Knowing when to stop is proper troubleshooting.
Clinical Use Tip
- Always have a backup pump ready when troubleshooting high-risk infusions.
- Avoid troubleshooting on pumps attached to active patients.
- Document all alarms and steps taken before removing the device from service.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
User reports repeated occlusion alarms during infusion of normal saline.
Cause
What was observed during troubleshooting.
Example:
Tubing was kinked near the pump outlet; syringe initially misaligned.
Resolution
What action was taken.
Example:
Straightened tubing, reseated syringe, and verified free-flow. Pump now operates without occlusion alarms.
Helpful Details to Include
- Tubing inspected: kinked tubing found or clear.
- Syringe seating: proper alignment confirmed.
- Alarm pattern: continuous or intermittent.
- Flow rate: verified and within specification.
- Final device status: normal operation after troubleshooting or removed from service.
Final Thought
Logical, stepwise troubleshooting preserves patient safety and prevents unnecessary device downtime. External causes account for most occlusion alarms, so start there before assuming internal failure. Proper documentation using the CCR method ensures clarity for future reference and repair.
That is successful troubleshooting.