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What This Guide Helps With
Troubleshooting chemical level alarms, dosing failures, or disinfectant errors caused by empty containers, sensor issues, or improper connections.
Step-by-Step Troubleshooting
Ensure Patient Safety First
- Do not attempt troubleshooting during an active reprocessing cycle with a scope intended for patient use
- Remove scope and use another AER if needed
Expected: No risk to patient from improperly disinfected scope
Why it matters: Chemical dosing directly impacts high-level disinfection effectiveness
Verify the Reported Error and Behavior
- Observe the exact alarm or message on the display
- Note chemical type (disinfectant, alcohol, detergent)
- Determine if error occurs at startup or mid-cycle
Expected: Clear identification of which chemical system is affected
Why it matters: Narrows troubleshooting to the correct supply system
Check Chemical Container Levels (Most Common Cause)
- Inspect all chemical containers connected to the unit
- Verify disinfectant, detergent, and alcohol containers are not empty
- Replace any low or empty containers
- Ensure correct chemical type is installed
Expected: Containers have adequate fluid levels
Why it matters: Low or empty containers will trigger dosing failures
Inspect Chemical Pickup Tubing and Connections
- Check tubing from containers to the AER
- Ensure pickup tubes are fully inserted into containers
- Look for kinks, cracks, or air gaps
- Confirm tubing is securely connected to ports
Expected: Continuous, airtight fluid path
Why it matters: Air in the line or loose tubing prevents proper dosing
Check Container Caps and Float Sensors
- Ensure caps are properly seated
- Inspect floats for sticking or obstruction
- Verify no debris is interfering with sensors
Expected: Sensors move freely and detect fluid levels correctly
Why it matters: False low-level readings can stop dosing even when fluid is present
Verify Correct Chemical Installation and Recognition
- Ensure correct chemical type is used per facility standard
- Check for proper bottle orientation or keyed connectors
- Reseat containers if needed
Expected: No mismatch or recognition errors
Why it matters: Incorrect or unrecognized chemicals can trigger dosing faults
Check for Air in Lines / Prime System (If Applicable)
- Run any available prime or flush function
- Observe tubing for air gaps
Expected: Smooth fluid flow with no air pockets
Why it matters: Air prevents accurate chemical delivery
Restart the System and Reattempt Cycle
- Power cycle the AER
- Start a new cycle and monitor dosing phase
Expected: No chemical alarms during operation
Why it matters: Confirms issue was external and resolved
If the Problem Persists
If chemical levels, tubing, and sensors have been verified and errors continue, the issue is likely internal (pump failure, sensor malfunction, or control board issue).
Remove the device from service, label it Out of Service, and send for repair or bench evaluation.
Knowing when to stop prevents unsafe disinfection conditions and protects patient safety.
Clinical Use Tip
Never bypass or ignore chemical alarms. If proper dosing cannot be confirmed, the scope must not be used. Always move to a functioning AER before continuing reprocessing.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"AER reporting chemical level error and unable to start disinfection cycle."
Cause
What was observed during troubleshooting.
Example:
"Disinfectant container empty and pickup tube drawing air."
Resolution
What action was taken.
Example:
"Replaced disinfectant container, primed system, and verified successful cycle completion."
Helpful Details to Include (If Known)
- Chemical levels verified
- Tubing condition (kinks, air, loose connections)
- Alarm message displayed
- Any priming performed
- Indicator lights or warnings
- Cycle completion status after fix
- Final device status (returned to service or removed)
Final Thought
Chemical dosing errors should always be approached from the outside in. Most issues are simple—empty containers or loose tubing—but the impact is critical. Proper escalation protects patients and ensures disinfection integrity.
That is successful troubleshooting.