Buffalo PlumeSafe Whisper 602 User manual

BUFFALO FILTER

Smoke Evacuation Systems

SERVICE MANUAL

PlumeSafe® Whisper

TM

602

Smoke Evacuation System

SM9600 $5.00
April 15,1999

BUFFALO FILTER

Smoke Evacuation Systems

Buffalo Filter

595 Commerce Drive

Buffalo, NY 14228

[phone] • [phone]

FAX: [phone]

Email: [e-mail]

Web: www.buffalofilter.com

BUFFALO FILTER

Smoke Evacuation Systems

Table of Contents

Mode of Operation ………………………………………………………………..2
Section A.

Cleaning & Mainten ance ...................................................................................... 3

Section B.

Regulations and Compliance................................................................................. .4

Section C.

Periodic Inspection ............................................................................................... 6

Section D.

Calibration & Adjustments..................................................................................... 7

Section E.

Troubleshooting................................................................................................... 8

Section F.

System Operation & Instructions ........................................................................... 9

Section G.

System Diagram..................................................................................................16

Section H.

Electrical Schematics ...........................................................................................19

Section I.

Disassembly/Assembly Instructions.......................................................................22

Section J.

Systems Specifications.........................................................................................24

Section K.

Ordering Parts ....................................................................................................24

Section L.

Replacement Parts List ........................................................................................25

Section M.

Terms & Warranty...............................................................................................30

BUFFALO FILTER

Smoke Evacuation Systems

PlumeSafe® Whisper 602 Service Manual

2

Mode of Operation

The PlumeSafe Whisper 602 Smoke Evacuation Filtration System is designed to remove smoke
and noxious odors from the smoke plume generated while performing laser and electrosurgical
procedures.

These evacuation systems are designed with high suction and high flow rate centrifugal action
pumps. The ultra-quiet motor is used to draw the smoke plume from the surgical site through the
vacuum tubing and into the ViroSafe® filter where the smoke plume is purified by a series of
filters and carbon. A single disposable filter is used to simplify the installation and removal during
filter changes. This filter is completely enclosed to further protect the healthcare personnel from
potential contamination. The ViroSafe® filter contains four different filter stages within a single
housing to decontaminate the smoke plume.

The ViroSafe® filter is used with the PlumeSafe Whisper 602 Smoke Evacuation System.

The first stage of filtration is a pre-filter whose function is to trap and remove gross particulate
and casual fluid, while capturing some micro-organisms.

The second stage of filtration is a VLSI (Very Large-Scale Integrated) grade ULPA (Ultra Low
Penetration Air) high-tech, patented1 filter designed to capture particulate and micro-organisms
down to 0.01µm at an efficiency of 99.99995%. Each ULPA filter is pre-tested and certified
before use and is impregnated with a chemical agent.

The third stage of filtration uses virgin coal grade activated carbon for the removal and
adsorption of odors and toxic gases produced by the burning of tissue. These harmful gases are
a health hazard to those healthcare workers who breathe them. For this reason, the highest
quality virgin coal grade activated carbon is used. This activated carbon preferentially removes
toxic organic gases rather than water vapor.

The fourth stage of filtration is an expanded foam and filtration media, both of which are also
impregnated with a chemical agent, used to trap activated carbon fines from migrating out of the
filter.

1

U.S. Patent: #5,874,052

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Section A.
Cleaning & Maintenance

The procedure for cleaning and maintenance of the PlumeSafe Whisper 602 is as follows:

1. Clean the entire surface of the system with an appropriate surface disinfectant after each
procedure. (Please avoid abrasive cleaners)

2. Clean the filter housing with an appropriate surface disinfectant after each procedure. (Please
avoid abrasive cleaners)

3. Replug filter after each use.

4. Dispose the vacuum hose and all 'single' use disposable parts after each procedure. Dispose
of in the appropriate manner for your locale.

5. Change the ViroSafe® filter at the prescribed number of hours for the filter being used.
Failure to change the filter will affect the performance of the system.

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PlumeSafe® Whisper 602 Service Manual

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Section B.
Regulations and Compliance

The operational information contained in this section is intended for the customer review of
compliance issues. The information pertains to the use of Buffalo Filter products both
domestically and internationally:

1. The PlumeSafe Whisper 602 complies with IEC601.1 electrical specifications in the following
systems: PlumeSafe Whisper 602 - 120V/60Hz, 100V/50Hz & 60Hz , 220V/50 Hz,
240V/50Hz

2. The PlumeSafe Whisper 602 Smoke Evacuation System(s) has a classification under the
UL2601-1, Clause 5.1 of : CLASS 1 Equipment

3. The PlumeSafe Whisper 602 Smoke Evacuation System(s) has an identification under the
UL2601-1, Clause 5.2 according to the degree of protection against electric shock: Type B
Equipment

4. The PlumeSafe Whisper 602 Smoke Evacuation System(s) has an identification under the
UL2601-1, Clause 5.3 according to the degree of protection against harmful ingress of water:

Ordinary Equipment (enclosed equipment without protection against ingress of
water)

5. The PlumeSafe Whisper 602 Smoke Evacuation System(s) has a classification under the
UL2601-1, Clause 5.4 according to the method of sterilization or disinfection recommended by
BUFFALO FILTER: Unplug System. Wipe system with a damp cloth containing mild

surface disinfectant solution, or soapy water. Wipe dry with a clean cloth. Do not
steam sterilize or autoclave.

6. The PlumeSafe Whisper 602 Smoke Evacuation System(s) has a classification under the
UL2601-1, Clause 5.5 according to the degree of safety of application in the presence of
flammable anesthetic mixture with air or with oxygen or nitrous oxide: Equipment not

suitable for use in the presence of Flammable Anesthetic mixture with air or with
oxygen or nitrous oxide.

7. The PlumeSafe Whisper 602 Smoke Evacuation System has a classification under the UL2601­1, Clause 5.6 according to the mode of operation: Continuous Operation

8. The fuses used on the circuit board are to be serviced by an authorized Buffalo Filter
technician as follows: 120V/60Hz, 100V/50 Hz & 60 Hz, 220V/50Hz and 240V/50Hz
use a 0.0625A/250V fuse

9. The PlumeSafe Whisper 602 Smoke Evacuation System and all filters and accessories are not
intended for contact with patients.

10. The PlumeSafe Whisper 602 Smoke Evacuation System is in full compliance with the Medical
Devices Directive II, Council Directive 93/42/EEC of 14 June 1993

11. The PlumeSafe Whisper 602 Smoke Evacuation System complies with the City of Los

Angeles Electrical Codes.

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PlumeSafe® Whisper 602 Service Manual

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Cautions and Warnings

Please note that all Cautions and Warnings should be read and understood prior to any operation
of this equipment. Only personnel who have been properly trained in its operation should operate
the PlumeSafe Whisper 602 Smoke Evacuation System.

A "Warning" is a situation in which improper operation of the system could adversely affect the
operator of the equipment or the patient.

A "Caution" is a situation in which the PlumeSafe Whisper 602 or other equipment could be
damaged by improper operation.

WARNINGS:

• The ViroSafe

accordance with your local codes or regulations. These filters may be disposed or incinerated
whichever is appropriate for your locale.

• The ViroSafe

used with the PlumeSafe Whisper 602 system, should not be used for more than is prescribed
in the filter instructions. Failure to change these filters may result in decreased filter efficiency
and contamination of the electric motor, vacuum pump, and sound absorbing components
within the system.

• If casual fluid is expected to be introduced into the ViroSafe

Whisper 602 system, fluid collection devices must be installed with the vacuum hose
assembly. Failure to install a fluid collection device could cause filter blockage and electrical
damage.

CAUTIONS:

®

filters are completely disposable. Please handle these disposable filters in

®

filter should be changed according to the instructions. The ViroSafe® filter,

®

filter and/or the PlumeSafe

• Using any other filters or accessories not manufactured by Buffalo Filter may cause damage

to the system and will be cause for voiding the warranty.

• DO NOT block either the tubing or the filter. If either becomes clogged or occluded, or if the

airflow through either is significantly restricted, the motor/blower could overheat and cause
the system to fail. The failure may be only a blown circuit but could cause complete motor
failure.

• When suctioning fluids into the fluid collection container with any system, it is recommended

that a 1/4" or smaller wand or silicone/PVC tubing be used at the patient end. Using anything
larger than 1/4" tubing may offer flow rates that are too high for suctioning fluids in and
around the surgical area.

• Care must be exercised in the installation of all hoses, adapters and suction canisters. Failure

to follow the procedures outlined in this manual may result in overheating of the motor and
be cause for voiding the warranty. Wear protective equipment and use "Universal
Precautions" when handling used equipment.

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Special Note:

Use "Universal Precautions" procedure whenever

Section C.
Periodic Inspection

The PlumeSafe Whisper 602 Smoke Evacuation System is engineered to provide the end user
with many years of trouble free service. In order to maintain the system in top operating order
the system should be inspected according to the following schedule:

AFTER EACH USE:

1. Check filter life indicator, anticipate filter replacement.

2. The system should be inspected for signs of physical damage and fluid or solid contamination
after each use.

3. The filter should be inspected for physical damage, fluid or solid contamination, and filter life
after each use. Please replace the filter if filter life has been expended.

ONCE A WEEK:

1. Check the "Service" light on the membrane keypad. If the light is lit, contact Buffalo Filter for
service instructions.

2. Check the filter for physical damage, fluid or solid contamination, and filter life. If filter life
has been expended, please replace the filter.

3. Examine the entire system for physical damage. Contact your local distributor or Buffalo Filter
for service instructions if damaged.

YEARLY INSPECTIONS:

1. Check the "Service" light on the membrane keypad. If the light is lit, contact Buffalo Filter for
service instructions.

handling contaminated filters or smoke evacuation
equipment.

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PlumeSafe® Whisper 602 Service Manual

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Section D.
Calibration & Adjustments

The PlumeSafe Whisper 602 Smoke Evacuation System is completely adjusted at the time of
manufacture so that no additional adjustment to the system is necessary.

There is no need to calibrate any part of the PlumeSafe Whisper 602 Smoke Evacuation System,
all calibration is performed at the factory.

If the "Service" light is illuminated at any time, contact your local distributor or Buffalo Filter for
service instructions.

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PlumeSafe® Whisper 602 Service Manual

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Section E.
Troubleshooting

Problem Potential Cause Corrective Action

1. Smoke Evacuation System
is operational but suction is
minimal or none.

1. Smoke Evacuator System
does not function even
though "ON" button is
pressed.

1. Filter not seated completely

2. Filter clogged

3. Vacuum hose clogged

4. Motor/Blower obstructed

1. Not plugged into electrical
outlet or system not
powered up with switch

2. Circuit breaker(s) tripped

3. Footswitch/Remote Switch
plugged in

4. Electronic system failure

1. Re-install ViroSafe® filter,
press firmly into place and
inspect for obstructions

2. Replace ViroSafe® filter

3. Check or replace hose

4. Contact your local
distributor or Buffalo Filter

1. Check power outlet or
check to be sure system is
powered up with switch on
side

2. Reset circuit breaker(s) on
back of system

3. Unplug footswitch or
remote switch

4. Contact your local
distributor or Buffalo Filter

2. "Service" light is lit. 1. Motor/Blower needs

3. Motor/Blower operated
intermittently.

servicing.

1. Incorrect power to system

2. Electronic system failure

1. Contact your local
distributor or Buffalo Filter

1. Check the wall socket to be
sure the correct power is
supplied to system.

2. Contact your local
distributor or Buffalo Filter

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PlumeSafe® Whisper 602 Service Manual

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Section F.
System Operation & Instructions

Operation of the PlumeSafe Whisper 602 Smoke Evacuation Filtration System is as follows:

1. Remove the Smoke Evacuator from the packaging and inspect for any damage that may have
occurred during shipment. If any damage is present, please notify carrier immediately for
damage assessment.

2. Inspect the filter section of the system to insure that no packing debris has fallen into the
filter chamber. Remove any debris.

3. Install a ViroSafe® filter per the directions enclosed in the filter box.

4. Connect any adapters, hoses, tubing, electrosurgical pencils, etc. to complete the installation.

5. Electrically connect the system into a grounded 120V/60Hz electrical outlet. (If international,
use appropriate voltage/frequency and a grounded connection.)

6. Press the ON/OFF rocker switch on the side of the system to the ON position.

7. Press the ON/OFF button on the membrane key panel to activate the motor.

8. Press the suction control UP ARROW button to 100%, then press the vacuum adjust DOWN
ARROW button to 20%. Repeat to assure smooth operation.

9. Press the UP or DOWN ARROW buttons on the suction adjust again, both up or down, to
verify the smooth operation of the motor speed from high to low speed and back again.

WARNING: If casual fluid is expected to be introduced into the ViroSafe® Filter or

PlumeSafe Whisper 602 system, fluid collection devices must be
installed with the vacuum hose assembly. Failure to install a fluid
collection device could cause filter blockage and electrical damage.

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Note:

Please make certain to read these instructions before installing or operating

this equipment. Failure to do so could result in improper usage, damage to

FILTER LIFE REMAINING

Electronic System Controls

100%

FOOT

SWITCH

80%

60%

40%

SUCTION
CONTROL

100% 80% 60%

40%

20% 0%

REPLACE NEW

20%

Electronic system controls on the PlumeSafe Whisper 602 products are easy to understand and
simple to use. The membrane control panel on the front of the smoke evacuation filtration
system is identical for domestic and international systems. The membrane control panel is used
to control the power, motor speed and the filter life indicator.

the system, and/or personal injury.

The following are descriptions of the membrane panel controls for the PlumeSafe Whisper 602
system:

• POWER

There are two ON/OFF switches on each system. The ON/OFF switch that disables the
electrical power to the system is located on the side of the system. The ON/OFF switch for
the electronic membrane control panel is located on the front of the systems.

To turn the system electrical power on, press the rocker switch on the side of the system to
the ON position. To turn the system electrical power OFF press the rocker switch to the OFF
position.

To turn the system motor ON, press the ON/OFF button on the membrane panel until the
motor is running. To turn the system motor OFF, press the ON/OFF button again.

POWER

ON

OFF

FILTER LIFE

RESET

SERVICE

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Note:

On any Buffalo Filter smoke evacuator, there are two circuit breakers for the "hot"

• SUCTION CONTROL

The SUCTION CONTROL for air suction is adjusted by way of the internal speed
microprocessor controller. The control UP ARROW button can be pressed to increase the air
suction and DOWN ARROW button can be pressed to decrease the air suction. Control of the
air suction can be done at any time with or without the motor running. Setting the air suction
control at the lowest setting that still removes the smoke plume will lower the system noise.
Each time either arrow is pressed the air suction will increase or decrease by 10%. When two
lights are lit on the flow control panel the actual airflow is the percentage between the two lit
numbers.

• FOOTSWITCH/REMOTE SWITCH

A footswitch or remote switch can be added to the system by simply plugging in a Buffalo
Filter footswitch (P/N FS10003) or a Buffalo Filter Remote Switch Activator (P/N RSA1002)
into the electrical jack on the side of the system.

When the footswitch is plugged in, the system may be turned on or off by pressing the
footswitch pedal once for each operation. When not using the footswitch, please unplug and
store away. For footswitch operation the power switch needs to be in the ON position. When
the footswitch is plugged in, the light on the membrane control panel entitled
FOOTSWITCH/REMOTE SWITCH will light to let the operator know the footswitch or remote
switch is active.

When using the remote switch activator, please refer to the instruction sheet that
accompanies that product.

• CIRCUIT BREAKER

Two (2) 15 AMP for domestic or two (2) 8 AMP for international circuit breakers are installed
as standard on each system to electrically protect both the system and the operator from
damage or injury. If the system is overheated or if there is an electrical surge in the system
the circuit breaker(s) will "trip" and the system will not operate. In order to re-start the
system press the circuit breaker button into its original position.

and "common" wires. Both circuit breakers act in the same manner. If either circuit
breaker is tripped, press the circuit breaker button back into its original position.

• FILTER LIFE REMAINING INDICATOR

The filter life indicator on the membrane control panel allows the operator to know the status
of the life of the filter being used The filter life indicator for the PlumeSafe Whisper 602
system is factory set for 6 hours. These settings correspond to the actual filter life of the
ViroSafe® filter for any system. After any filter is changed, the RESET button must be fully
reset for the next filter. Pressing, and holding down the reset button for 5 seconds, can
accomplish this. If the reset button is accidentally pressed at any time, the filter life indicator
will not reset unless the button is held down for 5 seconds.

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PlumeSafe® Whisper 602 Service Manual

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Ø PlumeSafe Whisper 602:

The filter life indicator button labeled ‘RESET HOLD’ must be pressed and held for 5
seconds for the filter life indicator to fully reset. Install a ViroSafe® filter into the
PlumeSafe Whisper 602 system per the installation instruction contained in this
operator's manual. When the PlumeSafe Whisper 602 system is turned on, the filter
life indicator will light up all the GREEN, AMBER and RED LEDs indicating that there is
still adequate life in the filter. When the filter has been used for 4 hours, the AMBER
and RED lights will be illuminated to indicate that the ViroSafe® filter is nearing the
end of its useful life. After 6 full hours have elapsed, the RED light will start blinking to
indicate that the filter has expended it useful life and needs to be changed. At this
time the ViroSafe® filter should be changed according to the removal instructions
included in the operator's manual included with your PlumeSafe Whisper 602.

• SERVICE LIGHT INDICATOR

The RED service light indicator on the front membrane panel will illuminate after 500 hours of
operation. When this occurs, all non-essential membrane panel functions except the on/off
switch and the motor speed control for continuing the system operation will become non­operational until servicing can be completed.

WHEN THE SERVICE LIGHT COMES ON, PLEASE CONTACT YOUR LOCAL
DISTRIBUTOR OR BUFFALO FILTER FOR SERVICE INSTRUCTIONS ON THE
SYSTEM.

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PlumeSafe® Whisper 602 Service Manual

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10 Foot Power

Footswitch

Footswitch Installation/Operation

71mm(2.80")

27mm(1.86")

1. Remove the Footswitch from the packaging and inspect for any damage that may have
occurred during shipping.

2. Turn system off before installing Footswitch.

3. Connect the plug to the outlet on the system labeled "Footswitch". The PlumeSafe Whisper
602 system has a Footswitch inlet jack on the side of the system.

4. Turn the system ON to activate the Footswitch. The footswitch pedal will automatically
become active once the plug is inserted into the footswitch socket on the system, and the
light on the membrane control panel will become illuminated.

5. Press the footswitch pedal once to activate the system.

6. Press the UP or DOWN ARROWS of the vacuum adjust to the desired air suction.

7. Press the footswitch again to deactivate the system.

If the footswitch is not in use, remove the footswitch and store away until needed again.

96mm(3.78")

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Remote Switch Activator Installation/Operation

The Buffalo Filter Remote Switch Activator (RSA1002) is designed for use with any brand of
Electrosurgical Generator (ESU) that incorporates a Buffalo Filter Smoke Evacuation System. The
RSA1002 operates essentially in the same manner as a footswitch; the smoke evacuator is turned
on and off by pressing the "CUT" or "COAG" button on the ESU pencil.

The RSA1002 uses a patent pending2 technology to sense the harmonic vibrations emitted by all
electrosurgical generator units. These vibrations are recognized by the RSA1002, and will activate
the smoke evacuator when the vibrations are present. Other operating room noises, tones,
vibrations, beeps and personal loud noises should not activate the RSA1002.

Instruction Overview

1. Remove RSA1002 from the package, check for damage.

2. Clean area on ESU with alcohol (apply caution when using flammable liquids) before
installing RSA1002. Remove adhesive backing and place on ESU according to ESU "diagram"
for your particular ESU generator.

3. Turn on Smoke Evacuation and adjust suction control to 50%, turn on ESU and adjust
speaker volume to 50%.

4. Plug in the RSA1002 into jack labeled "Footswitch" or "Remote Switch" on the smoke
evacuator.

5. Adjust the RSA1002 for both "CUT" & "COAG"; see Adjustment Instructions that come with
the remote switch activator.

6. Operate the smoke evacuator remotely with the ESU hand control pencil by pressing either
"CUT" or "COAG" button.

Refer to the instructions that accompany the Remote Switch Activator for additional
installation instructions and detailed placement of the Remote Switch.

If the Remote Switch Activator is not in use, remove the Remote Switch Activator and store away
until needed again.

2

U.S. Patent Pending: #08/909,902

BUFFALO FILTER

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PlumeSafe® Whisper 602 Service Manual

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SYSTEM OPERATION

1. Please follow the instructions for the proper and safe installation of the filter system before
proceeding with the operation of the system. The installation of the disposable ViroSafe®
filter is described in the Operators Manual that accompanied the product.

2. Once the system is properly installed and operating according to the above instructions, the
operator may choose to increase or decrease the amount of suction. Pressing the UP or
DOWN ARROW buttons on the membrane keypad will selection of a higher or lower setting.
The 20% setting is the lowest suction strength and the 100% setting is the highest suction
strength. Any setting in between can be used in order to remove smoke, fumes and toxic
gases from the surgical site. Each pressing of either arrow increases or decreases the suction
setting by 10%.

Note: For the most efficient use of the virgin coal grade activated carbon, please use
the lowest vacuum setting possible. This vacuum setting should be the lowest setting
that clears the surgical field of smoke plume.

3. At any time during the operation of the smoke evacuator, the vacuum can be adjusted to the
desired setting. After setting the suction adjust to the highest setting, if you are still not
clearing the field, this is an indication to change the disposable ViroSafe® filter.

4. When the filter life indicator FLASHES RED, this is an indication that the ViroSafe® filter has
reached the end of its useful life and needs to be changed. Please refer to the instructions
in the operator's manual provided with your Porta PlumeSafe Whisper 602 to properly change
the filter.

If any problems occur during in-service, please refer to Section E - Troubleshooting.

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Airflow through the PlumeSafe Whisper 602

Section G.
System Diagram

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PlumeSafe Whisper 602 Explosion View

PER

Circuit

Breaker

F
O
O
T

J
A
C
K

234

10111213141516

Plu

meS

a

f

e

1

8

9

6

5

POWER

FOOT
SWITCH

SUCTION
CONTROL

FILTER LIFE REMAINING

FILTER LIFE

100% 80% 60% 40% 20% 0%

RESET

REPLACE

SERVICE

1

SMOKE EVACUATION SYSTEM

S

I

H

W

7

15

1

4

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PlumeSafe Whisper 602 Shell Insulation

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Section H.

Electrical Schematics

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NOTE: Before performing any work on the PlumeSafe Whisper 602 make certain the

system is turned off and the electrical plug has been disconnected from the wall
power outlet.

WARNING: If fluid is expected to be introduced into the ViroSafe® Filter and/or the PlumeSafe

Whisper 602 system, fluid collection devices must be installed with the vacuum
hose assembly. Failure to install a fluid collection device could cause filter blockage
and electrical damage.

CAUTION: Using any other filter or accessory not manufactured by Buffalo Filter may cause

damage to the system and will be cause for voiding the warranty.

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PlumeSafe® Whisper 602 Service Manual

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Section I.
Disassembly/Assembly Instructions

WARNING: ELECTRICAL SHOCK HAZARD!

Before performing any work on the PlumeSafe Whisper 602 make certain the
system is turned off and the electrical plug has been disconnected from the wall
power outlet.

Please refer to the PlumeSafe Whisper 602 System diagram in the previous section
for details.

DISASSEMBLY INSTRUCTIONS

In order to field service the Buffalo Filter PlumeSafe Whisper 602 Smoke Evacuation System, the
system will need to be disassembled. Read the instructions below before attempting to service
the system.

The disassembly of the PlumeSafe Whisper 602 Smoke Evacuation System is as follows:

1. Turn the system upside down as to expose the base where the four (4) wheels are
mounted.

2. Spaced equally around the inside perimeter of the hexagonal base are six (6) button head
fasteners. Using a 1/8” Allen Wrench remove all six (6) and the base will separate from
the rest of the system.
NOTE: Some earlier systems had six (6) button head fasteners around the outside
perimeter of the shell which will require a 5/32” Allen Wrench.

3. Remove the acoustical insulation from the shell and stack each piece on top of each other
keeping the orientation of each piece the same as inside the system.
NOTE: When reinstalling the insulation it is very important to reinstall in the same way it
was removed. Remember that the insulation not only dampens noise but also has
openings that aid in two critical airflow pathways, cool air in and hot air out. Refer to the
explosion view of the insulation for additional help in reinstalling the insulation.

4. When removing the insulation, some connecting wires to the power entry module on the
back of the system will have to be removed first.

5. The circuit breaker can be removed by first removing the two (2) wires from the back of
the circuit breaker. The removal of the circuit breaker can be accomplished by pressing
the tabs on either side of the breaker and pushing the breaker to the outside of the shell.
Note: The international systems require the removal of two (2) circuit breakers.

6. To remove the power entry module, press the small tabs on the back of the component
and remove from the back of the system.

7. Disconnect all electrical motor leads and using a 1/8” Allen Wrench remove the bolts
holding the motor to the filter basket assembly.

8. Carefully remove the motor from its mount. Next remove the motor mount gasket.
NOTE: The direction of the exhaust airport is critical because during reinstallation it must

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22

point toward the front of the system. The front of the system is where the controller
board is mounted.

9. Using a 3/8” socket with a long extension remove the four (4) nuts that hold the filter
basket in place.

10. Remove the filter basket from the top of the system.

11. Remove the Footswitch/Remote Switch inlet jack by removing the nut on the outside of
the shell with a 1/2" wrench turning counterclockwise. Note: Do not attempt to
disconnect the footswitch wiring from printed circuit board (PCB), as the entire footswitch
jack assembly will be removed with the PCB.

12. For this step, you will need to be electrically grounded. Remove the 5 bolts, type 6-32,
from the circuit board using a #2 Phillips screwdriver or a flat screwdriver for some earlier
production models. Carefully remove the circuit board and place in an anti-static holder.

NOTE: You must be grounded before servicing any part of the controller board
or removing it from the shell. Failure to be grounded when removing the PCB
could cause permanent electrical damage.

13. If the microprocessor needs to be replaced on the controller board you must be grounded
prior to servicing the controller board. Locate the microprocessor on the controller board.
If necessary, using a chip puller, remove the microprocessor from the circuit board.

NOTE: No other components should be removed from the circuit board other
than the microprocessor.

14. If necessary the fuse can be replaced on the controller board by using a fuse puller to
remove the 0.0625 amp fuse from the circuit board. (This is only applicable on newer
models where the circuit board has quick disconnect fuse clips. This is not applicable to
older models where the fuse is soldered to the board).

NOTE: No other components should be removed from the circuit board other
than the fuse.

15. If necessary on all international systems, remove the RFI filter by unscrewing the two (2)
Phillips head fasteners and removing the wires connections.

16. If any of the wheels need to be serviced they can be easily removed as follows: Using a
3/8” nut driver or open end wrench, remove the four (4) nuts from the base of the wheel.

17. Note: Refer to the explosion view of all the components in this Service Manual to correctly
guide you through all of the disassembly/assembly steps.

REASSEMBLY INSTRUCTIONS

For reassembly of the PlumeSafe Whisper 602 Smoke Evacuation System, please
follow the above instructions in reverse order.

Note: Refer to the Electrical Schematic in Section H for the correct wire terminations during
assembly.

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PlumeSafe® Whisper 602 Service Manual

23

Section J.
Systems Specifications

Specifications PlumeSafe

Whisper 602

Buffalo Filter
Part Number

Flow Rate MAX. ­CFM (LPM)

Motor Rating-CFM
(LPM)
Motor Stages 3 2 2 3

PSW0602 PSW0602/220 PSW0602/240 PSW0602/100

1 1/4" = 40(1133)

7/8" = 33(935)
Buffalo Filter ESU
Pencil = 4.4(125)

110 (3115) 111 (3144) 111 (3144) 110 (3115)

PlumeSafe
Whisper
602/220

1 1/4" = 59(1671)

7/8" = 42(1189)

Buffalo Filter ESU

Pencil = 5(142)

PlumeSafe
Whisper
602/240

1 1/4" = 60(1699)

7/8" = 43(1217)

Buffalo Filter ESU

Pencil = 5(142)

PlumeSafe
Whisper
602/100

1 1/4" = 40(1133)

7/8" = 33(935)
Buffalo Filter ESU
Pencil = 4.4(125)

Static Suction,
inches H2O (mbar)
Electrical Power:

AMPS 5.4 8.0 8.0 5.4

Volts 120 220 240 100
Frequency (Hz) 50 & 60 50 & 60 50 & 60 50 & 60
Dimensions:

Height cm) 20” (50.8) 20” (50.8) 20” (50.8) 20” (50.8)
Width (cm) 14” (35.6) 14” (35.6) 14” (35.6) 14” (35.6)

Length (cm) 14” (35.6) 14” (35.6) 14”(35.6) 14” (35.6)
Weight, lbs. (kg) 28.5 (13.0) 28.5 (13.0) 28.5 (13.0) 28.5 (13.0)
Filter ViroSafe® ViroSafe® ViroSafe® ViroSafe®
Filtration Efficiency 99.99995% 99.99995% 99.99995% 99.99995%
Filtration Rating

75" H2O

(187)

0.01µm 0.01µm 0.01µm 0.01µm

95.2" H2O
(231)

95.2" H2O
(231)

75" H2O

(187)

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PlumeSafe® Whisper 602 Service Manual

24

Section K.
Ordering Parts

Please order all parts, accessories and replacement filters for the PlumeSafe Whisper 602 by
contacting your local distributor or Buffalo Filter directly at:

1-800-343-2324 (US only)

Or

716-835-7000

(If calling internationally, use International Dialing Codes)

FAX: [phone]

E-mail: [e-mail]

Web Site: http://www.buffalofilter.com

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Section L.
Replacement Parts List

PlumeSafe Whisper 602

120V / 50 & 60Hz

# Quantity Part Number Description

1 1
2 1
3 1
4 1
5 1
6 1
7 2
8 1

9 1
10 1
11 1
12 1
13 2
14 1
15 1
16 1
17 1
18 1
19 5
20 1
21 6
22 5
23 2
24 4
25 2
26 24
27 1
28 4
29 1
30 1
31 8
32 1

HOUSING 602W Whisper 602 Housing
MOTOR 120 DC DC Brushless Motor
GSKT MM WSP Gasket for Motor, SC-42 Closed Cell
HANDLEWHISPR Handle For Whisper 602
HANDLE FOAM Foam for Whisper 602 handle
CORD WRAP Cord Wrap for Whisper 602
CIRCUIT 15 US – 15Amp Circuit Breaker
PWR EN MD.08 Power Entry Module (.080")
PCB-DB26 ASY Whisper 602 PCB w/26" jack
CHP W6 Chip W6
PLUG/CORD602 Plug/Cord 12' AEC60, AEC250
WIRE ASSBLY Wire Assembly for Whisper 602 – Complete w/E-Terms
GASKET LED LED Gasket
LBL WHIS S/N Label Kit for Whisper 602
LBL CITY LA Label for City of LA Approval
BOX WHISPER Box for Whisper 602 System
KEYPADBFGRFX Buffalo Filter Membrane Switch Graphics
MEMBRANEBLNK Membrane Blank
BOLT10-32 .5 Bolt 10-32 0.5" SS
BOLT10-32.75 Bolt 10-32 0.75" Long
BOLT6-32 .5" Bolt 6-32 0.5" Long -PAN HD
WASHER #6S Star washer #6 electrical
WASHER 1/4"L Lock Washer 1/4" split ring
WASHER #10F Flat washer #10
NUT JAM10-32 Jam Nut 10-32, Zinc
NUT 10-32 10-32 Lock Nuts S/S
WALL PLATE Wall Plate Suction Canister
WHEELS 2" Whisper 602 Wheels
RUBBER FEET Cylindrical Isolator
INSULKIT WSP Insulation Kit for Whisper 602
ISOLATORS Motor Isolators
MANUAL602/12 602/1202/Whisper/TURBO Operator’s Manual

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PlumeSafe Whisper 602

220V / 50 & 60Hz

# Quantity Part Number Description

1 1 HOUSING 602W Whisper 602 Housing
2 1 MOTOR 220/240 Motor 220/240V International
3 1 GSKT MM WSP Gasket for Motor, SC-42 Closed Cell
4 1 HANDLEWHISPR Handle For Whisper 602
5 1 HANDLE FOAM Foam for Whisper 602 handle
6 1 CORD WRAP Cord Wrap for Whisper 602
7 2 CIRCUIT 8 Euro – 8Amp Circuit Breaker
8 1 PWR EN MD.08 Power Entry Module (.080")
9 1 PCB-AC26 ASY Whisper 602 PCB w/26" jack

10 1 CHPW220/50/6 Chip W220/50/6
11 1 PLUG/CORD602 Plug/Cord 12' AEC60, AEC250
12 1 WIRE ASSBLY Wire Assembly for Whisper 602 – Complete w/E-Terms
13 2 GASKET LED LED Gasket
14 1 LBL WSP KIT Label Kit for Whisper 602
15 1 LBL CITY LA Label for City of LA Approval
16 1 BOX WHISPER Box for Whisper 602 System
17 1 KEYPADBFGRFX Buffalo Filter Membrane Switch Graphics
18 1 MEMBRANEBLNK Membrane Blank
19 8 BOLT10-32 .5 Bolt 10-32 0.5" SS
20 1 BOLT10-32.75 Bolt 10-32 0.75" Long
21 5 BOLT6-32 .5" Bolt 6-32 0.5" Long -PAN HD
22 5 WASHER #6S Star washer #6 electrical
23 2 WASHER 1/4"L Lock Washer 1/4" split ring
24 4 WASHER #10F Flat washer #10
25 2 NUT JAM10-32 Jam Nut 10-32, Zinc
26 26 NUT 10-32 10-32 Lock Nuts S/S
27 1 WALL PLATE Wall Plate Suction Canister
28 4 WHEELS 2" Whisper 602 Wheels
29 1 RUBBER FEET Cylindrical Isolator
30 1 INSULKIT WSP Insulation Kit for Whisper 602
31 8 ISOLATORS Motor Isolators
32 1 MANUAL602/12 602/1202/Whisper/TURBO Operator’s Manual
33 1 REF6EHT1 PN#6EHT1
34 1 LBL CE SMALL CE Label Small

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PlumeSafe Whisper 602

240V / 50 & 60Hz

# Quantity Part Number Description

1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

1 HOUSING 602W Whisper 602 Housing
1 MOTOR 220/240 Motor 220/240V International
1 GSKT MM WSP Gasket for Motor, SC-42 Closed Cell
1 HANDLEWHISPR Handle For Whisper 602
1 HANDLE FOAM Foam for Whisper 602 handle
1 CORD WRAP Cord Wrap for Whisper 602
2 CIRCUIT 8 Euro – 8Amp Circuit Breaker
1 PWR EN MD.08 Power Entry Module (.080")
1 PCB-AC26 ASY Whisper 602 PCB w/26" jack
1 CHP W240/50/6 Chip W240/50/6
1 PLUG/CORD602 Plug/Cord 12' AEC60, AEC250
1 WIRE ASSBLY Wire Assembly for Whisper 602 – Complete w/E-Terms
2 GASKET LED LED Gasket
1 LBL WSP KIT Label Kit for Whisper 602
1 LBL CITY LA Label for City of LA Approval
1 BOX WHISPER Box for Whisper 602 System
1 KEYPADBFGRFX Buffalo Filter Membrane Switch Graphics
1 MEMBRANEBLNK Membrane Blank
8 BOLT10-32 .5 Bolt 10-32 0.5" SS
1 BOLT10-32.75 Bolt 10-32 0.75" Long
5 BOLT6-32 .5" Bolt 6-32 0.5" Long -PAN HD
5 WASHER #6S Star washer #6 electrical
2 WASHER 1/4"L Lock Washer 1/4" split ring
4 WASHER #10F Flat washer #10
2 NUT JAM10-32 Jam Nut 10-32, Zinc

26 NUT 10-32 10-32 Lock Nuts S/S

1 WALL PLATE Wall Plate Suction Canister
4 WHEELS 2" Whisper 602 Wheels
1 RUBBER FEET Cylindrical Isolator
1 INSULKIT WSP Insulation Kit for Whisper 602
8 ISOLATORS Motor Isolators
1 MANUAL602/12 602/1202/Whisper/TURBO Operator’s Manual
1 REF6EHT1 PN#6EHT1
1 LBL CE SMALL CE Label Small

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PlumeSafe® Whisper 602 Service Manual

28

PlumeSafe Whisper 602

100V / 50 & 60Hz

# Quantity Part Number Description

1 1 HOUSING 602W Whisper 602 Housing
2 1 MOTOR 120 DC DC Brushless Motor
3 1 GSKT MM WSP Gasket for Motor, SC-42 Closed Cell
4 1 HANDLEWHISPR Handle For Whisper 602
5 1 HANDLE FOAM Foam for Whisper 602 handle
6 1 CORD WRAP Cord Wrap for Whisper 602
7 2 CIRCUIT 15 US – 15Amp Circuit Breaker
8 1 PWR EN MD.08 Power Entry Module (.080")
9 1 PCB-DB26 ASY Whisper 602 PCB w/26" jack

10 1 CHP W6 Chip W6
11 1 PLUG/CORD602 Plug/Cord 12' AEC60, AEC250
12 1 WIRE ASSBLY Wire Assembly for Whisper 602 – Complete w/E-Terms
13 2 GASKET LED LED Gasket
14 1 LBL WHIS S/N Label Kit for Whisper 602
15 1 LBL CITY LA Label for City of LA Approval
16 1 BOX WHISPER Box for Whisper 602 System
17 1 KEYPADBFGRFX Buffalo Filter Membrane Switch Graphics
18 1 MEMBRANEBLNK Membrane Blank
19 8 BOLT10-32 .5 Bolt 10-32 0.5" SS
20 1 BOLT10-32.75 Bolt 10-32 0.75" Long
21 5 BOLT6-32 .5" Bolt 6-32 0.5" Long -PAN HD
22 5 WASHER #6S Star washer #6 electrical
23 2 WASHER 1/4"L Lock Washer 1/4" split ring
24 4 WASHER #10F Flat washer #10
25 2 NUT JAM10-32 Jam Nut 10-32, Zinc
26 26 NUT 10-32 10-32 Lock Nuts S/S
27 1 WALL PLATE Wall Plate Suction Canister
28 4 WHEELS 2" Whisper 602 Wheels
29 1 RUBBER FEET Cylindrical Isolator
30 1 INSULKIT WSP Insulation Kit for Whisper 602
31 8 ISOLATORS Motor Isolators
32 1 MANUAL602/12 602/1202/Whisper/TURBO Operator’s Manual
33 1 REF10EHT1 PN#10EHT1

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PlumeSafe® Whisper 602 Service Manual

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Section M.
Terms & Warranty

SPECIFICATIONS. All product specifications are subject to change without notice.

SHIPMENT OF ORDER. Buffalo Filter will try to accommodate individual customer requests for shipping method. Buffalo Filter
reserves the right to decide shipping method on prepaid orders. Care is exercised in the checking and packaging of all merchandise
to avoid error, but should discrepancies arise, claims should be made within 24 hours after delivery.

All products are shipped F.O.B Buffalo Filter's facilities, and risk of loss transfers to the purchaser upon tender of delivery to the
carrier at our dock. If the merchandise is damaged after risk of loss has transferred, a claim must be made to the carrier involved.
Buffalo Filter will provide reasonable assistance to customers in pursuing these claims.

RETURN OF MATERIAL. In the event of an error by Buffalo Filter, products may be returned to Buffalo Filter for correction of such
error. In all other cases, returns will only be accepted with the prior consent of Buffalo Filter, in its sole discretion, and will be
accepted only in exchange for merchandise of an equivalent dollar value, less a reasonable restocking and handling charge.

In all cases, returns will not be accepted unless a pre-authorized return number is obtained from Buffalo Filter in advance. This
number must be clearly marked on the exterior of the packaging before returning products to Buffalo Filter. All transportation costs
must be prepaid by the shipper and all risks of loss and damage of goods are the responsibility of the shipper. Unauthorized returns
will be refused. Include a copy of the packing papers and/or invoice with the return. Buffalo Filter shall have no obligation to refund
the purchase price of any returned merchandise.

ENTIRE AGREEMENT. By acceptance of products from Buffalo Filter, Purchaser acknowledges and agrees to all of the terms and
conditions contained herein. No additional or different terms or conditions shall apply unless expressly accepted by Buffalo Filter in
writing in advance. All matters involving the validity, interpretation and application of this agreement shall be controlled by the laws
of New York State without regard to conflicts of laws rules..

JURISDICTION. Purchaser hereby consents to the jurisdiction of the New York Courts with respect to any controversy or dispute
arising out of this agreement or the merchandise sold hereunder.

LIMITED WARRANTY. Buffalo Filter will replace without charge, or at its option, refund the purchase price of, any goods which
Buffalo Filter determines to have contained a defect in material or workmanship as of the date of shipment for a period of three (3)
years from the date of delivery for P/N PSWTURBO and for a period of one (1) year from the date of delivery for all other goods,
provided, however, that Buffalo Filter is promptly notified of any suspected defect and is given the opportunity to inspect the goods in
question and the installation and use thereof. Using any filter not manufactured by Buffalo Filter may cause damage to the system
which will not be covered by this warranty.

THE FORGOING WARRANTY IS THE ONLY WARRANTY MADE BY BUFFALO FILTER AND IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT LIMITATION, THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. ALL WARRANTIES IMPLIED BY ANY COURSE OF
DEALING OR USAGE BETWEEN THE PARTIES ARE EXPRESSLY EXCLUDED AND NO PROMISE OR AFFIRMATION OF
FACT MADE BY ANY AGENT OR REPRESENTATIVE OF BUFFALO FILTER SHALL GIVE RISE TO ANY LIABILITY OR
OBLIGATION.

LIMITATION OF LIABILITY AND INDEMNIFICATION BY PURCHASER. BUFFALO FILTER SHALL NOT BE LIABLE IN ANY CASE
FOR SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND. IN NO CASE SHALL BUFFALO
FILTER'S LIABILITY EXCEED THE AMOUNT PAID BUFFALO FILTER BY PURCHASER FOR THE SPECIFIC SYSTEM
GIVING RISE TO THE LIABILITY. PURCHASER AGREES TO INDEMNIFY AND HOLD BUFFALO FILTER HARMLESS FROM
AND AGAINST ALL LIABILITIES, CLAIMS, AND DEMANDS OF THIRD PARTIES OF ANY KIND RELATING TO THE USE OF
PRODUCTS PURCHASED HEREUNDER.

CONFIDENTIAL INFORMATION. Any information, drawings, plans, or specifications furnished by Buffalo Filter have been developed
at Buffalo Filter's expense, are confidential and proprietary to Buffalo Filter. Recipients are granted a limited license to use such items
to install, operate, and maintain the products with which they are supplied and are not permitted to disclose such items or to use
them for any other purpose.