Conmed System 5000 Service manual

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Service Manual

E L E C T R O S U R G I C A L U N I T

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LIMITED WARRANTY

For a period of two years following the date of delivery,

CONMED Corporation warrants the CONMED System

5000™ Electrosurgical Generator against any defects in

material or workmanship and will repair or replace (at

CONMED’s option) the same without charge, provided

that routine maintenance as specified in this manual has

been performed using replacement parts approved by

CONMED. This warranty is void if the product is used in

a manner or for purposes other than intended.

525 French Road

Utica, New York 13502 U.S.A.

U.S. Patent Nos. 4,961,739 - 5,152,762 - 5,626,575-

6,830,569 - 6,835,082 - 6,875,210 - 6,939,347 -

D477,082 - D477,408.

For Technical Service or Return Authorization Phone:

303-699-7600 / 1-800-552-0138 Extension 5274

Fax 303-699-1628

For Customer Service or to order parts phone:

1-800-448-6506 / 315-797-8375 / Fax 315-735-6235

or contact your CONMED Representative.

European Authorized Representative

MDSS GmbH

Schiffgraben 41

D - 30175 Hannover

Germany

The revision level of this manual is specified by the

highest revision letter found on either the inside front cover

or enclosed errata pages (if any).

Manual Number 60-8017-ENG Rev. R 01/08

Unit Serial Number_________________________________

Page 3

Table of Contents

& List of Illustrations

Section Title Page

3.0 Theory of Operation ................................................................................... 3-1

3.1 Mode Descriptions .................................................................................................. 3-1

3.1.1 Cut Major Modes ..............................................................................................................................3-1

3.1.2 COAG Major Modes .........................................................................................................................

3.1.3 Bipolar Major Modes ........................................................................................................................

3.1.4 Advanced Specialty Modes ................................................................................................................

3.2 System Overview ..................................................................................................... 3-2

3.2.1 High Voltage Power Supply (HVPS) ................................................................................................3-3

3.2.2 RF Amplifier and Transformer ..........................................................................................................

3.2.3 Electrosurgical Outputs .....................................................................................................................3-5

3.2.4 Activation Command Sensing ...........................................................................................................

3.2.5 Automatic Return Monitor (A.R.M.

3.2.6 Low Voltage Power Sources ..............................................................................................................

3.2.7 System Controllers and Monitor .......................................................................................................

3.2.8 Low Voltage Power Monitoring ........................................................................................................

3.2.9 Operator Control Panel .....................................................................................................................

3.2.10 Activation Tones ................................................................................................................................

3.2.11 Activation Relay Connector ...............................................................................................................3-7

™) .............................................................................................3-5

3.3 Optional System Configurations ............................................................................. 3-7

4.0 Maintenance ................................................................................................ 4-1

4.1 General Maintenance Information ........................................................................... 4-1

4.2 Maintenance Personnel ............................................................................................

4.3 Assembly Breakdown/Parts Access .......................................................................... 4-1

4.3.1 Top Cover Removal and Replacement ...............................................................................................4-1

4.3.2 Bezel Removal and Replacement .......................................................................................................

4.3.3 Processor Board Removal and Replacement ......................................................................................4-3

4.3.4 Transformer Board Removal and Replacement ..................................................................................

4.3.5 Output Board Removal and Replacement .........................................................................................

4.3.6 RF Amp Board Removal and Replacement .......................................................................................

4.3.7 Low Voltage Power Supply Module Removal and Replacement ........................................................

4.3.8 High Voltage Power Supply Removal and Replacement ....................................................................

4.3.9 Rear Panel with Board Removal and Replacement ............................................................................

4.3.10 Back Panel Board Removal and Replacement ....................................................................................

4.3.11 Display Boards Removal and Replacement ........................................................................................

4.3.12 Power Transistor Replacement ...........................................................................................................

4.4 Cleaning ................................................................................................................. 4-8

4.5 Periodic Inspection .................................................................................................

4.6 Periodic Performance Testing ............................................................................................................4-9

4.6.1 Chassis Ground Integrity ...................................................................................................................

4.6.2 Displays, Alarms and Commands ......................................................................................................

4.6.3 Output Power ...................................................................................................................................

4.6.4 RF Leakage Measurement ...............................................................................................................

4.6.5 Line Frequency Leakage ..................................................................................................................

4.6.7 Output Coupling Capacitor Check ..................................................................................................

4.7 System Calibration ................................................................................................ 4-14

4.7.1 Calibration Preliminaries .................................................................................................................4-14

4.7.2 Selecting the Mode to Calibrate ......................................................................................................

4.7.3 Calibrating a Monopolar Mode .......................................................................................................

4.7.4 Calibrating Bipolar Modes ..............................................................................................................

3-1 3-2 3-2

3-4

3-5

3-5 3-5 3-6 3-6 3-6

4-1

4-2

4-3 4-4 4-4 4-5 4-6

4-6 4-7 4-7 4-8

4-8

4-9 4-9

4-9 4-10 4-12 4-14

4-16 4-16 4-16

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Section Title Page

4.7.5 Calibrating A.R.M.™ ......................................................................................................................4-16

4.7.6 Completing Calibration ...................................................................................................................

4-17

4.8 Last Fault Code Retrieval and Clear ..................................................................... 4-17

4.8.1 Last Fault Code Retrieval ...............................................................................................................4-17

4.8.2 Clearing Last Fault Codes ...............................................................................................................

4-18

4.9 Displaying Optional System Configuration ........................................................... 4-18

4.10 DACview ..............................................................................................................

4.11 Setting the Clock ..................................................................................................

4.12 Troubleshooting ....................................................................................................

4.12.1 HVPS Troubleshooting Hints .........................................................................................................4-23

4-20 4-21 4-21

4.13 Parts Ordering Information .................................................................................. 4-24

4.14 Fault Codes ...........................................................................................................

4-24

Figure/Title Page

Figure 3.1 RF Controller Block Diagram ................................................................................................................3-3

Figure 3.2 System Block Diagram ...........................................................................................................................

Figure 4.1 Calibration Procedure Flow Chart ........................................................................................................

Figure 4.2 DIP Switch Positions ...........................................................................................................................

Figure 4.3 Module Diagram ...................................................................................................................................

Figure 4.4 A12 Back Panel PCB Assembly .............................................................................................................

Figure 4.5 A9 RF Power Supply PCB Assembly ....................................................................................................

Figure 4.6 A7 RF Transformer PCB Assembly .......................................................................................................

Figure 4.7 A6 RF Amplifier PCB Assembly .........................................................................................................

Figure 4.8 A5 RF Output PCB Assembly ............................................................................................................

Figure 4.9 A4 Microcontroller PCB Assembly ......................................................................................................

Figure 4.10 A2 Display Controller PCB Assembly ...............................................................................................

Figure 4.11 A3 Display Light Panel PCB Assembly .............................................................................................

3-4 4-15 4-18

A-1 A-4 A-7

A-9 A-11 A-14 A-19 A-21 A-23

Table 4.1 Monopolar Cut Mode RF Output Power Accuracy .................................................................................

Table 4.2 Monopolar Coag Mode RF Output Power Accuracy .............................................................................

Table 4.3 Bipolar Mode RF Output Power Accuracy ............................................................................................

Table 4.4 Allowable RF Leakage Current to Ground ............................................................................................

Table 4.5 Allowable RF Leakage Current - Inactive Monopolar Outputs ..............................................................

Table 4.6 Allowable RF Leakage Current - Inactive Bipolar Outputs ...................................................................

Table 4.7 Line Frequency Allowable Leakage - Inactive .........................................................................................

Table 4.8 Line Frequency Allowable Leakage - Active ...........................................................................................

Table 4.9 DIP Switch Settings ...............................................................................................................................

Table 4.10 DACview Channels ..............................................................................................................................

Table 4.11 Troubleshooting ...................................................................................................................................

Table 4.12 Fault Codes ..........................................................................................................................................

Schematic 4.1 Interconnect Diagram ......................................................................................................................

Schematic 4.2 A12 Back Panel PCB .......................................................................................................................

Schematic 4.3a A9 RF Power Supply PCB - Power Factor Controller ....................................................................

Schematic 4.3b A9 RF Power Supply PCB - Forward Converter ...........................................................................

Schematic 4.4 A7 RF Transformer PCB .................................................................................................................

Schematic 4.5 A6 RF Amplifier PCB ...................................................................................................................

Schematic 4.6a A5 RF Output PCB - Interconnect & Switching Isolation ...........................................................

Schematic 4.6b A5 RF Output PCB - Relays & Sensing ......................................................................................

Schematic 4.7a A4 Microcontroller PCB - Controller Interconnect ......................................................................

Schematic 4.7b A4 Microcontroller PCB - Microcontroller ..................................................................................

Schematic 4.7c A4 Microcontroller PCB - RF Controller .....................................................................................

Schematic 4.7d A4 Microcontroller PCB - RF Monitor .......................................................................................

Schematic 4.8 A2 Display Controller PCB ...........................................................................................................

Schematic 4.9 A3 Display Light Panel PCB .........................................................................................................

4-9 4-10 4-10 4-11 4-12 4-12 4-12 4-13 4-19 4-20 4-21 4-25

A-2 A-3 A-5 A-6

A-8 A-10 A-12 A-13 A-15 A-16 A-17 A-18 A-20 A-22

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Theory of Operation

Section 3.0

System 5000™ functions and essential circuit information are provided in this section. This section begins with a description of the key parameters for each mode. This is followed by an overview of how the system functions and some key operational information for the modules within the system.

3.1 Mode Descriptions

The key functional parameters for each mode are presented here. Nominal mode specifications are provided in section 1.2.11.

3.1.1 Cut Major Modes

Major mode

CUT PURE 391 KHz None None

Minor Mode

BLEND 1 391 KHz 16 pulses

BLEND 2 391 KHz 11 pulses

BLEND 3 391 KHz 10 pulses

Activation of Pulse Cut will make the selected cut mode, Pure Cut, Blend 1, Blend 2, or Blend 3 active for 70 milliseconds every 600 milliseconds.

NOTE: The low duty cycle of Pulsed Cut mode makes the average power very low – about 12%– when compared with the power displayed on the

RF frequency Modulation: Number of

Pulses, Time on/off

40µs/10µs

28µs/23µs

26µs/24µs

front panel. The period is also long causing most ESU analyzers to provide erratic or erroneous readings. Correct power can be verified by mea suring the peak to peak current and comparing the value with the current measured in the non-pulsed mode.

Modulation: Frequency & period

20 KHz

50µs

20 KHz

50µs

20 KHz

50µs

3.1.2 COAG Major Modes

Major mode

COAG PINPOINT 391 KHz 4 pulses

Minor Mode RF frequency Modulation: Number

of Pulses, Time on/off

10µs/40µs

STANDARD 562 KHz Single pulse 39 KHz

SPRAY 562 KHz Single pulse 19 KHz

Modulation: Frequency & period

20 KHz

50µs

Activation of Pulse Coag will make the selected coag mode, either Standard or Spray, active for

2.5 milliseconds every 5 milliseconds. Displayed power setting will represent the average power being delivered which is approximately half the power delivered during the pulses.

Standard and Spray Coag modes are fundamental ly different from the Cut modes in that the reso

nant circuit of the RF Amplifier and Transformer combination is excited by the energy of a single pulse, causing the resonant circuit to ring until the energy is dissipated. Circuitry in the amplifier

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provides further damping to dissipate the energy more quickly to minimize RF leakage effects. Spray Coag provides the maximum open circuit voltage for which the system is rated.

3.1.3 Bipolar Major Modes

Major mode

BIPOLAR MACRO 391 KHz None None

Minor Mode

MICRO 391 KHz None None

RF fre quency

Modulation: Number of

Pulses, Time on/off

Modulation: Frequency & period

3.1.4 Advanced Specialty Modes

Specialty Mode Effect

General Normal open surgery mode – Parameters noted above.

Fluids Temporarily increases power upon activation for faster initiation. Duration and power increase

vary with mode and power setting

Lap Limits maximum peak voltage for safer laparoscopic surgery. This action does affect the load

curves when in high impedance tissue, or using normally high voltage modes.

3.2 System Overview

Mains power is converted to electrosurgical output power through the High Voltage Power Supply (HVPS), the RF Amplifier, and the Transformer and Output sections of the system.

Mains power is converted to high voltage direct current power in the HVPS to supply the RF Amplifier. This universal input power factor cor rected, single output, switch mode power supply is adjustable under software control with 10-bit resolution. The HVPS output and power factor correction sections of the HVPS can be enabled or disabled under software control. The HVPS uses a current mode two-switch forward converter topology with short circuit protection and over voltage limiting.

Pulses generated in the RF Controller are ampli fied to electrosurgical power and voltage levels in the RF Amplifier and Transformer portions of the power train. The RF Amplifier and Transformer form a resonant switched mode amplifier with multiple outputs that are selected on a mode-bymode basis using relays on the primary and sec ondary side of the transformers. One transformer is used for monopolar outputs, while the other transformer is for the bipolar output.

Electrosurgical power flows from the RF Amplifier and Transformer sections to the Output section where the power is switched to the specific electrosurgical outputs. The Output section also has circuitry to detect activations from accessories

and the circuitry to perform the Automatic Return Monitor (A.R.M.™) function to ensure the integ rity of the dispersive electrode connection.

The power section also includes a number of out put voltage and current sensors that are used by the RF Controller for control of power delivery and by the Monitor to detect errant output condi tions.

The RF Controller is a Digital Signal Processor (DSP) that generates an RF Amplifier drive sig nal based upon measured parameters compared with settings-based parameters. The pulse train sequence is a settings-based parameter that is dependent on the selected mode. Target power, current limit, voltage limit, and impedance thresh olds are all settings-based parameters derived from a load curve that is specific to the front panel power setting. The RF Controller samples electrosurgical output voltage and output cur rent from sensors over 450,000 times per second and uses these sampled values to calculate output power and sensed impedance. The output power, output current, output voltage, and sensed imped ance are compared with corresponding settingsbased parameters of target power, current limit, voltage limit, and impedance threshold; respec tively; and the RF Controller adjusts the width of individual pulses within each mode-based pulse train sequence in a closed-loop fashion to control corresponding output power. The RF Controller also adjusts the HVPS output more slowly, allow ing adjustment of the RF Amplifier drive pulses

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Voltage

sampled

450,000

times per

second

Current

sampled

450,000

times per

second

Power

setting –

watts

displayed

on the front

panel

Calculate measured resistance

Calculate measured

power

Compare

Desired

Power

Measured

Power

Adjust output

waveform

(power)

Patient

100

120

140

160

180

200

0 500 1000 1500 2000

180

Figure 3.1 RF Controller Block Diagram

to optimize the electrosurgical output waveform. Finally, the RF Controller minimizes RF leakage currents using the CONMED Leakage Abatement System (CLAS™), which imposes a duty cycle on the electrosurgical output when sensed impedance and output voltage exceed settings-based imped

ance thresholds and voltage limits in the Coag modes.

The RF Monitor is also a DSP, but it is used to monitor the system for a variety of conditions that could lead to safety problems, including:

• The Monitor has independent sensors for out put voltage and current, which it uses to cal

culate power for comparison with the power that the RF Controller senses and for com

parison with the generator power setting.

• To ensure that the correct outputs are acti

vated, the Monitor also independently senses current at each of the outputs, look

ing for current flow that would indicate electrosurgical power at outputs other than the selected output.

• The Monitor senses the voltage at the output of the HVPS to ensure that it is reasonable for the power setting.

• The Monitor senses the audio output to ensure that a tone occurs whenever electrosurgical outputs are active.

• The RF Amplifier drive signal is sensed by the Monitor to detect improper frequencies or improper pulse sequences for the selected mode.

• The Monitor independently compares the activation signal with that seen by the System Controller to ensure that the activation signal is consistent.

The Monitor has the capability to independently disable the electrosurgical output if a problem is detected.

The System Controller provides the primary con trol interface to the user and other outside sys tems, including the serial interface, the activation relay, tone generation, and displays.

Finally, the Display accepts all user input and provides all user feedback. The Display is controlled by the System Controller through a serial interface and illuminates the LED display elements in a time division multiplexed fashion; the illuminated LED display elements are actually on less than half the time. The Display also provides for user input through the buttons on the control panel, includ ing switch de-bouncing and conditioning.

Figure 3.2 illustrates the key elements of the sys tem in block diagram form.

3.2.1 High Voltage Power Supply (HVPS)

The HVPS is comprised of a Power Factor Control (PFC) section and a Forward Converter (FC) section. The PFC converts Mains power to approximately 400 volts using techniques that ensure the mains current into the supply is sinusoidal and in phase with the mains voltage. By doing so, RMS current and harmonic distor tion are reduced. The Forward Converter then

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Real Time Clock (5K)

Indicators:

Power, Mode,

& bipolar

current

Displays

Keyboard

Modes / Power

Activation

Request

System

Controller

RF Controller

RF Monitor

RF Amp

RF Output

Board

HV Power

Supply

Bip

Mon

RFHVSup

MRF H1 SN MRF H2 SN MRF FT SN

MRF BP ISN

MRF BP VSN

MRF MP ISN

MRF MP VSN

M HVDC

/HV EN

Tone

Mon

WF EN

WFORM

DAMP CNTL

RLY DRV

RF BP IS

RF BP VS

RF MP IS

RF MP VS

HV SET

PFC EN

BIP TONE

ACT TONE

AL TONE

RS232

ACT RLY

Serial Interface

Connector

Activation Relay

Connector

Host

Bus

SPI

Patient

RF INH

Mon

Transformer

Board

VARM

Figure 3.2 System Block Diagram

converts the PFC output to an adjustable DC voltage for use by the RF amplifier.

The System Controller can enable or disable the PFC section of the HVPS. The PFC is normally enabled during operation to ensure a resistive load is presented to the Mains.

The Forward Converter is a switch-mode power converter that adjusts its operating frequency between 25KHz and 100KHz to ensure proper resolution for the commanded output volt age. Isolation between Mains power and the

3-4

HVPS output occurs in the Forward Converter. Forward Converter output voltage is set from the RF Controller by the /HVSET signal. The RF Monitor enables the output of the HVPS. The forward converter includes current limiting on the output and has provisions to shutdown when the output of the Low Voltage Supply exceeds limits.

3.2.2 RF Amplifier and Transformer

The RF Amplifier and Transformer portions use a switch-mode resonant amplifier to convert the power from the HVPS to the RF energy neces

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sary for electrosurgery. One may think of the amplifier as a high-speed switch that pulses cur rent through a resonant circuit, which is formed by the monopolar or bipolar transformer together with capacitors and inductors connected to the transformer primary and secondary windings. Two Metal-Oxide-Semiconductor Field Effect Transistors (MOSFETs) are connected in a paral lel fashion provide the switching. The pulses to drive the gates on the MOSFETs in this arrange ment come from the RF Controller. Adjusting the width of the drive pulses regulates the output power in this arrangement; as the pulses become longer, the output power increases. As noted in the RF Controller discussion, the RF Controller compares the output power with the desired power and adjusts the pulse width to minimize the difference.

A drive of several pulses at a frequency that closely matches the resonant frequency of the amplifier characterize Cut, Blend, and Pinpoint modes, and the output pulses substantially correspond to the drive. Spray and Standard Coag modes, how ever, are characterized by pulses that occur less frequently where the amplifier is allowed to “ring” at its resonant frequency. A damping capability is provided to enhance the surgical effect by damp ing the ringing effect for each drive pulse.

Because the transformer windings and the reso nant frequencies between the cut and coag modes are different, a method of selecting resonating components is implemented using relays. These relays switch in the relevant components for the selected mode based upon commands from the System Controller.

A Balun transformer is provided for the monopolar modes to reduce differences between the source and return currents, thus reducing RF leakage.

Finally, the RF Amplifier and Transformer provide capabilities for sensing RF output current and voltage. These are transformer-isolated representations of the current flowing in the leads and the voltage across the output, which are supplied to the RF Controller and the Monitor processors.

3.2.3 Electrosurgical Outputs

Relays are provided to isolate electrosurgical out puts and select which outputs are active. The System Controller selects the appropriate output relays based upon activation command inputs.

The Monitor utilizes sensors implemented on each electrosurgical output to determine whether cur rent is flowing only to the correct outputs. In the event that current flows in an output that is not selected, the Monitor can independently disable RF.

The System 5000™ output panel connectors are illuminated to aid visibility in low lighting situ ations. This illumination is provided by a single LED on the display board that is distributed to the receptacles through a fiber-optic bundle.

3.2.4 Activation Command Sensing

Each of the Hand Controlled Accessory recep tacles incorporate inputs that are used to sense an activation command from the user. Each monopolar hand controlled accessory receptacle has an input for cut and an input for coag. The bipolar receptacle incorporates a single activation input. Each of these five inputs is isolated from the other electrosurgical outputs and from other low-level circuitry in the system. All are powered by a multiple output isolated power supply. The footswitch activation inputs on the back panel are configured in a similar way and share one of the isolated power supply outputs.

3.2.5 Automatic Return Monitor (A.R.M.™)

The patient return connector interfaces to single and dual dispersive electrodes using a two-pin connector. A.R.M.™ circuitry uses an actively driven impedance measurement circuit, which allows the System Controller to detect the type of dispersive electrode connected and verify its integrity.

3.2.6 Low Voltage Power Sources

The low voltage power supply is a medical-grade universal input offline triple output switching power supply. The power supply is active anytime Mains power is connected to the unit with the Mains power switch turned on.

3.2.7 System Controllers and Monitor

Three processors are used for system interface & control, RF control, and system monitor func tions. The ESU control section consists of dual channel architecture with two independent chan nels where one is used exclusively for RF output control and the other is used for safety monitor ing. All three of these processors are located on

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the Control board, along with circuitry to isolate them from RF noise.

• System Controller (System Microcontroller): A dedicated microcontroller that handles the entire user interface, Serial Interface, real time clock functions, and enables/disables the power factor control section of the HVPS using the PFC_EN signal. The System Controller can also disable the signal used to drive the RF Amplifier and can terminate RF drive at any time without interaction from either the RF Controller or the Monitor. The System Controller is comprised of an standard architecture microprocessor together with Field Programmable Gate Array (FPGA), which provides interface logic to a variety of signals, a 3.68MHz oscillator, independent voltage regulators, a processor supervisory reset circuit, and other interface logic.

• RF Controller: A DSP that is dedicated to the output and control of RF power using the DAMPCNTRL and RF_DRV outputs. To reduce the effects on the microproces sor circuits on the Controller board from RF noise at the output, DAMPCNTRL and RF_DRV are both differential mode signals running between the RF Controller and the RF Amplifier. The RF Controller is capable of disabling RF output power and put ting the system into a safe state without any interaction from the Monitor or the System Controller. The RF Controller indepen dently monitors the RF output voltage and current for control purposes through several scaled inputs. It sets the output voltage of the HVPS using the HV_SET signal dependent on the output Mode and power selected. The RF Controller controls the fan based upon temperature measurements supplied from the RF Amplifier through the System Controller. The RF Controller is comprised of a DSP, together with circuitry necessary for convert ing the signals used for control purposes between analog and digital form, independent voltage regulators, and other interface logic.

• RF Monitor: A DSP that is dedicated to safety monitoring activities. The Monitor is capable of disabling RF output power and putting the system into a safe state without any interac tion from the RF Controller or the System Controller. To ensure that the Monitor can correctly perform its function, the Monitor is

resistively isolated from the other two proces sors and has independent voltage regulation. The RF Monitor independently monitors a variety of inputs to detect safety problems and has control of disable signals for both the HVPS and RF Amplifier drive. The Monitor is comprised of the same DSP as the RF Controller, together with circuitry necessary for converting the signals monitored between analog and digital form, an FPGA to provide interface logic, independent voltage regula tors, isolation resistors and other interface logic.

3.2.8 Low Voltage Power Monitoring

The low voltage power supply is monitored in hardware and resets the processors if it is out of range. The microprocessor supervisory device on the Controller board monitors +5V and +3.3V and will reset the system should the levels drop approximately 0.3V. The Controller assembly has the circuit that will reset the system should the 3.3V supply exceed 3.6V. The High Voltage power supply has a circuit that will inhibit HVDC should the +5V supply exceed 5.7V.

3.2.9 Operator Control Panel

Keyboard: The main operator input device for choosing operating modes and settings is the membrane keyboard panel. Tactile-feedback mechanical switches allow the operator to set modes and adjust power settings.

Display Panel: Consists of 7-segment displays, discrete dual colored LED’s, and light bars that will display all controls and settings. LED display elements are illuminated in a time division multi plexed fashion; the illuminated LED display ele ments are actually on less than half the time.

Bipolar Current Meter: The System 5000™ has a bargraph display that provides an indication of measured bipolar impedance. A special

tone works in conjunction with this bargraph to indicate when the measured bipolar impedance exceeds a particular limit.

3.2.10 Activation Tones

Tone is generated for all activation requests, fault detection and changes made on the Control Panel. The System Controller generates the tone signal (ACT_TONE, AL_TONE, & BP_TONE), which is amplified by a driver on the Backpanel PCB Assembly. The activation tone and bipolar tone

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are individually adjustable, but alarm tones are not adjustable and are set to generate tone greater than 65 dB.

Circuitry on the Backpanel PCB permits the Monitor to verify the oscillation from voltage measured across the speaker, which provides confirmation that the speaker is indeed generat ing audible tones during activation. RF output is inhibited should the speaker drive current be absent or too low.

3.2.11 Activation Relay Connector

There is an Accessory Relay Connector, which provides a relay closure (SPST switch) that may be used for activating external accessories such as smoke evacuation units.

3.3 Optional System Configurations

An eight-position configuration dipswitch (S2), located on the Controller PCB Assembly (A4) allows a qualified service technician to change some of the factory default settings. With the exception of the DACview switch, the configura tion dipswitch settings are only detected when power is initialized, so any changes to the switch positions must be made with the main power off. Each switch is OFF in the Down position and ON in the UP position. The system detects changes in the DACview switch while power is on, so it is treated differently. Relevant informa tion for the configuration dipswitches appears in Section 4.9.

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This page has been intentionally left blank.

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Maintenance

Section 4.0

This section contains information useful in the maintenance and repair of the System 5000™.

WARNING: High voltages are present at the connections and within the System 5000™. Maintenance personnel should take precautions to protect themselves. Read the safety sum mary in Section 1.1.4 before working on the ESU.

4.1 General Maintenance Information

Although the System 5000™ has been designed and manufactured to high industry standards, it is recommended that periodic inspection and perfor mance testing be performed to ensure continual safe and effective operation.

Ease of maintenance was a primary consideration in the design of the System 5000™. Maintenance features of this unit include microprocessor aided troubleshooting aids and push button calibration, built in fault detection, circuit protection, and easy access to circuitry while the unit is operational. These features, coupled with the warranty, local support, loaner equipment, factory support, toll free phone service to the factory and available fac tory training ensure the user of a minimal mainte nance effort with extensive support available.

4.3.1 Top Cover Removal and Replacement

Top Removal:

1) Remove the two screws located on rear of unit as shown.

2) Pull back and up to remove top.

Cover Screws

4.2 Maintenance Personnel

Only qualified biomedical engineers should perform service on the System 5000™. Refer all servicing to a qualified biomedical engineer. If necessary, your CONMED sales representative will be happy to assist you in getting your equipment serviced.

4.3 Assembly Breakdown/Parts Access

CAUTION: This device contains components that can be damaged by static electricity. Proper handling by grounding of personnel during servicing is mandatory.

Following are instructions for unit disassembly and reassembly instructions.

Side Clips

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Top Replacement:

1) Place top approximately ¾” from front bezel on top of unit.

2) Press forward, aligning lip of front bezel with groove in top and side clips with tabs on cast ing.

3) Re-install screws.

3) Unlatch display ribbon cable, dispersive electrode connector, ReadiPlug™ cable connector and two ground connectors.

4) In most situations, it is not necessary to

remove the four power switch connectors. The bezel can be rotated off to the right side for output board removal. To fully remove the bezel, these connectors must be disconnected.

Slide top forward.

4.3.2 Bezel Removal and Replacement

Bezel Removal

1) Remove Top.

2) Remove two flat-head screws on side of bezel and two pan-head screws on bottom of bezel.

AC Power Switch

White

Blue

Black

Brown

Bezel Replacement:

1) Connect power switch connectors as shown, if required.

2) Connect dispersive electrode connector and ReadiPlug

™ cable connector prior to sliding

bezel into place.

3) Slide bezel into unit. As shown in figure, the output board insulator is positioned between the sheet metal base and the Output Board.

4-2

Insulating Sheet

4) Reconnect cables and replace and tighten screws.

Spring contacts are exposed and can be deformed, causing erratic operation. Handle with care.

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4.3.3 Processor Board Removal and Replacement

Processor Board Removal

1) Remove Top.

2) Loosen the two screws holding the board to slots in the brackets.

3) Unlatch the ribbon cable going to the display.

4) Pull board up and out of unit.

Processor Board Replacement:

1) Align board into the two slots of the brackets attached to the heatsinks. Align with con

nector on Output Board and press firmly to engage it fully. Tighten the two screws.

4.3.4 Transformer Board Removal and Replacement

3) Unlatch the ribbon cable and power cable on the top of the board.

4) Pull board towards inside of unit so screws line up with keyholes, then up and out of unit. The power cable to RF Amp must be unplugged to completely remove transformer board.

Transformer Board Replacement

1) Reverse board removal operation.

NOTE: When servicing unit, board can be sup ported in heatsink as shown. This will provide access to the lower boards while the unit is func tional.

Transformer Board Removal

1) Remove Top.

2) Loosen the two screws mounting the board to the keyhole slots on standoffs and two screws mounting the board to the heatsink.

Align slot in board with rib on heatsink.

Route cable through slot.

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Page 16

4.3.5 Output Board Removal and Replacement

4.3.6 RF Amp Board Removal and Replacement

Output Board Removal

1) Remove Top, Bezel and Processor Board.

Note: It is not necessary to remove power switch connections from the bezel.

2) Remove the seven cables along the rear side of the board and the three screws shown.

Spring contacts are exposed and can be deformed, causing erratic operation. Handle with care.

Output Board Replacement:

1) Prior to replacing board, assure that the insu lator sheet is positioned properly as shown.

RF Amp Board Removal

1) Remove Top, Bezel and Transformer Board.

2) Remove the four screws that attach the heatsink to the sheet metal chassis. One for the handle, one on the back panel, and two below the heatsink. Remove the two screws that attach the board to the sheet metal chassis as shown. Note: These screws are in holes, not slots.

3) Unlatch three cables – two cables from the RF Output Board and a cable from the RF Power Supply Board.

4) Loosen the smaller hex standoff.

5) Slide RF Amp Board with heatsink off the base as shown.

Note: The insulator sheet provides an important dielectric barrier. For safe operation, position over center standoff as shown.

2) Replace board on standoffs.

3) Route cables as they were prior to removal and connect them back to their proper con nectors.

4) Replace and tighten the three screws.

4-4

RF Amp Board Replacement:

1) Slide board with heatsink back into its previ

ous position on the sheet metal chassis. The heatsink has two pins that align into holes on the sheet metal chassis.

2) Tighten hex standoff onto board. It provides an electrical ground to Transformer Board.

3) Reinstall and tighten the six screws and latch the three cables.

Page 17

4.3.7 Low Voltage Power Supply Module Removal and Replacement

NOTE: This module is not user serviceable at the component level. If faulty, the entire cir

cuit board must be replaced. Replacements are available from CONMED Customer Service. Do not discard the module cover, mount

ing plate and hardware; the replacement part includes only the circuit board.

Low Voltage Power Supply Module Removal:

1) Remove Top Cover.

2) Loosen four screws located in slots and unlatch the two cables.

3) Slide Low Voltage Power Supply Module inward off the slots, then upward to remove.

Circuit Board

4) Remove the cover by removing four screws. Then remove the four standoffs to separate the Low Voltage Power Supply from its mounting plate.

NOTE: When servicing unit, board can be held in heatsink as shown. This will provide access to the lower boards while the unit is functioning.

Low Voltage Power Supply Module Replacement:

1) Replace Low Voltage Power Supply on mounting plate, fasten standoffs, replace cover and tighten screws.

2) Place Low Voltage Power Supply Module into unit on standoffs. Tighten the loose screws and latch the two connectors.

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Page 18

4.3.8 High Voltage Power Supply Removal and Replacement

High Voltage Power Supply Board Removal

1) Remove Top Cover. Position Transformer Board in its servicing position to gain access to screws. If desired, remove the Low Voltage Power Supply.

2) Unlatch the Mains Power Cable, RF Amp Cable, and Output Board Ribbon Cable.

3) Loosen the two screws holding the edge of the board to the chassis.

4) Remove the screw to the handle, the screw to the back panel, the two screws on the bottom of the heatsink and slide out the heatsink with the board attached.

Note: Observe the position of the insulating sheet under the High Voltage Power Supply. If the insulating sheet is removed, replace it as shown. It is important to maintain its function as a dielectric barrier and to protect the ribbon cable from the leads of the High Voltage Power Supply Board.

Insulating Sheet

4.3.9 Rear Panel with Board Removal and Replacement

High Voltage Power Supply Board Replacement:

1) Slide board with heatsink back into its previ ous position on the sheet metal chassis. The heatsink has two pins that align into holes on the sheet metal chassis.

2) Reinstall and tighten the six screws and latch the three cables.

Rear Panel with Back Panel Board Removal

1) Remove Top Cover.

2) Unlatch the Ribbon Cable.

3) Remove the four screws on the bottom of the Rear Panel, and the three screws shown on the Rear Panel.

4) Slide the Rear Panel with Back Panel Board back toward the handle and then down to remove.

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Rear Panel with Back Panel Board Replacement:

1) Slide Rear Panel with Back Panel Board back into place on the unit.

2) Reinstall and tighten the seven screws and latch the ribbon cable.

4.3.10 Back Panel Board Removal and Replacement

Back Panel Board Removal

1) Remove Top Cover and Rear Panel.

2) Unlatch the Activation Relay and Fan connectors.

3) Remove the four screws for the foot switch connectors, the two nuts on the volume potentiometers and the two screws to the rear panel sheet metal standoffs. This will free the Back Panel Board from the Rear Panel.

Back Panel Board Replacement:

1) Install Back Panel Board to Rear Panel

2) Reinstall and tighten the six screws, two nuts. Latch the RSA and fan cables.

7) Remove the Display Controller Board by separating it from the display board and pulling it off the studs. There are two 40-pin connec tors between these boards that may require separation by prying with a blunt object.

8) Remove the five hex standoffs and pull the Display board off the studs.

Display Boards Replacement

Caution: When reinstalling Boards and display shield, take care to route fiber optic cable as shown to avoid crimping it between the bezel and display shield.

4.3.11 Display Boards Removal and Replacement

Display Boards Removal

1) Remove the Top Cover and Bezel.

2) Remove 8 nuts and two ground cables on the back of the display shield.

3) Disconnect the ribbon cable and remove the sheet metal display shield.

4) Slide the round spacers off their studs.

5) Disconnect the flex circuit connector. Caution: The flex circuit has a short service loop and is fragile; handle with care.

6) Pull to disconnect the fiber optic cable from LED. Caution: The fiber optic cable is frag ile; handle with care.

1) Reinstall boards in the reverse order described above. Latch the flex circuit connector, press fiber optic cable onto the LED and press the Display Controller Board firmly into place on the two 40 pin connectors.

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4.3.12 Power Transistor Replacement

Caution: This device contains components that can be damaged by static electricity. Proper handling by grounding of personnel during servicing is mandatory.

All RF Power Supply and RF Amp components mounted to the heatsink may be replaced.

only components supplied by CONMED.

Follow these instructions for replacement:

1) No thermal compound is necessary, but the mating surfaces of the transistor, insulator pad and surface of casting should be clean. Always replace the insulator pad associated with the transistor. Always fasten or clamp the part to the heat sink surface prior to sol dering it to the board. This will assure good thermal contact is maintained.

2) In order to maintain alignment with the heat sink surface, the leads of these parts have been bent to the proper shape. They should be purchased from CONMED with bent leads.

3) When installing the RF Amp transistors or diodes, be sure to orient the Bellville washer as shown with the convex surface next to the head of the screw. Tighten screws to 5-7 inch pounds.

Use

4) When installing the RF Power Supply transistors or diodes, replace components as shown and ensure the insulating tube is installed over the clip. Locate the part on the clip so that the bend of the clip is approximately centered on the body of the part as shown. Tighten screw to 8-10 in-lbs. When tightening screw, hold the clip to prevent it from rotating. Clamp the part to the heatsink surface prior to soldering to the board.

4.4 Cleaning

The interior of the unit may be vacuumed or blown out as required. The exterior of the unit may be cleaned by wiping it with a cloth that has been dampened (not dripping) with a mild detergent such as Windex® or Formula 409®. Windex® is a registered trademark of the S.C. Johnson Company. Formula 409® is a registered trademark of the Clorox Company.

4.5 Periodic Inspection

The System 5000™ should be visually inspected at least every six months. This inspection should include checks for the following:

1) Damage to the power cord and plug.

2) The proper mating and absence of damage to the accessory connectors.

3) Any obvious external or internal damage to the unit.

4) An accumulation of lint or debris within the unit or heatsink.

5) Control Panel cuts, punctures, or dents.

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4.6 Periodic Performance Testing

4.6.3 Output Power

The System 5000™ should be tested for correct performance at least once every year. Every unit is supplied with a serialized Production Test Data Sheet that tabulates the results of the factory tests that were performed on the unit. This data is supplied so that it may be used as a reference for subsequent tests. Recommended periodic perfor

mance tests are listed in the following sections.

4.6.1 Chassis Ground Integrity

Connect a standard ohmmeter between the earth ground prong on the power plug and the Equipotential Ground Connection. Compensate for lead resistance. Confirm less than 0.2 ohms resistance is measured.

4.6.2 Displays, Alarms and Commands

Perform the Preliminary Functional Test procedure described in section 2.3.1 of this manual to verify proper operation of displays, alarms and com

mands.

1) Equipment Requirements:

a) Monopolar Footswitch

b) Bipolar Footswitch

c) Commercial ESU Tester (e.g. Dynatech

454A or equivalent) with 50 and 300 ohm loads for bipolar modes and a 500 ohm load for monopolar modes.

Note: Micro Bipolar is particularly sensitive to the load resistance. A 50 ohm load should be used for checking power to obtain the best results.

2) Use test leads to connect the ESU tester to the unit’s return electrode output and the footswitch controlled active output. Set the Load resistance per mode as indicated in Tables 4.1 and 4.2.

3) Perform the monopolar power tests indicated in Tables 4.1 and 4.2. The acceptance range is given in both Watts and Amps to accom modate available test equipment. It is not nec essary to test for both power and current.

Table 4.1 Monopolar Cut Mode RF Output Power Accuracy

Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)

Pure 500 10 7 13.0 0.118 0.161

Standard

Blend 1 500 10 7 13.0 0.118 0.161

Blend 2 500 10 7 13.0 0.118 0.161

Blend 3 500 10 7 13.0 0.118 0.161

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 100 90 110 0.424 0.469

500 200 180 220 0.600 0.663

500 300 270 330 0.735 0.812

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 100 90 110 0.424 0.469

500 200 180 220 0.600 0.663

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 100 90 110 0.424 0.469

500 200 180 220 0.600 0.663

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 100 90 110 0.424 0.469

500 200 180 220 0.600 0.663

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Table 4.2 Monopolar Coag Mode RF Output Power Accuracy

Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)

Spray 500 10 7 13.0 0.118 0.161

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 80 72 88 0.379 0.420

Standard

500 10 7 13.0 0.118 0.161

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 100 90 110 0.424 0.469

500 120 108 132 0.465 0.514

Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)

Pinpoint 500 10 7 13.0 0.118 0.161

500 20 17 23.0 0.184 0.214

500 50 45 55 0.300 0.332

500 100 90 110 0.424 0.469

500 120 108 132 0.465 0.514

Standard pulse

Spray pulse

500 10 7 13.0 0.118 0.161

500 20 17 23 0.184 0.214

500 60 54 66 0.329 0.363

500 10 7 13.0 0.118 0.161

500 20 17 23 0.184 0.214

500 40 36 44 0.268 0.297

4) Disconnect the ESU tester from the unit.

5) Use test leads to connect the ESU tester to the Bipolar Accessory outputs.

6) Perform the bipolar power tests indicated in Table 4.3. This table only provides the mini mum number of points to be tested.

Table 4.3 Bipolar Mode RF Output Power Accuracy

Mode Load (ohms) Power Setting Watts (min) Watts (max) Amps (min) Amps (max)

Macro Bipolar

Micro Bipolar

4.6.4 RF Leakage Measurement

RF Leakage can present a hazard in the operating room because electrosurgical currents can flow to the patient and operating room staff through unintended paths, which can cause injury. RF

300 10 7 13.0 0.153 0.208

300 20 17 23.0 0.238 0.277

300 50 45 55 0.387 0.428

300 90 81 99 0.520 0.574

50 10 7 13.0 0.374 0.510

50 25 22 28.0 0.663 0.748

50 50 45 55 0.949 1.049

leakage occurs because the total energy in the output voltage waveform is provided with a con ductive path through stray parasitic capacitance distributed within the generator and along the length of the leads. Table 4.4 presents the allowed RF leakage currents to ground.

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Table 4.4 Allowable RF Leakage Current to Ground

MEASURED TERMINAL ACTIVATED ACCESSORY MODE RF LEAKAGE (Ma)

Dispersive Electrode Coag Footswitch Standard Coag < 100

Dispersive Electrode Cut Footswitch Pure Cut < 100

Dispersive Electrode Left Hand Controlled Standard Coag < 100

Dispersive Electrode Right Hand Controlled Standard Coag < 100

Footswitched Active Coag Footswitch Standard Coag < 100

Left Hand Controlled Active Left Hand Controlled Standard Coag < 100

Right Hand Controlled Active Right Hand Controlled Standard Coag < 100

Bipolar Right Bipolar Footswitch Bipolar Macro < 67

Bipolar Left

Bipolar Footswitch

Bipolar Macro

< 67

Equipment:

• ESU Tester with RF Leakage function -OR-

• 0-250 mA RF Ammeter with a 200 ohm 10 W Non-inductive Resistor

• Patient Plate Adapter Plug

• 2 - Test leads, 1 m max. length

• 3 - Test leads, 10 cm max. length

• Wooden table approximately 1 m from floor.

NOTE: The CONMED Leakage Abatement System (CLAS™) controls RF leakage by puls

ing the output to reduce the RMS voltage during open circuit conditions, thus keeping the hazard ous energy below IEC safe limits. Use a measur

ing device that meets IEC specification for RMS measured over one second.

Procedure:

1) Ensure that the unit is fully assembled and all fasteners are tight.

2) Place the ESU tester or meter with resistor on the table so that they are at least 0.5m away from the unit under test and any other con

ductive surface.

3) Set the unit for full power for the modes noted in the table. Connect the ESU tester in accordance with the manufacturer’s instructions -OR- connect the 200-ohm noninductive resistor in series with the 250 mA RF ammeter to the Equipotential Ground Connection on the Rear Panel. Also make sure there are no connections to any output other than the one you are measuring.

WARNING: HAND CONTROL ACTIVATIONS SHOULD BE KEYED USING 3” OR LESS WELL-INSULATED JUMPER. USE OF AN INSULATING ROD TO INSERT THE JUMPER IS ADVISED TO PREVENT RF BURNS.

3) One at a time, connect test setup to each RF output terminal indicated in Table 4.4 and activate the unit using the corresponding command. Confirm no meter readings exceed the specified maximum. Hand control coag activations are accomplished by connecting a jumper between the left jack and center jack of the desired hand switched accessory jack.

RF leakage should also be measured between inac tive outputs and the Dispersive Electrode connec

tion. The procedure is as follows:

1) Set the unit for full power for the modes noted in Table 4.5. Connect the ESU tester according to manufacturer’s instructions OR- the 200-ohm non-inductive resistor in series with the 250 mA RF ammeter to the Dispersive Electrode connection on the front panel. Also make sure there are no connec

tions to any output other than the one you are measuring.

2) One at a time, connect this series combination to each RF output terminal indicated in Table 4.5 and activate the unit using the corresponding command. Confirm that no meter readings exceed the specified maximum.

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Table 4.5 Allowable RF Leakage Current - Inactive Monopolar Outputs

MEASURED TERMINAL ACTIVATED ACCESSORY MODE RF LEAKAGE (Ma)

Footswitched Active Left Hand Controlled Standard Coag <50

Footswitched Active Right Hand Controlled Standard Coag

Footswitched Active Bipolar Footswitch Bipolar Macro

Left Hand Controlled Active Right Hand Controlled Standard Coag

Left Hand Controlled Active Bipolar Footswitch Bipolar Macro

Right Hand Controlled Active Bipolar Footswitch Bipolar Macro

Bipolar Left Right Hand Controlled Standard Coag

<50

<20

<50

<20

<40

<48

Finally, RF leakage should be measured between the inactive bipolar outputs while a monopolar accessory is activated. Do the following:

1) Set the unit for full power for the bipolar mode noted in Table 4.6. Connect ESU tester

according to manufacturer’s instructions -ORthe 200-ohm non-inductive resistor in series with the 250 mA RF ammeter between the two bipolar output connections.

2) Activate and verify the limit in Table 4.6.

Table 4.6 Allowable RF Leakage Current - Inactive Bipolar Outputs

MEASURED TERMINAL ACTIVATED ACCESSORY MODE RF LEAKAGE (Ma)

Bipolar Right to Left Right Hand Controlled Standard Coag

4.6.5 Line Frequency Leakage

CAUTION: To prevent RF current from destroy

ing the test equipment and/or affecting leakage readings, set all power settings to zero.

Circuit ground and the Neutral (Low MAINS) must be connected together for UUT MAINS leakage testing.

WARNING: Electrocution Hazard. DO NOT

Equipment:

These tests are performed most conveniently using any good quality biomedical electrical safety tester.

Procedure:

1) Connect the electrical safety analyzer to make the measurements indicated in Table 4.7.

2) Mode: Measure leakage for Bipolar to Neutral and Chassis to Neutral.

<48

DISCONNECT circuit ground from Earth Ground unless an isolated MAINS power sup

ply is used.

Table 4.7 Line Frequency Allowable Leakage - Inactive

RF output to Neutral LINE GND LIMIT max

Equipotential Ground Normal Closed 30 µA

Equipotential Ground Reversed

Equipotential Ground

Equipotential Ground Reversed

Dispersive Electrode

Dispersive Electrode Reversed

Dispersive Electrode

Dispersive Electrode Reversed

Bipolar Output*

Bipolar Output* Reversed

Bipolar Output*

Bipolar Output* Reversed

*Measure the Bipolar Output with Bipolar connections shorted together.

Normal Open 270 µA

Normal Closed 15 µA

Normal Open 15 µA

Normal Closed 15 µA

Normal Open 15 µA

Closed 30 µA

Open 270 µA

Closed 15 µA

Open 15 µA

Closed 15 µA

Open 15 µA

4-12

Page 25

5) Since the System 5000™ monopolar active outputs are disconnected by relays when the unit is not activated, active-to-neutral leakage tests must be performed with the unit acti

vated in order to be valid.

6) With all power controls set to zero, measure the leakage current as in step 1 from each of

see Table 4.8; while that output is activated in Cut by the appropriate footswitch or hand control jumper. Hand control cut activations are accomplished by connecting a jumper between the two outer jacks of where the handcontrol accessory is plugged into the unit.

the three active output terminals to neutral;

Table 4.8 Line Frequency Allowable Leakage - Active

RF output to Neutral LINE GND ACTIVATION LIMIT max

Footswitched Active Normal Closed Monopolar Footswitched Cut 15 µA

Footswitched Active Reversed

Footswitched Active

Footswitched Active Reversed

Left Hand Controlled Active

Left Hand Controlled Active Reversed

Left Hand Controlled Active

Left Hand Controlled Active Reversed

Right Hand Controlled Active

Right Hand Controlled Active Reversed

Right Hand Controlled Active

Right Hand Controlled Active Reversed

Normal Open Monopolar Footswitched Cut 15 µA

Normal Closed Left Hand Controlled Cut 15 µA

Normal Open Left Hand Controlled Cut 15 µA

Normal Closed Right Hand Controlled Cut 15 µA

Normal Open Right Hand Controlled Cut 15 µA

Closed Monopolar Footswitched Cut 15 µA

Open Monopolar Footswitched Cut 15 µA

Closed Left Hand Controlled Cut 15 µA

Open Left Hand Controlled Cut 15 µA

Closed Right Hand Controlled Cut 15 µA

Open Right Hand Controlled Cut 15 µA

4.6.6 Automatic Return Monitor (A.R.M.™) Check

A.R.M.™ has two specific ranges that will be tested initially and then the circuit will be tested to verify that the circuit measures dissipative elec

trode resistance correctly. For this testing, only a Decade Resistance Box (DRB) and a dispersive electrode cable adapter are required. Connect the DRB to the Dispersive Electrode Receptacle using the dispersive electrode cable adapter.

A.R.M.™ may be reset by disconnecting the dispersive electrode connector or adjusting the DRB above 10K Ohms until the Single and Dual Dispersive Electrode Status/Alarm Indicators flash red in alternating fashion. Allow approximately two seconds after the DRB is changed before proceeding to the next step in the procedure. A.R.M.™ indicators not mentioned in the proce

dure must be off for each test.

1) Dual Electrode Alarm Limit: Set the DRB to 158 Ohms, then connect it to the Dispersive Electrode Receptacle and verify that the

Single and Dual Dispersive Electrode Status/ Alarm Indicators flash red in alternating fash ion.

2) Dual Electrode Upper Limit: Set DRB to 140 Ohms and verify that the Dual Dispersive Electrode Status/Alarm Indicator is flashing Green and a single bar in the Bargraph is illu minated.

3) Dual Electrode Lower Limit: Set the DRB to 15 Ohms and verify the Dual Dispersive Electrode Status/Alarm Indicator is flashing Green and eight bars in the Bargraph are illu minated.

4) Single Electrode Upper Limit: Set the DRB to 7 Ohms, then reset A.R.M.™ and verify the Single Dispersive Electrode Status/Alarm Indicator is Green and not flashing.

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Page 26

4.6.7 Output Coupling Capacitor Check

WARNING:

SETTINGS ARE AT 0 WATTS BEFORE CONDUCTING THIS TEST TO PREVENT INJURY TO PERSONNEL AND DAMAGE TO TEST EQUIPMENT.

NOTE: Not all capacitance meters will read prop erly for this test. The test frequency should be at or below 1 kHz for best accuracy. The following meters have been tried successfully: Fluke 189, Extech 285, Sencor LC75 and HP4284A (1 kHz setting or below).

1. Connect shorting plug to banana adapter to the two pin Dispersive Electrode Receptacle. Use 6” or less test leads to connect a capaci tance meter between the shorting plug adapter and the footswitched ReadiPlug Universal Accessory Receptacle.

2. Measure capacitance and confirm it is less than 0.5 nF.

3. Confirm cut power is set to 0, then activate and confirm capacitance is between 4.3 and

6.3 nF.

4. Do not activate for this bipolar test. Move test leads to Bipolar Output Accessory Receptacles. Confirm capacitance is between

9.6 and 14 nF.

ENSURE ALL POWER

™

4.7 System Calibration

The System 5000™ is calibrated during manufacture using equipment traceable to National Institute of Standards & Technology (NIST) standards and should retain its accuracy for a long period of time. Recalibrate the generator after repair or if it performs out of specification. Check the calibration in normal operating mode and only perform calibration if errors are identified.

The System 5000™ stores its calibration in non volatile semiconductor memory, so the calibration will be retained without any action on the part of the user or maintenance staff. Calibration should be checked in normal operating mode during annual preventative maintenance to ensure there is no change. Calibration is required when:

• “Err 140” occurs: An error is detected with the stored calibration values.

• “Err 143” occurs: One or more modes require calibration.

• The Controller board assembly (P/N 61-

6431), the Transformer board assembly (P/N 61-6445), or the Output board assembly (P/ N 61-6461) is replaced.

• Calibration differences are found during pre ventative maintenance.

4.7.1 Calibration Preliminaries

Calibration on the System 5000™ occurs in Calibration Operating Mode, which is entered by setting the system configuration DIP switches on the Controller board. Set the Calibration system configuration DIP switch (A4SW2.2) to the ON (UP) position and the Test system configuration DIP switch (A4SW2.1) to the OFF (DOWN) position. Other configuration DIP switch settings positions will not affect this. See Section 4.9 for system configuration DIP switch details.

With this configuration set, turn on power while pressing and holding the Remote Power Control Key. Release the Key when you hear the 4-tone sequence. When the Remote Power Control Key is released, CAL will appear in the Monopolar Cut Power Digital Display and the software revision will appear in the Monopolar Coag Power Digital Display for a few seconds. The display will then provide an indication of the calibration status:

ALL” will appear in the Monopolar Cut

• “ Power Digital Display if the calibration mem ory is empty.

• “

nEr” will appear in the Monopolar Cut

Power Digital Display, where “n” indicates how many major modes require calibration, will be displayed if only particular modes require calibration. All of the minor mode indicators will be illuminated and the minor modes needing calibration will flash.

[V”, “[0A”, “bP”, or “Pad” will appear in

• “ the Monopolar Cut Power Digital Display to indicate the major mode when only minor modes under that major mode require calibra tion. All of the minor mode indicators will be illuminated and the minor modes needing calibration will flash.

[V” will appear in the Monopolar Cut Power

• “ Digital Display with the Pure Cut Mode Indicator illuminated if all modes are cali brated.

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Page 27

Calibration

888 888 88

CAL rn

2Er

3Er

Cu 500 P

COA

PAd

ALL

Press Remote Power Control Key,

release when tones begin.

Press Remote Power Control Key.

Press Cut Mode

Scroll Key to select

Pure, Blend 1,

Blend 2 and Blend 3.

Press Monopolar Cut Power Adjustment

Keys to select Cu, COA, bP and PAd.

Set the Calibration System Configuration

Dipswitch on the Controller to the ON position

Turn main power switch on.

Connect indicated load

with meter to output

Activate.

Press Monopolar Coag Power Adjustment keys to

match power/current to Calibration Target.

Minimum activation 2 seconds, release.

COA

PAd 10

Press Coag

Scroll Key to select

Pinpoint, Spray

and Standard

Connect 10 ohm load Two-Pin

Dispersive Electrode Receptacle

Press Remote Power Control Key

Press Remote Power Control Key.

Press Remote Power Control Key

Press Bipolar Power Adjustment Key

Connect 150 ohm load Two-Pin

Dispersive Electrode Receptacle.

Press Monopolar Coag Power Adjustment Key

Press Bipolar Power Adjustment

Key.

PAd 150

End - Main power

switch off.

Set the Calibration System Configuration

Dipswitch on the Controller to the OFF position

Figure 4.1 Calibration Procedure Flow Chart

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Page 28

For all except the last of these, a single Press and release of the Remote Power Control Key is required to proceed past this point on the menu. After pressing this key, “ Monopolar Cut Power Digital Display with the Pure Cut Mode Indicator illuminated.

4.7.2 Sele

Press the Monopolar Cut Power Adjustment Keys to select the major mode to calibrate as displayed in the Monopolar Cut Power Digital Display. The selections are “ for Bipolar, or “ A.R.M.™ connection. If any of the minor modes under these major modes are not calibrated, the displayed major mode will flash.

Scroll between the monopolar minor modes using the Cut Mode Scroll Key or the Coag Scroll Key, as appropriate. Macro Bipolar is used to calibrate both of the Bipolar modes, so no scrolling is nec essary.

4.7.3 Calibrating a Monopolar Mode

This section applies to the Pure Cut, Blend 1, Blend 2, Blend 3, Pinpoint Coag, Standard Coag, and Spray Coag modes.

Calibration may be performed by measuring cur rent or by measuring power. To select between calibration using measured current and measured power, press the Bipolar Power Adjustment Keys to set the calibration units to either “A” for current or “P” for power.

The resistance to be used for calibration will appear in the Monopolar Coag Power Digital Display. Connect a resistor of this value between the output connection that is being used for cali bration and both pins on the Two-Pin Dispersive Electrode Receptacle.

Press and release the Remote Power Control Key to begin calibration. After this key is pressed, the target level appears in the Monopolar Coag Power Digital Display.

Activate using the appropriate Handswitch or Footswitch. Power will now flow to the resis tor. While monitoring either the current or the power, adjust the power up or down using the Monopolar Coag Power Adjustment Keys until the measured value is as close to the target level as possible. The activation must be maintained for a minimum of 2 seconds to ensure the calibration is valid. After the power is properly adjusted, release

cting the Mode to Calibrate

[V” for Cut, “[0A” for Coag, “Bp”

PAd” for the Dispersive Electrode

[V” will appear in the

the activation. Press and release the Remote Power Control Key to complete the calibration sequence for the selected minor mode.

After a minor mode has been calibrated, the associated minor mode indicator will quit flash ing. When all of the minor modes within a major mode have been calibrated, the major mode indicated in the Monopolar Cut Power Digital Display will quit flashing.

4.7.4 Calibrating Bipolar Modes

The Bipolar modes are calibrated using a method that is very similar to the Monopolar modes. Both Bipolar modes are calibrated with a single calibration of the Bipolar Macro mode.

The resistance to be used for calibration will appear in the Monopolar Coag Power Digital Display. Connect a resistor of this value between the two active connections in the Bipolar Accessory Receptacle.

Press and release the Remote Power Control Key to begin calibration. After this key is pressed, the target level appears in the Monopolar Coag Power Digital Display.

Activate using the Bipolar Footswitch. Power will now flow to the resistor. While monitoring either the current or the power, adjust the power up or down using the Monopolar Coag Power Adjustment Keys until the measured value is as close to the target level as possible. The activation must be maintained for a minimum of 2 seconds to ensure the calibration is valid. After the power is properly adjusted, release the activation. Press and release the Remote Power Control Key to complete the calibration sequence for the Bipolar mode.

After the Bipolar mode has been calibrated, the Macro Bipolar Indicator and the major mode indicated in the Monopolar Cut Power Digital Display will both quit flashing.

4.7.5 Calibrating A.R.M.™

A.R.M.™ is calibrated against a pair of known resistances.

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Press and release the Remote Power Control Key to begin calibration. The resistance to be used for calibration will appear in the Monopolar Coag Power Digital Display. Connect a resistor of this value ±1% between the two active connections in the Two-Pin Dispersive Electrode Receptacle.

Calibrate the particular value connected by press ing one of the Bipolar Power Adjustment Keys. When the value is accepted, a two-tone sequence will sound and the resistance in the Monopolar Coag Power Digital Display will quit flashing.

Now scroll to the other of the pair of known resistances using the Monopolar Coag Power Adjustment Keys. The resistance to be used for calibration will appear in the Monopolar Coag Power Digital Display. Connect a resistor of this value ±1% between the two active connections in the Two-Pin Dispersive Electrode Receptacle.

Calibrate the particular value connected by again pressing one of the Bipolar Power Adjustment Keys. When the value is accepted, a two-tone sequence will sound and the resistance in the Monopolar Coag Power Digital Display will quit flashing.

Press and release the Remote Power Control Key to complete A.R.M.™ calibration.

After A.R.M.™ has been calibrated, the major mode “PAd” indicated in the Monopolar Cut Power Digital Display will quit flashing.

4.7.6 Completing Calibration

Turn power off and set the Calibration system configuration DIP switch (A4SW2.2) to the OFF (DOWN) position. See Section 4.9 for system configuration DIP switch details. The ESU will be ready for normal operation the next time the power is turned on.

4.8 Last Fault Code Retrieval and Clear

Up to 20 error codes can be stored in memory for retrieval. Each error code stored is “date stamped” where the “time” and “date” the error occurred is also stored for retrieval. When retriev ing the error codes, it is also possible to retrieve the system settings when the error occurred.

4.8.1 Last Fault Code Retrieval

1) Turn the Main power on. While the unit is powering up, press the PC key until a tone occurs. This action will place the sys

tem in the Last Fault Code Mode (LFC). Electrosurgical outputs cannot be activated while the system is in LFC.

2) For 3 seconds: “ Cut Window, which is for Last Fault Codes. The Coag window will display “ is a numeric value for the software revision).

3) If any errors are stored in memory, the Cut Window will next display “Err”; the Coag window will display the error code (a numeric value); and the Bipolar Window will display the storage location of that error code.

Last Fault display

Pure Blend 1 Blend 2 Blend 3

4) Scroll through the stored error codes using the Bipolar Power Adjustment Keys. The error codes are stored Last in, First out. A “1” in the Bipolar Display shows the last error that occurred. Press the Bipolar Up key and a “2” will be displayed if more than one error occurred.

5) To retrieve the date and time of the error, it is necessary to have a Handcontrol accessory connected. Press the Cut activation switch and the “time” that the error occurred is dis played. Press the Coag activation switch and the “date” that the error occurred is displayed. Press both Cut and Coag activation switches and the Display Panel will show the system settings when the error occurred.

Time Display: Press Handcontrol Cut Switch

Hours can be set for A.M. or P.M. The time is

displayed as Hours - Minutes - Seconds.

Pure Blend 1 Blend 2 Blend 3

Date Display: Press Handcontrol Coag Switch

The date is displayed as Month - Day - Year.

Pure Blend 1 Blend 2 Blend 3

LF[” will be displayed in the

rX”, (where X

err 381 1

2P 23 12

09 28 04

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6) If the date defaults to 01 01 01 or the time

O N

1 2 3 4 5 6 7 8

TEST

CAL

SCOAG

DCUT

LAST

PCEN

defaults to 12P 0 1, then the Real Time Clock battery is low or the clock was not set on the last service. The battery voltage must be 2V or greater for the Real Time Clock to run.

a) The battery is being charged when the

main power is turned on. It takes about 12 hours to charge the battery if the bat tery is fully discharged.

b) To test the battery, connect a DVM to

the battery lead that is visible through the hole on the display shield (backside of the Display PCB assembly). Connect the other lead of the DVM to the GND test point on the Controller Assembly (TP6). Test the battery voltage with the main power turned off. The battery voltage should be 3V or greater.

c) Another way to test if the battery is

charged it to set the clock and date. Turn off the main power and then turn the main power back on. Press the PC key while the unit is powering up to enter the Last Fault Codes. If the clock displays 12P 0 1, then the battery is not charged or taking a charge.

4.8.2 Clearing Last Fault Codes

As errors occur, fault codes from earlier errors are erased in a last-in-first-out fashion. While it is not absolutely necessary to clear the older codes, clear ing the codes may be desirable in some situations.

• Pressing the Monopolar Cut Power Adjustment Down Key followed by the Remote Power Control Key will clear the

entire fault code memory. The cut window will display “

• Pressing the PC key again will display the optional system configuration settings.

4.9 Displaying Optional System Configuration

The optional system configuration DIP switch settings can be checked without removing the top cover.

• Turn on the main power. While the system is powering up, press and hold the PC Key on the Display panel until the Test Tone starts.

• Last Fault Codes are displayed initially. The Cut window will display “ window will display the software revision number for approximately 3 seconds, then the Last Fault Code will be displayed. (See the section on Last Fault Codes.)

• Press the PC Key again and the configuration DIP switch settings will be displayed. “0” is for OFF and a “1” is for ON.

The eight-position configuration DIP switch (S2), located on the Controller PCB Assembly (A4) allows a qualified service technician to change some of the factory default settings. The default switch is only read during Power On Self Test (POST) or when the system is powered on, so any changes to the switch positions should be

made with the main power off. Each switch is OFF in the down position and ON in the up position. Relevant information for each switch is described in Table 4.9 and the positions are illus trated in Figure 4.2.

[Lr” when codes are cleared.

LF[” and the Coag

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Figure 4.2 DIP Switch Positions

Page 31

Table 4.9 DIP Switch Settings

Config. Switch Position

1 TEST /

2 CAL/ Cut

3 SCOAG /

4 DCUT /

5 LAST /

6 PCEN /

7 Not used

8 DACview /

Title / Display Element

Cut 100’s

10’s

Cut 1’s

Coag 100’s

Coag 10’s

Coag 1’s

/ Bipolar 10’s

Bipolar 1’s

Default Description for Off Description for On

Off Run Mode. Required position for

surgery.

Off Run Mode. Required position for

surgery.

On Allows simultaneous activation

of two accessories for Pinpoint Coagulation.

Off Allows activation of only one active

accessory in cut modes.

On Defaults to Pure Cut, Pinpoint

Coag, and Macro Bipolar and sets all power levels to zero (0W) each time the system is initialized.

Off Allows the Remote Power Control

feature to be enabled by pressing the PCEN switch on the Display Panel.

Off Not used. Not used.

NA DACview - See below. DACview - See below.

Activates Test Mode, which inhibits most of the system level monitoring for trouble shooting purposes. When this switch is ON, the Remote PC Switch on the Display Panel must be pressed until the Test Tone begins. If the Remote PC key is not pressed, and Err 100 is displayed and the power must be cycled.

Required for calibration of output power and A.R.M. the Remote PC Switch on the Display Panel must be pressed until the Test Tone begins. If the Remote PC key is not pressed, and Err 100 is displayed and the power must be cycled.

Allows activation of only one accessory for Pinpoint Coagulation. Spray and Standard Coagulation modes always allow simulta neous activation of two accessories.

Allows activation of two active accessories in cut modes.

Defaults all modes and power levels to the settings the last time the system was pow ered down.

Inhibits the Remote Power Control fea ture.

When this switch is ON,

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4.10 DACview

DACview is a troubleshooting aid that allows access to internal readings. The feature allows output voltage, current and power that the system reads to be output to a DVM or oscilloscope. To use DACview, the system must be in the Test Mode.

1) Set the system for operation in Test Mode as described in the preceding section.

2) Connect a DVM to the Control Board test points labeled TP7 – DAC_VIEW and TP6 – AGND.

3) Turn the power on and press the PC key until the Test Tones begin.

4) Move the DACview switch (S2 position 8

5) The Monopolar Cut Power Digital Display is used to display the selected DACview chan nel. Since power was just initialized, the Monopolar Cut Power Digital Display will display “0” at this point. Select the desired channel using the Monopolar Cut Power Adjustment Keys.

6) Move the DACview switch (again, the change is recognized, not whether the switch is on or off). The cut power setting will be displayed.

7) To select a different location to monitor with a DVM, simply move the DACview switch and the memory locations will be displayed instead of the cut power. Select the desired selection and then move the DACview switch again.

– the change is recognized, not whether the switch is on or off).

Table 4.10 DACview Channels

Channel Source Function Scaling

0 No channel selected 1 Monitor RF RMS Power (300mS running average) 0.01 V / 1 W 2 Monitor RF RMS Power 0.01 V / 1 W 3 Monitor RF RMS Current 1 V / 1 A 4 Monitor RF RMS Voltage 0.001 V / 1 V 5 Monitor RF RMS Current (300mS running average) 1 V / 1 A 6 Monitor RF RMS Voltage (300mS running average) 0.001 V / 1 V 7 Monitor Max RMS RF Voltage during single activation 0.001 V / 1 V 8 Monitor Reserved- Future Use 9 Monitor H1 accessory, RMS current output 1 V / 1 A 10 Monitor H2 accessory, RMS current output 1 V / 1 A 11 Monitor FT accessory, RMS current output 1 V / 1 A 12 Monitor BP accessory, RMS current output 1 V / 1 A 13 Monitor +HV, High Voltage power supply output 0.01 V / 1 V 14 Monitor Max Power during single activation 0.01 V / 1 W 15 Monitor Max RMS Current during single activation 1 V / 1 A 16 Monitor Calculated output resistance 0.001 V / 1 OHM 17 Monitor A/D Input DC voltage offset 1 V / 1 V 18 Monitor Reserved- Future Use 19 System Controller A.R.M.TM resistance 0.01 V / 1 OHM 20 Controller Gate pulse width Variable 21 Controller Output RMS Voltage Variable 22 Controller Output RMS Current Variable 23 Controller Output impedance 0.2V/100 OHM 24 Controller Reserved- Future Use 25 Controller Reserved- Future Use 26 Monitor Calibrated POST RF cut mode voltage 0.001 V / 1 V 27 Monitor Calibrated POST RF coag mode voltage 0.001 V / 1 V

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4.11 Setting the Clock

The clock is only visible while in the Last Fault Display and the purpose of the clock is only to “Date/Time Stamp” system faults.

1) To set the clock, turn the Main power on. While the unit is powering up, press the PC key until a tone occurs. This action will place the system in the Last Fault Code Mode (LFC).

2) For 3 seconds: “LF[” will be displayed in the Cut Window, which is for Last Fault Codes. The Coag window will display “rX”, (where X is a numeric value for the software revision).

4) Press PC key: the display will show the DIP switch settings on the Controller Assembly.

5) Press PC key: the “Date” will be displayed as MO – DAY – YEAR. Press the Power Adjustment Keys associated with each win dow to set the date. Once the date is set,

Press the STORE” key that is below the Program Window scroll key to lock the date in memory.

6) Press PC key: the “Time” will be displayed as HOUR – MINUTE – SECONDS. Press the Power Adjustment Keys associated with each window to set the time. The Cut Window has either a “P” for PM. or “A” for AM. Once the time is set, Press the STORE” key that is below the Program Window scroll key to lock the time in memory.

7) Press PC key to return to the error code dis

play. To exit the Last Fault Code Mode, it is necessary to turn off the main power.

4.12 Troubleshooting

Listed in Table 4.11 are potential errors that may occur and problem solving ideas for each. All error codes (Err xxx) can only be cleared by cycling power. When an error code is displayed, reset the system to determine if the error can be cleared with a System Reset or if further service is required. Error codes are stored as Last Fault

Codes (See Last Fault Codes).

Table 4.11 Troubleshooting

Problem Possible Cause

Display Panel Blank when System is Powered on

Display:

Display: A[[ [P xx

Display:

A[[ xxx

LF[ xxx

Verify the power cord is fully seated in the power receptacle on the back of the System.

With the power cord disconnected, verify fuses are good and are installed prop erly in the receptacles on the back panel of the generator.

Remove the top cover and verify that the controller board and all harnesses are properly seated.

Check the Low Voltage Power Supply for +5V and +15V.

Accessory error – Faulty accessory is connected, a hand controlled accessory is erroneously actuated, or a footswitch is erroneously actuated. Ensure that footswitches are not stacked on top one another. A[[ rH and A[[ LH, indicate problems with the accessories connected to the right-hand and left-hand Hand Controlled Monopolar Accessory Receptacles, respectively. A[[ FS indicates a problem with the footswitch connected to either of the Monopolar or Bipolar Footswitch Connectors.

Control Panel error – Check for a faulty push button on the front control panel, a control panel push button that has been pushed while the unit is being turned on, or a faulty cable connection between the front panel and the display board.

Last Fault Codes – the Remote Power Control Key was pressed while power was initialized. The generator must be reset to clear this condition. See section 4.8.

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Problem Possible Cause

Display: [al

Display:

Single and Dual Dispersive Electrode Status / Alarm Indicators flash alternating red.

Flashing Decimal Points on the Display

No output power One or more connections inside the system are bad. Check:

Err xxx Refer to Table 4.12 for list of Err codes and possible causes. If an Err code

The system is in the Calibration Mode. Calibration Mode is selected when the configuration DIP switch in the second position on the Controller assembly is in the ON (Up) position and the Remote Power Control Key is pressed and held while power is turned on. See section 4.9.

appears, try cycling power. If it reappears, the unit should be taken out of service until a qualified biomedical engineer can diagnose the problem.

A Dispersive Electrode is not connected to the system

A Dual Dispersive Electrode is connected but is not properly applied to patient.

A Dispersive Electrode is connected to the System, but is not properly seated – ensure the connector is fully seated in the Two-Pin Dispersive Electrode Receptacle.

The system is in the Test Mode. Test Mode is selected when the configuration DIP switch in the first position on the Controller assembly is in the ON (Up) position and the Remote Power Control Key is pressed and held while power is turned on. monitoring is inhibited. See section 4.9.

• A6J1, controller

• A6J2, monopolar transformer board

• A6J3, high voltage power supply

• A6J4, bipolar output

• A7J1, controller

• A7J2, monopolar output

• Faulty accessory – blade not seated fully

• Output board jacks not making contact

Low voltage power supplied to A6 is bad. Check:

• +15V

• -15V

• -5V

Shorted RF Amplifier power MOSFET. Note: A better indication of the problem will be provided by cycling power, which will allow the generator to find a fault during POST.

• Remove A6 JMP1 and A6 JMP2.

• Using an ohmmeter measure between drain and ground on Q3 and Q4 for low resistance.

• Using an ohmmeter measure between gate and ground on Q3 and Q4 for low resistance.

• If either exhibit low resistance, either replace the faulty MOSFET or replace the RF Amplifier.

HVPS output too low.

• Configure system for test mode operation.

• Unplug the connector A6J3 on the RF Amplifier.

• Set the system for Pure cut at 35 watts.

• Activate and ensure A9LED2 is brightly illuminated.

Improper gate drive.

• Configure system for test mode operation.

• Verify that the input to A6U1 is switching between –5V and 0 volts when the system is activated, and that this signal is synchronous with crossing transi tions of RF_DRV and /RF_DRV.

• Verify that A6 GATE_A and A6 GATE_B are at –5V when not activated.

Note: When the Test Mode is active, most of the internal safety

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Problem Possible Cause

Incorrect monopolar output Bad calibration – Recalibrate

Ensure the load resistor is correct when checking output power.

Bad voltage or current feedback. Check:

• A7 RF_MP_VSN, monopolar voltage sense

• A7 RF_MP_ISN, monopolar current sense

• These signals should match the Monitor voltage and current sense, MRF_MP_VSN and MRF_MP_ISN, respectively.

Incorrect bipolar output Bad calibration – Recalibrate

Ensure the load resistor is correct when checking output power.

Bad voltage or current feedback. Check:

• A5 RF_BP_VSN, bipolar voltage sense

• A5 RF_BP_ISN, bipolar current sense

• These signals should match the Monitor voltage and current sense, MRF_BP_VSN and MRF_BP_ISN, respectively.

4.12.1 HVPS Troubleshooting Hints

• Danger: Use an isolation transformer when working on Mains side! A line on the printed circuit board and on the schematic identifies the Mains side of the HVPS.

WARNING: LOSS OF POWER SUPPLY ISOLATION CAN CAUSE ELECTRICAL SHOCK. WHEN SERVICING THE HIGH VOLTAGE POWER SUPPLY, ASSUME INTERNAL ISOLATION IS COMPROMISED UNTIL VERIFIED OTHERWISE.

• For best access for HVPS measurements, place both the Low Voltage Power Supply and the Transformer Boards in their service positions; that is, mounted vertically in the appropri

ate heatsink mounting slots. See mechanical access section for details.

• Make sure the LED for the circuit you’re working on is OFF when making connections or touching circuitry.

•Observe both LEDs during POST. The PFC LED should always be on when power is on. It will become momentarily brighter dur

ing POST. The Forward Converter LED will normally be off unless it has been recently activated. After activation it will slowly fade to off. During POST, it should turn on dimly, then brightly, then fade. The brightness of both LEDs corresponds to the output voltage of the corresponding circuit.

• Check Line Voltage input, HVSET, MHVEN, PFC_EN, and +15, +5, GND con

nections for proper operation before replacing parts.

• If LED2 does not light during POST, unplug the RF Amplifier and cycle power – there might be a short on the RF Amplifier.

• If fuses are blown, Q3 is probably shorted. Also check surrounding components for fail

ure if Q3 is found to be bad.

• If the Forward Converter output will not exceed about 70Vdc, the PFC output voltage is probably too low. (This limit will vary with input line voltage.)

• The Forward Converter gate pulse width should be close to 50% with no input voltage while HVSET is low.

•If the PFC output voltage is changing with heavy load, try increasing mains voltage with a variable transformer. If this stabilizes the PFC output voltage, PFC current sense cir cuitry is probably at fault. This is not gener

ally a problem with 220V inputs.

• The PFC can be disabled for safer low volt

age Forward Converter troubleshooting – by shorting TP11(PFC_EN) to TP4(-HV). Use a variable transformer to set the desired input voltage to the Forward Converter.

• Check the clock frequency and reference volt

age on both the PFC controller and Forward Converter controller integrated circuits. The PFC clock must have PFC enabled to func

tion correctly.

• If the output voltage for either PFC or

Forward Converter is too high, check the feedback resistors.

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• The Forward Converter will oscillate with brief output bursts when the output current limit is active. This is generally caused by shorted MOSFETS on the RF Amplifier.

• At low output current, the PFC will cycle on and off. This is normal.

• When replacing a MOSFET, check all the gate drive components.

• Resistance measured between TP7 and TP4 (-HV) when power is off should be greater than 100K ohms. Resistance measured between U2P15 (VCC) and TP4 when power is off should be greater than 100K ohms.

• If either of above is low, Q3 or the associated protection diodes are suspect. If these are removed and the measured resistance contin ues to be low, U2 is probably failed.

• The forward converter can be disconnected from the Power Factor Controller for trouble shooting the PFC. Do this by removing the E1-E2 wire. Be sure to note the routing of the wire through T1 so it can be reconnected correctly. Incorrect polarity can damage the Forward Converter.

4.14 Fault Codes

This section of the manual contains a table of fault codes. Each numeric fault code is listed along with a description of the fault, possible causes and things to check, and corrective actions.

4.13 Parts Ordering Information

To obtain replacement parts or additional information regarding your unit, write or telephone according to the contact information as listed on the inside front cover of this manual, or contact your CONMED distributor. To ensure prompt service, please provide the following information:

Model Number

Serial Number

Reference Designator and Description of Part

Conmed Part Number (if known)

Quantity Desired

Mailing or Shipping Address

Preferred Shipping Means (if any)

Purchase Order Number (if applicable)

Your Name

If you are returning a unit, obtain a Return Authorization (R.A.) Number from CONMED Technical Services. Please mark the R.A. number on the outside of the carton for prompt service.

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Table 4.12 Fault Codes

Err Code

Description

Possible Cause

Things to check

Correction

100

Test or CAL mode dip switch with no remote power con

trol key press

The Remote Power Control Key must be depressed when power initialized until the test tones sound. Release this key before the last tone sounds.

Cycle system power while pressing the Remote Power Control Key and determine if this error is repeated.

Replace the Controller assembly. 101

Controller/Monitor DIP switch mis

match

The System Controller and the Monitor do not detect the same settings for the Configuration Dipswitches.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

102

Corrupted communications between the System Controller and Monitor

The data transmitted from the System Controller to the Monitor through the HPI port is faulty. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

103

Corrupted communications between the System Controller and RF Controller

The data transmitted from the System Controller to the RF Controller through the HPI port is faulty. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

104

Monitor TOKEN not incremented, monitor program scrambled

The data transmitted from the System Controller to the Monitor through the HPI port is faulty. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

105

Controller failed ram test

The System Controller memory errors have been detected during POST.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

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Err Code

Description

Possible Cause

Things to Check

Correction

106

RF controller bootload program does not match control

ler ROM table

The program transmitted from the System Controller to the RF Controller through the HPI port at startup is faulty. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

107

Monitor bootload program does not match controller ROM table

The program transmitted from the System Controller to the Monitor through the HPI port at startup is faulty. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

108

RF TOKEN not incremented, RF controller program scrambled

The program transmitted from the System Controller to the RF Controller through the HPI port at startup is faulty or has been corrupted after initialization. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

109

Communications lost during POST tests

Communications through the HPI port are faulty. This could be caused by damage to components associated with the HPI bus on the Controller, permit

ting electromagnetic inter

ference to upset one of the processors.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

112

Pre-activation handshake, monitor does not read an activation signal

The activation signals detected by the System Controller and the Monitor do not match.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

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Err Code

Description

Possible Cause

Things to Check

Correction

113

Pre-activation handshake, moni

tor does not read a tone signal

Prior to enabling electrosurgical output power, the Monitor ensures that an activation tone is present. This error occurs if the activation tone is not present when the Monitor checks prior to enabling electrosurgical output power.

Increase the tone volume by adjusting the Volume Control on the back panel of the generator. Cycle system power and deter

mine if this error is repeated. Configure system for test mode operation. Check the tone drive signal from the Controller assembly while the unit is activated. Lack of a signal indicates a problem with the Controller assembly. Check for a proper TONE_ MON signal to the control

ler. Lack of a signal indicates a problem with the Back Panel assembly.

Replace the Controller assembly. Replace the Back Panel assembly.

114

Display or keyboard SPI commu

nication failure

Communication between the Control assembly and the Display assembly over the SPI bus is faulty.

Cycle system power and determine if this error is repeated. Check SPI_SCK, SPI_MOSI, and SPI_MISO to see signals toggle.

Replace the cable between the Display and the Controller. Replace the Controller assembly. Replace the Display assembly.

117

5.0 volt too low

5-volt power in the system is too low.

Check the output of the low voltage power supply. Verify that the ADC reference voltages on the Controller are

2.5 volts.

If the power supply voltage is out of limits, replace the power supply. If the power sup

ply is within lim

its, replace the Controller assembly.

118

5.0 volt too high

5-volt power in the system is too high.

Check the output of the low voltage power supply. Verify that the ADC reference voltages on the Controller are

2.5 volts.

If the power supply voltage is out of limits, replace the power supply. If the power sup

ply is within lim

its, replace the Controller assembly.

122

System Controller flash program CRC does not match the calculated CRC

The self-check CRC for the System Controller is not internally consistent, indicat

ing an error in the stored software.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

135

A.R.M.™ calibration (10/150 Ohm) EEprom CRC failed

The CRC for the calibration coefficient memory is not self consistent, indicating an error in the stored calibra

tion coefficients.

Recalibrate the A.R.M.™ system. See section 4.7.

Replace the Controller assembly if the system will not calibrate.

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Err Code

Description

Possible Cause

Things to Check

Correction

136

A.R.M.™ circuit dropped below .4V (circuit failed)

The A.R.M.™ circuit on the Output assembly or the A.R.M.™ sensing circuit on the Controller assembly has failed.

Verify proper voltage on the VARM signal entering the Controller assembly.

Replace the Output assembly if VARM entering the Controller is faulty. Replace the Controller assembly if VARM appears correct.

137

RF controller calibration EEPROM CRC failed

The CRC for the calibration coefficient memory is not self consistent, indicating an error in the stored calibra

tion coefficients.

Recalibrate the entire system.

Replace the Controller assembly if the system will not calibrate.

138

Monitor calibration EEPROM CRC failed

The CRC for the calibration coefficient memory is not self consistent, indicating an error in the stored calibra

tion coefficients.

Recalibrate the entire system.

Replace the Controller assembly if the system will not calibrate.

139

During calibration, not all points were entered for the mode

The calibration was not completed in the correct manner.

Recalibrate any uncalibrated modes. See Section 4.7.

Replace the Controller assembly if the system will not calibrate.

140

A calibration EEPROM CRC failed (POST ERROR)

The CRC for the calibration coefficient memory is not self consistent, indicating an error in the stored calibra

tion coefficients.

Recalibrate any uncalibrated modes. See Section 4.7.

Replace the Controller assembly if the system will not calibrate.

141

Test and cal dip switches are both turned on

The Calibration and Test Configuration Dipswitches are both in the ON position. At least one of these must be in the OFF position.

Change the Calibration and Test Configuration Dipswitches to the desired state, cycle system power, and determine if this error is repeated.

Replace the Controller assembly.

142

RF PWM (RF_PROT) gate protection circuit shutdown

The pulse width commanded by the RF Controller exceeds the maximum allowed for the selected mode.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

143

The unit or a mode was never calibrated

The system or a mode was never calibrated. The Controller was replaced but not calibrated.

Calibrate any modes that need calibration.

Replace the Controller assembly if the system will not calibrate.

4-28

Page 41

Err Code

Description

Possible Cause

Things to Check

Correction

144

RF controller and Monitor power lev

els do not match

The Monitor and RF Controller and constantly checking to ensure they see the same electrosurgical out

put power during activation. This error occurs if the power they sense does not match. This typically results from differences between the independent Monitor and RF Controller sensing circuits.

Use DACView to troubleshoot the Monitor. Verify that the output power is consistent with displayed power setting. Check voltage and current sens

ing channels for both the RF Controller and the Monitor.

Replace the Controller assembly. Troubleshoot the RF voltage (Vsense) and current (Isense) feedback circuits for the activated mode. 170

Controller waveform inhibit failed (will not dis

able RF) (POST ERROR)

The Monitor has detected that the System Controller cannot disable the RF Drive signal during POST.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

200

Modality function timed out while waiting for ADC DMAs to finish

Component failure on Controller assembly SPI circuitry.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly. 201

RF Controller emulation restart.

Programming function only

Return to ConMed.

202

Inter-processor communications error

Controller Assembly - Host Port

Replace the Controller assembly.

204

Processor system clock change failed

The clock frequencies that run the microprocessors normally change after they are initialized. This error occurs when they do not change to the correct fre

quency.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

205

Halt mode active beyond limit

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

206

RF Controller discovered run time bad CRC.

Errors found in software downloaded from the System Controller to the RF Controller during initializa

tion.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly. 207

Unexpected mode change while active

The selected output mode changed while the system is activated.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

236

Bad CRC on modality coeffi

cients

Calibration problem.

Recalibrate the system.

Replace the Controller assembly if calibration is not accepted.

4-29

Page 42

Err Code

Description

Possible Cause

Things to Check

Correction

237

POST memory failure.

Errors found in microprocessor memories during power initialization.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

239

RF Controller rejected a calibra

tion value

Calibration failed for one or more modes.

Confirm proper load resistor and power measurement. Configure system for test mode operation. Check for proper HVPS output voltage while activated in test mode. Check for proper RF output power while activated in test mode. Cycle system power and deter

mine if this error is repeated.

Repair or Replace the HVPS. Repair or Replace the RF Amplifier. Repair or Replace the RF Transformer board. Repair or Replace the RF output board. Replace the Controller assembly.

311

POST Monitor memory failure.

Errors found in Monitor microprocessor memory during power initialization.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

314

POST Monitor or RF controller clock failure

RF Controller or Monitor clock oscillator failure detected during POST.

Check for 10 MHz clock frequency input to RF Controller and Monitor processors. Verify that the ribbon cable con

nector, J1, is properly connected to the Transformer Assembly, A7.

Replace the controller assembly. 315

POST Monitor activation circuitry failure

The states of the activation request signals detected by the Monitor do not match the states detected by the System Controller.

Check for active high activation request on lines running to the Monitor.

Replace the controller assembly.

320

Monitor failed program CRC test

Errors found in software downloaded from the System Controller to the Monitor during initializa

tion.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly. 321

Monitor failed calibration data CRC test

Monitor calibration data is corrupted.

Recalibrate all system modes.

Replace the Controller assembly.

322

Monitor or RF controller did not return to IDLE state

Activation continues after activation command ceases.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

4-30

Page 43

Err Code

Description

Possible Cause

Things to Check

Correction

330

POST RF AC voltage cut feedback too low (A/D channel 0)

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel. The limits for this compari

son are set when the system enters calibration mode.

Configure the system for Calibration mode operation and initialize power. Configure the system for test mode operation and cycle power. Measure HVPS output, RF Amplifier drive, RF Amplifier output, and voltage sensing channel.

Replace the controller assembly, the HVPS, the RF Amplifier, the Transformer board depending on the specific cause of the failure.

331

POST RF AC voltage cut feedback too high (A/D channel 0)

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel. The limits for this compari

son are set when the system enters calibration mode.

See above.

332

POST RF AC voltage coag feedback too low (A/D chan

nel 2)

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel. The limits for this compari

son are set when the system enters calibration mode.

See above.

333

POST RF AC voltage coag feedback too high (A/D channel 2)

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel. The limits for this compari

son are set when the system enters calibration mode.

See above.

4-31

Page 44

Err Code

Description

Possible Cause

Things to Check

Correction

334

POST RF AC voltage coag feedback too low (A/D chan

nel 1)

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel. The limits for this compari

son are set when the system enters calibration mode.

See above.

335

POST RF AC voltage coag feedback too high (A/D channel 1)

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel. The limits for this compari

son are set when the system enters calibration mode.

See above.

336

Calibration RF AC voltage cut feed

back too high

Monitor senses electrosurgical voltage out

put too high during POST test, indicating excessive voltage from HVPS, exces

sive drive from the RF Controller, or a failed volt

age sensing channel.

Check for proper performance of the RF Amplifier, the HVPS, and the voltage and current sense channels. Verify that all cables are properly connected.

See above.

337

Calibration RF AC voltage cut feed

back too low

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel.

See above.

See above. 338

Calibration RF AC voltage coag feed

back too high

Monitor senses electrosurgical voltage out

put too high during POST test, indicating excessive voltage from HVPS, exces

sive drive from the RF Controller, or a failed volt

age sensing channel.

See above.

4-32

Page 45

Err Code

Description

Possible Cause

Things to Check

Correction

339

Calibration RF AC voltage coag feed

back too low

Monitor senses electrosurgical voltage out

put too low during POST test, indicating insufficient voltage from HVPS, insuf

ficient drive from the RF Controller, failed RF Amplifier, or a failed voltage sensing channel.

See above.

340

Monitor Timer0 interrupt failed

One of the timers internal to the Monitor is failed.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

341

Monitor Timer0 interrupt failed POST

Failure of one of the timers internal to the Monitor detected during POST.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

342

Monitor Timer1 interrupt failed POST

Failure of one of the timers internal to the Monitor detected during POST.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

343

Monitor has lost communications - controller TOKENS not incremented

Reset machine and if error repeats, then replace Controller Assembly or replace U9.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly. 344

Monitor Isense DMA or SPI hung

The Monitor DMA or SPI interface to one of the ADCs has failed.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

345

Monitor Power DMA or SPI hung

The Monitor DMA or SPI interface to one of the ADCs has failed.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

350

Monitor output channel current sensor failure

Current detected by the monitor through the output channel current sensor that is used to detect a stuck out

put relay does not match the current sensed by the power monitoring sensor. This typically indicates that there is a problem with the output channel current sens

ing circuit.

Configure the system for test mode operation and cycle power. Use DACview to compare the output channel current with the output current while activating at constant power into a fixed load.

Repair or Replace the RF Amplifier. Repair or Replace the RF Transformer board. Repair or Replace the RF output board. Replace the Controller assembly.

351

Monitor sensed over power condi

tion for 300mS running average

Over power at the electrosurgical output has persisted for more than 300 ms.

Configure the system for test mode operation and cycle power. Measure the actual power into a fixed load. If power is correct, verify proper operation of the Monitor voltage and current sensing circuits. If power is correct, verify proper operation of the RF Controller voltage and current sensing cir

cuits, the HVPS, and the RF Amplifier.

Repair or Replace the HVPS. Repair or Replace the RF Amplifier. Repair or Replace the RF Transformer board. Repair or Replace the RF output board. Replace the Controller assembly.

4-33

Page 46

Err Code

Description

Possible Cause

Things to Check

Correction

352

Monitor sensed 4x over power condition for short period

Excessive power at the electrosurgical output was detected for a short period of time.

Recalibrate the system. Configure the system for test mode operation and cycle power. Measure the actual power into a fixed load. If power is correct, verify proper operation of the Monitor voltage and current sensing circuits. If power is correct, verify proper operation of the RF Controller voltage and current sensing cir

cuits, the HVPS, and the RF Amplifier.

Repair or Replace the HVPS. Repair or Replace the RF Amplifier. Repair or Replace the RF Transformer board. Repair or Replace the RF output board. Replace the Controller assembly.

357

Monitor sensed power @ 0W dial power setting

The Monitor has sensed electrosurgical output power during activation while the power is set to zero.

cuits, the HVPS, and the RF Amplifier.

Repair or Replace the HVPS. Repair or Replace the RF Amplifier. Repair or Replace the RF Transformer board. Repair or Replace the RF output board. Replace the Controller assembly.

358

Monitor sensed gate drive in idle @ 0W dial power setting

The Monitor has detected a drive signal while the system is not activated.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

359

Monitor sensed peak voltages above the LAP Limit

The Monitor has detected voltage peaks in excess of the limits while the system is activated in Lap Advanced Specialty mode.

cuits, the HVPS, and the RF Amplifier.

Repair or Replace the HVPS. Repair or Replace the RF Amplifier. Repair or Replace the RF Transformer board. Repair or Replace the RF output board. Replace the Controller assembly.

360

Monitor program counter landed on an unused interrupt vector

Monitor processor anomaly.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

371

Monitor will not disable RF waveform on the Controller assembly during POST

POST has determined that the Monitor cannot disable the RF waveform.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

4-34

Page 47

Err Code

Description

Possible Cause

Things to Check

Correction

372

Monitor will not disable high voltage during POST

POST has determined that the Monitor cannot disable the HVPS. The ribbon cable providing control to the HVPS is not properly connected.

Verify that all cables are properly connected. Configure the system for test mode operation and verify prop

er voltages on HV_MON. Cycle system power and deter

mine if this error is repeated.

Repair or replace the HVPS. Replace the Controller assembly.

373

Damping circuit failed POST – damping not detected.

The Monitor detected a failure in the RF Amplifier damping drive signal during POST.

Configure system for test mode operation. Verify that the RFDAMP_DR signal switches high immediately preceding each RF Drive pulse and switches low following each RF Drive pulse while activat

ing in Spray or Standard Coag modes. Verify correct operation of the damping circuitry on the RF Amplifier.

Repair or replace the RF Amplifier assembly. Replace the Controller assembly.

374

Damping circuit failed POST – damping stuck on,

The Monitor detected a failure in the RF Amplifier damping drive signal during POST. No RF output.

Verify that all internal cables are properly connected. Configure system for test mode operation. Verify that the RFDAMP_DR signal switches high immediately preceding each RF Drive pulse and switches low following each RF Drive pulse while activat

ing in Spray or Standard Coag modes.

Repair or replace the RF Amplifier assem

bly. Q1 may have failed. Replace the Controller assembly.

379

RF calibration failed POST

System calibration required on one or more modes.

cuits, the HVPS, and the RF Amplifier.

Replace the Controller assembly if the system will not calibrate.

4-35

Page 48

Err Code

Description

Possible Cause

Things to Check

Correction

381

No tone feedback during POST

The Monitor did not detect tones during POST. This typically occurs because of a problem in the tone genera

tion circuitry.

Listen for tones during POST. Verify that all internal cables are properly connected. Increase the tone volume by adjusting the Volume Control on the back panel of the generator. Cycle system power and deter

ler. Lack of a signal indicates a problem with the Back Panel assembly.

Replace the Controller assembly. Repair or replace the Back Panel assembly.

382

Activation without a tone

The Monitor did not detect a tone during activation. This typically occurs because of a problem in the tone generation circuitry.

Listen for a tone during activation. Verify that all internal cables are properly connected. Increase the tone volume by adjusting the Volume Control on the back panel of the generator. Cycle system power and deter

ler. Lack of a signal indicates a problem with the Back Panel assembly.

Replace the Controller assembly. Repair or replace the Back Panel assembly.

383

RF Current sensed at an unselected output.

The Monitor has sensed current flowing at an output that has not been selected. This may indicate a faulty or stuck output relay.

Arrange the system with fixed loads connected to all outputs. Activate each output in turn while monitoring all outputs for current.

Replace or repair the Output assembly. Replace the Controller assembly.

4-36

Page 49

Err Code

Description

Possible Cause

Things to Check

Correction

384

POST HVDC to 30V failed- supply too low

The HVPS output is too low during POST.

Cycle system power and determine if this error is repeated. Watch LED2 on the HVPS dur

ing POST and confirm that it illuminates. If not, disconnect the cable between the HVPS and the RF Amplifier and cycle while again watching LED2. If it is now illuminated, a problem with the RF Amplifier is likely. Configure system for test mode operation. Verify HVPS control signals from the controller are correct while activated. Verify the HVPS is function

ing correctly – see HVPS Troubleshooting Guidelines

Verify that all cables are properly con

nected. Replace the Controller assembly. Replace or repair the HVPS. Replace or repair the RF Amplifier.

385

POST HVDC to 30V failed- supply too high

The HVPS output is too high during POST.

Cycle system power and determine if this error is repeated. Configure system for test mode operation. Verify HVPS control signals from the controller are correct while activated. Verify the HVPS is function

ing correctly – see HVPS Troubleshooting Guidelines

Replace the Controller assembly. Replace or repair the HVPS.

386

POST HVDC to 140V failed- supply too low

The HVPS output is too low during POST.

Cycle system power and determine if this error is repeated. Watch LED2 on the HVPS dur

ing correctly – see HVPS Troubleshooting Guidelines

Verify that all cables are properly con

nected. Replace the Controller assembly. Replace or repair the HVPS. Replace or repair the RF Amplifier.

387

POST HVDC to 140V failed- supply too high

The HVPS output is too high during POST.

ing correctly – see HVPS Troubleshooting Guidelines

Replace the Controller assembly. Replace or repair the HVPS.

4-37

Page 50

Err Code

Description

Possible Cause

Things to Check

Correction

388

POST monitor timed out- did not respond to a POST command

Reset machine and if error repeats, then replace Controller Assembly

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

389

Dial setting over maximum limit

The front panel power setting exceeds the limit for the selected mode.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

391

Monitor detected the wrong RF waveform

The Monitor has detected an improper RF Amplifier drive waveform or frequency for the selected mode.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

392

Monitor detected a pulse mode on-time that was too long

The active pulse mode pulses are longer than the nominal duration limits.

Cycle system power and determine if this error is repeated.

Replace the Controller assembly.

393

Vbias signal too high

The reference voltages on one or more of the ADCs on the Controller are too high.

Verify 2.5VDC on the voltage sense pins of the ADC when the system is not activated. Verify that all cables are properly connected.

Replace the Controller assembly.

394

Vbias signal too low

The reference voltages on one or more of the ADCs on the Controller are too low.

Verify 2.5VDC on the voltage sense pins of the ADC when the system is not activated. Verify that all cables are properly connected.

Replace the Controller assembly.

4-38

Page 51

Schematics & BOMs

Appendix A

This appendix contains printed circuit board layouts, parts lists and schematic diagrams for the System 5000™.

To assist in the location of components on the printed circuit boards, a “grid” system is used. The parts lists contain the component grid locations, shown in parentheses after the reference designator. The letter and number; i.e. “(A/1)”; correspond to a grid shown on the printed circuit board layout. Boards that are double-sided, with components installed on both sides, have the location prefixed with a “T” for top of the board, and “B” for the bottom of the board. Therefore, a component’s location within an approximate one-inch grid can be determined similar to locating cities on a roadmap.

Listed are the replaceable parts available from CONMED. Many of the more common parts may be available from local electronic suppliers.

Bill of Material: Chassis & Top Assembly

REF. DES. CONMED P/N DESCRIPTION

MISC. CHASSIS/TOP ASSEMBLY COMPONENTS

N/A 030257005 SCREW BDR HD/PH,4-40X3/8 N/A 030257103 SCREW,BDR HD,PH,6-32X1/4L N/A 030257104 SCREW, 6-32 X .312 N/A 030257105 SCREW,BDR HD,PH,6-32 X3/8 N/A 030257109 SCREW,BDR HD,PH16-32X3/4 N/A 030257111 SCREW,6-32X1”,PH,PHILLIPS N/A 030446007 SCREW FH PH BLK 4-40X1/2 N/A 030446107 SCREW FH PH BLK 6-32X1/2 N/A 10044020 STANDOFF,NYLON,6-32,1 1/4 N/A 61-6350004-00 BEZEL ASSEMBLY SYS,5000 A3 61-6411001-00 ASSY,PWB,DSPL CNTLR A2, SYS 5K A2 61-6415001-00 ASSY,PWB,DSPL PANEL A3,SYS 5K A4 61-6431002-00 ASSY,A3 MICROCTL,SYS,2/5 FPGA A6 61-6441001-00 ASSY, RF AMP, SYS A2/A5 A7 61-6445001-00 ASSY, RF XFMR PWB, SYS A2/A5 A9 61-6451001-00 ASSY,RF PWRSPLY+PFC A9,SYS2/5K A5 61-6461001-00 ASSY A5,OUTPUT BD,SYS 2/5ESU A12 61-6471001-00 ASSY,A12,BACKPANEL,SYS 5K N/A 61-6536001-00 HARNESS,LOW V DC,SYS2/5K N/A 61-6537001-00 HARNESS,LINE VOLTAGE,SYS 2/5K N/A 61-6598001-00 SUB-ASSY, FAN WIRES, A2/A5 N/A 61-6599001-00 TOP GROUND, A2/A5 N/A 61-6599002-00 BASE GROUND, A2/A5 N/A 61-6603001-00 SUB-ASSY,FUSE HOLDER,A2/A5,BL N/A 61-6603002-00 SUB-ASSY,FUSE HOLDER,A2/A5,BRN N/A 61-6604001-00 SUB-ASSY, 3.5 mm JACK, A2/A5 N/A 61-6606001-00 SUB-ASSY, CONNECTOR, A2/A5 N/A 62-0260001-00 CABLE TIE N/A 62-0335005-00 STANDOFF, HEX 6-32 X 1 7/8 N/A 62-0343002-00 NUT KEPS 6-32 N/A 62-0418003-00 WASHER LOCK IT #6 N/A 62-0620004-00 TUBE HS RNF100 TYPE1 3/16 N/A 62-0797003-00 RETAINING RING 1/8” N/A 62-0797004-00 RETAINING RING 3/16” N/A 62-1206003-00 STUD,GND EQUIV M6 THREAD N/A 62-4065001-00 POWER SUPPLY, TRIPLE, 40W N/A 62-4236315-00 FUSE5X20mm TD HGH BRK CAP 3.15A (230V ONLY) N/A 62-4236630-00 FUSE5X20mm TD HGH BRK CAP 6.3A (120V ONLY) N/A 62-4236800-00 FUSE5X20mm TD HGH BRK CAP 8.0A (100V ONLY) N/A 62-4511001-00 FILTER, IEC INLET N/A 62-4884002-00 TAPE, INSULATING N/A 62-5314001-00 LABEL,GROUND

REF. DES. CONMED P/N DESCRIPTION

N/A 62-6144001-00 HARNESS ASSY, 34 CONDUCTOR N/A 62-6145002-00 HARNESS ASSY,SHIELD26COND 8.5” N/A 62-6207001-00 ELECTRODE N/A 61-7041001-00 READIPLUG CABLE N/A 62-6209001-00 PUSH BUTTON, MOLDED, A2/A5 N/A 62-6210001-00 FRONT,BEZEL N/A 62-6211001-00 4MM BANANA JACK N/A 62-6212001-00 BANANA JACK , HC N/A 62-6213001-00 JACK RETAINER N/A 62-6214001-00 PIN RETAINER N/A 62-6215001-00 RETURN PAD PIN N/A 62-6216001-00 BASE, F.C. RECEP. MECH A2/A5 N/A 62-6217001-00 JACK ARM, F.C. RECP MECH A2/A5 N/A 62-6218001-00 JACK INSRT F.C. RECP MECH A2/A N/A 62-6219001-00 PIVOT PIN F.C. RECP MECH A2/A5 N/A 62-6220001-00 LINK, F.C. RECEP MECH A2/A5 N/A 62-6232001-00 INSULATOR, OUTPUT BOARD A2/A5 N/A 62-6249001-00 SHIELD, DISPLAY N/A 62-6269001-00 DISPLAY LIGHT CHANNEL N/A 62-6275001-00 BEZEL FIBER OPTIC CABLE N/A 62-6289001-00 STANDOFF BRASS HEX 6-32 .25 L N/A 62-6331001-00 CONTROL PANEL,SYSTEM 5000 N/A 62-6341001-00 SWITCH RKR PWR DP 125V 16A N/A 62-6477001-00 SPRING COMP .468 OD 1.0 L N/A 62-6477002-00 SPRING COMP .312 OD .38L N/A 62-6478001-00 SPACER AL .25 OD .14 ID .25 L N/A 62-6479001-00 RIVET PUSH NYLON .115 X .395 L N/A 62-6480001-00 PUSHNUT .062” SHAFT N/A 62-6484001-00 BASE,CHASSIS,SYS 2500/5000 N/A 62-6485001-00 HANDLE N/A 62-6490001-00 FASTENER,TUFLOK, .155 DIA N/A 62-6493001-00 PLATE BTM, DC POWER SUPPLY N/A 62-6494001-00 COVER, DC POWER SUPPLY,A2/A5 N/A 62-6504001-00 TOP COVER A2/A5 N/A 62-6508001-00 SCREW, TYPE AB, #8x1/2 N/A 62-6511001-00 SILICONE TUBE, 3/16x1/8 N/A 62-6514001-00 CUSTOM HEX STANDOFF N/A 62-6525001-00 MOUNTING CLIP, TOP COVER N/A 62-6534001-00 SCREW & WASHER ASSY, SQ. CONE N/A 62-6534002-00 SCREW & WASHER ASSY,SQ. CONE N/A 62-6534003-00 SCREW & WASHER ASSY, BLK N/A 62-6543001-00 COVER, RS232, A2/A5 N/A 62-6569001-00 NUT, PANEL, HEX 3/8-32 N/A 62-6580001-00 PROTECTOR, RIBBON CABLE N/A 62-6631002-00 KEEPER N/A 62-6684001-00 CORE, RIBBON CABLE

Figure 4.3 Module Diagram

A-1

Page 52

Schematic 4.1 Interconnect Diagram

A-2

Page 53

Schematic 4.2 A12 Back Panel PCB

A-3

Page 54

Bill of Material: Back Panel PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6471-001 A12 BACK PANEL PCB ASSEMBLY

C1,C2,C3,C6,C7, 010262103 CAP,CER,Z5U,50V,20%,.01MF C8,C9,C10(C/1); C11(B/1);C14(C/2); C15,C16,C17(B/2); C18(D/2);C27(E/2); C29,C30,C31(D/5); C32(C/5);C41(D/7); C42(C/7);C45,C46, C47(E/7);C48(B/8); C49(A/10) C4(A/1);C22(C/4); 62-6153106-00 CAP,ELEC,LO-PROFILE,10UF C25(D/1);C40(A/6) C5(D/1);C33(D/5); 62-0267003-00 CAP,CER,Z5U,.33UF,50V,20% C36,C37,C39(D/6); C38(C/6) C12(C/2);C19(C/3); 010262104 CAP,CER,Z5U,50V,20%,0.1MF C23,C24(B/4); C26(B/6);C43(C/7); C44(B/7) C20(C/3) 010262102 CAP,CER,Z5U,50V,20%,.001M D2(B/3);D4(D/2); 010029000 DIODE, IN914B D5(A/8) J1(A/1) 62-0279002-00 CONNECTOR J2(D/2) 62-4857005-00 HEADER, DIN W/LATCH 34 PIN J3(A/3) 62-0279001-00 CONNECTOR RECEPTACLE J4(A/3) 62-1390001-00 HEADER, RA, .100 SOL, 2 CKT J5(E/4) 62-2845001-00 HEADER,STRAIGHT,.100, 2 PIN J6(A/7) 62-6308002-00 CONN, 15 PIN, PCB, D-SUB, FEM J7(D/4) 62-1390003-00 HEADER,RT ANGLE,4P .100 K1(B/1) 62-6237001-00 RELAY, LOW PROFILE, 12V Q1(C/4) 62-4239001-00 TRANSISTOR, 2N3904 Q2(D/5) 62-6522001-00 TRANSISTOR, PNP, POWER Q3(A/7);Q4(A/9) 62-4239002-00 TRANSISTOR NPN 2N4401 R1(A/1);R3(E/1); 010166101 RES, 100 OHM 1/4W 5% CARBON R10,R13(A/2); R29(E/6); R30,R31,R32(E/5); R33,R34,R39(D/5); R43,R44(C/7) R2(A/1); 010166181 RES,FX,1/4W,5%,180 R11,R12(A/2)

REF. DES. CONMED P/N DESCRIPTION

R4(B/2);R5(C/2);R6, 010166102 RES, 1K OHM 1/4W 5% CARBON R8(D/2);R25(C/4) R7(C/2);R16(C/4) 010166332 RES,FX,1/4W,5%,3.3K R9(D/2);R47(B/8) 010166562 RES,FX,1/4W,5%,5.6K R14(C/3) 010316201 RES,FX,1/8W,1%,1.00K R15(B/3);R26(C/4) 010166271 RES,FX,1/4W,5%,270 OHM R17(C/2) 010166104 RES,FX,1/4W,5%,100K OHM R18(A/9);R19(A/7) 010166221 RES,FX,1/4W,5%,220 OHM R20(C/3) 010316269 RES,FX,1/8W,1%,5.11K R21(C/4) 010166473 RES, 47K OHM 1/4W 5% CARBON R22(B/3) 010316301 RES, FX1/8W,1%,10.0K R23(B/3) 010316242 RES,FX,1/8W,1%,2.67K R24(B/3) 010168820 RES,FX,1W,5%,82 OHM R27(C/4);R45(B/7) 010166272 RES, 2.7K OHM 1/4W 5% CARBON R28(C/4) 010166201 RES FX,1/4W,5%, 200 OHM R35, R38(D/5) 010166472 RES, 4.7K OHM 1/4W 5% CARBON R40(D/6) 62-1693009-00 RES FLAMPRF, 12 OHM, 3W, 5% R41(A/6) 010167120 RES,FX,1/2W,5%,12 OHM R42(A/8) 010167082 RES,FX,1/2W,5%, 8.2ohm R46(A/7) 010166133 RES, CARBON, 1/4W, 5%, 13K OHM R48(A/8) 010166911 RES,FX,1/4W,5%,910 RA1(A/9);RA2(A/10) 010595103 POTENTIOMETER, 10K OHM S1(E/7) 62-3651003-00 SWITCH, DIP, 6 POS N/A 62-6238001-00 SPEAKER, 8 OHM TP1(D/1),TP3(D/3), 020361101 TEST POINTS TP4(C/3) TP2(D/1) 62-6325001 TEST POINT, BLACK, 0.200 LONG U1,U2,U3(C/1) 010647001 I.C., OPTO COUPLER U4(C/2) 010281000 IC,QUAD VOLT COMP., LM339 U5(C/2) 62-1374001-00 IC XSTR ARRAY ULN2003 U6(D/6) 62-6236001-00 IC, RS232 TRANSCEIVER VR1(B/7) 62-0417001-00 REGULATOR VOLTAGE 5V N/A 62-6476001-00 STANDOFF,.312Lx4-40,SELF CLIN N/A 62-6476002-00 STANDOFF, PCB #4-40 X 1/4” N/A 030446107 SCREW FH PH BLK 6-32X1/2 N/A 080334000 WIRE, SOLID, 22AWG,WHT N/A 62-0343001-00 NUT KEPS 4-40 N/A 62-0649002-00 SEALANT,LOCTITE #222-31 50ML N/A 62-3608004-00 SCREW 4-40X5/16 PN HD PHL N/A 62-3608005-00 SCREW,4-403/8 PN HD PHL N/A 62-6476003-00 STANDOFF, .312L x 6-32 N/A 62-6763001-00 GASKET, SPEAKER, SYS 2500/5000

Figure 4.4 A12 Back Panel PCB Assembly

A-4

Page 55

Schematic 4.3a A9 RF Power Supply PCB - Power Factor Controller

A-5

Page 56

Schematic 4.3b A9 RF Power Supply PCB - Forward Converter

A-6

Page 57

Bill of Material: RF Power Supply PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6451-002 A9 RF POWER SUPPLY PCB ASSEMBLY

BR1(F/1) 62-6310001-00 BRIDGE RECTIFIER, PC MOUNT C1(F/9);C15, 62-0267001-00 CAP,CER,Z5U,.01UF,50V,20% C20(B/7);C16, C25(B/8);C17(A/8) C2(F/8) 62-6482003-00 CAP CER DISC 180PF 1000V 10% C3(F/4);C5(F/3) 62-6531004-00 CAP,POLYE,.22uF,630VDC, 10% C4(E/1);C29(C/2) 62-6140001-00 CAP,FILM,X2,0.68uF,275VAC,10% C6(F/4) 62-6140002-00 CAP,FILM,Y2,2200pF,250VAC,20% C7(C/3) 62-6530001-00 CAP, ALUM,ELECTROLYTIC C8(C/8);C40(D/8); 62-6419334-00 CAP,MET,PP,250V,5%,0.33UF C51(D/9) C9(C/8) 62-6138001-00 CAP,ELECT,100UF,200V,20% C10(C/7);C28(B/2) 62-6533001-00 CAPACITOR, CER. DISC, 550V C11(A/8);C23(B/2); 62-0267002-00 CAP,CER,Z5U,.1UF,50V,20% C31(B/4);C34(A/4); C36(B/9);C37(A/2); C47(A/9); C52,C53,C54(A/3) C12(C/4);C13(D/3); 62-0267006-00 CAP,CER,Z5U,1.0UF,50V,20% C14(A/7);C21(B/2); C35,C44,C49(B/5); C39(A/1);C45(A/2); C48(B/6) C18(B/2);C30(B/4) 62-0267009-00 CAP,CER,C0G,270PF,50V,5% C19(B/5);C27(A/2) 62-0267004-00 CAP,CER,C0G,100PF,50V,5% C22,C23(B/2); 62-4083001-00 CAP, ELEC., MIN., 47uF, 25V C24(B/5) C26,C33(A/2); 62-0267016-00 CAP,CER,COG,0.001UF,50V,5% C41(B/5) C32(A/3) 62-0267017-00 CAP,CER,Z5U,0.047UFD,50V,20% C42(B/6) 62-3575004-00 CAP, MET, .047MFD, 50V 5% C43(B/5) 62-0267010-00 CAP,CER,C0G,680PF,50V,5% C46(A/2) 62-3575009-00 CAP, MET, .15MFD, 50V, 5% C50(B/2) 62-6531006-00 CAP,POLYE,.1uF,250VDC, 10% D1(F/4) 62-4068002-00 DIODE,HIGH VOLTAGE/SPEED D2,D3(E/6) 62-6117002-00 DIODE, UF1005 600V 75nS D4(F/8);D5(F/9) 62-4068001-00 DIODE, HIGH VOLTAGE/SPEED D6,D8(F/5);D7, 62-0292002-00 DIODE, ZENER, 1N5245B D9(F/6);D15(B/3) D10(F/3) 010318013 SUPPRESSOR, VOLTAGE, 1.5KE15 D11(F/2) 62-4865001-00 DIODE, 1N5401 D13,D14,D20(C/4); 62-0290002-00 DIODE, 1N914B D17(B/2); D19,D22(C/5) D16(B/1);D18(F/2) 62-3313002-00 DIODE, SCHOTTKY, SB1100 J1(C/1) 62-6300006-00 CONN,HEADER,0.156,3 POS J2(A/9) 62-4857003-00 HEADER, DIN W/LATCH 14 PIN

REF. DES. CONMED P/N DESCRIPTION

L1(F/9) 62-6159001-00 INDUCTOR,OUTPUT,1.2mH,5A L2(E/4) 62-6391001-00 INDUCTOR,PFC BOOST,585uH,7ARMS L3(C/1);L4(D/1) 62-6139001-00 IND,LINE FLTR,68UH,8ADC LED1(C/4); 62-4056001-00 LED, RED LED2(C/7) Q1(F/6);Q2(F/5) 62-5590001-00 MOSFET N-CHAN 500V 0.52 TO-220 Q3(F/3) 62-6311002-00 MOSFET,N-CHAN,600V,.19,TO-220 Q4(C/6);Q5(A/6) 010630001 XISTOR,FET, 2N7000 Q6(A/4) 62-4239001-00 TRANSISTOR, 2N3904 Q7(B/3) 62-1694003-00 TRANSISTOR, POWER, IRF820 Q8(D/5) 62-7107001-00 POWER MOSFET, IRLU024 R1(F/2) 62-6334001-00 RES,CURRENT SENSE,.05ohm,1%,3W R2(F/2);R42(D/5) 62-3062001-00 RES,ZERO OHM R3(F/6);R4(F/5) 62-0364008-00 RES, 5.1, 1/4W, 5% R5(D/8) 62-3859001-00 RES, 10K 5W 5% R6,R20(C/2) 010628393 RES,MET OX,FX,2W,5%,39K OHM R7(E/7) 010654201 RES WW 200 OHMS 5W 10% R8(C/7);R38, 62-6408385-00 RES,MF,100K 1/2W 1% R63(B/6) R9(C/7);R39(A/2) 62-0961314-00 RES, 18.2K, 1/4W, 1% R10(B/7) 62-0364113-00 RES 120K, 1/4W, 5% R11,R22(B/4); 62-0961426-00 RES,MF,267K,1/4W,1% R69,R70(B/3) R12(A/8);R16(A/2); 62-0961289-00 RES, MF, 10.0K, 1/4W, 1% R21,R28,R32(B/7) R13(B/8) 62-0961290-00 RES,MF,10.2K,1/4W,1% R14(B/8) 62-0961197-00 RES, MF, 1.10K 1/4W 1% R15(B/5);R34,R35, 62-0364087-00 RES, 10K, 1/4W, 5% CF R47(B/8);R53(A/9); R61(A/4) R17(B/2);R19(A/1) 62-0364123-00 RES 330K, 1/4W, 5% R18(B/9) 62-6408393-00 RES,MF,121K,1/2W,1% R23(B/8);R27(B/5) 62-0364063-00 RES, 1K 1/4W 5% CF R24(B/7);R64(B/6) 62-0961260-00 RES, 4.99K, 1/4W, 1% R25(B/2);R41(A/1) 62-0364125-00 RES, 390K, 1/4W, 5% R26(A/1) 62-0961230-00 RES, MF, 2.43K, 1/4W, 1% R29(B/1) 62-0961185-00 RES,825 1/4W 1% MF R30(E/1) 62-4609005-00 RES MF 2W 5% 150K R31,R55(A/9) 62-0364002-00 RES, CF, 3.0 OHM, 1/4W, 5% R33(A/1) 62-0364098-00 RES,30K,1/4W, 5% R36(A/1) 62-0364072-00 RES, 2.4K, 1/4W, 5% CF R37(C/6) 62-0364055-00 RES, 470 1/4W 5% CF R40(C/6) 62-0364015-00 RES, 10, 1/4W, 5% R43(A/5) 62-0961285-00 RES 9.09K 1/4W 1% R44(A/2) 62-0364096-00 RES, 24K, 1/4W, 5% R45(C/6) 62-0364046-00 RES, 200, 1/4W, 5% CF R46(C/5) 62-0961001-00 RES, MF, 10 OHM, 1/4W, 1% R48(B/8);R51(A/8) 62-0364135-00 RES, 1.0M, 1/4W, 5% CF R49(A/5) 62-0961331-00 RES, MF, 27.4K, 1/4W, 1% R50(B/9) 62-0961234-00 RES, MF, 2.67K, 1/4W, 1% R52(A/5);R66(A/3) 62-0364094-00 RES, 20K, 1/4W, 5%

REF. DES. CONMED P/N DESCRIPTION

R54(A/1) 62-0364088-00 RES, 11K, 1/4W, 5% R56(C/6) 62-0961237-00 RES,2.87K,1/4W, 1% R57(A/5) 62-0364070-00 RES, 2K, 1/4W, 5% CF R58(A/5) 62-0364049-00 RES, 270, 1/4W, 5% R59(A/6);R65(B/6) 62-0364039-00 RES, 100 1/4W 5% CF R60(B/4) 62-0961252-00 RES,4.12K, 1/4W, 1% R62(B/6) 62-0961318-00 RES, MF, 20.0K, 1/4W, 1% R67(D/2) 010618392 RES,FX,MO,NI,5W,5%,3.9K R71(B/3);R72(A/4) 62-0961240-00 RES, MF, 3.09K, 1%, 1/4W R73(A/4) 62-0364101-00 RES, 39K, 1/4W, 5% R74(B/4) 62-0364132-00 RES, 750K, 1/4W, 5% RL1(F/1) 62-5589002-00 RES,INRUSH LIMITER,5.0ohm,8A T1(E/7) 62-3948001-00 INDUCTOR,CURR SNS,50T CEN.TAP T2(E/7) 62-6160002-00 TRANSFORMER, HV SUP SWITCHING T3(D/5) 62-6323002-00 TRANSFORMER, GATE DRIVE TP1(B/4);TP3(C/9); 020361101 TEST POINTS TP5,TP6,TP9(B/9); TP7,TP18(B/3); TP8,TP11(A/4); TP10,TP14(B/7); TP12(C/5); TP15(A/9); TP16(F/7); TP19(A/3) TP2(B/9);TP4(B/4); 62-6325001-00 TEST POINT,BLACK, 0.200 LONG TP13(B/6) U1(A/7) 62-4257001-00 IC QUAD COMPARATOR LM339 U2(B/2) 62-5388001-00 I.C.,POWER FACTOR CONTROL U3(A/5) 62-6116001-00 IC CURRENT MODE CONTROL PWM U4(A/4) 010480001 IC,OPTOCOUPLER,CNY17-3 U5(A/3) 62-6656001-00 IC COMPARATOR SINGLE LOW PWR VR1(B/4) 62-3957001-00 IC,VOLT REF. 2.5V 1%,TO-92 XQ7(B/3) 62-2726005-00 HEATSINK, TO220 PC 20C/W XR1(F/1) 62-4594002-00 VARISTOR, METAL OXIDE 275VAC N/A 10044036 STANDOFF, NYLON, 6-32, 2 1/4 N/A 61-6540001-00 HARNESS,HV SUPPLY,SYS 2/5K N/A 62-0431001-00 WIRE BARE BUS 22AWG N/A 62-0260001-00 CABLE TIE .085 WIDE N/A 62-0622002-00 WIRE HI VOLTAGE #22 10KV N/A 62-4768001-00 BRACKET,MOUNTING N/A 62-4926001-00 BUMPER, RUBBER, SELF-ADHESIVE N/A 62-6132001-00 BRACKET, STRAP, GND SHIELD N/A 62-6400003-00 THERMAL PAD, RFPS TO-220 N/A 62-6400004-00 THERMAL PAD, RFPS BR N/A 62-6486001-00 NUT TINNERMAN 6-32 N/A 62-6525002-00 MOUNTING CLIP, TRANSISTOR N/A 62-6525003-00 MOUNTING CLIP, TRANSISTOR N/A 62-6534002-00 SCREW & WASHER ASSY,SQ. CONE N/A 62-6544001-00 GROUND CLIP, PWB MOUNT N/A 62-6556002-00 DIE CAST RIGHT SIDE, A2/A5 N/A 62-6670001-00 TUBE, SPIRAL WRAP, KAPTON

Figure 4.5 A9 RF Power Supply PCB Assembly

A-7

Page 58

Schematic 4.4 A7 RF Transformer PCB

A-8

Page 59

Bill of Material: RF Transformer PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6445-001 A7 RF TRANSFORMER PCB ASSEMBLY

C1(C/6);C10(D/7) 62-5404003-00 CAP.,CER., 1KV, 3300pF +/- 20% C2,C4,C5(G/8); 62-0267009-00 CAP,CER,C0G,270PF,50V,5% C6(F/8) C7(G/3);C12(C/8) 62-0267002-00 CAP,CER,Z5U,.1UF,50V,20% C8,C9(C/1) 62-6623002-00 CAP, MET, PP, 780 PF, 1250V C13(B/6) 010261472 CAP,POLYPROP,2KV,4700 PF C14,C16(D/5); 62-0265007-00 CAP CER DISC 47PF 6KV 20% C15(C/5) C19,C22(D/2); 010261102 CAP,POLYPROP,2KV,1000 PF C20,C21(C/2) D10,D12(G/7); 62-0290002-00 DIODE, 1N914B D13,D14(F/7) J1(B/8) 62-4857003-00 HEADER, DIN W/LATCH 14 PIN J2(B/7) 62-6230303-00 CONN, 3 CKT .093” PWB VERTICAL K1(F/1);K2(F/2) 62-3473004-00 RELAY, REED, HV, 14V R1,R9,R10,R11(G/7) 62-0961068-00 RESISTOR MF 1/4W 1% 49.9 R2,R3(G/8) 62-0961080-00 RES, MF 66.5 OHM, 1/4W, 1% R4(C/6);R18(E/6) 010628561 RES,MET OX,FX,2W,5%,560 OHM R12(G/8);R15(F/8) 62-0364039-00 RES, 100 1/4W 5% CF R13(F/8);R17(G/7) 62-0961030-00 RES, 20 OHM, 1/4 W, 1% R14(F/8);R16(G/7) 62-3062001-00 RES,ZERO OHM T1(C/3) 61-6652001-00 XFMR, MONOPOLAR OUTPUT A2/A5 T2(F/4) 61-6653002-00 XFMR, BALUN, SYS 2500/5000 T3(D/7);T6(D/6) 61-4069001-00 XFRMR, V-SENSE, MONO T4,T5(F/7) 62-3948001-00 INDUCTOR,CURR SNS,50T CEN.TAP TP1(F/8) 62-6325001-00 TEST POINT,BLACK, 0.200 LONG N/A 62-6534002-00 SCREW & WASHER ASSY,SQ. CONE N/A 030080000 WASHER,FLAT,1/4X9/16X1/16 N/A 030463405 BOLT,HEX WASHER HD,1/4-20 N/A 62-0418006-00 WASHER LOCK INT TOOTH 1/4 N/A 62-5339001-00 SCREW,1/4-20 X 1/2 FH PHIL N/A 62-6512001-00 CAP, TOROID N/A 62-6555002-00 HEX STANDOFF, 1/4-20, 1.44 L N/A 61-6685001-00 HARNESS,XFMR BD,SYS 2500/5000 N/A 62-0260001-00 CABLE TIE .085 WIDE N/A 62-0622002-00 WIRE HI VOLTAGE #22 10KV N/A 62-1621002-00 KAPTON TAPE, 3/4” N/A 62-5586001-00 WIRE, TRIPLE INS. TEFZEL 24AWG,RED N/A 62-5586002-00 WIRE,TRP INS. TEFZEL24AWG,BLUE N/A 62-6320001-00 STANDOFF, WIRE, 1”, THK PWB

Figure 4.6 A7 RF Transformer PCB Assembly

A-9

Page 60

Schematic 4.5 A6 RF Amplifier PCB

62-6443-002

A-10

Page 61

Bill of Material: RF Amplifier PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6441-002 A6 RF AMPLIFIER PCB ASSEMBLY

C2(A/5);C5(A/4); 62-0267016-00 CAP,CER,COG,0.001UF,50V,5% C11(B/5);C30(B/4) C3(A/8) 62-4082001-00 CAP,MET,PP .047uF 1.25K VDC 5% C4(D/2);C6(E/4) 010261222 CAP,POLYPROP,2KV,2200 PF C7(A/2) 010261152 CAP,POLYPROP,2KV,1500 pF C8,C43,C44, 62-0267019-00 CAP, CER COG 0.01UF 50V 5-10% C65(B/5);C39(A/6) C9(B/3) 62-6419475-00 CAP,MET,PP,250V,5%,4.7UF C12(E/5) 010261223 CAP,POLYPROP,22000pF 2KV C13(B/4);C23(D/10); 62-4083001-00 CAP, ELEC., MIN., 47uF, 25V C46(D/9);C47(E/9) C14(D/4) 010261153 CAP,POLYPROP,15000pF 2KV C15,C16,C21,C48, 62-0267002-00 CAP,CER,Z5U,.1UF,50V,20% C49(D/9);C17,C31, C54(B/4);C18(B/3); C22(E/8);C51(C/6); C52(D/8);C53(B/5); C55(B/6);C66(D/10) C20(D/6) 62-6138001-00 CAP,ELECT,100UF,200V,20% C24(B/6) 62-0267008-00 CAP,CER,C0G,68PF,50V,5% C26(D/7) 010614151 CAP,CER,COG,(NPO),150 PF C27,C35,C45(B/5); 62-0267018-00 CAP, CER X7R 1UF 50V 10% C36(B/6) C32(A/3) 62-6638221-00 CAP, CER DISK 220PF 2KV 5&10% C42(D/7) 62-0267017-00 CAP,CER,Z5U,0.047UFD,50V,20% C56(B/8);C57(B/9) 010261682 CAP,POLYPROP,2KV,6800PF C58(B/4) 010614470 CAP,CER,COG,50V,5%,47PF C59(A/2) 62-0265004-00 CAP CER DISC .1UF 500V C60(D/3) 62-0265008-00 CAP,CER,DISC,.05uF,500V,20% D1(A/2) 62-6130001-00 DIODE, HI VOLTAGE, HI SPEED D3(D/7);D6(A/5); 62-0290002-00 DIODE, 1N914B D7(A/4) D4(A/2) 62-6637001-00 DIODE SCHOTTKY SIL-CAR 6A 600V D5(C/3) 62-0292003-00 DIODE, ZENER 1N5228B D14(A/1) 62-1683001-00 DIODE, HV, MUR4100E D15(A/2) 010318103 SUPPRESSOR, VOLT, KE350A D16(A/1) 010318102 SUPPRESOR,VOLTAGE,1.5KE300A J1(D/9) 62-4857004-00 HEADER, DIN W/LATCH 16 PIN J2(C/4) 62-6230304-00 CONN,4 CKT .093” PWB VERTICAL J3(E/6) 62-3598004-00 HEADER, STR. PIN, 3 CKT, TIN J4(C/9) 62-6230302-00 CONN,2 CKT, .093” PWB VERTICAL J5(A/4);J6(A/3); 62-6619001-00 CONN,SHRT LK,INS,RED,.04x.2 J7,J8(A/5) J5(A/4);J6(A/3); 62-6624001-00 CONN CAGE JACK PRESS .04 AU/NI J7,J8(A/5) K1(D/4) 62-6195002-00 RELAY,POWER PCB,DPDT,12VDC K2(D/3) 62-6195001-00 RELAY,POWER PCB, SPDT, 12 VDC K3(D/5) 62-6673001-00 RELAY,PCB,DPST,12VDC,5KV,10A L2(B/5) 050119001 FERRITE SHIELD BEAD L3(E/6) 62-6636022-00 INDUCTOR, FIXED RADIAL L5(D/2) 61-7104001-00 INDUCTOR, CUT, CURRENT LIMIT Q1(A/6) 62-6321001-00 MOSFET, IXTH13N110, 1100V, 13A Q3(A/5);Q4(A/4) 62-6635001-00 MOSFET, 17A, 800V, 0.29 OHM R1(A/9);R2(A/8); 62-6309001-00 RESISTOR, PWR, 100W, 15OHMS 1% R3(A/7) R4(A/5);R45(A/4) 62-6660001-00 RES SMALL MF 1W 5% 30 R5(A/7) 62-6674001-00 RES SMALL MF 1/4W 1% 10.0 R6(B/5) 62-6674066-00 RES SMALL MF 1/4W 1% 47.5 R7,R23,R32(D/7); 62-6674322-00 RES SMALL MF 1/4W 1% 22.1K R35(E/8) R8,R9(E/8); 62-6674289-00 RES SMALL MF 1/4W 1% 10.0K R18,R42(D/8)

REF. DES. CONMED P/N DESCRIPTION

R10(A/5);R11(B/5) 62-5748002-00 RES,10 OHM 5% SM. 1W FUSIBLE R14,R29(D/8); 62-6674162-00 RES SMALL MF 1/4W 1% 475 R28(D/7);R38,R39, R47(E/7) R15(B/4);R16(B/6) 62-6674226-00 RES SMALL MF 1/4W 1% 2.21K R20(D/7) 62-6674139-00 RES SMALL MF 1/4W 1% 274 R21(D/7) 62-6674193-00 RES SMALL MF 1/4W 1% 1.00K R22(D/7) 62-6674235-00 RES SMALL MF 1/4W 1% 2.74K R26(D/7) 62-6674210-00 RES SMALL MF 1/4W 1% 1.50K R30(D/8);R37(E/7) 62-6674306-00 RES SMALL MF 1/4W 1% 15.0K R33(D/7);R34(E/7) 62-6674356-00 RES SMALL MF 1/4W 1% 49.9K R43(E/8) 62-6674097-00 RES SMALL MF 1/4W 1% 100 RT1(A/1) 62-6420103-00 THERMISTOR 10K OHM 10% T1(B/7) 61-4067001-00 TRANSFORMER, BIPOLAR T2(C/3) 62-6655001-00 CORE, FERRITE, PLANAR E T2(C/3) 62-6655002-00 CORE, FERRITE, PLANAR PLATE TP1(A/7);TP2(A/5); 62-6325001-00 TEST POINT,BLACK, 0.200 LONG TP3(A/6);TP4(E/6); TP5(E/8);TP6(A/8); TP7(A/3);TP8(D/8); TP9(D/9); TP11(E/9); TP12(E/10); TP13(A/4); TP14(B/4) U1(B/6) 62-6634002-00 DRIVER, MOSFET, 14A, TO-220 U2(D/8) 62-6136001-00 IC QUAD RS485 LINE RCVR 16 DIP U3(B/4) 62-4081001-00 MOSFET DRIVER VR1(D/9) 010367001 VOLTAGE REGULATOR -5V 7905CT N/A 030257103 SCREW,SLT,PH,SEMS EW,6-32X1/4L N/A 62-4842001-00 TAPE, FOAM N/A 62-6678001-00 CLAMP, PLANAR E-CORE, A2/A5 N/A 62-6679001-00 BOTTOM BRACKET, PLANAR E-CORE N/A 030241003 NUT,SELF-CLINCH,PCB, 4-40 N/A 62-5740001-00 HEATSINK TO-220 PC 1.18x.95x.5 N/A 030080000 WASHER,FLAT,1/4X9/16X1/16 N/A 030257005 SCREW BDR HD/PH,4-40X3/8 N/A 030463405 BOLT,HEX WASHER HD,1/4-20 N/A 62-0260001-00 CABLE TIE .085 WIDE N/A 62-0343001-00 NUT KEPS 4-40 N/A 62-0418006-00 WASHER LOCK INT TOOTH 1/4 N/A 62-1621002-00 KAPTON TAPE, 3/4” N/A 62-4286001-00 INSULATOR CLAMP T0220 0.69X0.2 N/A 62-4768001-00 BRACKET,MOUNTING N/A 62-4842002-00 TAPE, FOAM 5/8” x 5/8” N/A 62-4926001-00 BUMPER, RUBBER, SELF-ADHESIVE N/A 62-5339001-00 SCREW,1/4-20 X 1/2 FH PHIL N/A 62-6132001-00 BRACKET, STRAP, GND SHIELD N/A 62-6312001-00 CLAMP, TRANSISTOR N/A 62-6400001-00 THERMAL PAD, TO-220 N/A 62-6400005-00 THERMAL PAD, TO-247 N/A 62-6486001-00 NUT TINNERMAN 6-32 N/A 62-6512001-00 CAP, TOROID N/A 62-6534002-00 SCREW & WASHER ASSY,SQ. CONE N/A 62-6544001-00 GROUND CLIP, PWB MOUNT N/A 62-6555001-00 HEX STANDOFF, 1/4-20, .500 L N/A 62-6556001-00 DIE CAST LEFT SIDE, A2/A5 N/A 62-6671001-00 DAMPENING PAD N/A 62-6681001-00 FENCE, HV AMP, SYS. 2500/5000 N/A 62-0419003-00 WASHER FLAT #6 N/A 62-6760001-00 WASHER BELLEVILLE #6-32 N/A 62-6761001-00 SCREW, SCH, HEX, BLK, #6-32 N/A 62-6745001-00 ADHESIVE, LOCTITE 324 N/A 62-6745002-00 ADHESIVE, LOCTITE 7649

Figure 4.7 A6 RF Amplifier PCB Assembly

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Schematic 4.6a A5 RF Output PCB - Interconnect & Switching Isolation

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Page 63

Schematic 4.6b A5 RF Output PCB - Relays & Sensing

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Page 64

Bill of Material: RF Output PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6461-003 A5 RF OUTPUT PCB ASSEMBLY

C1(K/6);C8(J/6); 62-6137001-00 CAP MET PP .01UF 1600V 10% C39(A/6) C2(K/2);C5,C7(K/5); 62-0267002-00 CAP. DIP CER 0.1UF C11(I/3);C14(I/1); C17(I/5);C20(H/5); C21(H/7);C26(F/7); C27(F/1); C29,C31(F/6); C35,C37(C/1) C3(K/3);C9(J/2) 62-0267009-00 CAP,CER 270PF 50V C4(K/3);C15(H/3); 62-0267001-00 CAP. DIP CER 0.01UF C16(I/4);C19(H/4); C28,C30(F/4) C6(J/5);C18(I/7); 62-0268001-00 CAP. ELEC 10UF 16V C24(F/7);C43(K/2) C10(I/3) 62-4083001-00 CAP, MIN ELECTRO. 47uF, 25V C12(I/2) 62-1677009-00 CAP,0.0022UF 50V 10% C13(I/3) 62-6764223-00 CAP,PP FILM .022uF,250V C22(I/7);C23(H/7); 62-1677004-00 CAP,METPE 0.33UF 100V 5% C25,C32(F/7); C38,C40(B/7) C33(D/3) 62-0267004-00 CAP. DIP CER 100PF C34,C36(C/2) 62-1677005-00 CAP,METPE 0.22UF 100V 5% C41(J/6);C42(J/5) 62-5404003-00 CAP.,CER.,HV, 3300pF +/- 20% D1,D2,D3(L/3); 62-0290002-00 DIODE,1N914B D4(K/3);D5(J/6); D6(K/2);D11(I/6); D12(I/2);D13(H/2); D14(H/3);D15(G/2); D16(G/3);D17(F/6); D18,D19(D/3) J1(F/1) 62-3986003-00 CONN,SOCKET,FEMALE,STRAIGHT J2(J/1) 62-3598001-00 HEADER FRICT LOK 24CKT ST J3(H/1) 62-4857005-00 HEADER, DIN W/LATCH 34 PIN J4(G/1) 62-4079001-00 WR HARNESS,RBN,14PIN, 3.9” J5(E/1) 62-4079003-00 WR HARNESS,RBN,16 PIN, 3.9” J6(B/1) 62-4079002-00 WR HARNESS, RBN, 14 PIN, 6.3” J8(C/6) 62-3598004-00 HEADER, STR. PIN, 3 CKT, TIN J9(A/5) 62-3598003-00 HEADER FRICT LOCK GOLD J10(K/7);J12(J/7); 62-6205001-00 CONTACT, SHORT OUTPUT J14,J15(H/8); J16(G/8);J17(F/8); J18,J19(E/8) J11(J/7) 62-6206001-00 CONTACT, LONG OUTPUT K1,K2(G/5);K3(D/5) 62-3473004-00 RELAY REED, HV, 14V L1(A/2) 62-4178001-00 INDUCTOR 20MH L2(G/7);L3(E/7); 61-6597001-00 EMI SUPPRESSOR ASSY, TOMBSTONE L4(D/5) Q1(H/3) 010476001 TRANS.MOSFET,DIP,100V,1A Q2,Q3(D/3) 62-4239001-00 TRANSISTOR NPN 2N3904 R1(L/3);R4(K/3); 62-0961030-00 RES, 20 OHM, 1/4 W, 1% R21(H/2);R23(G/2); R31(D/3)

REF. DES. CONMED P/N DESCRIPTION

R2,R3(L/3) 62-0961097-00 RES, 100 1/4W 1% R5(K/3);R12(J/2) 62-0961132-00 RES, MF, 232, 1% .25W R6,R38,R39(K/3); 62-0961108-00 RES, MF, 130 OHM, 1/4W, 1% R11(J/2) R7(K/2);R10(J/6); 62-0364087-00 RES, 10K, 1/4W, 5% R17(I/6);R27(F/6) R8,R9(J/6);R15, 62-0364045-00 RES, 180, 1/4W,5% R16(I/6);R18(H/3); R19,R20(H/6); R25,R26,R28, R29(F/6) R13(I/2) 62-0365061-00 RES, 820, 1/2W, 5% R22(H/2);R24(G/2); 62-3062001-00 RES,ZERO OHM R30(D/2) R32,R33(D/2) 62-0364104-00 RES, 51K, 1/4W, 5% R34(B/3);R37(B/2) 62-0364025-00 RES, 27, 1/4W, 5% R35(B/2) 62-0364072-00 RES, 2400, 1/4W, 5% R14(I/2) 62-0961273-00 RES, 6810, 1/4W, 1% R36(B/2) 62-0961305-00 RES, MF, 14.7K, 1/4W, 1% R40(J/7);R41(J/4) 62-0365057-00 RES, 560, 1/2W, 5% T1(L/3);T2(K/3) 62-0622002-00 WIRE HI VOLTAGE #22 10KV T1(L/3);T2(K/3); 62-3948001-00 50T CEN.TAP(IND.CURR.SENSE) T5,T6(G/3);T7(D/3) T3(K/6);T10(J/5) 61-3069002-00 XFMR,V-SNS,BIPOLAR,TMBSTN MNT T4(J/3) 61-6224002-00 ASSY, XFMR,CONTINUITY DETECTOR T8(C/3) 62-4177001-00 XFMR ARM OSC EX T9(A/4) 61-4176007-00 XFMR ARM ISOLATION A SERIES TP1(K/1);TP2, 020361101 TEST POINT, BLK. TP3(J/1);TP4(F/1); TP5,TP6(A/2); TP7(I/2) U1(K/4);U3(I/5); 62-4238001-00 OPTOISOLATOR, OPI1264A U4(H/5);U5,U6(F/5) U2(H/3) 62-0301001-00 IC TIMER NE555N U7(C/1) 62-1374003-00 IC TRANSISTOR ARRAY 18 PIN VR1(B/2) 62-3957002-00 IC, VOLT REF.10.0V 1%, TO -92 N/A 62-0753003-00 NUT HEX NYLON 6-32 N/A 62-4278001-00 SCREW6-32X1/2 BDGH SL NY N/A 62-4278005-00 SCREW. NYLON, #6-32x3/4 N/A 62-5234001-00 BUSHING ARM XFMR N/A 030263029 WASHER,SHLD,NYL,.750X.152 N/A 030285205 SCREW,PAN HD,NYL,8-32X2/3 N/A 030421210 SPACER,HEX,NYL.,8-32X.750 N/A 61-6538002-00 HARNESS, BIP, SYS 2500/5000 N/A 61-6539001-00 HARNESS,RF MONO, SYS 2/5K N/A 61-6662001-00 WIRE HARNESS, SYS 2500/5000 N/A 62-0260001-00 CABLE TIE N/A 62-0620009-00 TUBE HS RNF 100 TYPE 2 3/8 CLR N/A 62-5586001-00 WIRE, TRIPLE INS. TEFZEL 24AWG N/A 62-5586002-00 WIRE,TRP INS. TEFZEL24AWG,BLUE N/A 62-6296001-00 FENCE, BIPOLAR N/A 62-6320001-00 STANDOFF, WIRE, 1”, THK PWB N/A 62-6513001-00 FENCE, HV, 2.1x.125 SLOT

Figure 4.8 A5 RF Output PCB Assembly

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Schematic 4.7a A4 Microcontroller PCB - Controller Interconnect

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Schematic 4.7b A4 Microcontroller PCB - Microcontroller

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Schematic 4.7c A4 Microcontroller PCB - RF Controller

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Page 68

Bill of Material: Microcontroller PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6431-002 A4 MICROCONTROLLER PCB ASSEMBLY

C1,C3(TD/8); 62-3998101-00 CAP.CER.CHIP,50V,5%,SMT,100 C9(TC/8); C14,C20(TB/11); C31(BD/7); C116,C117,C118, C119,C120,C129, C130(BB/10); C160,C161(BA/10); C164,C169(TB/3); C165(BC/5); C166,C167, C171(BC/4); C168,C170(BC/3) C2(TD/4);C8(TC/2); 62-3995104-00 CAP.CER.Y5V,25V,SMT,.1uF C10(TC/4); C29,C33(BD/7); C30,C39(BD/4); C32(BD/8); C34(BD/6); C35(BD/3); C36(BD/11); C40,C50,C67, C83,C88(BC/11); C41,C42,C61,C71, C84,C92,C99,C100, C101(BC/10); C43,C44,C51,C72, C93,C102,C103, C104(BC/9); C45,C52,C59,C60, C68,C89,C105(BC/8); C47,C69,C85,C90, C91(BC/7); C48,C49,C54,C64, C65,C87,C115(BC/4); C53,C86,C94,C97, C106(BC/5); C55,C56, C66,C74(BC/3); C57,C58,C70(BC/2); C63,C73,C95, C96(BC/6); C121(BB/8); C122(BB/2);C123, C124,C125(BB/1); C126,C127,C140, C142,C144(BB/11); C128,C141, C145(BB/10); C139(BB/12); C147,C148(BB/9); C149,C157, C158(BA/10); C154(BA/9); C155,C156(BA/11); C163(BA/3) C4(TD/3);C5(TD/4); 62-6392001-00 CAP,CER,25V,20%,1.0uF,SMT C6(TC/11); 62-6192106-00 CAP.ELEC.25V,10uF,SMT C16(TB/1); C18(TB/8); C19(TB/11) C7(TD/12); 62-6192476-00 CAP.ELEC.25V,47uF,SMT C13(TC/8); C15(TC/12); C17(TB/1); C28(TA/11) C11,C12(TC/1) 62-6328225-00 CAP CER Z5U 50V 20% SMT 2.2UF C21(TB/9); 62-6248102-00 CAP.,CER.CHIP,X7R,10%,25V,SMT C62(BC/6); C150,C151,C152, C153(BA/11); C162(BA/10) C22,C26(TA/11) 62-6741334-00 CAP,CER,0805,X74,16V,SMT C23,C27(TA/12) 62-3999027-00 CAP CER C0G 50V 10% SMT 2.7PF C24,C25(TA/11) 62-6123102-00 CAP CER C0G 50V 10% SMT 1000PF

REF. DES. CONMED P/N DESCRIPTION

C37(BD/9); 62-3995103-00 CAP.CER.Y5V,25V,SMT,10.000,01 C38(BD/4); C46(BC/8); C107,C108,C109, C110,C111,C112, C113,C114(BC/7); C131,C132,C133, C134,C135,C136, C137,C138(BB/9); C143(BB/11); C146(BB/10); C159(BA/10) D1,D2(TD/3) 62-3957004-00 IC, VOLT REF.5.0V,1%,SMT,TO-92 D3(TC/3);D33(TC/5) 62-6197001-00 DIODE, ZENER, 1/2W, SMT, 4.3V D4,D23,D24,D25, 62-3990001-00 SCHOTTKY DIODE,SER.BAT42W,SMT D26,D27,D28, D29,D30,D31, D32,D40(TC/4); D5,D6,D7,D8, D9,D10,D11, D12,D13(TC/2); D14,D15,D16, D17,D18,D19, D20,D21,D22, D38,D39(TC/3); D41(TC/5) J1(TA/6) 62-3986001-00 CONN,PLUG,MALE,RIGHT ANGLE J2(TD/10) 62-4857002-00 HEADER, DIN, W/LATCH, 26 PIN J3(TD/6);J4(TD/7) 62-6196014-00 HEADER,UNSHRD’D,.025STR.14PIN J5(TD/8) 62-6196010-00 HEADER,UNSHRD’D,.025STR,10PIN L1(TB/2);L2(TB/3); 62-6340001-00 CHOKE,COMMON MODE,4 GATE,SMT L3,L4(TB/4); L8(TB/6); L9,L10(TB/7); L17(TA/1);L18(TA/2) L5,L6,L7(TB/5); 62-6338001-00 FERRITE BEAD, SMT L11,L12(TB/8); L13(TB/9); L15,L20(TA/9); L22,L23,L24(BB/5); L25,L26,L27(BB/4); L28,L29,L30, L31(BB/3); L32,L33,L34, L48,L49(BB/2); L35,L36,L50, L51(BB/1); L37(BB/8); L38,L39,L40, L41(BB/7); L42,L43(BB/6); L44(BB/9); L46,L47(BA/5); L72,L74(BA/9); L77(BA/3) L14(TB/9); 62-6339001-00 CHIP INDUCTOR, 1206, SMT L16,L19(TA/9); L21(BB/8); L45(BB/9); L52(BA/8); L53,L54,L55, L56,L57(BA/7); L58,L59,L60, L61,L62(BA/6); L63(BA/5); L64,L65,L66(BA/4); L67,L68,L69, L70,L76(BA/3); L71(BA/2); L73,L75(BA/9) LED1(TC/5) 62-3941001-00 LED, SMT, GREEN LED2(TA/10) 62-3941002-00 LED, SMT, RED R1(TD/3) 62-3947191-00 RES.1/10W,1%,SMT,866 OHM R2(TD/3) 62-3946511-00 RES. 1/2W, 5%, SMT, 510 OHM R45(BD/8); 62-3945102-00 RESISTOR,1/10W,5%,SMT,1K OHM R44(BD/12); R66(BC/7); R92(BC/6); R117(BC/9); R150(BA/10); R152,R153, R154,R155(BA/11); R157(BA/9)

{continued on next page}

Schematic 4.7d A4 Microcontroller PCB - RF Monitor

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REF. DES. CONMED P/N DESCRIPTION

61-6431-002 A4 MICROCONTROLLER PCB ASSEMBLY {continued from previous page}

R4,R5,R6(TC/9); 62-3945471-00 RESISTOR,1/10W,5%,SMT,470 OHM R46,R55,R63, R65,R72,R118, R119(BC/9); R50,R56, R120(BC/8); R51(BC/7); R54,R62,R83, R85(BC/10); R59(BC/5); R88(BC/6); R90(BC/11); R105(BC/3); R107,R108,R109, R110,R111,R112, R113,R114, R115(BC/2); R116(BC/12); R127,R129(BC/4); R131,R133(BB/2); R136(BB/12); R137(BB/11); R147(BB/10) R7,R9,R10, 62-3945101-00 RESISTOR,1/10W,5%,SMT, 100 OHM R11(TC/5); R17(TB/8); R31,R34, R37(BD/8); R38(BD/7); R68,R87(BC/6); R86(BC/7) R8(TC/8);R12, 62-3945120-00 RESISTOR,1/10W,5%,SMT,12 OHM R13,R14(TB/11); R21(TB/12) R15(TB/11); 62-3945103-00 RESISTOR,1/10W,5%,SMT,10K OHM R23(TB/12); R24,R25, R27(TA/12); R43(BD/4); R58,R61(BC/10) R16(TB/11);R139, 62-3947258-00 RES.1/10W,1%,SMT,3.92K OHM R140(BB/8) R18(TB/8); 62-3945472-00 RESISTOR,1/10W,5%,SMT,4.7K OHM R19(TB/11); R33(BD/4); R39,R40(BD/10); R73(BC/9); R91(BC/10); R130(BB/2); R165(BA/3) R22(TB/11); 62-3947166-00 RES. 1/10W,1%,SMT,475 OHM R26(TA/11); R35,R36(BD/4) R28,R29(TA/9); 62-3947234-00 RES.1/10W,1%,SMT,2.21K OHM R145(BB/6);R164, R166(BA/9) R41,R42(BD/9); 62-3945470-00 RES,1/10W,5%,SMT,47-OHM R47,R48,R49, R64,R69(BC/9); R57,R60,R71, R82(BC/10); R99(BC/8); R134(BD/10) R52(BC/7); 62-3945104-00 RESISTOR,1/10W,5%,SMT,100K OHM R132(BB/2); R160,R162(BA/11) R53(BC/4) 62-3947273-00 RES.1/10W,1%,SMT,5.62 K OHM R3(TD/7); 62-3945272-00 RESISTOR,1/10W, 5%, SMT, 2.7KOHM R30,R32(BD/8); R67,R84(BC/7); R138(BB/10) R70(BC/7) 62-3945681-00 RES.,1/10W,5%,SMT, 680 OHM R74(BC/6); 62-3947301-00 RES.1/10W,1%,SMT,10.0 K OHM R79(BC/3); R81(BC/2); R96,R98(BC/4); R75(BC/3); R121(BC/5)

REF. DES. CONMED P/N DESCRIPTION

R76,R101(BC/3); 62-3947230-00 RES. 1/10W,1%,SMT,2K OHM R93,R123(BC/4) R77(BC/3); 62-3947213-00 RES. 1/10W,1%,SMT,1.33K OHM R94(BC/4) R78(BC/3); 62-3947204-00 RES.,1/10W,1%, SMT, 1.07K OHM R95(BC/4) R89(BC/6) 62-3947281-00 RES.1/10W,1%,SMT,6.81 K OHM R100,R104(BC/3); 62-3947201-00 RES.1/10W,1%,SMT,1.0K OHM R122,R126(BC/4); R148,R158(BA/12); R168,R169(TB/3); R170,R171(TC/3); R173,R174,R175, R176(TC/4) R102(BC/3); 62-3947259-00 RES. 1/10W,1%,SMT,4.02K OHM R124(BC/4) R103(BC/3); 62-3947159-00 RES., 1/10W, 1%, SMT, 402 OHM R125(BC/4) R106(BC/3); 62-3947497-00 RES. 1/10W, 1%, SMT, 877 OHM R128(BC/4) R135(BB/4); 62-3947266-00 RES.1/10W,1%,SMT,4.75 K OHM R141,R142(BB/8); R143,R144(BB/6) R146(BB/6) 62-3947268-00 RES.1/10W,1%,SMT,4.99K OHM R149,R159(BA/12) 62-3947168-00 RES.1/10W,1%,SMT,499 OHM R151(BA/7) 62-3947151-00 RES.1/10W,1%,SMT,332 OHM R156(BA/10) 62-3945151-00 RES.,1/10W,5%,SMT, 150 OHMS RP1(TD/6); 62-3997332-00 RESIST.NET.8,SMT,2%,3.3KOHM RP5(TB/6) RP2(TD/6); 62-3997470-00 RESIST.NET.8,SMT,2%,47 OHM RP10(TB/10) RP3(TC/8); 62-3996101-00 RESIST.NET 7,SMT,2%,100 OHM RP4(TC/10) RP6(TB/7); 62-3997102-00 RESIST.NET.8,SMT,2%,1.0KOHM RP9(TB/9) RP7(TB/7) 62-3997473-00 RES,NET.8,SMT,2%,47K OHMS RP8(TB/9) 62-3997202-00 RESIST.NET.8,SMT,2%,2.0KOHM RP11(TA/9) 62-3997101-00 RESIST.NET.8,SMT,2%,100OHM RP12(TA/10) 62-3996470-00 RESIST.NET.7,SMT,2%,47 OHM S1(TD/4) 62-3988002-00 SWITCH, PSH BTN, 230/260g, SMT S2(TD/5) 62-3987001-00 SWITCH, DIP, 8 POLE, SMT TP1(TD/4); 020361101 TEST POINT, BLK. TP2,TP3(TC/6); TP4,TP5(TC/7); TP7,TP8(TC/5); TP9(TB/6); TP10(TB/12); TP11,TP12(TA/8); TP13(TA/10) TP6(TC/5) 62-6325001-00 TEST POINT, BLACK, 0.200 LONG U1(TD/4) 62-3982001-00 DUAL PROCESSOR SUPERVISOR, SMT U2(TC/2); 62-3992001-00 SERIAL ANA-TO-DIG CONV., SMT U3(TC/3); U7(TC/4) U4,U5(TC/5); 62-3932001-00 OCTAL BUFFER/DRIVER U8(TC/6) U6(TC/7) 61-6627001-00 PRGRMD DEVICE, ACTEL, MONITOR U9(TC/9); 62-3991001-00 FX’D-PNT DIG. SIG. PROC., SMT U10(TC/10) U12(TC/6) 62-3993001-00 QUAD. DIG-TO-ANA CONV., SMT U13(TB/12) 62-3981001-00 VOLTAGE COMPARATOR, SMT U14(TB/10) 61-6625001-00 PRGRMD DEVICE,ACTEL,CONTROLLER U15(TB/11) 62-6393001-00 MICROCONTROLLER,ATmega128L-8AC U16(TA/12) 62-6397001-00 IC DUAL ULTRA-FAST COMPAR SMT VR1(TD/11) 62-3936001-00 800mA,LDO ADJ. REG.,3.3 V VR2(TB/8); 62-6396001-00 VOLTAGE REG., FX, 1.8V, SMT VR3(TB/12) X1(TC/1);X2(TC/12) 62-6524001-00 TERMINAL, SCREW, PWB MOUNTED Y1(TC/8);Y2(TB/11) 62-5885002-00 CLOCK OSCILLATOR, 10.000 MGz Y3(TB/10) 62-5885001-00 CLOCK OSCILLATOR, 3.6864 MHz

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Figure 4.9 A4 Microcontroller PCB Assembly

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Page 70

Schematic 4.8 A2 Display Controller PCB

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Page 71

Bill of Material: Display Controller PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6411-001 A2 DISPLAY CONTROLLER PCB ASSEMBLY

BAT1(BB/9) 62-6305001-00 BATTERY, LITH, COIN, 3V C1(TA/2); 62-3995104-00 CAP.CER.Y5V,25V,SMT,100.000.1 C2,C3(TB/2); C4,C5,C7,C9(BB/2); C10,C15(BB/3); C14(TA/3); C16(TC/3); C26(TA/4); C27,C28(TC/5); C32(TA/6); C33(TA/7); C36(TB/7) C6(TC/2);C11(TC/3) 62-6192106-00 CAP.ELEC.25V,10uF,SMT C8(TC/2);C19(TC/3); 62-6248102-00 CAP.,CER.CHIP,X7R,10%,25V,SMT C20(TB/3); C22(TB/4); C23,C25(TC/4); C31,C37,C38, C39,C40(TA/8) C12(TC/2);C35(TA/7) 62-3995103-00 CAP.CER.Y5V,25V,SMT,10.000,01 C13(TC/3);C34(TA/7) 62-3998101-00 CAP.CER.CHIP,50V,5%,SMT,100 C18(TC/3) 62-6192475-00 CAP.ELEC,25V,4.7uF,SMT C29(TA/6) 62-3999473-00 CAP.CER.CHIP,25V,10%,SMT,47000 C30(TA/6) 62-6748474-00 CAP.CER.6.3V 10% SMT 470000pF D1(BB/6) 62-6229001-00 LED, T-1 3/4, WHITE J1(TC/3) 62-4857002-00 HEADER, DIN, W/LATCH, 26 PIN J2(TA/9) 62-6306112-00 HEADER,UNSHR,12PIN,90DEG,TIN J3(TA/1);J4(TC/7) 62-6333040-00 HEADER,FEM,40P,.25”SQ,LO-PROF R1(TA/1);R2, 62-3945470-00 RES,1/10W,5%,SMT,47-OHM R4,R5,R6,R9, R10,R11(TA/2); R7,R13(TC/2); R14,R15, R21(TC/3); R19,R22(TB/3); R26(TB/4); R28,R31,R32,R36, R37,R38,R39,R40, R41(TA/4); R30,R34(TC/4); R42,R43,R44,R45, R46,R47,R48(TA/5); R50(TB/5); R56,R58,R61,R62, R63,R64(TC/7); R59,R60(TA/7); R65,R66,R67,R68, R69,R70,R71,R72, R73(TC/8); R74,R75,R76, R77,R78,R79, R80,R81(TC/9); R82,R83(TC/10) R3,R8(TB/2); 62-3945472-00 RESISTOR,1/10W,5%,SMT,4.7K OHM R12(TC/2); R16,R20(TC/3); R25(TB/4); R29,R33(TC/4); R49(TA/5);R51,R52, R53,R54(TA/6); R57(TA/7) R17,R18(TA/3); 62-3945103-00 RESISTOR,1/10W,5%,SMT,10K OHM R24(TB/3) R55(TA/8) 62-3945332-00 RESISTOR,1/10W,5%,SMT 3.3K OHM R84,R87,R88(TA/8); 62-3945473-00 RESISTOR,1/10W,5%,SMT,47K OHM R85,R86(TA/7) RP1(TA/8) 62-3997102-00 RESIST.NET.8,SMT,2%,1.0KOHM TP1(TC/6); 020361101 TEST POINT, BLK. TP2,TP3(TB/1) U1(TC/2);U2(TB/2); 62-6186002-00 8 CHAN.TRANS.AR.SMT,ULN2803 U7(TB/4);U8(TC/4); U9(TC/5); U10(TB/6); U12(TB/7) U3(TB/2) 61-6629001-00 PROGRAMMED DISP. DVR, A5 U4(TB/3) 62-3932001-00 OCTAL BUFFER/DRIVER U5(TA/3) 62-6303001-00 REAL TIME CLOCK, SERIAL, SMD U11(TA/7) 62-3935001-00 20-KEY ENCODER,SM.OUTLINE I.C. XD1#N/A 62-6131001-00 LED HOLDER, T-1, 90 DEGREE Y1(TA/3) 62-4085001-00 CRYSTAL OSCILL, 32.768KHz, SMT

Figure 4.10 A2 Display Controller PCB Assembly

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Page 72

Schematic 4.9 A3 Display Light Panel PCB

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Page 73

Bill of Material: Display Light Panel PCB Assembly

REF. DES. CONMED P/N DESCRIPTION

61-6415-001 A3 DISPLAY LIGHT PANEL PCB ASSEMBLY

C1(TA/7);C2(TB/2); 62-3995104-00 CAP.CER.Y5V,25V,SMT,100.000.1 C3(TC/4);C4(TC/6) C5(TC/3);C6(TC/10) 62-6191106-00 CAP.ELEC.35V,LOW ESR,10uF,SMT D1,D2(TB/2); 62-6304001-00 DIODE, SIGNAL, SMD D3,D4(TC/3) D5,D6,D7, 62-6239001-00 LED, SMT, WHITE D8(TC/5); D9,D10, D12(TC/8); D11(TC/9); D13(TC/10); D14,D15, D16(TC/11) DIS1,DIS4(TB/1); 62-6124002-00 LED, SMT, BRIGHT ORANGE DIS2,DIS3,DIS5, DIS6(TA/1); DIS7(TB/2); DIS8,DIS9(TA/2); DIS14,DIS15, DIS16,DIS18, DIS19,DIS22, DIS23,DIS26(TB/3); DIS17,DIS20, DIS21,DIS24, DIS25(TA/3); DIS27,DIS29(TB/4); DIS32,DIS35, DIS38(TB/6); DIS33,DIS34, DIS36,DIS37, DIS39,DIS40(TA/6); DIS41,DIS42, DIS44(TB/7); DIS48,DIS49, DIS51,DIS52(TA/9); DIS54,DIS55(TA/10) DIS10(TC/2) 62-3462001-00 LED BAR GRAPH 10 SEG GRN DIS11,DIS12(TB/2) 62-6301001-00 LED-SQUARE, BI-COLOR DIS13(TA/2) 62-6228001-00 7-SEGMENT LED, .39” DIS28,DIS30(TB/4); 62-5795002-00 LED,7 SEG, .8” GRN DIS31(TB/5); DIS43(TB/7); DIS45(TB/8); DIS46(TB/9); DIS57(TB/10); DIS59(TB/11)

REF. DES. CONMED P/N DESCRIPTION

DIS56(TB/10); 62-3462002-00 LED BAR GRAPH 10 SEG. YELLOW DIS58(TB/11) J3(BA/1);J4(BC/7) 62-6332040-00 HEADER,MALE,40P,.25”SQ,LO-PROF R1,R2,R3,R4(TB/1); 62-3945680-00 RESISTOR,1/10W,5%,SMT,68 OHMS R5,R6(TA/1); R23(TB/4);R24,R26, R30,R31,R32(TB/5); R35,R36,R38(TA/6); R37,R40,R43(TB/6); R52,R53,R56, R58,R59(TA/9); R57(TA/10) R7(TB/1);R9(TA/1); 62-3945472-00 RESISTOR,1/10W,5%,SMT,4.7K OHM R17,R19(TC/3); R20,R22(TB/4); R21(TC/4); R28(TC/5); R34(TB/6); R39,R42(TC/6); R41,R46(TA/6); R49(TA/7); R50(TB/7); R51(TB/8); R54,R55(TB/9); R62(TB/11); R63(TB/12) R8(TB/1);R15, 62-3945470-00 RES,1/10W,5%,SMT,47-OHM R16,R18(TC/3); R25(TC/4); R29(TC/5); R44,R45(TA/6); R64,R65(TC/7) R10,R11(TB/2); 62-3945181-00 RES.,1/10W,5%,SMT 180 OHMS R12,R13(TA/2) R14(TA/2) 62-3945103-00 RESISTOR,1/10W,5%,SMT,10K OHM R27,R33(TC/5); 62-3945101-00 RESISTOR,1/10W,5%,SMT, 100 OHM R47,R48(TC/7); R60(TC/10); R61(TC/11) TP1,TP2(TB/1) 020361101 TEST POINT, BLK. U1(TB/2);U4(TA/7) 62-6247001-00 I.C., FET DRIVER, 4427 U2(TC/4);U3(TC/6) 62-6187002-00 8 CHAN.SRC.DRV.SMT,UDN2982

Figure 4.11 A3 Display Light Panel PCB Assembly

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Conmed System 5000 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual