Force FX Electrosurgical Generator C Service Manual

Service Manual

Force FXTM

Electrosurgical Generator C

Preface

This manual and the equipment it describes are for use only by qualified medical professionals trained in the particular technique and surgical procedure to be performed. It is intended as a guide for servicing the Force FX Electrosurgical Generator C only. Additional users information is available in the Force FX Electrosurgical Generator C User’s Guide.

Equipment covered in this manual:

Covidien Force FX Electrosurgical Generator C

110 V ~ Nominal / 230 V ~ Nominal (auto selected)

The Force FX Electrosurgical Generator C Service Manual consists of two parts: the text (part 1 of 2) and a Schematics Supplement (part 2 of 2) which contains the schematics.

Device is compliant with the European Communities Council Directive 93/42/EEC, Medical Device Directive.

Conventions Used in this Guide

Warning

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Caution

Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

Notice

Indicates a hazard which may result in product damage.

Important

Indicates an operating tip or maintenance suggestion.

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Limited Warranty

Covidien warrants each covered product listed below to be free from defects in material and workmanship for normal use and service for the period(s) set forth below. Covidien’s obligation under this warranty is limited to the repair or replacement, at its sole option, of any product, or part thereof, which has been returned to it (or its authorized distributor) within the applicable time period shown below after delivery of the product to the original purchaser, and which examination discloses, to Covidien’s satisfaction, that the product is defective. This limited warranty does not apply to any product, or part thereof, which has been repaired or altered in a way so as, in Covidien’s judgment, to affect its stability or reliability, or which has been subjected to misuse, neglect, or accident.

The warranty periods for Covidien products are as follows:

ForceTriadTM Energy Platform

Electrosurgical Generators

Cool-tipTM RFA Generator

EvidentTM MWA Generator

RFG-3CTM Plus Lesion Generator

LigaSureTM Vessel Sealing System

LigaSureTM Reusable Instruments Mounting Fixtures (all models) Footswitches (all models)

ValleylabTM Argon Gas Delivery Unit II

RapidVacTM Smoke Evacuator

LigaSureTM Sterile Single Use Items

Cool-tipTM Sterile Single Use Items

Sterile Single Use Items

Patient Return Electrodes

One year from date of shipment One year from date of shipment

One year from date of shipment

One year from date of shipment

One year from date of shipment

One year from date of shipment

One year from date of shipment One year from date of shipment One year from date of shipment

One year from date of shipment

One year from date of shipment

Sterility only as stated on packaging

Sterility only as stated on packaging Sterility only as stated on packaging Shelf life only as stated on packaging

Notwithstanding any other provision herein or in any other document or communication, Covidien’s liability with respect to this limited warranty and the products sold hereunder shall be limited to the aggregate purchase price for the products sold to the customer.

This limited warranty is non-transferable and runs only to the original purchaser of the

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covered product(s). There are no warranties which extend beyond the terms hereof. Covidien disclaims any liability hereunder or elsewhere in connection with the sale of products and for any form of indirect, tort, or consequential damages.

This limited warranty and the rights and obligations hereunder shall be construed under and governed by the laws of the State of Colorado, USA. The sole forum for resolving disputes arising under or relating in any way to this limited warranty is the District Court of the County of Boulder, State of Colorado, USA.

Covidien reserves the right to make changes in covered products built or sold by it at any time without incurring any obligation to make the same or similar changes to equipment previously built or sold by it.

THE OBLICATION TO REPAIR OR REPLACE A DEFECTIVE OR NONPERFORMING PRODUCT IS THE SOLE REMEDY OF THE CUSTOMER UNDER THIS LIMITED WARRANTY. EXCEPT AS

EXPRESSLY PROVIDED HEREIN, COVIDIEN DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, ORAL OR WRITTEN, WITH RESPECT TO PRODUCTS, INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

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Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Conventions Used in this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Chapter 1. Introduction

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

List of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Service Personnel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Active Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Patient Return Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fire/Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electric Shock Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2. Controls, Indicators, and Receptacles

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Bipolar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bipolar Instrument Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Monopolar Cut Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Monopolar Coag Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Monopolar Instrument Receptacles . . . . . . . . . . . . . . . . . . . . . . 2-7

REM Alarm Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Rear Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Footswitch Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Monopolar Footswitch Receptacles . . . . . . . . . . . . . . . . . . . 2-9

Bipolar Footswitch Receptacle . . . . . . . . . . . . . . . . . . . . . . . 2-9

Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Activation Tone Volume Control . . . . . . . . . . . . . . . . . . . . . . . 2-10

Option Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Chapter 3. Technical Specifications

Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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Internal Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Audio Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 REM Contact Quality Monitor. . . . . . . . . . . . . . . . . . . . . . . . 3-4 Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 RF Activation Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Expansion Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Low Frequency (50–60 Hz) Leakage Current . . . . . . . . . . . . 3-6 High Frequency (RF) Leakage Current . . . . . . . . . . . . . . . . . 3-6 Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Power Cord Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Standards and IEC Classifications . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Class I Equipment (IEC 60601-1) . . . . . . . . . . . . . . . . . . . . . . 3-9 Type CF Equipment (IEC 60601-1)/Defibrillator Proof . . . . . 3-9 Liquid Spillage (IEC 60601-2-2 Clause 44.3) . . . . . . . . . . . . . 3-9 Electromagnetic Interference . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Electromagnetic Compatibility (IEC 60601-1-2 and

IEC 60601-2-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Voltage Transients (Emergency Generator Mains

Transfer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Maximum Output for Bipolar and Monopolar Modes . . . 3-14 Maximum Output for Ultrasonic Electrosurgery . . . . . . . . 3-15 Available Power Settings in Watts . . . . . . . . . . . . . . . . . . . 3-15 Output Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Output Power vs. Resistance Graphs. . . . . . . . . . . . . . . . . . . . . 3-18 Bipolar Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Monopolar Cut Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Monopolar Coag Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Chapter 4. Principles of Operation

Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Instant Response Technology . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Ultrasonic Electrosurgery . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Simultaneous Coag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

REM Contact Quality Monitoring System. . . . . . . . . . . . . . . 4-4

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Microcontrollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Main Microcontroller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Feedback Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Shared RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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I/0 Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Keyboard Interface and Activation Inputs. . . . . . . . . . . . . . 4-8

Power Supply Supervisor Circuit . . . . . . . . . . . . . . . . . . . . . . 4-9

A/D and D/A Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Waveform Generation (T_ON ASIC) . . . . . . . . . . . . . . . . . . . 4-9

T_ON Average Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Audio Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Serial Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Dosage Error Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Instant Response Algorithm . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Membrane Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

REM Connector/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

CEM Mechanism Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

RF Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

REM Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

LED and Seven-Segment Display Drivers . . . . . . . . . . . . . . 4-14

CEM Switch Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Mode Selection and Power Control Switches . . . . . . . . . . 4-15

Footswitch Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Footswitch Decode Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Audio Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Power Supply/RF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Power Supply/RF Board Interfaces . . . . . . . . . . . . . . . . . . . 4-20

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

RF Output Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Spark Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

RF Leakage Reduction Circuit . . . . . . . . . . . . . . . . . . . . . . . 4-27

REM Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

IsoBloc Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Temperature Sense Circuits. . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Chapter 5. Setup, Tests, and Adjustment

Setting Up the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Connections for Bipolar or Macrobipolar Surgery . . . . . . . 5-4 Setting the Bipolar Output . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Connections for Monopolar Surgery . . . . . . . . . . . . . . . . . . 5-6

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Selecting Cut and Coag Modes . . . . . . . . . . . . . . . . . . . . . . . 5-8 Simultaneous Coag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Using Two Generators Simultaneously. . . . . . . . . . . . . . . . 5-10 Connecting the CUSA Handpiece with CEM Nosecone . . . 5-11 Setting the Output Power. . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Simultaneous Coag with a CUSA System . . . . . . . . . . . . . . 5-12 Changing the Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Changing the Power Setting . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Activating the Surgical Instrument. . . . . . . . . . . . . . . . . . . 5-13

Periodic Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . 5-15 Inspecting the Generator and Accessories . . . . . . . . . . . . . 5-16 Inspecting the Internal Components . . . . . . . . . . . . . . . . . 5-17 Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Verifying REM Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Confirming Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Checking the Bipolar Output . . . . . . . . . . . . . . . . . . . . . . . 5-19 Checking Output for the Monopolar Cut Modes . . . . . . . 5-20 Checking Output for the Monopolar Coag Modes . . . . . . 5-22

Checking Low Frequency Leakage Current and

Ground Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Checking High Frequency Leakage Current . . . . . . . . . . . . 5-24 Calibrating the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Entering Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Exiting Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Verifying the Generator Data . . . . . . . . . . . . . . . . . . . . . . . 5-28 Adjusting the Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Checking and Adjusting the REM Oscillator Frequency

and Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Checking and Adjusting the Current Sense Gain. . . . . . . . 5-31 Checking and Adjusting the Voltage Sense Gain . . . . . . . 5-33 Checking and Adjusting the Reactance Gain . . . . . . . . . . . 5-36 Checking and Adjusting the ECON Factor . . . . . . . . . . . . . 5-38

Using the RS-232 Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Establish the Communications Link . . . . . . . . . . . . . . . . . . 5-42 Enter the Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Disconnect the Computer from the Generator . . . . . . . . . 5-46

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Chapter 6. Troubleshooting

Inspecting the Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Inspecting the Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Inspecting the Internal Components . . . . . . . . . . . . . . . . . . 6-3 Correcting Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Responding to System Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Correcting T_ON ASIC Malfunctions . . . . . . . . . . . . . . . . . . . . . 6-22 Correcting Battery-Backed RAM Malfunctions . . . . . . . . . . . . 6-24

Chapter 7. Replacement Procedures

Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Display Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Remove the Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Install the Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Display Board Seven-Segment LED Replacement. . . . . . . . . . . . 7-7 Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Footswitch Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Front Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Remove the Front Panel Assembly . . . . . . . . . . . . . . . . . . . . 7-9 Remove and Reinstall the Front Panel Components . . . . . . 7-9 Install the Front Panel Assembly. . . . . . . . . . . . . . . . . . . . . 7-10 Front Panel REM Module Replacement . . . . . . . . . . . . . . . . . . 7-11 Front Panel Power Switch Replacement . . . . . . . . . . . . . . . . . . 7-12 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Replacing Fuses in the Fuse Drawer . . . . . . . . . . . . . . . . . . 7-13 Replacing the Fuse on the Power Supply/RF Board. . . . . . 7-14 Left Front Heat Sink and Component Replacement . . . . . . . . 7-15 Remove the Left Front Heat Sink . . . . . . . . . . . . . . . . . . . . 7-15 Replace Left Front Heat Sink Components . . . . . . . . . . . . 7-16 Install the Left Front Heat Sink. . . . . . . . . . . . . . . . . . . . . . 7-16 Left Rear Heat Sink and Component Replacement . . . . . . . . . 7-17 Remove the Left Rear Heat Sink. . . . . . . . . . . . . . . . . . . . . 7-17 Replace Left Rear Heat Sink Components . . . . . . . . . . . . . 7-18 Install the Left Rear Heat Sink . . . . . . . . . . . . . . . . . . . . . . 7-18 Right Heat Sink and Component Replacement . . . . . . . . . . . . 7-19 Remove the Right Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Replace Right Heat Sink Components . . . . . . . . . . . . . . . . 7-20 Install the Right Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

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Low Voltage Power Supply Replacement . . . . . . . . . . . . . . . . . 7-22 Remove the Low Voltage Power Supply . . . . . . . . . . . . . . 7-22 Install the Low Voltage Power Supply . . . . . . . . . . . . . . . . 7-22 Power Entry Module Replacement . . . . . . . . . . . . . . . . . . . . . . 7-24 Remove the Power Entry Module. . . . . . . . . . . . . . . . . . . . 7-24 Install the Power Entry Module . . . . . . . . . . . . . . . . . . . . . 7-25 Power Supply/RF Board Replacement . . . . . . . . . . . . . . . . . . . . 7-26 Remove the Power Supply/RF Board Assembly . . . . . . . . . 7-26 Remove Components from the Old Board . . . . . . . . . . . . . 7-27 Install Components on the New Board. . . . . . . . . . . . . . . . 7-28 Install the Power Supply/RF Board Assembly . . . . . . . . . . . 7-29

Chapter 8. Repair Policy and Procedures

Responsibility of the Manufacturer . . . . . . . . . . . . . . . . . . . . . . 8-2 Returning the Generator for Service. . . . . . . . . . . . . . . . . . . . . . 8-2 Obtain a Return Authorization Number . . . . . . . . . . . . . . . 8-2 Clean the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Ship the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Returning Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Chapter 9. Service Parts

Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Control Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Display Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Footswitch Board Components . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Power Supply/RF Board Assembly . . . . . . . . . . . . . . . . . . . . . . . 9-15

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Power Supply/RF Board Components . . . . . . . . . . . . . . . . . . . . 9-19

x	Force FX Electrosurgical Generator C Service Manual

Chapter 1

Introduction

This manual provides instructions for servicing the Covidien Force FX Electrosurgical Generator C with Instant ResponseTM technology. This chapter introduces the features and components of the generator and reviews the precautions associated with generator repair.

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General Description

General Description

The Covidien Force FX Electrosurgical Generator C is an isolated output electrosurgical generator that provides the appropriate power for cutting, desiccating, and fulgurating tissue during bipolar and monopolar surgery.

It includes the following features:

•Instant Response technology

•Three bipolar modes: precise (low), standard (medium), and macro (macrobipolar)

•Three monopolar cut modes: low, pure, and blend

•Three monopolar coag modes: desiccate (low), fulgurate (medium), and spray (high)

•Support for simultaneous coagulation

•The REMTM Contact Quality Monitoring System

•Support for ultrasonic electrosurgery using the CUSA EXcelTM system and a CUSATM handpiece with a CUSA electrosurgical module (CEMTM) nosecone

•Handswitch or footswitch activation

•Recall of most recently used mode and power settings

•Adjustable activation tone volume

•An RF activation port, RS-232 serial port, and expansion port

•ValleylabTM Argon Gas Delivery Unit II system compatibility

List of Components

The Force FX Electrosurgical Generator C is a self-contained unit, consisting of a main enclosure (cover and base) and power cord.

The main components of the generator are the following:

•Front panel components—power switch; controls for setting the modes and output power; a button for recalling the power settings and modes that were used last; receptacles for connecting electrosurgical accessories; and indicators that alert you to the current settings and patient return electrode status.

•Rear panel components—volume control; three footswitch receptacles; power entry module; equipotential grounding lug; and three ports (serial port, RF activation port, and expansion port).

•Internal components—Control (microcontroller) board; Display board; Footswitch board; Power Supply/Radio Frequency (RF) board; low voltage power supply; fan; and heat sinks.

A handle is located on the underside of the chassis.

For details about the interaction of the main components and circuit board descriptions, refer to Chapter 4, Principles of Operation.

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Service Personnel Safety

Service Personnel Safety

Before servicing the generator, it is important that you read, understand, and follow the instructions supplied with it and with any other equipment used to install, test, adjust, or repair the generator.

Introduction

General

Warning

Use the generator only if the self-test has been completed as described. Otherwise, inaccurate power outputs may result.

The instrument receptacles on this generator are designed to accept only one instrument at a time. Do not attempt to connect more than one instrument at a time into a given receptacle. Doing so will cause simultaneous activation of the instruments.

Caution

Do not stack equipment on top of the generator or place the generator on top of electrical equipment (except a Valleylab Argon Gas Delivery Unit II or a CUSA EXcel unit). These configurations are unstable and/or do not allow for adequate cooling.

Provide as much distance as possible between the electrosurgical generator and other electronic equipment (such as monitors). An activated electrosurgical generator may cause interference with them.

Do not turn the activation tone down to an inaudible level. The activation tone alerts the surgical team when an accessory is active.

Notice

If required by local codes, connect the generator to the hospital equalization connector with an equipotential cable.

Connect the power cord to a wall receptacle having the correct voltage. Otherwise, product damage may result.

Active Accessories

Warning

Electric Shock Hazard Do not connect wet accessories to the generator.

Electric Shock Hazard Ensure that all accessories and adapters are correctly connected and that no metal is exposed.

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Service Personnel Safety

Caution

Accessories must be connected to the proper receptacle type. In particular, bipolar accessories must be connected to the Bipolar Instrument receptacle only. Improper connection may result in inadvertent generator activation or a REM contact quality monitor alarm.

Set power levels to the lowest setting before testing an accessory.

Notice

During bipolar electrosurgery, do not activate the generator until the forceps have made contact with the patient. Product damage may occur.

Patient Return Electrodes

Warning

Using a patient return electrode without the REM safety feature will not activate the REM Contact Quality Monitoring System.

Fire/Explosion Hazards

Warning

Danger: Explosion Hazard Do not install the generator in the presence of flammable anesthetics, gases, liquids, or objects.

Fire Hazard Do not place active accessories near or in contact with flammable materials (such as gauze or surgical drapes). Electrosurgical accessories that are activated or hot from use can cause a fire. Use a holster to hold electrosurgical accessories safely away from personnel and flammable materials.

Fire Hazard Do not use extension cords.

Fire Hazard For continued protection against fire hazard, replace fuses only with fuses of the same type and rating as the original fuse.

Electric Shock Hazards

Warning

Connect the generator power cord to a properly grounded receptacle. Do not use power plug adapters.

Do not connect a wet power cord to the generator or to the wall receptacle.

To allow stored energy to dissipate after power is disconnected, wait at least five minutes before replacing parts.

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Service Personnel Safety

Warning

Always turn off and unplug the generator before cleaning.

Do not touch any exposed wiring or conductive surfaces while the generator is disassembled and energized. Never wear a grounding strap when working on an energized generator.

When taking measurements or troubleshooting the generator, take appropriate precautions, such as using isolated tools and equipment, using the “one hand rule,” etc.

Potentially lethal AC and DC voltages are present in the AC line circuitry, high voltage DC circuitry, and associated mounting and heat sink hardware described in this manual. They are not isolated from the AC line. Take appropriate precautions when testing and troubleshooting this area of the generator.

High frequency, high voltage signals that can cause severe burns are present in the RF output stage and in the associated mounting and heat sink hardware described in this manual. Take appropriate precautions when testing and troubleshooting this area of the generator.

Servicing

Caution

Read all warnings, cautions, and instructions provided with this generator before servicing.

The generator contains electrostatic-sensitive components. When repairing the generator, work at a static-control workstation. Wear a grounding strap when handling electrostatic-sensitive components, except when working on an energized generator. Handle circuit boards by their nonconductive edges. Use an antistatic container for transport of electrostatic-sensitive components and circuit boards.

Notice

After installing a new low voltage power supply, verify that the voltages are correct.

Introduction

Calibration

Caution

To avoid inadvertent coupling and/or shunting of RF currents around the resistor elements, keep the resistors at least 4"(10.2 cm) away from any metal surface including tabletops and other resistors. This is especially true if several resistors are connected in series or parallel to obtain a specified value. Do not allow the resistor bodies to touch each other.

Notice

After completing any calibration step, proceed to the next step to save the values from the completed calibration step.

Do not activate the generator with any load resistor higher than 10 ohms (10 Ω) while calibrating the current sense gain. Otherwise, product damage will result.

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Service Personnel Safety

Notice

Do not activate the generator with any load resistor lower than 1000 Ω while calibrating the voltage sense gain for bipolar output. Otherwise, product damage will result.

Do not activate the generator with any load resistor lower than 3000 Ω while calibrating the voltage sense gain for the Low and Pure cut modes. Do not activate the generator with any load resistor lower than 2000 Ω while calibrating the voltage sense gain for the Blend mode. Otherwise, product damage will result.

Do not adjust the current sense gain (I factor), the voltage sense gain (V factor), or the reactance gain (Z factor) while the generator is activated.

After calibration, the generator will be ready to use only after you initiate the internal self-test by turning the generator off, then on.

Calibrate the generator after you install a new battery. Calibration values are lost when the battery is replaced.

Calibrate the generator after you install a new Control board. Otherwise, the default calibration values are used.

Calibrate the generator after you install a new heat sink or replace components on the heat sink. Component differences may affect output waveforms.

Calibrate the generator after you install a new Power Supply/RF board. Component differences may affect output waveforms.

Cleaning

Notice

Do not clean the generator with abrasive cleaning or disinfectant compounds, solvents, or other materials that could scratch the panels or damage the generator.

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Chapter 2

Controls, Indicators, and Receptacles

This chapter describes the front and rear panels, including all controls, indicators, receptacles, the fuse drawer, and ports.

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Front Panel

Front Panel

Layout of controls and indicators on the front panel

Recall button

Pressing this button sets the

REM alarm indicator

generator to the most recently

used mode and power settings.

Bipolar controls

Cut controls

Coag controls

CEM indicator

Bipolar	Monopolar 1/CEM
instrument	instrument
receptacle	receptacle

Power switch

This switch supplies power to the generator.

To turn on the generator, press (|).

To turn off the generator, press (O).

Monopolar 2 instrument receptacle

Patient return electrode receptacle

For monopolar electrosurgery, connect a patient return electrode to this receptacle.

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Bipolar Controls

Bipolar Controls

Buttons and indicators for bipolar controls

Bipolar display

Shows the power setting, in watts, for the selected mode.

Bipolar indicator

When you activate bipolar, this indicator illuminates blue and an activation tone sounds.

Mode indicators

Illuminate green when you press the corresponding mode button.

Power buttons		Receptaclesand	Indicators,Controls,
Press	to increase the power.
Press to decrease the power.

Precise mode button

Select for fine bipolar tissue desiccation.

Macro mode button

Select for macrobipolar output.

Standard mode button

Select for standard bipolar tissue desiccation. This is the default bipolar mode.

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Bipolar Instrument Receptacle

Bipolar Instrument Receptacle

Caution

Connect accessories to the proper receptacle type. In particular, bipolar accessories must be connected to the Bipolar Instrument receptacle only. Improper connection may result in inadvertent generator activation or a REM contact quality monitor alarm.

You can connect either a footswitching or handswitching bipolar instrument to the Bipolar instrument receptacle.

Connect a footswitching instrument with a two-pin connector.

or

Connect a handswitching instrument with a three-pin connector.

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Monopolar Cut Controls

Monopolar Cut Controls

Buttons and indicators for cut controls (monopolar)

Cut display

Shows the power setting, in watts, for the selected mode.

Cut indicator

When you activate cut, this indicator illuminates yellow and an activation tone sounds.

Mode indicators

Illuminate green when you press the corresponding mode button.

Power buttons		Receptaclesand	Indicators,Controls,
Press	to increase the power.
Press to decrease the power.

Low mode button

Select for a cut with little or no sparking.

Blend mode button

Select for slower cutting and additional hemostasis.

Pure mode button

Select for an even cut with little or no hemostasis. This is the default monopolar cut mode.

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Monopolar Coag Controls

Monopolar Coag Controls

Buttons and indicators for coag controls (monopolar)

Coag display

Shows the power setting, in watts, for the selected mode.

Coag indicator

When you activate coag, this indicator illuminates blue and an activation tone sounds.

Mode indicators

Illuminate green when you press the corresponding mode button.

Power buttons
Press	to increase the power.
Press to decrease the power.

Desiccate mode button

Select to desiccate the area of tissue that is in direct contact with the active electrode.

Spray mode button

Select to evenly coagulate a wide area of tissue with a spray of sparks; penetration is shallower and tissue area is larger than in fulgurate mode.

Fulgurate mode button

Select to fulgurate an area of tissue with a spray of sparks.

This unit is equipped with an additional fulgurate mode which incorporates a lower crest factor (LCF) than the factory default fulgurate mode. For details about this additional fulgurate mode, LCF Fulgurate, refer to Chapter 4, Before Surgery, in the

Force FX Electrosurgical Generator C User’s Guide.

Fulgurate is the default monopolar coag mode. However, the default coag mode can be changed to either Desiccate or Spray through the serial port on the rear panel.

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Monopolar Instrument Receptacles

Monopolar Instrument Receptacles

Warning

The instrument receptacles on this generator are designed to accept only one instrument at a time. Do not attempt to connect more than one instrument at a time into a given receptacle. Doing so will cause simultaneous activation of the instruments.

You can connect a footswitching or handswitching monopolar instrument to the monopolar receptacles. Some footswitching instruments may require a single-pin adapter (E0502 Series or E0017), available from Covidien.

Connect one monopolar instrument to the Monopolar 1/CEM Instrument receptacle:

•A single-pin footswitching instrument or a three-pin handswitching instrument or

•A four-pin CUSA handpiece with CEM nosecone. (The CEM indicator in the upper right of the front panel illuminates green.) Refer to Connecting the CUSA Handpiece with CEM Nosecone on page 5-11.

Connect one monopolar instrument to the Monopolar 2 Instrument receptacle:

Receptacles and	Indicators, Controls,

•A single-pin footswitching instrument or a three-pin handswitching instrument.

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REM Alarm Indicator

REM Alarm Indicator

This indicator illuminates red until you properly apply a REM PolyhesiveTM Patient Return Electrode to the patient and connect it to the generator. Then the indicator illuminates green. (When you connect an electrode without the REM safety feature, the indicator does not illuminate.)

If the REM system senses an alarm condition, the indicator flashes red until you correct the alarm condition—then the indicator illuminates green. (If you are using a return electrode without the REM safety feature, the red indicator light is extinguished when you correct the alarm condition.)

Rear Panel

Controls and receptacles on the rear panel

Power entry module

Volume control

	Option panel
Monopolar	Bipolar
Footswitch	Footswitch
receptacles	receptacle

Equipotential grounding lug

Use to connect the generator to earth ground.

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Footswitch Receptacles

Footswitch Receptacles

The rear panel contains three footswitch receptacles: two for monopolar and one for bipolar.

Monopolar Footswitch Receptacles

You must connect a monopolar footswitch if you connect a monopolar footswitching instrument to the generator.

Use only a Valleylab monopolar footswitch with the Force FX Electrosurgical Generator C. Use of an incompatible footswitch may cause unexpected output.

Connect a two-pedal Valleylab monopolar footswitch to the Monopolar 1 Footswitch receptacle.

1

The connected footswitch activates monopolar output for the instrument that is connected to the Monopolar 1/CEM Instrument receptacle on the front panel.

Connect a two-pedal monopolar footswitch to the Monopolar 2 Footswitch receptacle.

2

The connected footswitch activates monopolar output for the instrument that is connected to the Monopolar 2 Instrument receptacle on the front panel.

Bipolar Footswitch Receptacle

You must connect a bipolar footswitch if you connect a bipolar footswitching instrument to the generator.

Connect a single-pedal bipolar footswitch to the Bipolar Footswitch receptacle.

Receptacles and	Indicators, Controls,

The connected footswitch activates bipolar output for the instrument that is connected to the Bipolar Instrument receptacle on the front panel.

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Power Entry Module

Power Entry Module

The power entry module consists of a power cord receptacle and a fuse drawer.

Components in the power entry module

Fuse drawer

The fuse drawer contains two fuses. Refer to Fuse Replacement on page 7-13 for instructions on changing the fuses.

Power cord receptacle

Activation Tone Volume Control

Turn to adjust the volume of the tones that sound when the generator is activated (activation tone). To ensure that the surgical team is alerted to inadvertent activation, these tones cannot be silenced.

To increase the volume of activation tones, turn the knob clockwise.

To decrease the volume, turn the knob counterclockwise.

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Option Panel

A removable plate on the rear panel covers a serial port, an expansion port, and a radio frequency (RF) activation port. Remove this plate to obtain information through the RS232 port or to install a peripheral device such as a Bipolar Current Monitor, but retain the original cover plate. After obtaining information or removing a peripheral device, reinstall the original cover plate.

Caution

To avoid product damage, do not operate the Force FX Electrosurgical Generator C without an appropriate cover plate in place.

To review the technical specifications for each port, refer to page 3-5 and page 3-6.

The three ports behind the option panel

Expansion port

Allows a connected device to receive information about the RF voltage and current being generated as well as signal the generator to halt RF output.

Serial port

Allows connection of a computer to the generator. You can obtain information about the generator using RS-232 communications protocol or change the default coag mode from Fulgurate to Desiccate or Spray. Refer to Using the RS232 Serial Port on page 5-42, for instructions.

RF Activation port

Allows a connected device to receive information during RF activation of the generator, which will then generate a response in the device.

Option Panel

Receptacles and	Indicators, Controls,

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Chapter 3

Technical Specifications

All specifications are nominal and subject to change without notice. A specification referred to as “typical” is within ± 20% of a stated value at room temperature (77° F/25° C) and a nominal input power voltage.

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Performance Characteristics

Performance Characteristics

General

Output configuration	Isolated output
Cooling	Natural convection; side and rear panel vents; fan
Display	Eight digital seven-segment displays: 0.75" (1.9 cm)
	each
Mounting	Universal cart (UC8009), CUSA EXcel System, a
	Valleylab Argon Gas Delivery Unit II, or any stable flat
	surface

Dimensions and Weight

Width	14" (35.6 cm)
Depth	18" (45.7 cm)
Height	4 3/8" (11.1 cm)
Weight	<18 lb (< 8.2 kg)

Operating Parameters

Ambient temperature	50° to 104° F (10° to 40° C)
range
Relative humidity	30% to 75%, noncondensing
Atmospheric pressure	700 to 1060 millibars
Warm-up time	If transported or stored at temperatures outside the
	operating temperature range, allow one hour for the
	generator to reach room temperature before use.

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