Integra VALLEYLAB Cusa EXcel 8 User manual

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RpDO

=Falleylab. Service Manual

CUSA EXcel""-8 System

Preface

This

manual

and

the

equipment

describes

are for

use only

by qualified

medical

professionals

trained

the particular

technique

and

surgical

procedure

performed.

intended

guide

for

servicing the

CUSA

EXcel

ultrasonic surgical

aspirator

only.

Equipment covered in this manual

CUSA EXcel™ ultrasonic surgical aspirator

with 23

kHz

and

36 kHz

handpieces.

The CUSA

EXcel

"System

Service

Manual

consists

of two parts—the text

{part 1 of 2) and a Schematics Supplement (part 2 of 2), which contains the schematics.

Vatleytab Part Number 945 103 105

Effective Date October 2004

Trademark acknowledgements

CUSA EXcei™, TISSUE Select™, MacroTip™, MicroTip™, PrecisionTip™,

CEM™, and Force FX™ are trademarks of Valleylab.

Ajax“ is a registered trademark of the Colgate-Palmolive Company.

Comet“ is a registered trademark of Procter & Gamble.

Torgue Seal“ is a registered trademark of Organic Products Co.

Manufactured			by
Valleylab
a	division	of	Tyco	Healthcare	Group LP
Boulder,		Colorado		80301-3299	USA
©	2004 Valleylab			All rights	reserved. Contents of this publication may

not be reproduced in any form without the written permission of Valleylab.

Tyco Healthcare UK Ltd.

Gosport, PO13 OAS, UK

1-303-530-2300 Made in USA Printed in USA

C € Patent Information

0086	One or more	of the following U.S. patents		and corresponding foreign
	patents cover the CUSA EXcel system:
	4734964	4768496	4827911	4921476	4931047
	4988334	5015227	5190517	5421829	5466020
	5484398	5847046	6214817	6256859	6499858

ii	CUSA EXcel-8 System Service Manual

About This	Manual
The service	manual describes the CUSA EXcel ultrasonic surgical
aspirator. It	presents	the CUSA EXcel as a system that includes a console,
handpieces,	and accessories:

*Descriptions of the system, its functions, specifications, and theory of operation

*Step-by-step instructions on how to unpack, install, maintain,

calibrate, and troubleshoot the system

e Parts lists, board layouts, and schematics.

-	Organization
	We	have organized		this guide	to introduce	the safety issues, the system,
	and its functions. After safety				and the system, the guide gives instructions
	for	unpacking	the	system, then describes its components, technical
	specifications,		and	theory of	operation. The	next sections tell you how to

check out, maintain, troubleshoot, replace parts, and calibrate the system. A schematics supplement includes printed circuit board (PCB) layouts and schematics.

CUSA

EXcel-8

System

Service

Manual

iii

Conventions Used in this Guide

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

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.

D important

Indicates an operating tip or maintenance suggestion.

iv	CUSA EXcel-8	System Service Manual
iv

Table of Contents

Preface		ii
	About This		Manual	iii
	Organization		iii
	Conventions		Used in	this Guide	iv
List	of	Figures	xiii
List	of	Tables	xvi

Section	1.	Service			Personnel		Safety
Safety Information				1-1
Warnings,	Cautions,			and	Notices	1-1
General			1-2
Introduction				1-2
Unpacking		and		Installing the		CUSA	EXcel	System	1-2
Console Components					1-2
Technical		Specifications				1-2
Checkout		Procedures			1-3
Maintaining			the	CUSA EXcel		System		1-3
Troubleshooting					1-4
Replacement			Procedures			1-4
Calibration				1-5
Repair	Policy			1-5

Section	2.	Introduction
For Your	Information			2-1
Overview		2-2
Fragmentation			2-2
Tip Motion			2-2
Cooling			2-2
Irrigation		2-3
Aspiration	(Suction)			2-4
Handpieces			2-5
Wide Variety		of	Tips	2-5

Section	3.	Unpacking		and	Installing		the CUSA EXcel System
The Responsibility of the Manufacturer						3-1
Unpacking	the	CUSA	EXcel	System		3-2
Tools	You	Will	Need	3-2
Unpacking		Procedure		3-2
Preparing	the	CUSA	EXcel	Console	for	Use	3-8
Replacing		the Power Connector				3-9

CUSA

EXcel-8

System

Service

Manual

Replacing	Fuses (lf	Necessary)	3-10
Replacing a Control		Panel Overlay	(Optional)	3-11
installing	the Reference Card Set		3-15

Section

Console

Components

For Your

Information

4-1

Console

Overview

and

Structural

Features

4-2

LV,

Pole

4-3

Control

Panel

4-3

Arm

and

Arm

Housing

4-3

Housing

for

Irrigation

Pump

Head

and

Suction

Pinch

Valve

4-3

Console

Body

4-3

Shelf for

Suction

Canister

4-3

Casters

4-3

Control

Panel

4-4

Alerts

4-5

Lap Mode, Prime, Test, and

Status

Buttons

4-5

Displays

4-5

Status

Indicators

4-7

Setpoint

Adjustment

Buttons

4-7

Console

Body

Front

Panel

4-8

Handpiece

Connector

Receptacle

4-8

Suction

Pinch

Valve

4-9

System

Power

Switch

4-9

Irrigation

Pump

Head

4-9

Contamination

Guard

4-9

Retaining

Bail

for

Suction

Canister

4-9

Console

Body

Side

Panel

4-10

Control

Panel

4-11

Rotation

Lock

Handle

4-11

Housing

for

Irrigation

Pump

Head

and

Suction

Pinch

Valve =

4-11

LV.

Pole

4-11

1.V.

Pole

Release

Button

4-11

Arm

and

Arm

Housing

4-11

Arm

Release

Tab

4-11

Cooling

Water

Reservoir

4-11

Console

Body

Rear

Panel

4-12

Speaker

4-13

Volume

Control

4-13

Footswitch

Connector

Receptacle

4-13

Main

Switch

4-13

Fuses

4-13

Footswitch

4-13

CUSA

EXcel-8

System

Service Manual

AC PowerCord			4-15
Equipotential		Grounding Lug				4-15
Label	4-15
Cord Wraps		4-15
Storage	Compartment				4-15
Symbols on the Control Panel					4-16
Other Features		4-18
Filling the Cooling Water Reservoir							4-18
Raising/Lowering			the	Arm		4-18
Rotating	the	Control		Panel		4-19
Adjusting	the	Tone	Volume			4-19
Adjusting	the	I.V.	Pole		4-20

Section

Technical Specifications

Console

Dimensions

5-2

CUSA EXcel

Console

5-2

Footswitch

5-2

Console

Subsystems

5-2

Ultrasonic

5-2

Fluidic

System

5-3

Electrical

Requirements

5-3

Input

Power

Source

5-3

Power

Cords

5-3

Low

Frequency

Leakage

5-4

Duty

Cycle

5-4

Environment

5-4

Standards

and

IEC

Classifications

5-5

Class | Equipment (IEC 601-1)

5-5

Type

Applied

Part

Equipment

(IEC 601-1)

5-5

IPX

(IEC

529,

2601)

Footswitch

5-5

Electromagnetic

Interference

5-6

System

Power

Off /

Standby

5-6

Pinch

Point

the

Suction

Pinch

Valve

5-6

Fuse

Replacement

5-6

Footswitch

Symbols

5-6

Voluntary

Standards

5-7

Statutory

and

Regulatory

Requirements

5-7

EMC

Compatibility

5-7

Handpieces

5-12

Nominal

Frequencies

5-12

Dimensions

5-12

Tip Specifications

5-12

CUSA	EXcel-8	System	Service	Manual

vil

23	kHz	5-13
36	kHz	5-14

Section	6.		Principles			of	Operation
How the	Handpiece			Works			6-2
Electromechanical					Operation			6-2
Fragmentation					6-3
Cooling			6-3
How the TISSUE Select Feature Works								5-4
Inherent		Tissue		Selectivity			6-5
increasing			Tissue		Selectivity			6-5
TISSUE		Select		Reduces		Reserve		Power tothe	Tip	6-6
Benefits		of	TISSUE		Select		6-8
A Common			Misunderstanding of					the Amplitude	Setting	6-9

Section	7.			Circuit Theory
For Your	Information						741
Display	Board			7-2
General			Description				7-2
Fundamentals					of	Operation			72
Detailed			Circuit		Description				7-3
Machine	Control Board						7-4
Introduction						7-4
Irrigation				Pump			7-4
Suction			Pump			7-5
Cooling			Pump			7-6
Suction			Valve			7-6
Amplitude				Control			7-6
Valve		Controls.				7-7
Power		Control			Input		and	Output Signals		7-7
Valtage			Regulators				7-8
interface				Connectors				7-8
Ultrasonics Board-Ultrasonic Generator										7-8
Fundamentals					of	Operation			7-8
The	Main			Frequency			Loop		7-9
Bandpass				Filter		(BPF)		7-9
AGC/Error				Amplifier			Circuit		7-19
Phase		Compensator					7-11
Driver		Stage				7-11
Feedback				Signal			7-12
Bias	Circuitry					7-12
Frequency				Selection			Circuitry		7-12
Ultrasonics		Board-Other					Circuits		7-13
viii										CUSA EXcel-8 System Service Manual

Audible Alert		and Operation	Indicator	7-13
Valve	Drivers	7-13
Power and Other Signal Connections				7-13
Dual 24 V	Power	Supply Board	7-13

Section	8. Checkout		Procedures
Inspections		8-1
Footswitch		8-1
Power	Cord	8-2
Power On	Verification		8-2
Handpiece	Test	(Optional)	8-2

Section

Maintaining

the

CUSA

EXcel

System

For Your

Information

9-1

Recommended

Maintenance

Schedule

9-2

Clean

the

CUSA

EXcel

Console

9-3

Clean

the

Sterilizer

Case

9-3

Maintain

the

Handpiece

9-3

Clean

the

Handpiece

9-4

Lubricate

the Handpiece Connector O-Rings

9-5

Replace the Handpiece Connector O-Rings

9-5

Recalibrate

the

Handpiece

9-5

Maintain

the

Tip

Torquing

Set

9-6

Clean

the

Tip Torquing Set

9-6

Check the

Torque

the

Tip

Torquing

Wrench

9-6

Store

the

CUSA

EXcel

System

and

Accessories

9-7

CUSA

Console

9-7

Handpiece

9-7

Footswitch

9-7

CEM

Nosecone

9-7

Section

10.

Troubleshooting

For Your

Information

10-1

Troubleshooting

Safety

10-2

User

Troubleshooting

10-2

Responding

Alerts

10-3

General

Troubleshooting

10-6

Engineer

Troubleshooting

10-15

Guidelines

10-15

Flowcharts

10-15

No Power

10-16

Handpiece

Alarm

10-17

CUSA

EXcel-8

System

Service

Manual


Footswitch Alarm			10-18
Cooling		Water Alarm		10-19
Low	Suction		10-20
Low	irrigation		10-22
Vibration		Alarm	10-23

Section

11.

Replacement

Procedures

For

Your

Information

11-2

Console

Cavers

11-3

Open

the

Left

Cover

11-4

Open

the

Right

Cover

11-4

Open

the

Rear

Cover

11-4

Re-install

the

Left

Cover

11-5

Re-install

the

Right Cover

11-5

Re-install

the

Rear

Cover

11-5

Dual

Volt

Power

Supply

11-6

Remove

the

Dual

Volt

Power Supply

11-6

Install the Dual 24 Volt Power Supply

11-6

Ultrasonics and Machine Control Printed

Circuit

Boards

11-8

Remove

the

Ultrasonics

PCB

11-8

install

the

Ultrasonics

PCB

11-11

Remove

the

Control

Panel

Assembly

11-13

Remove

the

Machine

Control

PCB

11-14

Install the Machine Control PCB

11-14

install

the

Control

Panel

Assembly

11-15

Control

Head

Components

11-15

Remove

the

Control

Panel

Assembly

11-17

Remove

the

Machine

Control

PCB

11-18

Remove

the

Control

Panel

Overlay

11-18

Remove

the

Display

PCB

11-18

install

the

Display

PCB

11-19

Install

the

Control

Panel

Overlay

11-20

install the Machine Control PCB o

11-20

Install

the

Control

Panel

Assembly

11-20

Suction

Control

Valve

11-21

Remove

the

Suction

Control

Valve

11-21

Install the Suction Control Valve

11-27

Suction

Pump

and

Controller

Card

11-29

Remove

the

Suction

Pump

11-29

Install

the

Suction

Pump

—

11-34

Ready

for

Suction

Pump

Controller Card Replacement

11-35

Remove

the

Suction

Pump

Controller Card

11-36

CUSA EXcel-8

System Service Manual

Install the Suction Pump Controller Card

11-37

Suction

Pinch

Valve

11-38

Remove

the

Irrigation

Pump

Bezel

11-38

Remove the Suction Pinch Valve

11-38

Install

the

Suction

Pinch Valve

11-40

Instali

the

Irrigation

Pump

Bezel

11-40

Irrigation

Pump

Head

and

Gear

Motor

11-41

Remove

the

Irrigation

Pump

Bezel

11-41

Remove the Irrigation Pump Head

11-42

Install

the

Irrigation

Pump

Head

11-42

Remove the Irrigation Pump Gear

Motor

11-43

Install

the

Irrigation

Pump

Gear Motor

11-45

Replace

the

Irrigation

Pump

Bezel

11-45

Handpiece

Flow

Sensor

11-46

Remove the Handpiece Flow Sensor

11-46

Install the Handpiece Flow Sensor

11-48

Cooling

Water

Pump

Tubing

11-49

Tools

and

Materials

11-49

Remove the Cooling Water Pump

Head

11-49

Install Tubing and Re-Assemble the Cooling Water Pump

Head

11-50

Cooling

Water

Reservoir

O-Rings

11-51

O-Rings on the Cooling Water Reservoir

Connectors

11-51

Fuses

11-52

Section		12.	Calibration
For	Your	Information		12-1
Tools/Equipment Needed				for	Calibrations		12-2
DC	Bias	Power	Supply	12-2
Suction		Pump	12-3
Motor for the			Cooling Water		Pump	12-3
	Set	Up	123
	Procedure		12-4

Section	13.	Repair Policy
Return Equipment			for	Service	13-2
Obtaining		a Return		Authorization		Number	13-2
Returning		the	Console		13-2
Returning		the	Handpiece		13-9
Returning		Circuit		Boards	13-9
Ordering		Replacement Parts				13-9
Valleylab	Service		Centers		13-10

CUSA	EXcel-8	System	Service	Manual


Section	14.		Service		Parts	Lists
Ordering	Replacement			Parts		14-1
Replacement		Parts		14-2
Handpiece			Cooling		14-2
Irrigation			14-2
Miscellaneous				14-3
Power			14-4
Suction			14-4
Electronic	Parts		14-4
Ultrasonics			PCB Parts		14-5
Appendix		A.	Warranty
Schematics			Supplement.			Assembly Drawings and Schematics

xii	CUSA EXcel-8 System Service Manue

List

of Figures

Figure

2-1.

The pre-aspiration holes

and

threads

tips

2-3

Figure

2-2.

The

three

handpieces

the

CUSA

EXcel

system

2-5

Figure

3-1.

Replacing

fuses

3-10

Figure

3-2.

Disconnecting

control

panel

assembly

cables

3-11

Figure

3-3.

Removing

the

control

panel

overlay

3-12

Figure 3-4. _

Installing

the

control

panel

overlay

3-14

Figure

3-5.

Installing

the

reference

cards

3-15

Figure

4-1.

Console

structural

features

4-2

Figure

4-2.

Control

panel

features

4-4

Figure

4-3.

Control

panel

features

(continued)

4-6

Figure

4-4.

Console

body—front

view

4-8

Figure

4-5.

Console

body—view

the right

side

4-10

Figure

4-6.

Console—rear

view

4-12

Figure

4-7.

Console—rear

view

(continued)

4-14

Figure

4-8.

Control

panel

symbols

4-16

Figure

6-1.

The

handpiece

components

6-2

Figure

6-2.

Reserve power vs. TISSUE Select settings

6-7

Figure

6-3.

Reserve

power

vs.

amplitude

setting

6-9

Figure

7-1.

The

display

organization

the

control

panel

7-3

Figure

9-1.

Cleaning

the

handpiece

with

soft

cloth

9-4

Figure

9-2.

Replacing

the

handpiece

connector

o-rings

9-5

Figure

11-1.

Right

and

left

sides

the

console

11-3

Figure

11-2.

The

wiring

harness

the

dual

volt

power

supply

11-7

Figure

11-3.

Cables

the

ultrasonics

PCB

assembly

11-9

Figure

11-4.

The ultrasonics PCB fan assembly

connections

11-10

Figure

11-5.

Plugging

the

adapter

for

the

syphon valve cable assembly into the

connector at J6 on the ultrasonics

PBC

11-11

Figure

11-6.

Disconnecting

control

panel

assembly

cables

11-13

Figure

11-7.

Removing

the

Machine

Control

PCB

from

the

control

panel

assembly

11-14

Figure

11-8.

The

layers

control

head

components

11-16

Figure

11-9.

Disconnecting

control

panel

cables

11-17

Figure

11-10.

Disconnecting

the

50-pin

ribbon

cable

and

removing

the

Machine

Control

PCB

11-19

Figure

11-11.

Removing

the

Display

PCB

from

the control

head

assembly 11-19

Figure

11-12.

Removing

the

ends

from

the

suction

pump

chamber

11-23

CUSA

EXcel-8

System

Service

Manual

xiii

Figure 11-13.

Figure 11-14.

Figure 11-15.

Figure 11-16.

Figure 11-17.

Figure 11-18.

Figure 11-19.

Figure 11-20.

Figure 11-21.

Figure 11-22.

Figure 11-23.

Figure 11-24.

Figure 11-25.

Figure 11-26.

Figure 11-27.

Figure 11-28.

Figure 11-29.

Figure 11-30.

Figure 11-31.

Figure 11-32.

Figure 11-33.

Figure 11-34.

Figure 11-35.

Removing

the

suction

pump

enclosure

from

the

console

11-23

Disconnecting

the

suction

tube

at the

contamination

guard

90°

elbow

11-24

Disconnecting

the

suction

tube

from

the

left

end

the suction

control

valve

11-24

Pulling the strain relief bushing away from

the

manifold

bracket

11-25

Removing

the

manifold

bracket

from

the

console

11-25

Removing

the

suction

control valve

from

the

manifold

bracket

11-26

Removing

the

suction

hose

and

clamp

from the suction

control

valve

11-27

Removing

the

suction

tube

and

clamp

from

the

“T”

fitting

11-30

Pulling

the

split bushing

away

from

the

manifold

bracket

11-30

Disconnecting cables from the suction pump to the suction pump

controller

card

11-31

Removing

the

suction

tube and

strain

relief bushing

from the

suction

pump

and

its

wires

11-33

Removing

the

suction

pump

from

its

bracket

mount

11-33

Attaching

the

suction

pump

motor

its

mounting

bracket,

making

sure to

center

the

pump

the

bracket

11-34

Removing the cable clamps and screws from the suction pump

controller

card

11-36

Removing

the

irrigation

pump

bezel

11-39

Removing

the

suction

pinch

valve

11-39

Removing

the

irrigation

pump

bezel

11-41

Removing

the

irrigation

pump

head

11-42

Disconnecting

the

irrigation

pump

gear motor

from

the

control

card

11-43

Replacing

the

gear

motor/pump

head

coupler

the

motor

drive

shaft

11-44

Replacing

the

handpiece

flow sensor

11-47

Removing

the

end

bell

and tubing from

the

cooling

water pump

head

11-50

O-rings

cooling

water

reservoir

connectors

11-51

CUSA EXcel-8 System Service Manu

e tema

Schematics

Supplement

Schematic

The

console

rear

and

left

side

9-1

Schematic

Console

covers

and

panels

$-2

Schematic

Console

interior,

rear

and

left

side

S-3

Schematic

Console

miscellaneous

subsystems

S-4

Schematic

Subsystems

relating

suction

and

irrigation

5-5

Schematic

Arm

and

control

panel

assembly

S-6

Schematic

Interconnect

diagram,

sheet

S-7

Schematic

interconnect

diagram,

sheet

5-0

Schematic

Display

board

layout,

sheet1

S-9

Schematic

10.

Display

board

layout,

sheet 2

S-10

Schematic

11.

Display

board

schematic,

sheet

6 (sheet

blank, thus

not

shown)

S-11

Schematic

12.

Display

board

schematic,

sheet

S-12

Schematic

13.

Display

board schematic, sheet 4 of

5-13

Schematic

14.

Display

board

schematic,

sheet

of 6

5-14

Schematic

15.

Display

board

schematic,

sheet

5-15

Schematic

16.

Machine

control board layout, sheet1 of1

S-16

Schematic

17.

Machine

control

board

schematic,

sheet

0f6

S-17

Schematic

18.

Machine

control

board

schematic,

sheet

5-18

Schematic

19.

Machine

control

board

schematic,

sheet

S-19

Schematic

20.

Machine

control

board

schematic,

sheet

5-20

Schematic

21.

Machine

control

board

schematic,

sheet

S-21

Schematic

22.

Machine

control

board

schematic,

sheet

5-22

Schematic

23.

Ultrasonics board layout, sheet1 of2

5-23

Schematic

24.

Ultrasonics

board

layout,

sheet

of 2

S-24

Schematic

25.

Ultrasonics

board

schematic,

sheet

(sheet 1 blank,

thus not

shown)

5-25

Schematic

26.

Ultrasonics

board

schematic,

sheet

9-26

Schematic

27.

Ultrasonics

board

schematic,

sheet

5-27

Schematic

28.

Ultrasonics

board

schematic,

sheet

9-58

Schematic

29.

Ultrasonics

board

schematic,

sheet

S-29

Schematic

30.

Ultrasonics

board

schematic,

sheet

$-30

GUSA

EXcel-8

System

Service

Manual

List of Tables

Table

3-1.

Wire

colors

3-9

Table

3-2.

Fuse

values

3-10

Table

5-1.

Tip

Specifications—23

kHz

5-13

Table

5-2.

Tip

Specifications—36

kHz

5-14

Table

6-1.

On-off intervals for TISSUE

Select

6-6

Table

6-2.

Fragmentation

performance

vs.

TISSUE

Select settings

6-8

Table

7-1.

Irrigation

pump

voltage

steps

7-4

Table

7-2.

Suction

pump

voltage

steps

7-5

Table

7-3.

Cooling

pump

voltage

steps

7-6

Table

7-4.

Handpiece

amplitude

control

voltages

7-6

Table

9-1.

Routine

maintenance

tasks

9-2

Table

9-2.

Torque values for the torque

wrench

9-7

Table

11-1.

Cable connections on the ultrasonics

PCB

11-8

Table

11-2.

Ultrasonics

PCB fan

assembly

connectors

11-10

Table

11-3.

| Cable connections on the ultrasonics

PCB

11-12

Table

11-4.

Procedures to access control panel components

11-16

Table

11-5.

Suction

pump

cable

connections

the

controller

card

11-31

Table

11-6.

The

suction

pump

controller

card

cable

the

ultrasonics

PCB 11-36

Table

11-7.

Suction

pump

cable

connections

11-37

Table

11-8.

Irrigation

pump

control

card

connections

11-45

Table

11-9.

Fuse

values

11-52

Table

14-1.

Handpiece

cooling

replacement

parts

14-2

Table

14-2.

Irrigation

replacement

parts

14-2

Table

14-3.

Miscellaneous

replacement

parts

14-3

Table

14-4.

Power

replacement

parts 14-4

Table

14-5.

Suction

replacement

parts

14-4

Table

14-6.

Printed

circuit

board

spares

14-4

Table

14-7.

Ultrasonics

board

parts—resistors

14-5

Table

14-8.

Ultrasonics

board

parts—-diodes

14-5

Table

14-9.

Ultrasonics board partsFETs

14-6

Table

14-10.

Ultrasonics

board

parts—integrated

circuits

14-6

Table

14-11.

Ultrasonics

board

parts—connectors

14-7

Table

14-12.

Ultrasonics

board

parts—miscellaneous

14-8

xvi	CUSA EXcel-8 System Service Man

Service Personnel Safety

In this section:

* Safety information

e Warnings, Cautions, and Notices, organized by section.

Safety Information

The

safe

and effective servicing of ultrasonic

surgical

equipment

depends

to a

large

degree on

factors

solely under

the

control

the

service

person.

There is

substitute for a

properly

trained

and

vigilant

service

staff. It is

important

that you

read, understand,

and

the

procedures

supplied

with

this

ultrasonic

equipment.

Warnings,

Cautions,


and	Notices
Before		servicing the	CUSA	EXcel	console		or		handpieces, it	is important
that you read, understand, and follow						the		instructions and		the	warnings,
cautions, and notices supplied with it.						It	is	also important		that	you read,
understand, and follow the instructions							for any other equipment used to
install,		test, adjust,	or repair	the	CUSA	EXcel			system.

CUSA

EXcel-8

System

Service

Manual

Warnings, Cautions, and Notices

General

SM 1 Så RR ai

Federal (USA) law restricts this device to sale by or on the order of a physician.

Notice

Operating the console outside the specified voltage ranges may cause damage

to the	power	supply.
Introduction
Read	all warnings, cautions, notices and				instructions provided with the
CUSA	EXcel	system	before servicing it.
Read	the instructions,		warnings,	cautions,	and notices provided with the
CUSA	EXcel	handpieces before		servicing	them.

To avoid injury to surgical personnel, keep fingers away from the suction pinch valve.

Unpacking and Installing the CUSA EXcel System

prevent the

ramp from

falling

and

causing

injury,

sure

hold the

ramp in

the up position while cutting

the

corrugated

tab that

secures

to the

carton.

Notice

avoid

product

damage,

sure

insert

fuses that

are appropriate

the

power

supply:

220

240

—

T5A,

Time

Delay

(default)

120

~T10A,

Time

Delay

Console Components

To avoid injury to surgical personnel, keep fingers away from the suction pinch

valve.
Technical	Specifications
Explosion	Hazard Do not	use	the CUSA	EXcel system	in the presence of
flammable	anesthetics or	any	potentially	explosive or	flammable atmosphere.

CUSA EXcel-8 System Service Man

Warnings, Cautions, and Notices

To avoid injury to surgical personnel,					keep	fingers away from the suction pinch
valve while powering the unit on or off, activating vibration, or using fast flush.
Checkout		Procedures
Do not allow the handpiece				tip to contact		anyone	or anything	during		tip activation.
Contact may result in patient				injury,	user injury, or		handpiece	tip	damage.
Notice
To	avoid	product	damage,	NEVER	hold	the handpiece in your			hand	while using
the	torque	wrench	to tighten	or loosen the		tip.

Maintaining the CUSA EXcel System

«“«ὕ“όὃἃ«ᾱἃὃἃἝἃἝὃἝἃᾱἝἃ“ςἝ«ἄἃἄναυυαυυ0

Electric Shock

Hazard

Always

unplug

the CUSA

system

before

cleaning.

Notice

Do not rub, press, or touch any panels with solvents;

caustic,

corrosive, or

abrasive

cleaning

disinfectant

compounds;

other

materials

that

could

scratch the panels. Do not use

betadine-based

solution; it

will

cause

discoloration.

not allow

fluids

enter

the

chassis.

Do not clean the sterilizer case with abrasives. Product damage

will

result.

Product

damage

will

result

you

not

these

notices

when

cleaning

the

handpiece:

not

immerse

the

handpiece

cable

electrical

connector

liquid.

not

use

ultrasonic

automated

cleaners.

not

use chlorinated substances such as bleach

solution.

not

clean the handpiece with abrasives such as

Ajax,

Comet,

or steel

wool.

Product

damage

will

result

you

not

these

notices

when

cleaning

the

Tip Torquing

Set.

not

use ultrasonic or automatic washers.

not

autoclave.

not

use chlorinated substances such as bleach

solution.

E |

not

clean with

abrasives

such as

Ajax, Comet,

steel

wool.

№ э/е |8UU0SJ84 291A18S

CUSAEXcel-8

System

Service

Manual

Warnings, Cautions, and Notices

Troubleshooting

Electric

Shock

Hazard

not

touch any exposed wiring or conductive

surface

while the system is disassembled and energized. Never

wear

grounding

strap

when working on an energized system.

Electric

Shock

Hazard

Take

appropriate

precautions

(such

the

use

isolated

tools

and

equipment;

use

the “one hand rule,” etc.) when taking measurements

troubleshooting

the

system.

not

activate

vibration

the

CEM

handswitching

nosecone

while using

the tip

cleaner.

Tip

damage,

user

injury,

electrical

shock,

any

combination

these

effects

may

occur.

Notice

Electrostatic

Sensitive

Devices

This

unit

contains

electrostatic

sensitive

components.

When

repairing

the

system,

work

static

control

workstation.

Wear

grounding

strap

when handling electrostatic sensitive components.

Handle

circuit

boards

their

nonconductive

edges.

Use

antistatic

container

for

transport

electrostatic

sensitive components and circuit boards.

Replacement

Procedures

Electric

Shock

Hazard

Only

trained

biomedical

engineers

and

technicians are

authorized

to service

the

CUSA

EXcel

system.

Electric

Shock

Hazard

not

touch any exposed wiring or

conductive

surface

while

the

CUSA

EXcel

system

disassembled

and

energized. Never

wear

grounding

strap

when

working on an energized CUSA system.

Electric

Shock

Hazard

Take

appropriate

precautions

(such

the

use

isolated

tools

and

equipment;

use

the “one hand rule,” etc.) when taking measurements

troubleshooting

the

CUSA

EXcel

system.

High

Current

Hazard

not

touch

the

ultrasonics

PCB

heat

sink

while

the

CUSA

EXcel

system

energized.

The

heat

sink

is isolated

from

ground,

and can

deliver

very

high

current,

resulting

injury.

CUSA EXcel-8 System Service Manual

Warnings,

Cautions,

and

Notices

Notice

If you plan to connect the handpiece

for

activation,

ensure that

an I.V.

set

available to supply cooling irrigation solution to the

handpiece

tip. Otherwise,

damage

to the

tip

and/or

handpiece

may

result.

Electrostatic

Sensitive

Devices

This unit

contains

electrostatic

sensitive

components.

When

repairing

the system, work at a

static

control workstation.

Wear a grounding strap when

handling electrostatic

sensitive

components.

Handle

circuit

boards

their

nonconductive edges.

Use

antistatic

container

for transport

electrostatic sensitive

components

and circuit

boards.

When installing a new power supply, use the same screws and washers removed

from

the

power

supply.

too-long screw will damage the power supply.

avoid

product

damage,

do not

remove

the

jumper

cabie

or the connector at J4.

avoid

product

damage,

remove

the

ESD

wrist

strap

before connecting

cables

the

Machine Control

PCB.

avoid

product

damage,

when

handling

the

suction

pump

controller card,

not

turn the three white adjustment dials designated

current

limit

(R13),

max

speed (R12), and min speed (R11).

Calibration

High

Current

Hazard

not touch

the

ultrasonics

PCB

heat

sink

while

the

CUSA

EXcel

system

energized.

The

heat

sink

is isolated

from

ground, and

can

deliver

very

high

current,

resulting

in injury.

Repair Policy

To prevent the ramp from falling and causing injury, be sure to hold the ramp in the up position while stapling the corrugated tab that secures it to the crate.

Ajayes |l9uu0sJ9d 99IAJ9S

GUSA

EXcel-8

System

Service

Manual

Introduction

In this section:

e Overview

e Fragmentation e Irrigation

¢ Aspiration (Suction) * Handpieces

e Wide variety of tips.

For Your Information

Read all warnings, cautions, notices, and			instructions	provided	with	the	CUSA
EXcel system before servicing it.
Read the instructions, warnings, cautions,			and notices	provided	with	the	CUSA
EXcel handpieces before servicing them.
This section presents	the CUSA	EXcel	system general information; what it
is, what it does, and	(generally)	how it	works.

0054

EXcel-8

System

Service

Manual

Overview

The	CUSA EXcel		system is an ultrasonic surgical	aspirator that allows	a
surgeon		to remove tissue—selectively and with		precise control—from	the
body.	It	performs	three functions:

*Fragmentation

+Irrigation

*Aspiration (suction).

All three functions may occur at the same time.

The CUSA Excel system includes the following components:

+	The	console:
	4	The	console	body	houses electronics, pumps, and other parts that
		make	the system		work.
	4	The control panel allows the user to control the system.
e	The	handpiece		is the	handheld surgical device that actually touches
	the	patient.

e Accessories include a variety of items; for example, manifold tubing, a large selection of tips, a tip torquing base and torque wrench, and a sterilizer case.

Fragmentation

Tip	Motion
Fragmentation occurs when		the vibrating tip interacts with	tissue.	As the
tip	begins to move toward	tissue, it accelerates, impacts the	tissue,	then

penetrates the tissue. The acceleration, impact, and penetration produce a

combination	of direct	mechanical forces and hydrodynamic pressures that
burst cells.
For more information on how the handpiece works, refer to Section 6,
Principles of	Operation,	in this manual.

Cooling

The

high

frequency

vibration

generates

heat.

To reduce

the

heat,

the

CUSA

EXcel

system

includes

closed, recirculating cooling

water

system.

This

system pulls water

from

cooling

water

reservoir,

through a

tube

the

handpiece

cable,

through

the

handpiece,

and

through a

return

tube

the

handpiece

cable

the cooling

water

reservoir.

Cooling

water

flows

35 to

cc/min.

As it passes through the handpiece, the water removes heat.Normal handpiece temperature, in sustained heavy use, remains at about 40° C.

CUSA

EXcel-8

System Service Manuál

Irrigation

Figure 2-1.

The	pre-aspiration holes and threads
on	tips

							Irrigation
Use distilled water for the cooling							water system because it does not
contain	natural		minerals,		chemical additives, or organic materials that are
present	in	tap water.		Any	of	these	impurities in tap water can cause
problems		within	the	cooling		water	system.

Sterile irrigation fluid flows from an LV. set (bottle or bag and 1.V. administration tubing) to a variable speed peristaltic pump:

eThe pump moves fluid at 1 to 10 cc/min; default flow is 3 cc/min. Adjustment buttons (blue up/down arrows on black buttons at the

bottom

the

irrigation

display

column

on the control panel) allow

you

increase

or decrease

the

irrigation

flow.

e The

pump

can

also

accelerate

Fast Flush

speed,

pumping at

25 to 30 cc/min. The Fast Flush pedal on

the

CUSA

Excel

system

footswitch

activates

the

Fast

Flush

feature.

The pump pushes the fluid

through

the

manifold

irrigation

tubing

flue, a

sleeve

surrounding

the

vibrating

tip.

the

irrigation

fluid

passes

through

the flue, it cools the tip.

When

the

fluid

reaches

the

distal

end

the

tip,

much

as 99%

passes through two pre-aspiration holes in

the

tip,

eliminating

fluid

pooling

the

sterile field

and

continually

clearing the

suction

system.

The fluid that does not pass through the pre-aspiration

holes

irrigates

the

surgical

site

and

suspends

fragmented

tissue.

Pre-aspiration

Hole

(2)

Threads

lOH9nDOJUI

Aspiration (Suction)

A vacuum

pump

in the

console body provides up to 660 mm

mercury

maximum

vacuum

at sea

level.

Adjustment

buttons

(green

up/down

arrows

black

buttons

the

bottom

the

aspiration

display

column

the control

panel)

allow

you to increase or decrease

the

suction from 10

100% in

10%

increments.

The suction, which produces an air stream moving

toward

the

vacuum

pump,

pulls

irrigation

fluid, fragmented

tissue,

and

other materials

through

the

distal

end

of the surgical tip. From

the tip,

the

aspirated

materials

pass through

the

manifold

suction

tubing

into the

suction

canister. From the suction canister, the air stream continues to flow through a contamination guard that filters any remaining particulate

matter or moisture, preventing them from entering the vacuum pump.

A	suction pinch	valve	on the	front	of the console opens when the system is
on	and closes to	stop	suction	in the	following cases:

e When priming the irrigation system + When pressing the Fast Flush pedal

e In Run Status, when you release the Vibration pedal. In this case, the pinch valve closes for about one second, then re-opens.

*In Lap Mode, when you release the Vibration pedal. This suction

stoppage prevents depletion of the pneumoperitoneum.

To avoid injury to surgical personnel,			keep	fingers away			from	the suction	pinch
valve.
When	the System Power Switch	is	off,	the	suction	pump		remains	off and
the suction pinch valve remains closed.				A	button	on	the	front of the
suction	pinch valve allows you	to	open	the valve		manually.

CUSA

EXcel-8

System Service Mam”

Handpieces

Figure 2-2.

The three handpieces in the

CUSA EXcel system

Handpieces

The CUSA EXcel system includes three handpiece configurations:

e 36 kHz, straight (smaller handpiece, black body, blue connector) e 23 kHz, straight (gray body, green connector)

23 kHz, angled (gray body, green connector)

23 kHz	и	^
23 kHz	и
Straight

36 kHz Straight

UOH9nDOJiUI

Wide Variety of Tips

You	can use a wide	variety of tips with		the	CUSA	EXcel handpieces. Tips
vary in inside diameter, length,			and shape		(straight or curved). For
complete information on the tips that				are available		for each	handpiece,
refer	to Appendix B,	Accessories,	in the	CUSA	EXcel	System	User's Guide

EXcel-8

System

Service

Manual

Unpacking and Installing

the CUSA EXcel System

In this section:


e	The	responsibility			of	the	manufacturer
e	Unpacking		the	CUSA		EXcel			system
¢	Preparing		the	CUSA		EXcel			console for	use:
	4	Replacing		the	power			connector
	4	Replacing		fuses		(if	necessary)
	4	Replacing		a Control				Panel overlay		(optional)
	4	Installing		the	reference				card set.

The Responsibility of the Manufacturer

Valleylab is responsible for the				safety, reliability,	and performance of the
CUSA	EXcel system only		under	the following circumstances:
* The	person	unpacking	and	installing the unit	follows the installation
and	setup	procedures	in this manual.

+Authorized persons perform assembly operations, re-adjustments,

	modifications, or repairs.
*	The	electrical installation of the relevant room	complies	with local
	codes and regulatory requirements.
*	You	use the equipment in accordance with the	Valleylab	instructions
	for	use.

For warranty information, refer to the Preface section of this manual.

LUSA EXcel-

System

Service

Manual

3-1

Unpacking the CUSA EXcel System

The	CUSA	EXcel system arrives	in a corrugated cardboard	crate strapped
to a	wood	shipping pallet. The	corrugated cardboard crate	has several
components:

*Abottom, larger section contains the CUSA EXcel console and foam

packing	cushions.
+ A tray,	inserted	into the	top	of the crate	and supported	by the	top of
the crate walls,		contains	the	footswitch,	contamination	guards	(2),

service manual, inservice kit, and dust cover. e Alid covers the crate/tray assembly.

Tools You Will Need

e Utility knife

+Pliers (optional).

Unpacking Procedure

1. Cut the vertical bands on the shipping crate. Remove the bands.

Note: Save the box edge protectors for use when shipping the system.

2. Lift	the	lid	and	the	tray
from	the	crate.
Remove		the	contents
from	the	tray,		then	put
the tray		aside.

3-2	CUSA EXcel-8	System Service Man
3-2

Unpacking the CUSA EXcel System

3.Cut and remove the horizontal bands on the crate.

Note: Save the box edge protectors for use when shipping the system.

4.Remove the three plastic clips that hold the crate closed. (If the clip is

especially	tight, you may need to use pliers for this step.) Refer to the
following	figure.

a.Inside the clip, grasp the two horizontal bars near the locking

retainer (on the right side of the clip).

b.	Squeeze		the bars toward each other to release them from the
\|	locking		retainer.
c.	Pull	the	bars	toward you.	They	should	swing	outward.
d.	Pull	the	tab	at the bottom	of the	clip to	remove	the clip	from the

carton.

SU)Bupjoedur)

VSNO

[99XIpue

UIBISÁSGurexsu]

Unpacking the CUSA EXcel System

5. Open the crate.

6.Cut the corrugated tab

that	secures		the	ramp		to
the	carton.		Cut	as	close	as
possible		to	the	staples
that	hold	the tab			to the

ramp; you may want to use the tab again.

To	prevent	the	ramp	from falling	and causing injury, be sure to hold the ramp in
the	up position		while	cutting the	corrugated tab that secures it to the carton.
7.	Lower	the	ramp.

-8	System	Service Mani
CUSA EXcel

+ 209 hidden pages