Service Manual
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Service Manual
Force™ 2 Electrosurgical Generator
The following service instructions are for use only by personnel qualified to repair and service the equipment described in this manual. This service manual covers the installation and basic service instructions for the Force™ 2 Electrosurgical Generator. Also included are sections covering the technical specifications, circuit descriptions, and the testing of the generator. Instructions for use and cautions and warnings concerning electrosurgery are in the Force™ 2 Electrosurgical Generator User’s Guide supplied with the generator. Caution Federal (USA) law restricts this device to sale by or on the order of a physician. Equipment covered in this manual: Electrosurgical Generator
Vac Nominal
Hertz
Force™ 2-2 PCH
110-120
50-60
Force™ 2-8 PCH
220-240
50-60
The Force™ 2 Electrosurgical Generator Service Manual consists of two parts-the text (part 1 of 2) and a Schematics Supplement (part 2 of 2) which contains the schematics. Valleylab part number: 945 103 106 (1 of 2) Effective date: October 2004
Force™ 2 and REM™ are trademarks of Valleylab. The Force 2 generator is protected by one or more of the following U.S. patents and their foreign counterparts: 4,632,109, 4,658,819, 4,658,820, 4,827,927, 5,190,517. Manufactured by
Valleylab, a division of Tyco Healthcare Group LP Boulder, CO 80301-3299 USA Tyco Healthcare UK Ltd. Gosport, PO13 0AS, UK For information call
1-800-255-8522 / 1-303-530-2300
© 2004 Valleylab All rights reserved.
Made in USA Printed in USA
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Force 2 Service Manual
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.
Important Indicates an operating tip or maintenance suggestion.
Notice Indicates hazard which may result in product damage.
Controls, indicators, and receptacles on the unit appear in bold capital letters like this: PURE CUT.
ATTENTION
Refer to the accompanying documents.
Type CF equipment Low Leakage Suitable for cardiac use Defibrillator proof Drip Proof
CAUTION
To reduce the risk of electric shock, do not remove cover. Refer servicing to qualified service personnel.
The generator is high frequency isolated per IEC 601-2-2.
DANGER
Explosion Hazard: Do not use in the presence of flammable anaesthetics.
Force 2 Service Manual
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Valleylab Service Centers Valleylab Boulder, Colorado, 80301-3299 USA Ph: 303-530-2300 Toll Free: 800-255-8522 Tyco Healthcare Nederland B.V. Technical Service Center De Beverspijken 37 5221 EE ’s-Hertogenbosch THE NETHERLANDS Ph: 073-6312412 Fax: 073-6314540 Auto Suture France S.A. 2, rue Denis Diderot La Clef de Saint Pierre 78990 Elancourt, FRANCE Ph: 33 (0)1 30 79 80 40 Fax: 33 (0)1 30 79 85 73 Tyco Healthcare Deutschland Tempelsweg 26 47918 Tonisvorst, GERMANY Ph: 49 (0)2151 7096 92 Fax: 49 (0)2151 7096 67 For the UK, Europe, Middle East & Africa: Tyco Healthcare UK Limited Valleylab Service Centre Unit 1a Corinium Industrial Estate Raans Road Amersham Bucks. HP6 6YJ UNITED KINGDOM Ph: 44 (0)1494 789200 FAX: 44 (0)1494 789239 Tyco Healthcare Italia SpA Via Gaetano Crespi, 12 20134 Milano, ITALY Ph: 39 02 212181 Fax: 39 02 2640059 Tyco Healthcare Spain S.L. C/Fructuos Gelabert, 6 – 8 planta 8a, 08970 – Saint Joan DESPI Barcelona SPAIN Ph: 34-93-680-3370 Fax: 34-93-680-2457
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Tyco Healthcare Belgium B.V. Generaal De Wittelaan 9/5 B-2800 Mechelen BELGIUM Ph: 32-15-298111 Fax: 32-15-217987 Tyco Healthcare Austria GmbH Jochen Rindt Str. 37 A-1230 Vienna AUSTRIA Ph: 43-1-610-3441 Fax: 43-1-615-3808 Tyco Healthcare Norden AB (Denmark, Finland, Iceland, Norway, Sweden) Årstaängsvägen 11 B, II SE-117 43 Stockholm SWEDEN Ph. +46 8 585 605 00 Fax +46 8 585 605 06 Tyco Healthcare PTY Ltd Service & Technical Support 59 - 69 Halstead Street Hurstville NSW 2220 AUSTRALIA Ph: 61 2 9579 6066 Toll free hotline: 1800 350 702 Fax: 61 2 9585 1908 Tyco Healthcare Japan Regulatory Affairs Department Technical Support Section Customer Call Center 1-2-20 Heiwajima Ota-ku Tokyo-to JAPAN Toll Free : 0120-073-008 Ph: 03-3764-0733 Fax: 03-3764-0744 Auto Suture Company, Canada 4490 Garand Street Ville St. Laurent Quebec, CANADA H4R 2A2 Ph: 514-334 -7602 Fax: 514-331-5983
Force 2 Service Manual
Table of Contents Conventions Used in this Guide Valleylab Service Centers List of Figures
iii
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Section 1. Service Warnings and Cautions Section 2. Unpacking and Installation Unpacking the Force 2 Generator
2-1
Responsibility of the Manufacturer Preparing the Generator for Use Power Requirements
2-1 2-2
2-2
Check the Power Connector
2-2
Ensure Proper Grounding
2-3
Perform a System Check
2-3
Section 3. Description of Controls, Indicators, and Receptacles Controls
3-3
Indicators
3-4
Alarms
3-5
Receptacles
3-5
Rear Panel Functions
3-6
Section 4. Technical Specifications Standard Conditions of Measurement Operating Parameters
4-1
Storage and Shipping
4-1
Output Waveform
4-2
PCH Generator Output Characteristics Output Configuration
4-2
4-2
Input Power Source 4-3 Force 2-2 PCH Generator Force 2-8 PCH Generator
4-3 4-3
Line Regulation 4-3 Force 2-2 PCH Generator
4-3
Force 2-8 PCH Generator
4-3
High Frequency Risk Parameters
Force 2 Service Manual
4-1
4-4
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Low Frequency Leakage (50-60 Hz) 4-4 Force 2-2 PCH Generator 4-4 Force 2-8 PCH Generator (per VDE 0750 (IEC601-1), Section 19 for Class 1 Equipment) REM Contact Quality Monitor Audio Volume
4-5
4-5
Approximate Weight Size
4-4
4-5
4-5
Classification 4-5 Type CF Equipment per IEC 601-1 Drip Proof per IEC 601-1 4-5 Output Power vs. Impedance Graphs
4-5
4-6
Section 5. Circuit Descriptions Bipolar Display
5-1
Monopolar Control/Display 5-1 Mode Indicators 5-2 REM and RMOTE Indicators RF Indicators 5-3 External Memory 5-4 Interface
5-5
Power Supply RF Output
5-3
5-6
5-7
Section 6. Maintenance Procedures Routine Maintenance and Inspections Cleaning Instructions
6-1
General Testing Information
6-2
Recommended Test Equipment Power Up Self-Test Calibration
6-1
6-3
6-3
6-4
Calibration Procedure
6-4
REM Test Procedure
6-7
Line Frequency (50-60 Hz) Current Leakage Test Procedure
6-8
Bipolar and Monopolar Output RF Leakage Test Procedures
6-9
Typical Output Waveforms
6-10
TT-on Waveforms at TP12 on PSRF Board
6-13
RF Drive Waveforms at TP7-10 on PSRF Board Clamp Waveform at TP11 on PSRF Board Components Replacement Guidelines
vi
6-13
6-14
6-15
Force 2 Service Manual
Section 7. Manufacturer Service Returning the Equipment for Service Returning the Force 2 Generator
7-1
7-2
Returning Circuit Boards and Other Subassemblies
7-2
Section 8. Service Parts List Ordering Replacement Parts
8-1
Monopolar Control/Display Board Bipolar Display Board Interface Board
8-2
8-4
8-5
Power Supply RF Board Heatsink Assembly RF Out 8-13
8-8
8-13
HVDC 8-13 PS 8-13 Clamp 8-13 Generator Base Assembly
8-14
Appendix A. Warranty Schematics Supplement. Assemblies and Schematics
Force 2 Service Manual
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List of Figures Figure 3-1.
PCH Generator Front View 3-2
Figure 3-2.
PCH Generator Rear View 3-2
Figure 4-1.
PCH Generator Typical Output Power vs Load-Monopolar Cut Modes 4-6
Figure 4-2.
PCH Generator Typical Output Power vs Load-Monopolar Cut Modes (continued) 4-7
Figure 4-3.
PCH Generator Typical Output Power vs Load-Monopolar Coag Modes 4-8
Figure 4-4.
PCH Generator Typical Output Power vs Load-Bipolar Mode 4-9
Figure 6-1.
Pure Cut Bipolar
300 Ω Load 100 Ω Load 6-10
Figure 6-2.
Blend 1
300 Ω Load 6-10
Figure 6-3.
Blend 2
300 Ω Load 6-11
Figure 6-4.
Blend 3 Low Voltage Coag
300 Ω Load 300 Ω Load 6-11
Figure 6-5.
Coag
300 Ω Load 6-12
Figure 6-6.
1-Cut/Bipolar 2-Blend 1 3-Blend 2 4-Blend 3/LV Coag 5-Coag 6-13
Figure 6-7.
1-Cut/Bipolar 2-Blend 1 3-Blend 2 4-Blend 3/LV Coag 5-Coag 6-13
Figure 6-8.
Open Circuit 120W Coag 6-14
Schematics Supplement Schematic 1. Schematic 2.
System interconnect diagram S-4 Component/connector locations S-5
Schematic 3. Schematic 4.
Bipolar Display board S-6 Bipolar Display board S-7
Schematic 5. Schematic 6.
Heatsink assembly, RF out S-8 Heatsink assembly, clamp S-9
Schematic 7. Schematic 8.
Heatsink assembly, power supply S-10 Heatsink assembly, HVDC S-11
Schematic 9. Monopolar keyboard S-12 Schematic 10. Monopolar keyboard S-12 Schematic 11. Footswitch board S-13
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Force 2 Service Manual
Schematic 12. Power Supply board layout, page 1 of 2 S-15 Schematic 13. Power Supply board layout, page 2 of 2 S-16 Schematic 14. Power Supply board, page 1 of 6 S-17 Schematic 15. Power Supply board, page 2 of 6 S-18 Schematic 16. Power Supply board, page 3 of 6 S-19 Schematic 17. Power Supply board, page 4 of 6 S-20 Schematic 18. Power Supply board, page 5 of 6 S-21 Schematic 19. Power Supply board, page 6 of 6 S-22 Schematic 20. Interface board layout S-23 Schematic 21. Interface board, page 1 of 3 S-24 Schematic 22. Interface board, page 2 of 3 S-25 Schematic 23. Interface board, page 3 of 3 S-26 Schematic 24. Monopolar Control/Display board layout S-27 Schematic 25. Monopolar Control/Display board, page 1 of 13 S-28 Schematic 26. Monopolar Control/Display board, page 2 of 13 S-29 Schematic 27. Monopolar Control/Display board, page 3 of 13 S-30 Schematic 28. Monopolar Control/Display board, page 4 of 13 S-31 Schematic 29. Monopolar Control/Display board, page 5 of 13 S-32 Schematic 30. Monopolar Control/Display board, page 6 of 13 S-33 Schematic 31. Monopolar Control/Display board, page 7 of 13 S-34 Schematic 32. Monopolar Control/Display board, page 8 of 13 S-35 Schematic 33. Monopolar Control/Display board, page 9 of 13 S-36 Schematic 34. Monopolar Control/Display board, page 10 of 13 S-37 Schematic 35. Monopolar Control/Display board, page 11 of 13 S-38 Schematic 36. Monopolar Control/Display board, page 12 of 13 S-39 Schematic 37. Monopolar Control/Display board, page 13 of 13 S-40
Force 2 Service Manual
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Notes
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Force 2 Service Manual
SECTION
1
Service Warnings and Cautions
1
Danger Explosion Hazard Do not install the Force 2 generator in the presence of flammable anesthetics, gases, liquids, or objects. For continued protection against fire hazard, replace the fuse with those having the same type and rating as the original fuse.
Warning Electric Shock Hazard Always unplug the generator before cleaning. Electric Shock Hazard Do not connect a wet power cord assembly into the generator or into the wall outlet. Electric Shock Hazard Disconnect the power before replacing parts. Electric Shock Hazard Do not touch any exposed wiring or conductive surface while the generator is disassembled and energized. Never wear a grounding strap when working on an energized generator. Keep the handset electrode away from personnel. Use the accessory holster to hold the handset safely. Use the ACCESSORY output receptacle for connecting either a handswitch (threepin) or footswitch (one-pin) accessory, but not both at the same time. Connecting more than one accessory to the ACCESSORY output receptacle activates both accessories simultaneously. Electric Shock Hazard The power FETs and other components on the supply heatsink are at line potential. Use extreme caution when probing this circuitry. Take appropriate precautions (such as use of isolated tools and equipment; use of the “one hand rule,” etc.) when taking measurements or troubleshooting the generator.
Force 2 Service Manual
1-1
Caution This generator contains electrostatic sensitive components. When repairing the generator, work at a static control workstation. Wear a grounding strap when handling electrostatic sensitive components. Handle the circuit boards by their nonconductive edges. Use an antistatic container for transport of electrostatic sensitive components and circuit boards. Electric Shock Hazard Special caution should be used when working on the exposed Power Supply board as the heatsinks and many of the components are floating at potentially harmful voltage potentials. Use the footswitching ACCESSORY receptacle for generator output on the Force 2-8 PCH and Force 2-2 PCH generators.
1-2
Force 2 Service Manual
SECTION
2
Unpacking and Installation
2
Unpacking the Force 2 Generator Notify Valleylab to arrange for repair or replacement of any parts damaged from shipping. All returns must have approval from the Valleylab Customer Service Department. The return authorization number must be displayed on the package label. Refer to Section 7, Manufacturer Service, for further information. Carefully remove the Force 2 generator from the shipping package. Save the carton and packing materials to use when transporting the generator or when returning it for service. If you have any questions concerning the contents, contact Valleylab Customer Service at 1-800-255-8522 or your Valleylab representative.
Responsibility of the Manufacturer Valleylab is responsible for the safety, reliability, and performance of the equipment only within the limits of the warranty and other applicable laws if • Installation procedures in this manual are followed. • Assembly operations, extensions, re-adjustments, modifications, or repairs are carried out by persons authorized by Valleylab. • The electrical installation of the relevant room complies with local codes and regulatory requirements such as IEC and BSI. • The equipment is used in accordance with the Valleylab instructions for use.
Force 2 Service Manual
2-1
Preparing the Generator for Use
Preparing the Generator for Use The electrosurgical generator may be placed on a mounting cart available from Valleylab or any sturdy table or platform. It is recommended that carts have conductive wheels. Refer to hospital procedures or local codes for detailed information. Provide at least four to six inches of space around the sides and top of the generator for convection cooling. Under continuous use for extended periods of time, it is normal for the top and rear panel to be warm. Danger Explosion Hazard Do not install the Force 2 generator in the presence of flammable anesthetics, gases, liquids, or objects.
Power Requirements The Force 2-2 PCH Electrosurgical Generator is designed to operate at 110-120 Vac nominal, 50-60 Hz. The Force 2-8 PCH Electrosurgical Generator is designed to operate at 220-240 Vac nominal, 50-60 Hz.
Check the Power Connector The Force 2 generator is supplied with a hospital grade power cord and a three-prong power connector. If using the generator in an operating room with another type of receptacle, • International Only – The Valleylab representative in your country will equip your generator with the proper power cord for your country. • Domestic Only – The hospital is responsible for replacing the connector on the power cord. The power connector meets all requirements for safe grounding. Its purpose should not be defeated by using extension cords or three-prong to two-prong adapters. Periodically check the power cord assembly for damaged insulation or connectors. Always grasp cords by the connector. Do not pull on the cord itself.
2-2
Force 2 Service Manual
Ensure Proper Grounding
Ensure Proper Grounding To ensure patient safety, the Force 2 generator must be properly grounded. Important It is the user's responsibility to ensure that the electrical installation of the relevant room complies with local codes and regulatory requirements such as IEC and BSI.
The ground wire in the power cord connects to the unit chassis and ensures that no dangerous currents flow from the cabinet in the event of internal electrical failure. Do not use extension cords or three-prong or two-prong electrical adapters. Undesirable leakage currents are affected by the polarization of the 50-60 Hz input power. It is the responsibility of the user to ensure proper polarity and grounding of the power outlets supplying power to the unit. If required, use the equipotential ground cable supplied with the generator. The equipotential ground connector is located on the rear panel of the generator.
Unpacking and Installation
Perform a System Check Before placing the Force 2 generator into clinical use, perform a system check as described in Section 6, Power Up Self-Test.
Force 2 Service Manual
2-3
Notes
2-4
Force 2 Service Manual
SECTION
3
Description of Controls, Indicators, and Receptacles 3
This section describes the controls, indicators, and receptacles for accessories located on the front panel of the Force 2 generator.
Force 2 Service Manual
3-1
Figure 3-1. PCH Generator Front View
Figure 3-2. PCH Generator Rear View
MONOPOLAR FOOTSWITCH
BIPOLAR FOOTSWITCH
3-2
FOREIGN EQUIVALENTS AND U.S. PATENTS: 4416276, 4416277, 4632109, 4658819, 4658820, 4827927
250V, F8.0A - (110-120) 250V, F6.3A - (220-240) WARNING: RISK OF FIRE. REPLACE FUSE AS MARKED.
Force 2 Service Manual
Controls
Controls Standby – Press this button to place the electrosurgical generator in a hold
mode. You cannot activate the generator and all audio alarms are silenced. The generator’s memory retains the power settings and the display shows dashes. Ready – Press this button to place the generator into service with power
outputs, displays, and alarms fully functional.
Monopolar – Press this button to select the monopolar footswitch control for
activating the Accessory receptacle.
Bipolar – Press this button to select the bipolar output when using the
monopolar footswitch.
Power Up –Press this button to increase power in the selected mode.
A single press of the button increases the power setting by one watt. Continuously pressing the button gradually increases the power to maximum. Power Down – Press this button to decrease power in the selected mode.
A single press of the button lowers the power setting by one watt. Continuously pressing the button gradually decreases the power to minimum.
Blend 1 – Press this button to select cut with minimum hemostasis.
Blend 2 – Press this button to select cut with moderate hemostasis.
Blend 3 – Press this button to select cut with maximum hemostasis.
Force 2 Service Manual
3-3
Description of Controls, Indicators, and Receptacles
Pure Cut – Press this button to select cut with the lowest level of hemostasis.
Indicators
Power Control Pencil Mode – The power control pencil feature does not have a dedicated button to access this mode. Press the READY button and while holding it, press the CUT POWER DOWN button. The generator sounds a single tone and the RMOTE lamp illuminates. Low Voltage Coag – Low voltage coag does not have a dedicated button to access this mode. Press the READY button and while holding it, press the COAG POWER DOWN button. The generator displays an L in the hundreds digit of the coag power setting display.
Indicators Standby Indicator – Indicates generator is on, but cannot activate outputs.
Ready Indicator – Indicates generator is ready for use.
Cut Mode Indicators – One of four cut mode indicators illuminates to show the selected cut mode.
Power Setting Display – The digital power setting display is visible on the
generator in the ready mode. The displayed number indicates the nominal power in watts. When you activate the mode, the generator delivers this power to the patient. In the standby mode, the generator display shows dashes. Output Power Indicators – The indicator illuminates when that output power (cut, coag, bipolar) activates. One of the two distinct mode indicator tones sound in conjunction with the visual output power indicator. Low Voltage Coag Mode Indicator – An L in the hundreds digit of the coag power setting display indicates the low voltage coag mode selection.
Monopolar Indicator – This indicator illuminates when you select the generator's monopolar footswitch for monopolar accessory activation.
Bipolar Indicator – This indicator illuminates when you select the generator’s monopolar footswitch control to activate the bipolar output.
3-4
Force 2 Service Manual