Coviden Force FX User manual

Service Manual
Force FXTM
Electrosurgical Generator C

Service Manual Force FXTM Electrosurgical Generator C

ii Force FX Electrosurgical Generator C Service Manual
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.

Force FX Electrosurgical Generator C Service Manual iii
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:
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
ForceTriadTM Energy Platform One year from date of shipment
Electrosurgical Generators One year from date of shipment
Cool-tipTM RFA Generator One year from date of shipment
EvidentTM MWA Generator One year from date of shipment
RFG-3CTM Plus Lesion Generator One year from date of shipment
LigaSureTM Vessel Sealing System One year from date of shipment
LigaSureTM Reusable Instruments One year from date of shipment
Mounting Fixtures (all models) One year from date of shipment
Footswitches (all models) One year from date of shipment
ValleylabTM Argon Gas Delivery Unit II One year from date of shipment
RapidVacTM Smoke Evacuator One year from date of shipment
LigaSureTM Sterile Single Use Items Sterility only as stated on packaging
Cool-tipTM Sterile Single Use Items Sterility only as stated on packaging
Sterile Single Use Items Sterility only as stated on packaging
Patient Return Electrodes Shelf life only as stated on packaging

iv Force FX Electrosurgical Generator C Service Manual
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.

Force FX Electrosurgical Generator C Service Manual v
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

vi Force FX Electrosurgical Generator C Service Manual
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

Force FX Electrosurgical Generator C Service Manual vii
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

viii Force FX Electrosurgical Generator C Service Manual
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