Johnson & Johnson Ethicon Endo-Surgery ULTRACISION HARMONIC... User manual

ULTRACISION®HARMONIC SCALPEL®Service Manual

Chapter 1 - General Description
1.1 - The ULTRACISION HARMONIC SCALPEL System
Chapter 2 - Principles of Operation
2.1 - Hand Piece
2.2 - Generator and Foot Switch
Chapter 3 - Basic Operation
3.1 - Description of Controls, Indicators, and Connections
3.2 - Instrument Preparation and Hand Piece Attachment
3.3 - System Test
Chapter 4 - Initial Setup
4.1 - System Configuration
4.2 - Language Selection
4.3 - Line Rate Selection
Chapter 5 - Upper Level Diagnostics
5.1 - Trouble Shooting Guide
5.2 - Diagnostic Software
5.3 - Extended Functional Test
Chapter 6 - Detailed Diagnostics
6.1 - Test Equipment
6.2 - Hand Piece Assembly
6.3 - Generator and Foot Switch
6.3.1 - Power Entry Module
6.3.2 - AC Fusing and Distribution
6.3.3 - Compressor
6.3.4 - Low Voltage Transformer
6.3.5 - High Voltage Transformer
6.3.6 - Generator PCB
6.3.7 - Keyboard/Interlock PCB
6.3.8 - Microprocessor PCB
6.3.9 - Liquid Crystal Display
6.3.10 - Foot Switch
Chapter 7 - Specifications
7.1 -Generator
7.2 - Hand Piece
7.3 - Foot Switch
7.4 - Power Cord
7.5 - Transport and Storage
7.6 - Mode of Operation
3
3
6
9
9
16
27
ULTRACISION®HARMONIC SCALPEL®Service Manual
Table of Contents

ULTRACISION®HARMONIC SCALPEL®Service Manual
Table of Contents - continued
Appendix A - Diagnostic Service Mode - Flow Diagram
Appendix B - Wiring Diagrams and Schematic
115 Volt Wir ing (Model GEN01)
230 Volt Wiring (Models GEN22, GEN32)
115 Volt Routing (Model GEN01)
230 Volt Routing (Models GEN22, GEN32)
Generator PCB Schematic
Generator PCB Component Location
Keyboard/Interlock PCB Schematic
Keyboard/Interlock Component Location
CPU PCB Schematic
CPU PCB Component Location
Type CF, Isolated Applied Part Dangerous Voltage

2.1
Hand Piece
1.1
The
ULTRACISION
System
2.2
Generator and
Foot Switch
Chapter 1 - General Description
3
The ULTRACISION HARMONIC SCALPEL System is indicated for incising tissue when bleeding control and minimal
thermal injury are desired. The System’s instruments can be used as an adjunct to or substitute for electrosurgery and
steel scalpels. The System operates in two power modes, variable and full.
The ULTRACISION HARMONIC SCALPEL instrument blades vibrate longitudinally at 55 kilohertz. This ultrasonic
vibration at the blade enhances its cutting ability while the vibrating blade edge coagulates bleeders as tissues are
incised. Hemostasis occurs when tissue couples with the blade. This coupling causes collagen molecules within the
tissue to vibrate and become denatured, forming a coagulum.
The cutting power can be adjusted during the incision to increase or decrease coagulation and speed of cutting.
Coagulation of large bleeders can be accomplished by captive coagulation where the side of the blade is used to
compress and tamponade the vessel while a short duration of full power seals it.
Chapter 2 - Principles of Operation
The System consists of three major components, a Generator, a Hand Piece, and a Foot Switch. The Generator
produces a 55 kilohertz electric signal which is transmitted via a coaxial cable to the Hand Piece, which then
converts the electrical signal into ultrasonic, mechanical motion. A more detailed explanation follows.
The Hand Piece houses three major components that generate, amplify, and deliver ultrasonic energy to tissues.
When each component is attached to the other and tuned to 55 kilohertz, an acoustic drive train is formed. The
acoustic system or acoustic drive train consists of three components:
• Acoustic Transducer: converts the electrical energy into motion. The transducer consists of four piezoelectric
elements held in compression between two aluminum end bells. When an AC wave form is applied to the
transducer, the ceramics expand and contract to produce longitudinal motion.
• Acoustic Mount: attaches the acoustic drive train to the Hand Piece. The mount also provides mechanical
amplification of the longitudinal motion.
• Instrument Blade: couples the ultrasonic energy to the tissue and amplifies motion. In a laparoscopic
configuration, the blade is elongated by means of a "Laparosonic Extension." This extension allows the
ultrasonic energy to propagate from the Hand Piece to the instrument blade with minimal loss.
The Generator consists of ten modules that drive and cool* the Hand Piece. The Generator converts the AC line
voltage to a controlled DC level. The DC level is then remodulated at the resonant frequency of the Hand Piece. The
remodulated signal is then filtered and delivered to the Hand Piece where it resonates the acoustic train. A more
detailed description follows.
• Power Entry Filter: accepts a standard, hospital grade utility cord. It provides susceptibility filtering from the
external environment as well as suppressing electromagnetic emissions produced by the Generator that could be
conducted back through the power cord.
• AC Fusing and Distribution Components: provide line voltage to a cooling compressor, a high voltage
transformer, and a low voltage transformer. Fusing protects these assemblies and others from overload
conditions.
• Cooling Compressor: provides cooling air via a silicone hose to Hand Piece models HP050, HP051, HPTUV,
and H1TUV.
* Generator provides cooling to models HP050, HP051, HPTUV and H1TUV only.

•Low Voltage Transformer: produces low voltage AC that is later rectified, filtered, and regulated to produce
+5 VDC, +12 VDC, and -12 VDC. It also provides an important safety barrier. The voltage generated on the
secondary of the transformer is isolated - i.e. the voltage is not referenced to earth ground.
•High Voltage Transformer: produces high voltage AC (250 VAC) that is later rectified, filtered and regulated
to produce a variable DC level used in driving the Hand Piece. It also provides an important safety barrier. The
voltage generated on the secondary of the transformer is isolated - i.e. the voltage is not referenced to
earth ground.
•Generator PCB: produces power at ultrasonic frequencies to drive the Hand Piece. This is accomplished
as follows:
- An SCR switching circuit, filter, and software regulate power rectified from the high voltage transformer
to a predefined level, determined by the user-selected power level. Additionally, a zero crossing detection
circuit informs the software when the AC line voltage swings through zero volts. This allows the software
to schedule SCR firings.
- The DC voltage is then converted into a 55 kilohertz (+/-2 KHz) square wave by means of a
FET switching circuit.
- The 55 kilohertz square wave is then filtered by a resonant LC network to produce the sinusoidal wave
form that drives the hand piece.
In addition, the generator PCB contains a phase lock loop circuit that monitors the resonant frequency of
the Hand Piece and adjusts the 55 kilohertz up or down to stay at resonance, which changes with
temperature and load.
A secondary function of the Generator PCB is to provide a central point of connectivity for the other PCBs and
modules in the Generator.
The third function is to rectify, filter, and regulate the low voltage AC to generate the logic voltages. These
voltages are +5 VDC, +12 VDC, and -12 VDC. Logic voltage is also inverted to supply power for the
LCD back light.
•Keyboard/Interlock PCB: The Keyboard portion of this PCB informs the user of the operative state of the
ULTRACISION HARMONIC SCALPEL System using LED indicators. It also allows the user to change the default
settings as described in Chapter 3 of this manual and in the Generator Manual.
The interlock portion of this assembly acts as a shunt, placing a resistive load across the output to the blade
whenever it is not activated at the VAR or FULL power levels. The interlock is used to quickly stop the blade
motion once the Foot Switch pedal is released.
•Microprocessor PCB: The microprocessor PCB contains the software program that drives the ULTRACISION
HARMONIC SCALPEL System. The software monitors zero crossings, regulates DC voltage, processes button
and pedal activations, and drives the liquid crystal display. It also monitors performance of the generator PCB
and the acoustic drive train.
•Liquid Crystal Display: The liquid crystal display reports the operative mode of the ULTRACISION System.
It is driven by the microprocessor PCB via the generator PCB.
•Foot Switch: The Foot Switch module allows the user to activate the system in either variable or full mode
based on which foot pedal is being pressed. Pedal activations are communicated with the microprocessor via the
keyboard/interlock and generator PCB.
4
2.2
Generator and
Foot Switch
continued
Chapter 2 - Principles of Operation continued

Chapter 2 - Principles of Operation continued
5
POWER
ENTRY
MODULE/
FILTER
FUSING &
AC
DISTRIBUTION
HIGH VOLTAGE
TRANSFORMER
MICROPROCESSOR
PCB
GENERATOR
PCB
COMPRESSOR AIR (models HP050, HP051, HPTUV & H1TUV)
KEYBOARD
INTERLOCK
FOOT-
SWITCH
HAND PIECE
55 KHz
AC
LCD
LOW VOLTAGE
TRANSFORMER
Generator
System Overview

6
Chapter 3 - Basic Operation
3.1
Controls,
Indicators, and
Connections
STANDBY SAVE
FULLVARIABLEREADY
GENERATOR
ETHICON ENDO-SURGERY
54321
ULTRACISION
1
2
345
6
7
10
11
12 98
13
Note: This illustration shows Generator Model GEN01. In Model GEN32, the position of the air and electrical connectors is reversed.
Component Description
1Power Switch Controls the electrical power for the entire Generator. Push the switch up to turn power on, push
the switch down to turn power off.
2Green Power Indicator Light The light is illuminated when the Generator power is on.
320 Character Liquid Crystal In READY mode, this display indicates the selected variable power level. When the Hand Piece
Display is energized, this display indicates the active power level. “STANDBY” is displayed
when the Generator is in STANDBY mode.
When the Generator power is first turned on, this display briefly indicates that a SELF TEST is in
progress. This display is also used for alarm messages.
When activated by service personnel, this display also shows diagnostic information, language
selection, and Generator adjustment information.
4Increase Power Button Push this button to increase the variable power setting to the desired level, as displayed on the
liquid crystal display, from 1 (minimum power) to 5 (maximum power).
5Decrease Power Button Push this button to decrease the variable power setting to the desired level from 5 to 1.
6Save Button Push this button to save the currently selected variable power level so that it is automatically
displayed the next time the Generator power is turned on.
7Volume Turn this knob to adjust the sound of the Audio Annunciator. The sound level cannot be adjusted
to zero.
8Display Turn this knob to obtain the best liquid crystal display appearance for your particular lighting and
viewing angle.

7
Chapter 3 - Basic Operation continued
3.1
Controls,
Indicators, and
Connections
continued
3.2
Instrument
Preparation and
Hand Piece
Attachment
9Status Lights Ready Light. This light is illuminated when the system is ready to use. This light is off while the
Hand Piece is energized or in STANDBY mode.
Variable Light. This light is flashed on and off when the Hand Piece is energized at the
variable (VAR) power level.
Full Light. This light is flashed on and off when the Hand Piece is energized at the full
(FULL) power level.
10 Standby Button This button toggles between STANDBY and READY mode. Push this button once to enter
STANDBY mode. In STANDBY mode, all power is removed from the Hand Piece. The Increase,
Decrease, and Save buttons are disabled as is the Foot Switch. Use the STANDBY mode when
replacing instrument blades.
11 Release Button Push this button to detach the Hand Piece cord connection from the Cooling Air Source
Connector on the Generator.
12 Cooling Air Source Refer to the appropriate Hand Piece package insert.
13 Electrical Receptacle Delivers the energy from the Generator to the Hand Piece.
*Audio Annunciator The annunciator beeps to indicate instrument activity or to indicate error conditions. During
normal activation, the annunciator beeps on and off when either foot pedal is pressed. A slower
beep indicates that LEVEL 1 through LEVEL 4 is activated and a faster beep indicates that
LEVEL 5 is activated. If the generator does not energize the instrument, the annunciator will emit
a continuous beep when either pedal is pressed.
Instrument Preparation and Hand Piece Attachment
Step Instruction
1Ensure that the Generator Power Switch is off during instrument preparation.
WARNING: To avoid injury, the activatedULTRACISION HARMONIC SCALPEL
instrument should not be in contact with drapes or other flammable materials. During
prolonged activation, the instrument blades may become hot. Avoid unintended blade
contact with tissue, drapes, surgical gowns, or other unintended sites after activation.
2Plug the line cord into a grounded receptacle:
Model GEN01: 115 Vac, 60 Hz
Model GEN32: 230 Vac, 50 Hz
Note: Do Not Connect the Generator To An Ungrounded Outlet.
3Connect the Foot Switch to the rear panel of the Generator. Align the red dot on the Foot
Switch 4-pin connector with the red dot 4-pin connector on the lower left side of the
Generator back panel.

3.3
System Test
8
3.2
Instrument
Preparation and
Hand Piece
Attachment
continued
Chapter 3 - Basic Operation continued
4Attach the sterile ULTRACISION®HARMONIC SCALPEL®Hand Piece following the
appropriate package insert instructions:
Note: Refer to specific instrument package inserts for use of the Generator during surgical cases.
5Attach an instrument blade to the Hand Piece following the instructions listed in the
instrument’s package insert.
6Turn Generator power on.
7If the Hand Piece has been steam sterilized (autoclave or flash), wait 5 minutes with the
Hand Piece attached to the Generator and the Generator on to allow the Hand Piece to dry.
STANDBY Mode is recommended during this period of time.
8If the Generator is in STANDBY Mode, press the Standby Button to return it to READY
Mode. If the generator is not already at power level 5, select level 5 by using the Increase
Button.
Step Instruction
1Energize the blade by pressing a pedal on the Foot Switch.
2Apply the blade to wood, cardboard, or wax and verify the blade burns and cuts. If the
system fails this basic functional verification, refer to the upper level diagnostic section of
this manual (Chapter 5).
The ULTRACISION HARMONIC SCALPEL System is now ready for testing. After performing the very basic
tests which follow, the more detailed functional tests described in section 5.3 are recommended.
Caution: During this testing, the instrument blade will become active. Do not touch the blade!

9
Two features of the system are user programmable. They are the displayed language and line rate.
The system may be configured to display messages in languages other than the default setting of English. These
languages are French, Spanish, Italian, and German. Also, the system can be configured to run at 50 or 60 Hertz.
The system is preset at the factory such that all 115 VAC units (Model GEN01) are at 60 Hz, and all 230 VAC
units (Model GEN32) are at 50 Hz. If the line rate is set inappropriately, a system error will always be displayed at
normal power up. To change the language or line rate, refer to the following sections.
Follow steps 1 through 5 in section 3.2 to prepare the Generator for power up. Prior to turning the Generator on,
press and hold the Increase and Decrease Buttons simultaneously with one hand. While holding these two buttons
in, turn the Generator power on. Once the power light comes on, release the two buttons. The preset language and
software revision (1.35) should now be displayed. This indicates that the first page of the service mode is accessed.
If you are unable to access this first page of the service mode, refer to section 5.2.
In the first page of the service mode, different languages can be displayed by pressing the Increase Button. Once
the desired language is located, press the Save Button and turn the Generator off. All display messages will now be
in the newly selected language.
Enter the first page of the service mode as described above. Press the Standby Button to access the second page of
the service mode. In this second page, the display will indicate the line rate currently selected. The line rate may be
toggled between 50 Hz and 60 Hz by pressing the Increase Button.
A validation sequence is required to change the line rate. In addition to updating the line rate, the memory check
sum is updated and the error history is erased. This is explained in more detail in section 5.2. Before entering the
validation sequence, verify that the number following the letters CRC is 55947. If this is not the case, do not
continue with the validation (see section 5.2). Once 55947 is verified, enter Save, Increase, Decrease, Save, and
Standby sequentially. The Generator is now configured to operate at the selected line rate
Chapter 5 - Upper Level Diagnostics
This section discusses the most common problem areas and how to resolve these problems primarily through
modifications to usage and swapping of blades and hand pieces. This section is a good place to start once a
problem has been identified.
The testing sequence should proceed as follows:
1. Perform the basic functional test as described in section 3.3.
2. Starting with section 5.1 (Trouble Shooting Guide), work through the sub-sections (5.2 and 5.3) until
the problem is identified.
3. If the problem then is still unidentified, refer to Chapter 6 for a module by module diagnosis.
The following section lists the probable causes and corrective actions for error conditions that may occur during
operation of the ULTRACISION HARMONIC SCALPEL Generator. If the symptoms specified in this section are
inappropriate or the corrective actions are insufficient, consult a qualified hospital technician or call one of the
following numbers for service:
• 1-800-USE-ENDO (U.S. calls)
• 1-513-483-8901 (International calls - English speaking only)
4.2
Language
Selection
4.1
System
Configuration
4.3
Line Rate
Selection
Chapter 4 - Initial Setup
5.1
Trouble
Shooting Guide

10
Symptom:
The instrument blade fails to cut or coagulate or has less power than usual,
and the Generator emits intermittent beeps when the Hand Piece is activated.
Probable cause Corrective Action
Instrument blade is not attached securely After pushing the Standby Button on the Generator,
to the Hand Piece. manually tighten the instrument onto the Hand Piece
(finger tight only). Use the blade wrench to secure the
instrument completely to the Hand Piece by turning the
wrench clockwise until a “snap” is heard.
Symptom:
The instrument blade fails to cut or coagulate or has less power than usual,
and the Generator emits a steady tone when the Hand Piece is activated.
Probable cause Corrective Action
Contact with tissue or fluid is excessive and is Withdraw the instrument from tissue or fluid and use less
preventing the instrument blade from resonating. pressure when pushing against tissue.
Tissue fragment or coagulum is clinging to the Activate the Hand Piece for 1 or 2 seconds with the
instrument blade and preventing it from resonating. instrument in air to remove tissue, etc. If this fails, allow the
blade to cool and then wipe it with a sterile cloth. Handle
the instrument with caution as it may become hot during
operation in air.
Inside of Hand Piece is still warm from steam or Allow Hand Piece to cool at room temperature for 15-30
flash sterilization. minutes.
For Models HP050, HP051, H1TUV, HPTUV Leave both Hand Piece connectors attached to the Generator
only: Inside of Hand Piece is still damp from and leave the Generator power on and in STANDBY mode
steam or flash sterilization. for 5 minutes to allow the Hand Piece air flow to cool and
dry the Hand Piece.
Instrument blade is not attached securely to After pushing the Standby Button on the Generator,
the Hand Piece. manually tighten the instrument onto the Hand Piece (finger
tight only). Use the blade wrench to secure the instrument
completely to the Hand Piece by turning the wrench
clockwise until a “snap” is heard.
Instrument blade has visible or invisible defect Push the Standby Button on the Generator and replace
which prevents it from resonating. instrument blade and/or sheath.
For Models HP050, HP051, H1TUV, HPTUV only: Replace Hand Piece.
Hand Piece failure caused by immersion in liquid,
damage to power cable, or end of useful life.
Generator failure. Refer to section 6 for a module by module diagnosis or call
for service. (Numbers are listed at the beginning of this
chapter)
Chapter 5 - Upper Level Diagnostics continued
5.1
Trouble Shooting
Guide, continued

Symptom:
The Generator will not enter READY mode from STANDBY mode.
Probable cause Corrective Action
Foot Switch pedal is depressed while Release all pedals and switches while entering
pushing Standby Button. READY mode.
Symptom:
The Generator beeps and/or changes mode unexpectedly.
Probable cause Corrective Action
The Generator is located too close to an Locate the Generator at least one foot away from
electrosurgical generator. electrosurgical generators.
Hand Piece is defective. Replace the Hand Piece.
Foot Switch is defective. Replace the Foot Switch. Refer to Chapter 6 or call for
service. (Numbers are listed at the beginning of this section)
Electrical interference from hospital wall power Refer to Chapter 6 or call for service.
or other equipment in O.R. disturbs Generator.
Symptom:
End of instrument blade detaches, leaving the blade extension in the Hand Piece.
Blade was attached to the Hand Piece with Push Standby Button. Remove and discard the blade extender
excessive force. from the Hand Piece. Attach a new instrument blade to the
Hand Piece.
Material between the blade and the Hand Piece Push Standby Button. Remove and discard the blade base
has jammed the connection. from the Hand Piece. Clean the end of the blade mount
surface on the Hand Piece with alcohol and sterile gauze. Do
not immerse the Hand Piece in liquid.
Symptom:
READY light is not illuminated.
Probable cause Corrective Action
Generator is in STANDBY mode. Push the Standby Button to enter READY mode.
Foot Switch is depressed while the Release the Foot Switch until the Generator self-test
Generator is turned “on” and goes is completed and the READY light comes on.
through self-test.
Hand Piece is defective. Replace the Hand Piece.
Generator is defective. Turn Generator power off. Refer to Section 6 for a module by
module diagnosis or call for service.
11
Chapter 5 - Upper Level Diagnostics continued
5.1
Trouble Shooting
Guide, continued

Symptom:
The Generator display reads, “STOP! CHECK HAND PIECE - TURN OFF, THEN ON” and Generator
emits long and short beeps.
Probable cause Corrective Action
Hand Piece connection to Generator Turn Generator Power Switch off, check to see that electrical
is faulty. Hand Piece connector is securely attached to the Generator,
then turn the Power Switch back on.
Symptom:
The Generator display reads, “STOP! SYSTEM ERROR - TURN OFF, THEN ON” and Generator emits
bursts of long and short beeps.
Probable cause Corrective Action
Problem with hospital line voltage power source Turn Generator Power Switch off and then on again.
disturbed Generator or the Generator is faulty.
Symptom:
Liquid crystal display on Generator is difficult to read.
Probable cause Corrective Action
Change in lighting or Generator position. Readjust display control on Generator.
Symptom:
Air connector or Plug on Hand Piece cable will not fit into air connector on Generator.
Probable cause Corrective Action
Silver locking button on Generator air connector Unlock connector by pushing the silver Release Button.
is in locked position.
Symptom:
High-pitched screeching sound emitted from Hand Piece
Probable cause Corrective Action
Instrument blade is not fully seated on Re-tourque the instrument blade with an alternate torque
Hand Piece blade mount. blade wrench and/or clean the threaded Hand Piece blade
mount with an alcohol 4x4.
The Generator contains a built-in diagnostic mode accessible to service personnel. If a problem exists with the
system and resolution cannot be obtained through the Trouble Shooting Guide (section 5.1), enter the diagnostic
service mode as described below and diagrammed in Appendix A. Typically, once a problem has been identified, it
requires further diagnosis inside the Generator. To perform this detailed diagnosis, refer to section 6. NOTE: It is
important to read all of Chapter 6, which details disassembly, test equipment, and warnings, prior to performing
detailed diagnosis of any internal module.
Follow steps 1 through 5 in section 3.2 to prepare the Generator for power up. Prior to turning the Generator on,
press and hold the Increase and Decrease buttons simultaneously with one hand. While holding these two buttons
in, turn the Generator power on and verify the following:
1. Verify that the green power LED is illuminated. Proceed to the next step.
12
Chapter 5 - Upper Level Diagnostics continued
5.1
Trouble
Shooting Guide,
continued
5.2
Diagnostic
Software

The green power LED located on the keyboard PCB is driven from the +5 VDC supply on the generator
PCB. The most likely mode of failure is no AC voltage leading to the Generator PCB. If no other generator
activity is noticeable (i.e. air compressor noise, other LEDs, or displayed information), check the wall
outlet and the first two modules of the primary AC circuit as described in Chapter 6. If other generator
activity is noticed, verify that low voltage AC is reaching the generator card (see section 6.3.4) and that the
generator PCB is producing +5 VDC (see section 6.3.6).
2. For generators utilizing Hand Piece Models HP050, HP051, HPTUV, and H1TUV, verify that the
compressor is running by checking for vibrational noise from within the Generator and the release of
cooling air. Proceed to the next step.
The most likely mode of compressor failure is no AC voltage at the compressor. Verify that AC voltage is
being distributed from the fuses to the compressor (see Chapter 6).
For Hand Piece Models HP050, HP051, HPTUV, and H1TUV: If the compressor is vibrating but no
cooling air is being exhausted from the Hand Piece, check the air line in the Generator, the air inlet filter
(located on the side of the compressor), and the Hand Piece for blockage or rupture.
3. Verify that the first page of the service mode is accessed. This is indicated by the display reading the
preset language followed by software revision 1.35. Proceed to the next step.
Several modes of failure could exist at this point, as follows:
• SYSTEM ERROR is displayed:
This condition would most likely exist if the generator PCB is unable to regulate the DC voltage used
in driving the hand piece. This can be caused by either a faulty generator or microprocessor PCB.
Refer to section 6.3.6 to replace the generator PCB and re-test. If re-testing fails, refer to section 6.3.8
to replace the microprocessor PCB.
• CRC "Five digit number" followed by the line rate is displayed:
This indicates that the second page of the service mode has been accessed. When the software detects
a memory error during self test and the service mode is initiated, the software jumps to the second
page of the service mode. If the number following the CRC is 55947 and the line rate is appropriate
(see section 4.3 to change the line rate), enter the following software validation sequence. Press
sequentially Save, Increase, Decrease, Save, Standby. If this problem persists and 55947 is not the
number following CRC, replace the microprocessor PCB (see section 6.3.8).
• LEVEL # (typical message during normal power up) is displayed:
This will typically happen when the Increase and Decrease buttons were not held in during
power up. Turn the Generator off and re-attempt to access the service mode. This will also occur if
the Foot Switch is activated during power up. If the problem still exists, it usually indicates that the
keyboard PCB is faulty. Check all the cabling leading from and to the keyboard. If it appears intact,
replace the keyboard PCB (see section 6.3.7).
A less likely cause is a faulty generator or microprocessor PCB. If the problem persists, try
sequentially replacing these PCBs (see sections 6.3.6 and 6.3.8).
• Blank display:
Typically, when the display appears blank, the problem can be fixed by turning the viewing angle
adjustment pot on the front of the generator. If this fails to solve the problem, the cabling leading to the
display (and adjustment pot) or the microprocessor PCB is faulty. Verify that the cabling is intact and,
if the problem persists, replace the microprocessor and re-test (see sections 6.3.8 and 6.3.9). If there is
information on the display but it appears in a foreign language, press the Increase Button to review the
available languages. Once the desired language is located, press Save to select it (see section 4.2).
13
Chapter 5 - Upper Level Diagnostics continued
5.2
Diagnostic
Software,
continued

5.2
Diagnostic
Software,
continued
• Random characters:
Random or nonsense characters usually indicate a faulty microprocessor PCB.
Replace the microprocessor and re-test (see section 6.3.8).
In both cases above, if the display still does not work properly, refer to section 6.3.9 and replace it.
4. Press the Standby Button and advance to the second page of the service mode. Verify that CRC 55947 and
the proper line rate are displayed. Proceed to the next step.
If 55947 is not displayed, cycle the Generator power and re-attempt this test. If the problem persists,
replace the microprocessor PCB (see section 6.3.8).
If the line rate is inappropriate, refer to section 4.3 to change it.
5. Press the Standby Button and advance to the third page of the service mode. In this page,
the relative current, voltage, frequency, selected power level, and mode are displayed. Verify
that these values are within the normal operating parameters. Proceed to the next step.
From left to right, the display should indicate the following normal operating parameters:
Relative current Between 40 and 50 (mA)
Relative DC voltage Between 15 and 25 (v)
Output frequency Between 50,000 Hz and 60,000 Hz
Selected Power level Between 1 and 5
Operating Mode 6 (Refer to the value in the lower left hand
corner of the function boxes in Appendix A)
Possible Problems:
• Display voltage or current is low (< 15 or < 40 respectively):
The high voltage AC is not reaching the generator PCB or the generator PCB's switching power
supply is not working. Verify that the high voltage AC is at the generator PCB (see section 6.3.5). If
no AC is present, check the high voltage wiring, transformer, and fusing (see sections 6.3.5 and 6.3.2).
If AC is present, replace the generator PCB (see section 6.3.6).
• Display voltage or current is high (> 25 or > 50 respectively):
The power regulation circuit on the generator PCB is not functioning properly.
See section 6.3.6 and replace the PCB.
• Display frequency is high or low (> 60,000 or < 50,000):
The frequency control circuit on the generator PCB is not functioning properly.
See section 6.3.6 and replace the PCB.
6. Verify that the READY LED is now illuminated. Proceed to the next step.
If the READY LED does not come on, either the LED itself or the interlock circuitry on the keyboard PCB
is faulty. In either case, replace the keyboard and re-test (see section 6.3.7).
7. Verify that pushing either pedal on the Foot Switch causes the READY LED to go out.
If the READY LED does not go out while pressing either foot pedal, inspect the cabling leading from the
keyboard to the Foot Switch connector on the back of the Generator (see section 6.3.7). If the cabling
appears intact, replace the Foot Switch cable and re-test (see section 6.3.10). If the problem persists,
replace the keyboard PCB (see section 6.3.7).
14
Chapter 5 - Upper Level Diagnostics continued

5.3
Extended
Functional Test
5.2
Diagnostic
Software,
continued
Chapter 5 - Upper Level Diagnostics continued
8. Return to the second page of the service mode and review the error history list as follows:
Turn the Generator off. Access page one of the service mode by holding in the Increase and Decrease
buttons at power up. Press the Standby Button to access page two. CRC 55947 should now be displayed
followed by the line rate and error history.
The numbers in the far right of the display, separated by a "/", indicate the number and type of errors. Press the
Decrease Button to scroll through the last ten errors. An explanation of the error types follows:
Error No. Description
1-6 Not used and should never appear.
7 The check sum stored in memory does not agree with the calculated value.
This would be caused by an unreliable microprocessor PCB. See section
6.3.8 to replace the microprocessor.
8 The frequency control circuit on the generator PCB is not oscillating. See section 6.3.2
to check for a blown fuse. If all the fuses are intact, see section 6.3.6 to replace the
generator PCB.
9 A higher than normal voltage was detected on the output of the switching power supply
circuitry located on the generator PCB. This may be caused by either electrical interference
from other devices in the O.R. or by a faulty generator PCB. Verify that the Generator is not
within one foot of any other equipment (especially electrosurgical devices). If the problem
persists, replace the generator PCB (see section 6.3.6).
10 The cabling leading from the generator PCB to the keyboard became disconnected or
is intermittent.
11 The microprocessor PCB is unable to match the selected line rate with the actual frequency
of the line voltage. Verify that the Generator is configured for the appropriate line rate (see
section 4.3). If the problem persists, there is typically significant noise on the AC source.
NOTE: Whenever error numbers 7, 8, 9, or 11 are added to the error history, a SYSTEM ERROR
is displayed.
NOTE: The error history is erased whenever the validation sequence is entered from this second page of
the service mode. The validation sequence is described in section 4.3.
If a problem with the ULTRACISION System is still unidentified after performing the steps listed above, continue
the diagnosis with the Extended Functional Test.
If a problem exists with the system and resolution cannot be obtained through the Trouble Shooting Guide (section
5.1) and the Diagnostic Service Mode (section 5.2), proceed with the following steps to be performed at power up.
Again, it is important to read all of Chapter 6, which details disassembly, test equipment, and warnings, prior to
performing detailed diagnosis of any internal module.
CAUTION: During this testing, the instrument blade will become active. Do not touch the blade!
1. Turn the Generator on as described in steps 1 through 8 in section 3.2.
2. If not already at Level 1, press the Decrease Button until LEVEL 1 is displayed.
15

5.3
Extended
Functional Test,
continued
Chapter 5 - Upper Level Diagnostics continued
3. Activate the instrument blade by pressing the foot switch pedal labeled VAR. Verify that the VAR LED
flashes and that the Generator Audio Annunciator beeps. Activate the instrument blade by pressing the
foot switch pedal labeled FULL. Verify that the FULL LED flashes and that the annunciator beeps.
If the LED does not light, the keyboard PCB is faulty. See section 6.3.7 and replace the keyboard.
If the annunciator does not beep, check the cabling leading from the generator PCB to the volume
control pot on the front panel. Also, check the cabling leading from the annunciator to the keyboard.
If the cabling appears intact, either the drive circuitry in the generator PCB or the keyboard PCB is faulty.
Sequentially replace these boards and re-test (see section 6.3.6 and 6.3.7).
If the problem persists, replace the annunciator.
If the LED and annunciator stay on continuously, the Generator is unable to resonate the blade. Since the
previous sections of this manual have already identified the typical causes of this failure (blade failure,
blade attachment torque, Hand Piece failure, broken cabling inside the generator) it is most likely that
the LC filter network in the generator PCB is faulty. See section 6.3.6 and replace the generator PCB.
4. Activate the instrument blade by pressing the FULL pedal. Press the blade into wood, cardboard, or wax
and observe that the blade cuts. While holding the FULL pedal down, increase the pressure on the blade
until the blade is no longer able to resonate. This is indicated by a continuous tone and LED illumination.
While still holding the pedal down, remove the blade from the cutting material and verify that the blade
again starts to resonate. This is indicated by the normal LED flashing and a non-continuous tone. This
regaining of resonance is referred to as "lock recovery."
NOTE: A warm Hand Piece/instrument blade may not regain resonance. If this test fails, allow the Hand Piece
to cool for several minutes and cool the blade tip with water.
Since the previous sections of this manual have already identified the typical causes of failure to cut or
lock recover, it is most likely that the phase lock loop circuitry in the generator PCB is faulty. See section
6.3.6 and replace the generator PCB.
If a problem with the system is still unidentified after performing these four steps, proceed to the Detailed
Diagnosis section (Chapter 6) of the manual and test each module for the expected input and output.
Chapter 6 - Detailed Diagnostics
This section of the manual specifies the expected input and output of each module of the ULTRACISION System.
Previous sections of this manual will direct the service person to a specific module (sub-section) within this section.
Each sub-section specifies the testing procedure - including assembly/disassembly - and test equipment.
NOTE: Directions such as left and right assume that the reader is facing the
operator's panel.
Warning: High voltages and currents are used in the generator. Take electric
shock precautions.
Warning: Ultrasonic energy can cause severe burns. Handle acoustic components
with care.
Caution: Damage may be done to the generator if power is lost to the microprocessor PCB.
Whenever microprocessor PCB performance is in doubt, the high voltage power supply
should be disabled; refer to section 6.3.6 for instructions.
16

6.2
Hand Piece
Assembly
6.3
Generator and
Foot Switch
Chapter 6 - Detailed Diagnostics continued
The following is a list of the equipment required in order to perform this level of testing:
1. A digital voltmeter (FLUKE model 45 or equivalent) with insulated test probes
and clips.
2. A dual channel oscilloscope with x10 probes.
3. An autotransformer adjusted for nominal line voltage (115 or 230 volts).
4. A means of "floating" the generator ground - i.e. breaking the safety ground
connection at the line cord.
NOTE: For all the following tests, it is helpful to refer to the appropriate wiring diagram
(115 VAC or 230 VAC) located in Appendix B.
The majority of problems with hand pieces are covered in section 5.1, the Trouble Shooting Guide. The Hand Piece
itself is a permanently assembled device with no internal components that are serviceable. The Hand Piece has a
limited life and will eventually "wear out."
Because the sub-assemblies of the Hand Piece are inaccessible, this test verifies some aspects of continuity. This
test will partially determine if the Hand Piece has an open wire only but will not check all wires and will not
determine if the Hand Piece is worn out.
Hand Piece Models HP050, HP051, HPTUV, H1TUV
With the Hand Piece unplugged from the Generator:
Verify continuity between pins 4, 6, and 7 in the Hand Piece electrical connector.
For Models HP050 and HP051, verify continuity between pin 1 and the tip of the blade (see Figure 3 for pin
location.
For Models HPTUV and H1TUV, verify continuity betwen pin 2 and the tip of the blade (see Figure 3 for pin
location.
If an open wire is detected in a domestic hand piece (models HP050, HP051), un-screw the back of the electrical
connector and check for any broken wires. If breaks are noticeable, repair the connector in accordance with Figure
3. If no breaks are noticed or an international hand piece is being tested (permanently assembled connector), no
further testing can be performed. Replace the hand piece.
Hand Piece Models HP052, HP053, H2TUV, H3TUV
With the Hand Piece unplugged from the Generator:
For Models HP052 and HP053, verify continuity between pin 1 and the tip of the blade (see Figure 3 for pin
location.
For Models H2TUV and H3TUV, verify continuity betwen pin 2 and the tip of the blade (see Figure 3 for pin
location.
There is no method for repairing these hand pieces. If defective, these hand pieces must be replaced.
Access to the internal generator modules requires disassembly of the Generator. Remove the power cord and the six
phillips head machine screws from the bottom of the Generator enclosure and remove the top portion of the
enclosure shell.
The internal generator modules are now exposed. Additional disassembly may be necessary depending upon the
level of testing required.
Verify that the Hand Piece, Foot Switch, and instrument blade are appropriately attached to the Generator.
Proceed through the following sections until the problem module is identified.
17
6.1
Test
Equipment

Hand Piece Pin
Descriptions
Chapter 6 - Detailed Diagnostics - Figure 3
18
SENSE
(ORANGE)
GRD
(DRAIN)
GRD
(DRAIN 2)
SENSE
(ORANGE)
POWER
(BROWN) NO
CONNECTION
RETURN
(BLACK)
NO
CONNECTION
GRD
(DRAIN 2)
GRD
(DRAIN) POWER
(BROWN)
NO
CONNECTION
RETURN
(BLACK)
4
5
7
6
54
3
2
1
6
7
2
1
3
DOMESTIC
(HP050, HP051)
INTERNATIONAL
(H2TUV, H3TUV)
Hand Piece Models HP050, HP051, HPTUV, H1TUV
Hand Piece Models HP052, HP053, H2TUV, H3TUV
NO
CONNECTION
NO
CONNECTION
NO
CONNECTION
NO
CONNECTION POWER
NO
CONNECTION
RETURN
4
5
6
7
2
1
3
DOMESTIC
(HP052, HP053)
NO
CONNECTION
NO
CONNECTION
NO
CONNECTION
POWER NO
CONNECTION
RETURN
7
6
54
3
2
1
INTERNATIONAL
(HPTUV, H1TUV)
NO
CONNECTION

6.3.2
AC Fusing and
Distribution
Chapter 6 - Detailed Diagnostics continued
Warning: The output terminals of this device are live whenever the line cord is plugged into the Generator and into
a live outlet.
The power entry module is located on the left side of the back panel and wired with quick disconnect terminals. For
a functional description see section 2.2.
Verification:
1. Input power is supplied via the IEC appliance connector on the line cord. If not already so, insert the cord
fully into the back of this module.
2. The output terminals (black and white wires) should carry the appropriate line voltage regardless of the
position of the front panel power switch. Plug the cord into an outlet and verify this voltage.
3. In 115 VAC generators (Model GEN01) the entry module contains an external fuse drawer. Check these
fuses (see section 6.3.2) before deciding to replace this module.
Replacement:
1. Disconnect the line cord, remove the two terminals, de-solder the green grounding wire, and un-screw the
two machine screws securing the power entry module to the back panel.
2. Remove the power entry module and replace it with the appropriate part listed in Appendix C.
This module is located directly underneath the power entry module in 115 VAC generators (Model GEN01) and on
the far right in 230 VAC generators (Models GEN22 and GEN32). For a functional description see section 2.2.
Verification:
1. All fuses used in the generator are time delayed and therefore may appear closed when they are actually
open. Remove the power cord and test each fuse with an ohm meter to ensure they are closed.
2. In the 115 VAC generators, test the three fuses in the fuse block via the access holes. Also test the two
fuses located in the fuse drawer in the lower portion of the power entry module.
3. In the 230 VAC generators, test the six fuses in the fuse block via the access holes.
4. Refer to the wiring diagram in Appendix B and verify that the primary wiring is intact by re-inserting the
power cord, switching the generator on, and testing for the appropriate line voltages via the access holes in
the top of the fuse block.
5. If no voltage is detected and all the fusing and wiring is intact, replace the power switch on the
front panel.
Replacement:
1. For all replacements, disconnect the line cord and refer to Appendix C for the replacement
part number.
2. To replace fuses, lift the applicable hinged section of the fuse block and remove the fuse.
3. To replace an individual fuse housing or terminal block, unscrew the two stops at the ends of the fuse rail.
Slide the fuse housing or terminal block off the rail and remove the attached wires.
4. To replace the front panel power switch, remove the four terminals, squeeze the retaining tabs on the
switch and push it out through the front panel.
19
6.3.1
Power Entry
Module