Pfizer Valleylab Force 300 User manual

Service manual
Valleylab Force 300
Electrosurgical Generator
TED
JF
Valleylab.

Foreword
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
Valleylab
Force
300
Electrosurgical
Generator
only.
| Caution o : sido a 圖
Federal
(USA)
law
restricts
this
device
to
sale
by
or
on
the
order
of
a
physician.
Trademark acknowledgments:
Force
GSU®,
IsoBloc®,
and
REM®
are
registered
trademarks
of
Valleylab Inc
Teflon
is
a
registered
trademark
of
E.
I.
duPont
de
Nemours
&
Co.,
Inc.
Equipment covered in this manual:
Valleylab Force 300 Electrosurgical Generator
110
-
120
V“
nominal,
220
-
240V~
nominal
(auto
selected)
Valleylab
Part
Number:
945
103007
|
Effective
Date:
November,
1995
Patents
Pending
Manufactured by:
Valleylab Inc
Pfizer Hospital Products Group
5920 Longbow Drive
Boulder, Colorado 80301 USA
For information call:
1-800-255-8522
/
1-303-530-2300
/
TWX
910-940-2514
Distributed in Europe by:
Valleylab Europe
Zaventem, BELGIUM
Distributed in Asia/Pacific by:
Valleylab Australia
Sydney, AUSTRALIA
CE
0086
Made in USA
Printed in USA
© 1995 Valleylab Inc All rights reserved.
225 120 100

low the Service Manual is Organized
The Force 300 Service Manual should contain the sections listed below.
If any section is missing, please contact Valleylab.
Description Part Number Page Count
Foreword 225 120 100 10
Table of Contents
Service Centers
1 Introduction 225 120 029 6
2 Controls, Indicators, and Receptacles 225 120 030 14
3 Technical Specifications 225 120 101 18
4 Principles of Operation 225 120 032 30
5 Setup, Tests, and Adjustments 225 120 102 32
6 Troubleshooting 225 120 103 30
7 Replacement Procedures 225 120 035 36
8 Repair Policy and Procedures 225 120 036 4
9 Service Parts 225 120 104 14
10
Board Drawings and Schematics 225 120 105 22
Warranty 225 120 070 2
onventions Used in this Guide
nportant
dicates an
erating tip or
aintenance
uggestion.
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.
225 120 100

Table of Contents
Service
CenterS
ee
ix
1 Introduction
General
Description
«conocemos,
1-2
List
Of
Component
...........ccccccesecsesessssssscssssesonscasssacesesessscssssenssscesse
1-2
Service
Personnel
Safety...
1-3
General
Precautions
re
1-3
Active
Accessories...
emen
13
Patient
Return
Electrodes
er
1-3
Fire/Explosion
HazardSs
..............
iii
1-4
Electric
Shock
Hazards
iene
1-4
SeTVicimg
iii
1-5
Calibration
eee
1-5
es
1-6
2 Controls, Indicators, and Receptacles
Front
Panel
.onoociciconroniosononinconos
„2-2
Bipolar
Control
2-3
Changing
the
Bipolar
Power
Setting
......................................
2-3
Monopolar
Cut
Controls
.
.2-4
Changing
the
Cut
Mode
and
Power
Setting..........................
2-4
Monopolar
Coag
ControlS
에
아아아
2-5
Changing
the
Coag
ModeandPowerSetting....................
2-5
Changing
the
Maximum
Voltage
for
the
Desiccate
Mode...2-6
Bipolar
Instrument
Receptacle
2-7
Monopolar
Πηδίγιπιοπί
Κεεθρίας]θ6........
οι.
eeeeeesenne.
2-8
Single-Pin
Monopolar
Receptacle
...........................................
2-8
Multipin
Monopolar
Receptacle.
2-8
Front
Panel
Footswitch
Receptacle
and
Button..........................
2-9
Using
the
Front
Panel
Footswitch
for
Bipolar
Output.........
2-9
Using
the
Front
Panel
Footswitch
for
Monopolar
Output
..2-9
Patient
ReturnElectrodeMonitoring.......................................
2-10
REM
Alarm
Indicator
sseneresererenne
2-10
RearPanel...........................
nine
2-11
Rear
Panel
Footswitch
Receptacles
ue
2-12
Bipolar
Footswitch
Receptacle….…....................
2-12
Monopolar
Footswitch
Receptacles
......................................
2-12
Footswitch
Activation
Diagram
iene
2-13
225 120 100

3 Technical Specifications
Performance CharacteristCS re rzici onice reni ioninioninne 3-1
General usines 3-1
DimensionsandWeight.............................. 3-1
Operating Parameters re eersereeeereaaeareeacararrranes 3-2
Transport and Storage... ss 3-2
Duty Cycle iii 3-2
Imternal Memory eeeeeeeé 3-3
Audio Volume ss 3-3
Activation Tone .pe 3-3
INC A 3-3
REMContactOualityMonitor.......................... 3-4
Acceptable Resistance Range........................ n 3-4
Low Frequency (50-60 Hz) Leakage Current......................... 3-4
High Freguency (RF) Leakage Current „er 3-4
InputPower.......... emer 3-5
Standards and IEC Classifications .......... ur srrrireriziiz iii ez ozene 3-6
Class I Equipment iii 3-6
Type CF Equipment... iii 3-6
DripProot......................... ere 3-6
Electromagneticinterference.............................. 3-7
ElectromagneticCompatibiliy.................... 3-7
Voltage Transients 5. 3-7
DefibrilHlator Proof iii 3-7
Output CharacterlsticS ни ионов иоииинонозионезиеиньнно 3-8
AvailablePowerSettingsinWatts................................... 3-8
Bipolar sus 3-8
Monopolar Cut: Pure ss 3-8
Monopolar Cut: Blend... essere 3-8
Monopolar Coag: Desiccate and Fulgurate....................... 3-8
Maximum Output for Force 300 Modes................................. 3-9
Output Waveforms .pp iii 3-10
Bipolar eee 3-10
MonopolarCut..................... neee 3-10
Monopolar Coag ss 3-10
Output Power vs. Resistance Graphs.….....................… 3-11
Bipolar CTraph ss 3-11
Monopolar Cut GraphS ии 3-12
MonopolarCoagGrapls.................. 3-13
Output Power vs. Generator Зе 185............. линии, 3-15
200V Desiccate @ 300 Ohms... 3-15
300V Desiccate 20300Ohms...................... enn 3-15
Fulgurate @ 500 Ohms iii 3-16
Blend@300 OhmS renerne 3-16
Bipolar 21000Ohm$..................... 3-17
Pure Cut @ 100 Ohms eee 3-17
225 120 100

4 Principles of Operation
Block
Diagram
iii
aso
4-2
Functional
OvVerVie
Wense
4-3
EffectMode.....................................
0...
4-3
The
REM
Contact
Quality
Monitoring
System
.....................
4-3
REM
Alarm
Activation
линии
4-4
Electrodes
Without
the
REM
Safety
Feature...................
44
Control
Board
nr
4-5
MicrocontrollerS…
in
4-5
Main
Microcontroller
iii
4-5
MainMicrocontroller
Memory..............................
4-6
Battery-BackedRAM......................................
4-6
FeedbackMicrocontroller.............................................
4-6
Feedback
Microcontroller
Memory..................................
4-6
Shared
RAM
.........
ecran
4-7
I/O
Expansion
eee
4-7
Keyboard
Interface
and
Activation
Inputs
............................
4-7
Power
Supply
Supervisor
Circuit...
4-7
A/DandD/AConversion...............................
um.
4-8
Waveform
Generaton
(T_ON
ASIC)
………………………………………
4-8
TONAverageCheck...............................................
4-9
Audio Alarm
men
4-9
Serial
interface
μμ”
4-9
Dosage
Error
Algorithm.................
4-10
Effect
Mode
Algorithm
..............
eia
4-11
High
Impedance
Effect
Mode
Operation
......................
4-11
Analog
to
Digital
Saturation
n
4-11
Display
Board
„4-12
Bipolar,
Cut,
and
Coag
Power
Setting
Encoders.................
4-12
RF
Indicator
Lamps.…..........................................
4-12
LED
and
Seven-Segment
Display
Drivers
...........................
4-13
Mode
Selection
Switches
er
4-14
REM
Switch
Circuit...
iii
4-14
FrontPanelFootswitehhCircuit........................
4-15
Footswitch
Board
rennes
4-16
Power
Supply/RF
Board
sn
4-17
Power
Supply
/RF
Board
Interfaces...............................
4-17
High
Voltage
Power
Supply
eee
4-18
Power
Entry
Circuit
iii
4-18
Auto
Mains
Switching
Circuitry
iii
4-18
AC/DC
Converter...
4-19
DC/DCSwitchingRegulator....................................
4-19
Low
Voltage
Power
Supply...
4-21
225 120 100

ΕΕ Output Stage... nen 4-22
Primary Sense Circuits... renere 4-22
RedundantSenseCircuits................................... 4-23
Output Relays ............ ii gene 4-23
Вро]аг Мосе............... terrace areais 4-23
Cut Modes ie 4-24
¡ATACA A 4-24
Spark Control Circuit ss esse 4-25
RF Leakage Sensing and Reduction Circuits 4-26
REM Circuit inner 4-26
REM Oscillator iii 4-26
IsoBloc Circuit iii 4-27
ОзсШаю............ nn 4-27
Power Supply... sun 4-27
Optoisolators een 4-27
Audiolircuit................... een 4-28
Footswitch Decode Circuit eee 4-29
Temperature Sense Circuit .pe 4-30
Thermal Sensing een 4-30
5 Setup, Tests, and Adjustments
Setting Up the Generator ....5-2
Periodic Safety Check 5-3
Inspecting the Generator and Accessories ............................. 54
Inspecting the Internal Components иене 5-6
Testing the Gemerator iii 5-7
Verifying REM Function.............. лилии иен 5-8
Confirming Outputs................... iii 5-9
Checking Leakage Current and Ground Resistance........... 5-12
Calibrating the Force 300 5-14
Preparing for Calibration iii 5-15
Entering Calibration Mode... 5-15
Exiting Calibration Mode een: 5-16
6 Troubleshooting
Inspecting the Generator... rss ovn 6-1
Correcting Malfunctions irene 6-2
Responding to System Alarms rien 6-11
Correcting IC U3 Malfunctions............ iii 6-23
Correcting IC U6 Malfunctions.…................................. 6-24
Correcting T_ON ASIC Malfunctions.….....................… 6-27
Correcting Battery-Backed RAM Malfunctions .................. 6-29
225 120 100

7 Replacement Procedures
IMmterconnectDiagram.......................0...
....7-2
Battery
Replacement
이
이
이
아
아
아
아 아 이
아
아
아
아 아 아 아 아
아
아 아 어 이
아
아 나 이 이 이 이 이 이
이
에
이니
7-3
Control
Board
Replacement..….….................
7-4
Display
Board
Replacement
ene
7-5
Display
Board
Seven-Segment
LED
Replacement....................
7-6
Footswitch
Board
Assembly
Replacement................................
7-7
Front
Panel
Replacement
7-8
Front
Panel
Footswitch
Receptacle
Replacement....................
7-10
Front
Panel
Knob
Replacement
.
7-11
Front
Panel
Power
Switch
Replacement
.....................
nn
7-12
Front
Panel
REM
Lever
Replacement.........................
errare
7-13
Fuse
Replacement
see
7-14
Replacing
Fuses
in
the
Fuse
Drawer.....................................
7-14
Replacing
the
Fuse
on
the
Low
Voltage
Power
Supply
.....7-15
Replacing
the
Fuse
on
the
Power
Supply
/RF
Board..........
7-17
Handle
Replacement
7-18
Left
Front
Heat
Sink and
Component
Replacement...............
7-19
Left
Rear
Heat
Sink
and
Component
Replacement
................
7-21
Right
Heat
Sink
and
Component
Replacement.......................
7-24
Low
VoltagePowerSupplyReplacement.................................
7-27
PowerEntryModuleReplacement...........................................
7-29
PowerSuppiy/RFBoardReplacement.......................................
7-31
8 Repair Policy and Procedure
Responsibility of the Manufacturer 0000000000. 8-1
Obtaining a Return Authorization Number............................... 8-2
Returning Circuit Boards... essseeseeer 8-2
Returning the Generator for Service... лишили 8-3
Clearimg the Generator eee nenene ené 8-3
Shipping the Generator... renee 8-3
225 120 100 vil

9 Service Parts
Ordering ReplacementParts...................- een 9-1
Force 300 Assembly . et 9-2
Force 300 Illustrated Parts (Drawing 1 of 2) eee 9-2
Force 300 Illustrated Parts (Drawing 2 of 2) ини 9-3
Force 300 Parts List... 9-4
Control Board Components sense 9-7
Footswitch Board Components 9-7
Power Supply/RF Board ComponentS иен 9-8
10 Board Drawings and Schematics
Control Board …10-3
Display Board …10-7
Footswitch Board 10-11
Power Supply/RE Board ns ολο 10-13
Warranty
225 120 100

Service Centers
Valleylab Inc
Boulder, Colorado, USA
800-255-8522
Valleylab Australia
Sydney, AUSTRALIA
61-2-688-4888
Valleylab Benelux
Huis Ter Heideweg, HOLLAND
31-3069-32800
Valleylab Canada
Ontario, CANADA
800-668-1832
Valleylab Europe, Middle East and Africa
London, UNITED KINGDOM
44-181-961-9955
0181—961—9955 (within the U.K.)
Valleyiab France
c/o Howmedica
Lyon, FRANCE
33-78-096262
Valleylab Germany
Wichmannstrasse 4
D-22607 Hamburg
Postfach 520452
D-22594 Hamburg
GERMANY
49-(0)40-89 68 84
25 120 100

Notes
é 225 120 100

Introquction
This manual provides instructions for servicing the Valleylab Force 300
Electrosurgical Generator. This section introduces the features and
components of the generator and reviews the precautions associated
with generator repair.
Additional information about using the generator is available in the Force
300 User’s Guide.
25 120 029 1-1

Rel Roe E BR GE A ISA passos .
The Valleylab Force 300 is an isolated output electrosurgical generator
that provides the power for cutting, desiccating, and fulgurating tissue
during electrosurgery. The Force 300 is specifically designed for use in
bipolar or monopolar electrosurgery.
The main features of the generator are listed below:
* automatic control of output power in relation to tissue impedance
e standard bipolar mode
e two monopolar cut modes: pure and blend
* two monopolar coag modes: desiccate and fulgurate
e the Valleylab REM® Contact Quality Monitoring System, which
protects patients against burns at the patient return electrode site
e volume control for activation tones
The Force 300 can be used in conjunction with the Valleylab Force GSU®
System and the Valleylab Force Argon System. Refer to the Force GSU
User’s Guide and the Force Argon User’s Guide for more information.
For details about the Force 300 features, see Section 2, Controls, Indicators,
and Receptacles.
List of Components
The Valleylab Force 300 Electrosurgical Generator is a self-contained
unit. It consists of a main enclosure (cover and base) and power cord.
The main components of the generator are listed below:
e Front panel components include the power switch; controls for
setting the modes and output power; a footswitch receptacle and
button for selecting bipolar or monopolar output; receptacles for
connecting electrosurgical accessories, and indicators that alert you to
the selected modes and the patient return electrode status.
e Rear panel components include the power entry module, volume
al oro imo ic
control, two footswitch receptacles, and equipotential gi ounding sug.
» Internal components include the Control (microcontroller) Board,
Display Board, Footswitch Board, Power Supply /Radio Frequency
(RF) Board, low voltage power supply, and heat sinks.
A handle is located on the underside of the chassis.
Details about the interaction of the main components and circuit board
descriptions are in Section 4, Principles of Operation.
1-2
225 120 029

VCIVILS FCovillici vaIicly
Before servicing the Force 300, it is important that you read, understand,
and follow the instructions supplied with the generator and with any
other equipment used to install, test, adjust, or repair the generator.
General Precautions
Warning: Use the generator only if the self-test has been completed as
described. Otherwise, inaccurate power outputs may result.
Notice: Connect the power cord to a wall receptacle having the correct
voltage. Otherwise, product damage may result.
Warning: The multipin monopolar output receptacle is designed for
connecting either a handswitching (three-pin) or footswitching (one-pin)
accessory, but not both at the same time. Connecting more than one
accessory to the multipin receptacle will activate both accessories
simultaneously.
Caution: Do not stack equipment on top of the Force 300 or place the
generator on top of electrical equipment (except the Valleylab Force GSU
Unit). These configurations are unstable and/or do not allow for
adequate cooling.
Caution: Provide as much distance as possible between the
electrosurgical generator and other electronic equipment (such as
monitors). An activated electrosurgical generator may cause
interference
with them.
Caution: Do not turn the activation tone down to an inaudible level.
The activation tone alerts personnel when an accessory is active.
Notice: If required by local codes, connect the generator to the hospital
equalization connector with an equipotential cable.
Active Accessories
Caution: Accessories must be connected to the proper receptacle type.
In particular, bipolar accessories must be connected to the bipolar
receptacle only. Improper connection may result in inadvertent
generator activation or a REM Contact Quality Monitor alarm.
Patient Return Electrodes
Warning: Using a conventional patient return electrode without the
REM safety feature will not activate the Valleylab REM Contact Quality
Monitoring System.
25 120 029 1-3

o
Danger: Explosion Hazard. Do not install the generator in the presence
of flammable anesthetics, gases, liquids, or objects.
Warning: Fire Hazard. Do not place active accessories near or in contact
with flammable materials (such as gauze or surgical drapes).
Electrosurgical accessories that are activated or hot from use can cause a
fire. Use a holster to hold electrosurgical accessories safely away from
personnel and flammable materials.
Warning: Fire Hazard. Do not use extension cords.
Warning: Fire Hazard. For continued protection against fire hazard,
replace fuses only with fuses of the same type and rating as the original
fuse.
Electric Shock Hazards
Warning: Connect the generator power cord to a properly grounded
receptacle. Do not use power plug adapters.
Warning: Do not connect a wet power cord to the generator or to the
wall receptacle.
Warning: Disconnect the power cord before replacing parts. To allow
stored energy to dissipate after power is disconnected, wait at least five
minutes before replacing parts.
Warning: Always unplug the generator before cleaning.
Warning: Do not touch any exposed wiring or conductive surfaces while
the generator is disassembled and energized. Never wear a grounding
strap when working on an energized generator.
Warning: When taking measurements or troubleshooting the generator,
take appropriate precautions, such as using isolated tools and
equipment, using the “one hand rule,” etc.
Warning: Potentially lethal AC and DC voltages are present in the AC
line circuitry, high voltage DC circuitry, and associated mounting and
heat sink hardware described in this manual. They are not isolated from
the AC line. Take appropriate precautions when testing and
troubleshooting this area of the generator.
Warning: High frequency, high voltage signals that can cause severe
burns are present in the RF output stage and in the associated mounting
and heat sink hardware described in this manual. Take appropriate
precautions when testing and troubleshooting this area of the generator.
225 120 029

Servicing
Caution: Read all warnings, cautions, and instructions provided with
the Valleylab Force 300 Electrosurgical Generator before servicing.
Caution: The generator contains electrostatic-sensitive components.
When repairing the generator, work at a static-control workstation. Wear
a grounding strap when handling electrostatic-sensitive components,
except when working on an energized generator. Handle circuit boards
by their nonconductive edges. Use an antistatic container for transport
of electrostatic-sensitive components and circuit boards.
Notice: After installing a new low voltage power supply, verify that the
voltages are correct.
Calibration
Notice: After completing any calibration step, proceed to the next step to
save the values from the completed calibration step.
Notice: Do not activate the generator with any load resistor higher than
10 ohms while calibrating the current sense gain. Otherwise, product
damage will result.
Caution: To avoid inadvertent coupling and/or shunting of RF currents
around the resistor elements, keep the resistors at least four inches
(10.2 cm) away from any metal surface including tabletops and other
resistors. This is especially true if several resistors are connected in series
or parallel to obtain a specified value. Do not allow the resistor bodies to
touch each other.
Notice: Do not activate the generator with any load resistor lower than
750 ohms while calibrating the voltage sense gain for bipolar output.
Otherwise, product damage will result.
Notice: Do not activate the generator with any load resistor lower than
3000 ohms while calibrating the voltage sense gain for the pure cut mode.
Do not activate the generator with any load resistor lower than 2000 ohms
while calibrating the voltage sense gain for the blend mode. Otherwise,
product damage will result.
Notice: After calibration, the generator will be ready to use only after
you initiate the internal self-test by turning the generator off, then on.
Notice: Calibrate the generator after you install a new battery.
Calibration values are lost when the battery is replaced.
Notice: Calibrate the generator after you install a new Control Board.
Otherwise, the default calibration values are used.
225 120 029
1-5

Calibration
Notice: Calibrate the generator after you install a new heat sink or
replace components on the heat sink. Otherwise, component differences
may affect output waveforms.
Notice: Calibrate the generator after you install a new Power Supply /RF
Board. Otherwise, component differences may affect output waveforms.
Cleaning
Notice: Do not clean the generator with abrasive cleaning or disinfectant
compounds, solvents, or other materials that could scratch the panels or
damage the generator.
225 120 029

_ Controis, Indicators, ana
. Receptacles
The controls, indicators, and receptacles for accessories are located on
the front and rear panels of the Force 300. This section describes each
component of the generator and its function.
Detailed specifications for the generator are in Section 3.
Read all warnings, cautions, and instructions provided with the Valleylab
Force 300 Electrosurgical Generator before using.
25 120 030 2-1

Front rane
The front panel features are shown below. The bipolar, cut, and coag
controls are described in detail on the following pages. Additional
information about the footswitch receptacle, bipolar instrument
receptacle, monopolar instrument receptacles, and the REM patient
return electrode monitoring feature are also provided.
— Bipolar Controls — Cut Controls — Coag Controls
BIPOLAR
О
LTA
ο. ο οΏο ο
SS
(©) == VILA: や 上 回
LJ
Bipolar Footswitch Monopolar Patient
Instrument Button and Instrument Return
Receptacle Receptacie Receptacies Electrode
Receptacle
Power Switch REM Indicator —
This switch supplies power to the generator.
> To turn on the generator, press ( | ).
» To turn off the generator, press (O).
2.2 225 120 030
プ