Valleylab Force EZ - C Series User manual

Service Manual
Valleylab Force EZ™-C Series
Electrosurgical Generator
with Instant Response™Technology

ii Force EZ-C Series 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 Valleylab Force EZ™-C
Series Electrosurgical Generator only.
Equipment covered in this manual:
Force EZ™-C Series Electrosurgical Generator with Instant Response™Technology
100–120 V ~ (110 V ~ nominal), 220–240 V ~ (230 V ~ nominal) –
(user selectable)
The Service Manual, Force EZ™-C Series Electrosurgical Generator with Instant
Response™ Technology, 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: 1015435 (part 1 of 2)
Effective Date: November 2008
Trademark acknowledgements:
Force FX™. Force EZ™, Force Argon™, Force GSU™, SurgiStat™, REM™,
EDGE™, AccuVac™, PolyHesive™, and Instant Response™ are trademarks of
Valleylab.
Patent Information:
Protected by U.S. Pat. Nos. 5,599,344; and 5,628,745.
Manufactured by
Valleylab
a division of Tyco Healthcare Group LP
Boulder, Colorado 80301-3299 USA
European Representative:
Tyco Healthcare UK Ltd.
Gosport, PO13 0AS, UK
For information call:
1-303-530-2300
Made in USA
Printed in USA
©2008 Valleylab All rights reserved.
Caution
Federal (USA) law restricts this device to sale by or on the order of a physician.

Force EZ-C Series Service Manual iii
Important
Conventions Used in this Guide
Indicates an operating tip or
maintenance suggestion.
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.

iv Force EZ-C Series Service Manual
Warranty
Valleylab, a division of Tyco Healthcare Group LP, warrants each product
manufactured by it to be free from defects in material and workmanship under
normal use and service for the period(s) set forth below. Valleylab’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 Distributor within
the applicable time period shown below after delivery of the product to the
original purchaser, and which examination discloses, to Valleylab’s satisfaction,
that the product is defective. This warranty does not apply to any product, or part
thereof, which has been repaired or altered outside Valleylab’s factory in a way so
as, in Valleylab’s judgment, to affect its stability or reliability, or which has been
subjected to misuse, neglect, or accident.
The warranty periods for Valleylab products are as follows:
This warranty is in lieu of all other warranties, express or implied, including
without limitation, the warranties of merchantability and fitness for a particular
purpose, and of all other obligations or liabilities on the part of Valleylab.
Valleylab neither assumes nor authorizes any other person to assume for it any
other liability in connection with the sale or use of any of Valleylab’s products.
Notwithstanding any other provision herein or in any other document or
communication, Valleylab’s liability with respect to this agreement and products
sold hereunder shall be limited to the aggregate purchase price for the goods sold
by Valleylab to the customer. There are no warranties which extend beyond the
terms hereof. Valleylab disclaims any liability hereunder or elsewhere in
connection with the sale of this product, for indirect or consequential damages.
ForceTriad™Energy Platform One year from date of shipment
Electrosurgical Generators One year from date of shipment
RFG-3C™Plus Lesion Generator One year from date of shipment
LigaSure™Vessel Sealing System One year from date of shipment
LigaSure™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
Force Argon™Units One year from date of shipment
OptiMumm™Smoke Evacuator Two years from date of shipment
LigaSure™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

Force EZ-C Series Service Manual v
This 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 warranty is the
District Court of the County of Boulder, State of Colorado, USA.
Valleylab, its dealers, and representatives reserve the right to make changes in
equipment built and/or sold by them at any time without incurring any obligation
to make the same or similar changes on equipment previously built and/or sold by
them.

vi Force EZ-C Series Service Manual

Force EZ-C Series Service Manual vii
Table of Contents
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Conventions Used in this Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Section 1. Service Personnel Safety
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Warnings, Cautions, and Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fire/Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electric Shock Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Section 2. Introduction
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
List of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Instant Response Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bipolar Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Monopolar Cut and Coag Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Cut Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Coag Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
REM Contact Quality Monitoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
How the REM System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrodes Without the REM Safety Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Low (Desiccate) Coag Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
High (Fulgurate) Coag Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Recall of Most Recently Used Modes and Power Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Default Coag Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Original Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 3. Controls, Indicators, and Receptacles
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Rear Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Option Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Section 4. Technical Specifications
Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

viii Force EZ-C Series Service Manual
Dimensions and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Transport and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Internal Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Audio Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
REM Contact Quality Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
RF Activation Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Low Frequency (50-60 Hz) Leakage Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
High Frequency (RF) Leakage Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Standards and IEC Classifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Class I Equipment (IEC 60601-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Liquid Spillage (IEC 60601-2-2 Clause 44.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Electromagnetic Interference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Electromagnetic Compatibility (IEC 60601-1-2 and IEC 60601-2-2) . . . . . . . . . . . . . . . . . . . . . . . 4-9
Voltage Transients (Emergency Generator Mains Transfer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Available Power Settings in Watts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Maximum Output for Force EZ-C Series Electrosurgical Generator Modes . . . . . . . . . . . . . . . . 4-15
Output Waveforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Output Power vs. Resistance Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Section 5. Principles of Operation
Functional Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Instant Response Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
REM Contact Quality Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Microcontrollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Feedback Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Shared RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
I/0 Expansion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Keyboard Interface and Activation Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Power Supply Supervisor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
A/D and D/A Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Waveform Generation (T_ON ASIC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
T_ON Average Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Audio Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Serial Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Dosage Error Algorithm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Force EZ-C Series Service Manual ix
Instant Response Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Display Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Bipolar, Cut, and Coag Power Setting Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
RF Indicator Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
LED and Seven-Segment Display Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Mode Selection Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
REM Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Front Panel Footswitch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Footswitch Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Power Supply/RF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Power Supply/RF Board Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
High Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
RF Output Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Spark Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
RF Leakage Sensing and Reduction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
REM Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
IsoBloc Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Audio Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Footswitch Decode Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Temperature Sense Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Section 6. Setup, Tests, and Adjustments
Setting Up the Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Connections for Bipolar Surgery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Setting the Bipolar Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Connections for Monopolar Surgery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Set the Cut and Coag Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Using Two Generators Simultaneously. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Setting Up the Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Changing the Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Changing the Power Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Activating the Surgical Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Periodic Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Inspecting the Generator and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Inspecting the Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Verifying REM Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Confirming Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Checking the Monopolar Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Checking Low Frequency Leakage Current and Ground Resistance . . . . . . . . . . . . . . . . . . . . . 6-20

xForce EZ-C Series Service Manual
Checking High Frequency Leakage Current and Ground Resistance. . . . . . . . . . . . . . . . . . . . . 6-21
Calibrating the Force EZ-C Series Electrosurgical Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Entering Calibration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Exiting Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Calibration Step 1 – Verify the Force EZ-C Series Electrosurgical Generator Data . . . . . . . . . . 6-25
Calibration Step 2 – Adjust the Calendar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Calibration Step 3 – Adjust the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Calibration Step 4 – Check the REM Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Calibration Step 5 – Check and Adjust the Current Sense Gain. . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Calibration Step 6 – Check and Adjust the Voltage Sense Gain. . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Calibration Step 7 – Check and Adjust the Reactance Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Calibration Step 8 – Check and Adjust the ECON Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Section 7. Troubleshooting
Inspecting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Correcting Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Responding to System Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Correcting Integrated Circuit (IC) Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Correcting T_ON ASIC Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Correcting Battery-Backed RAM Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Section 8. Replacement Procedures
Interconnect Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Display Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Remove the Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Install the Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Display Board Seven-Segment LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Footswitch Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Remove the Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Remove and Reinstall the Front Panel Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Install the Front Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Force EZ-C Series Service Manual xi
Front Panel Footswitch Receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Front Panel Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Front Panel Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Front Panel REM Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Replacing Fuses in the Fuse Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Replacing the Fuse on the Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Replacing the Fuse on the Power Supply/RF Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Left Front Heat Sink Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Remove the Left Front Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Replace the Left Front Heat Sink Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Install the Left Front Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Left Rear Heat Sink Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Remove the Left Rear Heat Sink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Replace the Left Rear Heat Sink Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Install the Left Rear Heat Sink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Right Heat Sink Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Remove the Right Heat Sink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Replace the Right Heat Sink Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Install the Right Heat Sink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Remove the Low Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Install the Low Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Power Entry Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Remove the Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Install the Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Power Supply/RF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Remove the Power Supply/RF Board and Heat Sinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Install the Power Supply/RF Board and Heat Sinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Section 9. Repair Policy and Procedures
Responsibility of the Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Returning the Generator for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

xii Force EZ-C Series Service Manual
Returning Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Section 10. Service Parts
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Force EZ-C Series Electrosurgical Generator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Generator Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Control Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Footswitch Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Power Supply/RF Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Force EZ-C Series Service Manual xiii
List of Figures
Figure 3-1. The front panel 3-2
Figure 3-2. The front panel - continued 3-4
Figure 3-3. Controls and receptacles on the rear panel 3-6
Figure 3-4. The option panel on the generator rear panel with the plate removed to show the serial and RF activation
ports 3-8
Figure 4-1. Standard Bipolar mode — load resistance vs. output power 4-17
Figure 4-2. Pure mode — load resistance vs. output power 4-18
Figure 4-3. Blend mode — load resistance vs. output power 4-18
Figure 4-4. Low 1 (Desiccate) mode — load resistance vs. output power 4-19
Figure 4-5. Low 2 (Desiccate) mode — load resistance vs. output power 4-19
Figure 4-6. Low 3 (Desiccate) mode — load resistance vs. output power 4-20
Figure 4-7. High 1 (Fulgurate) mode — load resistance vs. output power 4-20
Figure 4-8. High 2 (Fulgurate) mode — load resistance vs. output power 4-21
Figure 4-9. Standard Bipolar mode @ 100 ohms — generator setting vs. output power 4-22
Figure 4-10. Standard Bipolar mode — peak voltage vs. output power 4-22
Figure 4-11. Pure mode @ 300 ohms — generator setting vs. output power 4-23
Figure 4-12. Pure mode — peak voltage vs. output power 4-23
Figure 4-13. Blend mode @ 300 ohms — generator setting vs. output power 4-24
Figure 4-14. Blend mode — peak voltage vs. output power 4-24
Figure 4-15. Low 1 (Desiccate) mode @ 500 ohms — generator setting vs. output power 4-25
Figure 4-16. Low 1 (Desiccate) mode — peak voltage vs. output power 4-25
Figure 4-17. Low 2 (Desiccate) mode @ 300 ohms— generator setting vs. output power 4-26
Figure 4-18. Low 2 (Desiccate) mode — peak voltage vs. output power 4-26
Figure 4-19. Low 3 (Desiccate) mode @ 300 ohms— generator setting vs. output power 4-27
Figure 4-20. Low 3 (Desiccate) mode — peak voltage vs. output power 4-27
Figure 4-21. High 1 (Fulgurate) mode @ 500 ohms— generator setting vs. output power 4-28
Figure 4-22. High 1 (Fulgurate) mode — peak voltage vs. output power 4-28
Figure 4-23. High 2 (Fulgurate) mode @ 500 ohms— generator setting vs. output power 4-29
Figure 4-24. High 2 (Fulgurate) mode — peak voltage vs. output power 4-29
Figure 5-1. A block diagram of the Force EZ-C Series generator 5-2
Figure 6-1. Bipolar connections (footswitch activation from the Bipolar Footswitch receptacle on the rear panel) 6-4
Figure 6-2. Bipolar connections (footswitch activation from the Footswitch receptacle on the front panel) 6-4
Figure 6-3. Bipolar connection (handswitching instrument) 6-5
Figure 6-4. Monopolar connections (handswitching instrument) 6-6
Figure 6-5. Monopolar connections (footswitch activation from the Monopolar Footswitch receptacle on the rear
panel) 6-6
Figure 6-6. Monopolar connections (footswitch activation from the Footswitch receptacle on the front panel) 6-7
Figure 6-7. The leakage current test circuit 6-20
Figure 8-1. Electric cable connections 8-2
Figure 8-2. Power switch and cable connections 8-12

xiv Force EZ-C Series Service Manual
Figure 8-3. Left front heat sink components 8-18
Figure 8-4. Left rear heat sink components 8-20
Figure 8-5. Right heat sink components 8-22
Figure 8-6. Connections to the low voltage power supply 8-25
Figure 8-7. Cable connections to the power entry module 8-27
Figure 10-1. Exploded view of Force EZ-C Series Electrosurgical Generator parts 10-3
Figure 10-2. Top view of Force EZ-C Series Electrosurgical Generator parts, after assembly 10-4

SECTION
1
Force EZ-C Series Service Manual 1-1
1Service Personnel Safety
Valleylab stresses safety in the use and servicing of its
electrosurgical equipment. This section presents the following:
• Safety information
• Warnings, Cautions, and Notices
Refer to the Preface, Conventions, for further information on
Warnings, Cautions, and Notices.

Safety Information
1-2 Force EZ-C Service Manual
Safety Information
The safe and effective servicing of electrosurgical equipment depends to a large
degree on factors solely under the control of the service person. There is no
substitute for a properly trained and vigilant service staff.
Warnings, Cautions, and Notices
Before servicing the generator, it is important that you read, understand, and
follow the instructions supplied with it and with any other equipment used to
install, test, adjust, or repair the generator.
General
Warning
Patient Safety – Use the generator only if it has completed the self-test as
described. Otherwise, inaccurate power outputs may result.
The instrument receptacles on this generator are designed to accept only one
instrument at a time. Do not attempt to connect more than one instrument at a
time into a given receptacle. Doing so will cause simultaneous activation of the
instruments.
Caution
Do not stack equipment on top of the generator or place the generator on top of
electrical equipment (except a Force Argon Unit). These configurations are
unstable and/or do not allow adequate cooling.
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.
Do not turn the activation tone down to an inaudible level. The activation tone
alerts the surgical team when an accessory is active.
Notice
If required by local codes, connect the generator to the hospital equalization
connector with an equipotential cable.
To avoid product damage, connect the power cord to a wall receptacle having the
correct voltage.

Warnings, Cautions, and Notices
Service Personnel Safety
Force EZ-C Service Manual 1-3
Active Accessories
Patient Return Electrodes
Fire/Explosion Hazards
Caution
Connect accessories to the proper receptacle type. In particular, connect bipolar
accessories to the Bipolar Instrument receptacle only. Improper connection may
result in inadvertent generator activation or a REM Contact Quality Monitor
alarm.
Warning
Using a patient return electrode without the REM safety feature will not activate
the Valleylab REM Contact Quality Monitoring System.
Warning
Danger: Explosion Hazard –þDo not install the generator in the presence of
flammable anesthetics, gases, liquids, or objects.
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 patients, surgical team, and
flammable materials.
Fire Hazard – Do not use extension cords.
Fire Hazard – For continued protection against fire hazard, replace fuses only
with fuses of the same type and rating as the original fuse.

Warnings, Cautions, and Notices
1-4 Force EZ-C Service Manual
Electric Shock Hazards
Servicing
Warning
Connect the generator power cord to a properly grounded receptacle. Do not use
power plug adapters.
Do not connect a wet power cord to the generator or to the wall receptacle.
To allow stored energy to dissipate after power is disconnected, wait at least five
minutes before replacing parts.
Always turn off and unplug the generator before cleaning.
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.
When taking measurements or troubleshooting the generator, take appropriate
precautions, such as using isolated tools and equipment, using the “one hand
rule,” etc.
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.
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.
Caution
Read all warnings, cautions, and instructions provided with this generator before
servicing.
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.

Warnings, Cautions, and Notices
Service Personnel Safety
Force EZ-C Service Manual 1-5
Calibration
Cleaning
Caution
To avoid inadvertent coupling and/or shunting of RF currents around the resistor
elements, keep the resistors at least 10.2 cm (4 in.) 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
After completing any calibration step, proceed to the next step to save the values
from the completed calibration step.
Do not activate the generator with any load resistor higher than 10 ohms while
calibrating the current sense gain. Otherwise, product damage will result.
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.
Do not activate the generator with any load resistor lower than 3000 ohms while
calibrating the voltage sense gain for the pure cut mode. Otherwise, product
damage will result.
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.
After calibration, the generator will be ready to use only after you initiate the
internal self-test by turning the generator off, then on.
Calibrate the generator after you install a new battery. All data stored in internal
memory, including calibration constants, is lost when the battery is replaced.
Calibrate the generator after you install a new Control board. Otherwise it uses
default calibration values.
Calibrate the generator after you install a new heat sink or replace components
on the heat sink. Component differences may affect output waveforms.
Calibrate the generator after you install a new Power Supply/RF board.
Component differences may affect output waveforms.
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.

1-6 Force EZ-C Service Manual