Valleylab CUSA EXcel-8 User manual

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DO
=Falleylab. Service Manual
CUSA EXcel""-8 System

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
CUSA
EXcel
ultrasonic
surgical
aspirator
only.
Equipment covered in this manual
CUSA
EXcel™
ultrasonic
surgical
aspirator
with
23
kHz
and
36
kHz
handpieces.
The CUSA EXcel "System Service Manual consists of two parts—the text
{part 1 of 2) and a Schematics Supplement (part 2 of 2), which contains the
schematics.
Vatleytab Part Number 945 103 105
Effective Date October 2004
Trademark acknowledgements
CUSA EXcei™, TISSUE Select™, MacroTip™, MicroTip™, PrecisionTip™,
CEM™, and Force FX™ are trademarks of Valleylab.
Ajax“ is a registered trademark of the Colgate-Palmolive Company.
Comet“ is a registered trademark of Procter & Gamble.
Torgue Seal“ is a registered trademark of Organic Products Co.
Manufactured by
Valleylab
a division of Tyco Healthcare Group LP
Boulder, Colorado 80301-3299 USA
© 2004 Valleylab All rights reserved. Contents of this publication may
not be reproduced in any form without the written permission of
Valleylab.
Tyco Healthcare UK Ltd.
Gosport, PO13 OAS, UK
1-303-530-2300 Made in USA Printed in USA
C € Patent Information
0086 One or more of the following U.S. patents and corresponding foreign
patents cover the CUSA EXcel system:
4734964 4768496 4827911 4921476 4931047
4988334 5015227 5190517 5421829 5466020
5484398
5847046 6214817 6256859 6499858
ii CUSA EXcel-8 System Service Manual

About This Manual
The service manual describes the CUSA EXcel ultrasonic surgical
aspirator. It presents the CUSA EXcel as a system that includes a console,
handpieces, and accessories:
* Descriptions of the system, its functions, specifications, and theory of
operation
* Step-by-step instructions on how to unpack, install, maintain,
calibrate, and troubleshoot the system
© Step-by-step instructions on how to replace specific components
e Parts lists, board layouts, and schematics.
- Organization
We have organized this guide to introduce the safety issues, the system,
and its functions. After safety and the system, the guide gives instructions
for unpacking the system, then describes its components, technical
specifications, and theory of operation. The next sections tell you how to
check out, maintain, troubleshoot, replace parts, and calibrate the system.
A schematics supplement includes printed circuit board (PCB) layouts
and schematics.
CUSA
EXcel-8
System
Service
Manual
iii

rr
m
Conventions Used in this Guide
indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
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.
A
D important
Indicates an operating tip or
maintenance suggestion.
iv
CUSA
EXcel-8
System
Service
Manual

Table of Contents
Preface ii
About This Manual iii
Organization iii
Conventions Used in this Guide iv
List of Figures xiii
List of Tables xvi
Section 1. Service Personnel Safety
Safety Information 1-1
Warnings, Cautions, and Notices 1-1
General 1-2
Introduction 1-2
Unpacking and Installing the CUSA EXcel System 1-2
Console Components 1-2
Technical Specifications 1-2
Checkout Procedures 1-3
Maintaining the CUSA EXcel System 1-3
Troubleshooting 1-4
Replacement Procedures 1-4
Calibration 1-5
Repair Policy 1-5
Section 2. Introduction
For Your Information 2-1
Overview 2-2
Fragmentation 2-2
Tip Motion 2-2
Cooling 2-2
Irrigation 2-3
Aspiration (Suction) 2-4
Handpieces 2-5
Wide Variety of Tips 2-5
Section 3. Unpacking and Installing the CUSA EXcel System
The Responsibility of the Manufacturer 3-1
Unpacking the CUSA EXcel System 3-2
Tools You Will Need 3-2
Unpacking Procedure 3-2
Preparing the CUSA EXcel Console for Use 3-8
Replacing the Power Connector 3-9
CUSA
EXcel-8
System
Service
Manual

K
Replacing Fuses (lf Necessary) 3-10
Replacing a Control Panel Overlay (Optional) 3-11
installing the Reference Card Set 3-15
Section 4. Console Components
For Your Information 4-1
Console Overview and Structural Features 4-2
LV,
Pole 4-3
Control Panel 4-3
Arm and Arm Housing 4-3
Housing for Irrigation Pump Head and Suction Pinch Valve 4-3
Console Body 4-3
Shelf for Suction Canister 4-3
Casters 4-3
Control Panel 4-4
Alerts 4-5
Lap Mode, Prime, Test, and Status Buttons 4-5
Displays 4-5
Status Indicators 4-7
Setpoint Adjustment Buttons 4-7
Console Body Front Panel 4-8
Handpiece Connector Receptacle 4-8
Suction Pinch Valve 4-9
System Power Switch 4-9
Irrigation Pump Head 4-9
Contamination Guard 4-9
Retaining Bail for Suction Canister 4-9
Console Body Side Panel 4-10
Control Panel 4-11
Rotation Lock Handle 4-11
Housing for Irrigation Pump Head and Suction Pinch Valve = 4-11
LV. Pole 4-11
1.V. Pole Release Button 4-11
Arm and Arm Housing 4-11
Arm Release Tab 4-11
Cooling Water Reservoir 4-11
Console Body Rear Panel 4-12
Speaker 4-13
Volume Control 4-13
Footswitch Connector Receptacle 4-13
AC Main Switch 4-13
Fuses 4-13
Footswitch 4-13
vi
CUSA
EXcel-8
System
Service
Manual

AC PowerCord 4-15
Equipotential Grounding Lug 4-15
Label 4-15
Cord Wraps 4-15
Storage Compartment 4-15
Symbols on the Control Panel 4-16
Other Features 4-18
Filling the Cooling Water Reservoir 4-18
Raising/Lowering the Arm 4-18
Rotating the Control Panel 4-19
Adjusting the Tone Volume 4-19
Adjusting the I.V. Pole 4-20
Section 5. Technical Specifications
Console Dimensions 5-2
CUSA EXcel Console 5-2
Footswitch 5-2
Console Subsystems 5-2
Ultrasonic 5-2
Fluidic System 5-3
Electrical Requirements 5-3
Input Power Source 5-3
Power Cords 5-3
Low Frequency Leakage 5-4
Duty Cycle 5-4
Environment 5-4
Standards and IEC Classifications 5-5
Class | Equipment (IEC 601-1) 5-5
Type BF Applied Part Equipment (IEC 601-1) 5-5
IPX - 8 (IEC 529, UL 2601) Footswitch 5-5
Electromagnetic Interference 5-6
System Power Off / Standby 5-6
Pinch Point in the Suction Pinch Valve 5-6
Fuse Replacement 5-6
Footswitch Symbols 5-6
Voluntary Standards 5-7
Statutory and Regulatory Requirements 5-7
EMC Compatibility 5-7
Handpieces 5-12
Nominal Frequencies 5-12
Dimensions 5-12
Tip Specifications 5-12
CUSA
EXcel-8
System
Service
Manual
vil

K
23 kHz 5-13
36 kHz 5-14
Section 6. Principles of Operation
How the Handpiece Works 6-2
Electromechanical Operation 6-2
Fragmentation 6-3
Cooling 6-3
How the TISSUE Select Feature Works 5-4
Inherent Tissue Selectivity 6-5
increasing Tissue Selectivity 6-5
TISSUE Select Reduces Reserve Power tothe Tip 6-6
Benefits of TISSUE Select 6-8
A Common Misunderstanding of the Amplitude Setting 6-9
Section 7. Circuit Theory
For Your Information 741
Display Board 7-2
General Description 7-2
Fundamentals of Operation 72
Detailed Circuit Description 7-3
Machine Control Board 7-4
Introduction 7-4
Irrigation Pump 7-4
Suction Pump 7-5
Cooling Pump 7-6
Suction Valve 7-6
Amplitude Control 7-6
Valve Controls. 7-7
Power Control Input and Output Signals 7-7
Valtage Regulators 7-8
interface Connectors 7-8
Ultrasonics Board-Ultrasonic Generator 7-8
Fundamentals of Operation 7-8
The Main Frequency Loop 7-9
Bandpass Filter (BPF) 7-9
AGC/Error Amplifier Circuit 7-19
Phase Compensator 7-11
Driver Stage 7-11
Feedback Signal 7-12
Bias Circuitry 7-12
Frequency Selection Circuitry 7-12
Ultrasonics Board-Other Circuits 7-13
viii CUSA EXcel-8 System Service Manual

Audible Alert and Operation Indicator 7-13
Valve Drivers 7-13
Power and Other Signal Connections 7-13
Dual 24 V Power Supply Board 7-13
Section 8. Checkout Procedures
Inspections 8-1
Footswitch 8-1
Power Cord 8-2
Power On Verification 8-2
Handpiece Test (Optional) 8-2
: Section 9. Maintaining the CUSA EXcel System
For Your Information 9-1
Recommended Maintenance Schedule 9-2
Clean the CUSA EXcel Console 9-3
Clean the Sterilizer Case 9-3
Maintain the Handpiece 9-3
Clean the Handpiece 9-4
Lubricate the Handpiece Connector O-Rings 9-5
Replace the Handpiece Connector O-Rings 9-5
Recalibrate the Handpiece 9-5
Maintain the Tip Torquing Set 9-6
Clean the Tip Torquing Set 9-6
Check the Torque on the Tip Torquing Wrench 9-6
Store the CUSA EXcel System and Accessories 9-7
CUSA Console 9-7
Handpiece 9-7
Footswitch 9-7
CEM Nosecone 9-7
Section 10. Troubleshooting
For Your Information 10-1
Troubleshooting Safety 10-2
User Troubleshooting 10-2
Responding to Alerts 10-3
General Troubleshooting 10-6
Engineer Troubleshooting 10-15
Guidelines 10-15
Flowcharts 10-15
No Power 10-16
Handpiece Alarm 10-17
|
CUSA
EXcel-8
System
Service
Manual
*

K
Footswitch Alarm 10-18
Cooling Water Alarm 10-19
Low Suction 10-20
Low irrigation 10-22
Vibration Alarm 10-23
Section 11. Replacement Procedures
For Your Information 11-2
Console Cavers 11-3
Open the Left Cover 11-4
- Open the Right Cover 11-4
Open the Rear Cover 11-4
Re-install the Left Cover 11-5
Re-install the Right Cover 11-5
Re-install the Rear Cover 11-5
Dual 24 Volt Power Supply 11-6
Remove the Dual 24 Volt Power Supply 11-6
Install the Dual 24 Volt Power Supply 11-6
Ultrasonics and Machine Control Printed Circuit Boards 11-8
Remove the Ultrasonics PCB 11-8
install the Ultrasonics PCB 11-11
Remove the Control Panel Assembly 11-13
Remove the Machine Control PCB 11-14
Install the Machine Control PCB 11-14
install the Control Panel Assembly 11-15
Control Head Components 11-15
Remove the Control Panel Assembly 11-17
Remove the Machine Control PCB 11-18
Remove the Control Panel Overlay 11-18
Remove the Display PCB 11-18
install the Display PCB 11-19
Install the Control Panel Overlay 11-20
install the Machine Control PCB o 11-20
Install the Control Panel Assembly 11-20
Suction Control Valve 11-21
Remove the Suction Control Valve 11-21
Install the Suction Control Valve 11-27
Suction Pump and Controller Card 11-29
Remove the Suction Pump 11-29
Install the Suction Pump — 11-34
Ready for Suction Pump Controller Card Replacement 11-35
Remove the Suction Pump Controller Card 11-36
x
CUSA
EXcel-8
System
Service
Manual