Valleylab Force FX-8C User manual

Service Manual
Force FX ™ -8C
Electrosurgical Generator
with Instant Response ™ Technology

ii Force FX-8C 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 FX™-8C Electrosurgical Generator only. Additional
information about using the generator is available in the Force FX™-8C
Electrosurgical Generator User’s Guide .
Equipment covered in this manual:
Valleylab Force FX™-8C Electrosurgical Generator with
Instant Response™ Technology—
100–120 V ~ Nominal, 220–240 V ~ Nominal (auto selected)
The Force FX™-8C Electrosurgical Generator Service Manual 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:
945 103 068
Effective Date:
September 2000
Trademark Acknowledgments:
Force GSU™ Argon System, PolyHesive™ Adhesive Conductor, REM™
Contact Quality Monitoring System, Force EZ™ Electrosurgical
Generator, Force Argon™ II-20 System, Instant Response™ Technology,
The EDGE™ Coated Electrode, ACCUVAC™ Smoke Evacuation
Attachment, and CUSA™ or CUSA EXcel™ Ultrasonic Surgical Aspirator
are trademarks of Valleylab.
Teflon is a registered trademark of E.I du Pont de Nemours and Company.
Patent Information:
Protected by U.S. Pat. Nos. 4,416,276; 4,416,277; 4,658,820; 5,599,344; and
5,628,745.
Manufactured by:
Valleylab,
a division of Tyco Healthcare Group LP
Boulder, Colorado 80301-3299 USA
Tyco Healthcare UK Ltd.
Gosport, PO130AS, UK
For information call:
1-303-530-2300
Made in USA
Printed in USA
©2000 Valleylab All rights reserved. Contents of this publication may not
be reproduced without the written permission of Valleylab.
Caution
Federal (USA) law restricts this device to sale by or on the order of a physician.

Force FX-8C 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 FX-8C Service Manual
Table of Contents
Preface
ii
Conventions Used in this Guide
iii
List of Figures
x
Section 1. Introduction
General Description
1-2
List of Components
1-3
Service Personnel Safety
1-3
General
1-3
Fire/Explosion Hazards 1-4
Electric Shock Hazards
1-5
Servicing
1-5
Calibration 1-6
Cleaning
1-6
Section 2. Controls, Indicators, and Receptacles
Front Panel
2-2
Bipolar Controls
2-3
Bipolar Instrument Receptacle
2-4
Monopolar Cut Controls
2-5
Monopolar Coag Controls 2-6
Monopolar Instrument Receptacles
2-7
REM Alarm Indicator
2-7
Rear Panel
2-8
Footswitch Receptacles
2-9
Monopolar Footswitch Receptacles
2-9
Bipolar Footswitch Receptacle
2-9
Power Entry Module
2-10
Activation Tone Volume Control
2-10
Option Panel
2-11
Section 3. Technical Specifications
Performance Characteristics
3-1
General 3-1
Dimensions and Weight
3-2
Operating Parameters
3-2
Transport and Storage 3-2
Duty Cycle
3-3
Internal Memory
3-3
Audio Volume
3-3

Force FX-8C Service Manual v
REM Contact Quality Monitor
3-4
Serial Port
3-5
RF Activation Port
3-5
Expansion Port
3-5
Low Frequency (50–60 Hz) Leakage Current
3-6
High Frequency (RF) Leakage Current
3-6
Input Power
3-7
Standards and IEC Classifications
3-8
Class I Equipment (IEC 601-1)
3-8
Type CF Equipment (IEC 601-1)/Defibrillator Proof 3-8
Drip Proof (IEC 601-2-2)
3-9
Electromagnetic Interference
3-9
Electromagnetic Compatibility (IEC 601-1-2 and IEC 601-2-2)
3-9
Voltage Transients (Emergency Generator Mains Transfer)
3-9
Output Characteristics
3-10
Maximum Output for Bipolar and Monopolar Modes
3-10
Maximum Output for Ultrasonic Electrosurgery
3-10
Available Power Settings in Watts
3-11
Output Waveforms
3-12
Output Power vs. Resistance Graphs 3-14
Bipolar Graphs
3-14
Monopolar Cut Graphs
3-17
Monopolar Coag Graphs 3-20
Section 4. Principles of Operation
Block Diagram
4-2
Functional Overview
4-3
Instant Response Technology
4-3
Ultrasonic Electrosurgery 4-3
Simultaneous Coag
4-3
REM Contact Quality Monitoring System
4-4
Control Board
4-5
Microcontrollers
4-5
Main Microcontroller
4-5
Feedback Microcontroller
4-6
Shared RAM
4-7
I/0 Expansion
4-7
Keyboard Interface and Activation Inputs
4-7
Power Supply Supervisor Circuit
4-8
A/D and D/A Conversion
4-8
Waveform Generation (T_ON ASIC)
4-8
T_ON Average Check
4-9
Audio Alarm
4-9

vi Force FX-8C Service Manual
Serial Interface
4-9
Dosage Error Algorithm
4-10
Instant Response Algorithm 4-11
Front Panel
4-12
Membrane Keyboard
4-12
Power Switch
4-12
REM Connector/Switch
4-12
CEM Mechanism Switch
4-12
Display Board
4-13
RF Indicator Lamps
4-13
REM Indicators
4-13
LED and Seven-Segment Display Drivers
4-13
CEM Switch Circuit
4-14
Mode Selection and Power Control Switches
4-14
Footswitch Board
4-15
Footswitch Decode Circuit
4-15
Audio Circuit 4-16
Power Supply/RF Board
4-17
Power Supply/RF Board Interfaces
4-18
High Voltage Power Supply 4-18
Low Voltage Power Supply 4-21
RF Output Stage 4-21
Spark Control Circuit 4-24
RF Leakage Reduction Circuit 4-25
REM Circuit 4-25
IsoBloc Circuit 4-25
Temperature Sense Circuits 4-26
Section 5. Setup, Tests, and Adjustments
Setting Up the Generator 5-2
Connections for Bipolar or Macrobipolar Surgery 5-4
Setting the Bipolar Output 5-5
Connections for Monopolar Surgery 5-6
Selecting Cut and Coag Modes 5-8
Simultaneous Coag 5-8
Using Two Generators Simultaneously 5-9
Connecting the CUSA Handpiece with CEM Nosecone 5-10
Setting the Output Power 5-11
Simultaneous Coag with a CUSA System 5-11
Changing the Mode 5-11
Changing the Power Setting 5-11
Activating the Surgical Instrument 5-12

Force FX-8C Service Manual vii
Periodic Safety Check 5-13
Recommended Test Equipment 5-13
Inspecting the Generator and Accessories 5-14
Inspecting the Internal Components 5-15
Testing the Generator 5-16
Verifying REM Function 5-17
Confirming Outputs 5-17
Check the Output for the Cut Modes 5-19
Check the Output for the Coag Modes 5-20
Checking Low Frequency Leakage Current and Ground Resistance 5-21
Checking High Frequency Leakage Current 5-23
Calibrating the Generator 5-24
Preparing for Calibration 5-25
Entering Calibration Mode 5-25
Exiting Calibration Mode 5-26
Verify the Generator Data 5-26
Adjust the Calendar 5-27
Adjust the Clock 5-28
Check and Adjust the REM Oscillator Frequency and Impedance 5-29
Check and Adjust the Current Sense Gain 5-30
Check and Adjust the Voltage Sense Gain 5-32
Check and Adjust the Reactance Gain 5-34
Check and Adjust the ECON Factor 5-36
Using the RS-232 Serial Port 5-40
Establish the Communications Link 5-40
Enter the Commands 5-41
Disconnect the Computer from the Generator 5-44
Section 6. Troubleshooting
Inspecting the Generator 6-1
Inspecting the Receptacles 6-2
Inspecting the Internal Components 6-3
Correcting Malfunctions 6-4
Responding to System Alarms 6-10
Correcting IC U3 Malfunctions 6-19
Correcting IC U6 Malfunctions 6-21
Correcting T_ON ASIC Malfunctions 6-23
Correcting Battery-Backed RAM Malfunctions 6-25
Section 7. Replacement Procedures
Interconnect Diagram 7-2
Battery Replacement 7-3

viii Force FX-8C Service Manual
Control Board Replacement 7-4
Display Board Replacement 7-5
Remove the Display Board 7-5
Install the Display Board 7-6
Display Board Seven-Segment LED Replacement 7-7
Fan Replacement 7-8
Footswitch Board Replacement 7-8
Front Panel Replacement 7-9
Remove the Front Panel Assembly 7-9
Remove and Reinstall the Front Panel Components 7-9
Install the Front Panel Assembly 7-10
Front Panel REM Module Replacement 7-11
Front Panel Power Switch Replacement 7-12
Fuse Replacement 7-13
Replacing Fuses in the Fuse Drawer 7-13
Replacing the Fuse on the Power Supply/RF Board 7-14
Left Front Heat Sink and Component Replacement 7-15
Remove the Left Front Heat Sink 7-15
Replace Left Front Heat Sink Components 7-16
Install the Left Front Heat Sink 7-16
Left Rear Heat Sink and Component Replacement 7-17
Remove the Left Rear Heat Sink 7-17
Replace Left Rear Heat Sink Components 7-18
Install the Left Rear Heat Sink 7-19
Right Heat Sink and Component Replacement 7-20
Remove the Right Heat Sink 7-20
Replace Right Heat Sink Components 7-21
Install the Right Heat Sink 7-22
Low Voltage Power Supply Replacement 7-23
Remove the Low Voltage Power Supply 7-23
Install the Low Voltage Power Supply 7-24
Power Entry Module Replacement 7-25
Remove the Power Entry Module 7-25
Install the Power Entry Module 7-26
Power Supply/RF Board Replacement 7-27
Remove the Power Supply/RF Board Assembly 7-27
Remove Components from the Old Board 7-28
Install Components on the New Board 7-29
Install the Power Supply/RF Board Assembly 7-30

Force FX-8C Service Manual ix
Section 8. Repair Policy and Procedures
Responsibility of the Manufacturer 8-1
Returning the Generator for Service 8-2
Obtain a Return Authorization Number 8-2
Clean the Generator 8-2
Ship the Generator 8-3
Returning Circuit Boards 8-3
Service Centers 8-4
Section 9. Service Parts
Ordering Replacement Parts 9-1
Generator Assembly 9-2
Parts List 9-4
Front Panel Assembly 9-6
Parts List 9-8
Control Board Components 9-9
Display Board Components 9-10
Footswitch Board Components 9-11
Power Supply/RF Board Assembly 9-14
Parts List 9-16
Power Supply/RF Board Components 9-18
Appendix A. Warranty
Schematics Supplement. Board Drawings and Schematics

xForce FX-8C Service Manual
List of Figures
Figure 2-1. Layout of controls and indicators on the front panel 2-2
Figure 2-2. Buttons and indicators for bipolar controls 2-3
Figure 2-3. Buttons and indicators for cut controls (monopolar) 2-5
Figure 2-4. Buttons and indicators for coag controls (monopolar) 2-6
Figure 2-5. Controls and receptacles on the rear panel 2-8
Figure 2-6. Components in the power entry module 2-10
Figure 2-7. The three ports behind the option panel 2-11
Figure 3-1. Output power versus impedance for Precise bipolar mode 3-14
Figure 3-2. Precise bipolar mode—output power vs. peak voltage 3-14
Figure 3-3. Output power versus impedance for Standard bipolar mode 3-15
Figure 3-4. Standard bipolar mode—output power vs. peak voltage 3-15
Figure 3-5. Output power versus impedance for Macrobipolar mode 3-16
Figure 3-6. Macrobipolar mode—output power vs. peak voltage 3-16
Figure 3-7. Output power versus impedance for Low cut mode 3-17
Figure 3-8. Low cut mode—output power vs. peak voltage 3-17
Figure 3-9. Output power versus impedance for Pure cut mode 3-18
Figure 3-10. Pure cut mode—output power vs. peak voltage 3-18
Figure 3-11. Output power versus impedance for Blend cut mode 3-19
Figure 3-12. Blend cut mode—output power vs. peak voltage 3-19
Figure 3-13. Output power versus impedance for Desiccate 1 coag mode 3-20
Figure 3-14. Desiccate 1 coag mode—output power vs. peak voltage 3-20
Figure 3-15. Desiccate 2 coag mode—load resistance vs. output power 3-21
Figure 3-16. Desiccate 2 coag mode—output power vs. peak voltage 3-21
Figure 3-17. Desiccate 3 coag mode—load resistance vs. output power 3-22
Figure 3-18. Desiccate 3 coag mode—output power vs. peak voltage 3-22
Figure 3-19. Output power versus impedance for Fulgurate coag mode 3-23
Figure 3-20. Fulgurate coag mode—output power vs. peak voltage 3-23
Figure 3-21. Output power versus impedance for LCF Fulgurate mode 3-24
Figure 3-22. LCF Fulgurate mode—output power vs. peak voltage 3-24
Figure 3-23. Output power versus impedance for Spray coag mode 3-25
Figure 3-24. Spray coag mode—output power vs. peak voltage 3-25