Valleylab Force 2-2 PCH User manual

Service Manual
Force
™
2
Electrosurgical Generator

ii Force 2 Service Manual
The following service instructions are for use only by personnel qualified
to repair and service the equipment described in this manual.
This service manual covers the installation and basic service instructions
for the Force™ 2 Electrosurgical Generator. Also included are sections
covering the technical specifications, circuit descriptions, and the testing
of the generator. Instructions for use and cautions and warnings
concerning electrosurgery are in the Force™ 2 Electrosurgical Generator
User’s Guide supplied with the generator.
Equipment covered in this manual:
The Force™ 2 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:
945 103 106 (1 of 2)
Effective date:
October 2004
Force™ 2 and REM™ are trademarks of Valleylab.
The Force 2 generator is protected by one or more of the following U.S.
patents and their foreign counterparts: 4,632,109, 4,658,819, 4,658,820,
4,827,927, 5,190,517.
Manufactured by
Valleylab, a division of Tyco Healthcare Group LP
Boulder, CO 80301-3299 USA
Tyco Healthcare UK Ltd.
Gosport, PO13 0AS, UK
For information call
1-800-255-8522 / 1-303-530-2300
© 2004 Valleylab All rights reserved.
Made in USA
Printed in USA
Caution
Federal (USA) law restricts this device to sale by or on the order of a physician.
Electrosurgical Generator Vac Nominal Hertz
Force™ 2-2 PCH 110-120 50-60
Force™ 2-8 PCH 220-240 50-60

Force 2 Service Manual iii
Important
Conventions Used in this Guide
Indicates an operating tip or
maintenance suggestion.
Controls, indicators, and receptacles on the unit appear in bold capital
letters like this:
PURE CUT
.
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 hazard which may result in product damage.
ATTENTION
Refer to the accompanying documents.
Type CF equipment
Low Leakage
Suitable for cardiac use
Defibrillator proof
Drip Proof
CAUTION
To reduce the risk of electric shock, do not remove cover. Refer servicing
to qualified service personnel.
The generator is high frequency isolated per IEC 601-2-2.
DANGER
Explosion Hazard: Do not use in the presence of flammable anaesthetics.

iv Force 2 Service Manual
Valleylab Service Centers
Valleylab
Boulder, Colorado, 80301-3299
USA
Ph: 303-530-2300
Toll Free: 800-255-8522
Tyco Healthcare Nederland B.V.
Technical Service Center
De Beverspijken 37
5221 EE ’s-Hertogenbosch
THE NETHERLANDS
Ph: 073-6312412
Fax: [phone]
Auto Suture France S.A.
2, rue Denis Diderot
La Clef de Saint Pierre
78990 Elancourt, FRANCE
Ph: 33 (0)1 30 79 80 40
Fax: [phone]
Tyco Healthcare Deutschland
Tempelsweg 26
47918 Tonisvorst, GERMANY
Ph: 49 (0)2151 7096 92
Fax: [phone]
For the UK, Europe,
Middle East & Africa:
Tyco Healthcare UK Limited
Valleylab Service Centre
Unit 1a
Corinium Industrial Estate
Raans Road
Amersham
Bucks. HP6 6YJ
UNITED KINGDOM
Ph: 44 (0)1494 789200
FAX: [phone]
Tyco Healthcare Italia SpA
Via Gaetano Crespi, 12
20134 Milano, ITALY
Ph: 39 02 212181
Fax: [phone]
Tyco Healthcare Spain S.L.
C/Fructuos Gelabert, 6 – 8 planta 8a,
08970 – Saint Joan DESPI
Barcelona
SPAIN
Ph: 34-93-680-3370
Fax: [phone]
Tyco Healthcare Belgium B.V.
Generaal De Wittelaan 9/5
B-2800 Mechelen
BELGIUM
Ph: 32-15-298111
Fax: [phone]
Tyco Healthcare Austria GmbH
Jochen Rindt Str. 37
A-1230 Vienna
AUSTRIA
Ph: 43-1-610-3441
Fax: [phone]
Tyco Healthcare Norden AB (Denmark,
Finland, Iceland, Norway, Sweden)
Årstaängsvägen 11 B, II
SE-117 43 Stockholm
SWEDEN
Ph. [phone]
Fax [phone]
Tyco Healthcare PTY Ltd
Service & Technical Support
59 - 69 Halstead Street
Hurstville NSW 2220
AUSTRALIA
Ph: 61 2 9579 6066
Toll free hotline: [phone]
Fax: [phone]
Tyco Healthcare Japan
Regulatory Affairs Department
Technical Support Section
Customer Call Center
1-2-20 Heiwajima Ota-ku Tokyo-to JAPAN
Toll Free : 0120-073-008
Ph: 03-3764-0733
Fax: [phone]
Auto Suture Company, Canada
4490 Garand Street
Ville St. Laurent
Quebec, CANADA H4R 2A2
Ph: 514-334 -7602
Fax: [phone]

Force 2 Service Manual v
Table of Contents
Conventions Used in this Guide
iii
Valleylab Service Centers
iv
List of Figures
viii
Section 1. Service Warnings and Cautions
Section 2. Unpacking and Installation
Unpacking the Force 2 Generator
2-1
Responsibility of the Manufacturer
2-1
Preparing the Generator for Use 2-2
Power Requirements
2-2
Check the Power Connector
2-2
Ensure Proper Grounding
2-3
Perform a System Check
2-3
Section 3. Description of Controls, Indicators, and Receptacles
Controls
3-3
Indicators
3-4
Alarms 3-5
Receptacles
3-5
Rear Panel Functions
3-6
Section 4. Technical Specifications
Standard Conditions of Measurement
4-1
Operating Parameters
4-1
Storage and Shipping
4-1
Output Waveform
4-2
PCH Generator Output Characteristics
4-2
Output Configuration 4-2
Input Power Source
4-3
Force 2-2 PCH Generator
4-3
Force 2-8 PCH Generator
4-3
Line Regulation
4-3
Force 2-2 PCH Generator
4-3
Force 2-8 PCH Generator
4-3
High Frequency Risk Parameters
4-4

vi Force 2 Service Manual
Low Frequency Leakage (50-60 Hz)
4-4
Force 2-2 PCH Generator
4-4
Force 2-8 PCH Generator
(per VDE 0750 (IEC601-1), Section 19 for Class 1 Equipment)
4-4
REM Contact Quality Monitor
4-5
Audio Volume
4-5
Approximate Weight 4-5
Size
4-5
Classification
4-5
Type CF Equipment per IEC 601-1
4-5
Drip Proof per IEC 601-1
4-5
Output Power vs. Impedance Graphs 4-6
Section 5. Circuit Descriptions
Bipolar Display
5-1
Monopolar Control/Display
5-1
Mode Indicators
5-2
REM and RMOTE Indicators 5-3
RF Indicators
5-3
External Memory
5-4
Interface
5-5
Power Supply
5-6
RF Output 5-7
Section 6. Maintenance Procedures
Routine Maintenance and Inspections
6-1
Cleaning Instructions
6-1
General Testing Information
6-2
Recommended Test Equipment
6-3
Power Up Self-Test
6-3
Calibration
6-4
Calibration Procedure
6-4
REM Test Procedure 6-7
Line Frequency (50-60 Hz) Current Leakage Test Procedure
6-8
Bipolar and Monopolar Output RF Leakage Test Procedures
6-9
Typical Output Waveforms
6-10
TT-on Waveforms at TP12 on PSRF Board
6-13
RF Drive Waveforms at TP7-10 on PSRF Board
6-13
Clamp Waveform at TP11 on PSRF Board
6-14
Components Replacement Guidelines
6-15

Force 2 Service Manual vii
Section 7. Manufacturer Service
Returning the Equipment for Service
7-1
Returning the Force 2 Generator
7-2
Returning Circuit Boards and Other Subassemblies
7-2
Section 8. Service Parts List
Ordering Replacement Parts
8-1
Monopolar Control/Display Board
8-2
Bipolar Display Board
8-4
Interface Board
8-5
Power Supply RF Board 8-8
Heatsink Assembly
8-13
RF Out
8-13
HVDC
8-13
PS
8-13
Clamp
8-13
Generator Base Assembly
8-14
Appendix A. Warranty
Schematics Supplement. Assemblies and Schematics

viii Force 2 Service Manual
List of Figures
Figure 3-1. PCH Generator Front View 3-2
Figure 3-2. PCH Generator Rear View 3-2
Figure 4-1. PCH Generator Typical Output Power vs Load—Monopolar Cut
Modes 4-6
Figure 4-2. PCH Generator Typical Output Power vs Load—Monopolar Cut
Modes (continued) 4-7
Figure 4-3. PCH Generator Typical Output Power vs Load—Monopolar Coag
Modes 4-8
Figure 4-4. PCH Generator Typical Output Power vs Load—Bipolar Mode 4-9
Figure 6-1. Pure Cut 300 ΩLoad
Bipolar 100 ΩLoad 6-10
Figure 6-2. Blend 1 300 ΩLoad 6-10
Figure 6-3. Blend 2 300 ΩLoad 6-11
Figure 6-4. Blend 3 300 ΩLoad
Low Voltage Coag 300 ΩLoad 6-11
Figure 6-5. Coag 300 ΩLoad 6-12
Figure 6-6. 1-Cut/Bipolar
2-Blend 1
3-Blend 2
4-Blend 3/LV Coag
5-Coag 6-13
Figure 6-7. 1-Cut/Bipolar
2-Blend 1
3-Blend 2
4-Blend 3/LV Coag
5-Coag 6-13
Figure 6-8. Open Circuit 120W Coag 6-14
Schematics Supplement
Schematic 1. System interconnect diagram S-4
Schematic 2. Component/connector locations S-5
Schematic 3. Bipolar Display board S-6
Schematic 4. Bipolar Display board S-7
Schematic 5. Heatsink assembly, RF out S-8
Schematic 6. Heatsink assembly, clamp S-9
Schematic 7. Heatsink assembly, power supply S-10
Schematic 8. Heatsink assembly, HVDC S-11
Schematic 9. Monopolar keyboard S-12
Schematic 10. Monopolar keyboard S-12
Schematic 11. Footswitch board S-13

Force 2 Service Manual ix
Schematic 12. Power Supply board layout, page 1 of 2 S-15
Schematic 13. Power Supply board layout, page 2 of 2 S-16
Schematic 14. Power Supply board, page 1 of 6 S-17
Schematic 15. Power Supply board, page 2 of 6 S-18
Schematic 16. Power Supply board, page 3 of 6 S-19
Schematic 17. Power Supply board, page 4 of 6 S-20
Schematic 18. Power Supply board, page 5 of 6 S-21
Schematic 19. Power Supply board, page 6 of 6 S-22
Schematic 20. Interface board layout S-23
Schematic 21. Interface board, page 1 of 3 S-24
Schematic 22. Interface board, page 2 of 3 S-25
Schematic 23. Interface board, page 3 of 3 S-26
Schematic 24. Monopolar Control/Display board layout S-27
Schematic 25. Monopolar Control/Display board, page 1 of 13 S-28
Schematic 26. Monopolar Control/Display board, page 2 of 13 S-29
Schematic 27. Monopolar Control/Display board, page 3 of 13 S-30
Schematic 28. Monopolar Control/Display board, page 4 of 13 S-31
Schematic 29. Monopolar Control/Display board, page 5 of 13 S-32
Schematic 30. Monopolar Control/Display board, page 6 of 13 S-33
Schematic 31. Monopolar Control/Display board, page 7 of 13 S-34
Schematic 32. Monopolar Control/Display board, page 8 of 13 S-35
Schematic 33. Monopolar Control/Display board, page 9 of 13 S-36
Schematic 34. Monopolar Control/Display board, page 10 of 13 S-37
Schematic 35. Monopolar Control/Display board, page 11 of 13 S-38
Schematic 36. Monopolar Control/Display board, page 12 of 13 S-39
Schematic 37. Monopolar Control/Display board, page 13 of 13 S-40

Notes
x Force 2 Service Manual

SECTION
1
Force 2 Service Manual 1-1
1Service Warnings and Cautions
Danger
Explosion Hazard Do not install the Force 2 generator in the presence of
flammable anesthetics, gases, liquids, or objects.
For continued protection against fire hazard, replace the fuse with those having
the same type and rating as the original fuse.
Warning
Electric Shock Hazard Always unplug the generator before cleaning.
Electric Shock Hazard Do not connect a wet power cord assembly into the
generator or into the wall outlet.
Electric Shock Hazard Disconnect the power before replacing parts.
Electric Shock Hazard Do not touch any exposed wiring or conductive surface
while the generator is disassembled and energized. Never wear a grounding
strap when working on an energized generator.
Keep the handset electrode away from personnel. Use the accessory holster to
hold the handset safely.
Use the ACCESSORY output receptacle for connecting either a handswitch (three-
pin) or footswitch (one-pin) accessory, but not both at the same time. Connecting
more than one accessory to the ACCESSORY output receptacle activates both
accessories simultaneously.
Electric Shock Hazard The power FETs and other components on the supply
heatsink are at line potential. Use extreme caution when probing this circuitry.
Take appropriate precautions (such as use of isolated tools and equipment; use
of the “one hand rule,” etc.) when taking measurements or troubleshooting the
generator.

1-2 Force 2 Service Manual
Caution
This generator contains electrostatic sensitive components. When repairing the
generator, work at a static control workstation. Wear a grounding strap when
handling electrostatic sensitive components. Handle the circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic
sensitive components and circuit boards.
Electric Shock Hazard Special caution should be used when working on the
exposed Power Supply board as the heatsinks and many of the components are
floating at potentially harmful voltage potentials. Use the footswitching
ACCESSORY receptacle for generator output on the Force 2-8 PCH and Force 2-2
PCH generators.

SECTION
2
Force 2 Service Manual 2-1
2Unpacking and Installation
Unpacking the Force 2 Generator
Notify Valleylab to arrange for repair or replacement of any parts
damaged from shipping. All returns must have approval from the
Valleylab Customer Service Department. The return authorization
number must be displayed on the package label. Refer to Section 7,
Manufacturer Service, for further information.
Carefully remove the Force 2 generator from the shipping package. Save
the carton and packing materials to use when transporting the generator
or when returning it for service.
If you have any questions concerning the contents, contact Valleylab
Customer Service at 1-800-255-8522 or your Valleylab representative.
Responsibility of the Manufacturer
Valleylab is responsible for the safety, reliability, and performance of the
equipment only within the limits of the warranty and other applicable
laws if
• Installation procedures in this manual are followed.
• Assembly operations, extensions, re-adjustments, modifications, or
repairs are carried out by persons authorized by Valleylab.
• The electrical installation of the relevant room complies with local
codes and regulatory requirements such as IEC and BSI.
• The equipment is used in accordance with the Valleylab instructions
for use.

Preparing the Generator for Use
2-2 Force 2 Service Manual
Preparing the Generator for Use
The electrosurgical generator may be placed on a mounting cart available
from Valleylab or any sturdy table or platform. It is recommended that
carts have conductive wheels. Refer to hospital procedures or local codes
for detailed information.
Provide at least four to six inches of space around the sides and top of the
generator for convection cooling. Under continuous use for extended
periods of time, it is normal for the top and rear panel to be warm.
Power Requirements
The Force 2-2 PCH Electrosurgical Generator is designed to operate at
110-120 Vac nominal, 50-60 Hz.
The Force 2-8 PCH Electrosurgical Generator is designed to operate at
220-240 Vac nominal, 50-60 Hz.
Check the Power Connector
The Force 2 generator is supplied with a hospital grade power cord and a
three-prong power connector. If using the generator in an operating room
with another type of receptacle,
• International Only – The Valleylab representative in your country will
equip your generator with the proper power cord for your country.
• Domestic Only – The hospital is responsible for replacing the
connector on the power cord.
The power connector meets all requirements for safe grounding. Its
purpose should not be defeated by using extension cords or three-prong
to two-prong adapters. Periodically check the power cord assembly for
damaged insulation or connectors. Always grasp cords by the connector.
Do not pull on the cord itself.
Danger
Explosion Hazard Do not install the Force 2 generator in the presence of
flammable anesthetics, gases, liquids, or objects.

Ensure Proper Grounding
Unpacking and Installation
Force 2 Service Manual 2-3
Important
Ensure Proper Grounding
To ensure patient safety, the Force 2 generator must be properly grounded.
It is the user's responsibility to
ensure that the electrical installation
of the relevant room complies with
local codes and regulatory
requirements such as IEC and BSI.
The ground wire in the power cord connects to the unit chassis and
ensures that no dangerous currents flow from the cabinet in the event of
internal electrical failure. Do not use extension cords or three-prong or
two-prong electrical adapters.
Undesirable leakage currents are affected by the polarization of the
50-60 Hz input power. It is the responsibility of the user to ensure proper
polarity and grounding of the power outlets supplying power to the unit.
If required, use the equipotential ground cable supplied with the
generator. The equipotential ground connector is located on the rear panel
of the generator.
Perform a System Check
Before placing the Force 2 generator into clinical use, perform a system
check as described in Section 6, Power Up Self-Test.

Notes
2-4 Force 2 Service Manual

SECTION
3
Force 2 Service Manual 3-1
3Description of Controls, Indicators,
and Receptacles
This section describes the controls, indicators, and receptacles for
accessories located on the front panel of the Force 2 generator.

3-2 Force 2 Service Manual
Figure 3-1.
PCH Generator Front View
Figure 3-2.
PCH Generator Rear View
MONOPOLAR
FOOTSWITCH
BIPOLAR
FOOTSWITCH
FOREIGN EQUIVALENTS AND
U.S. PATENTS: 4416276, 4416277,
4632109, 4658819, 4658820,
4827927 WARNING: RISK OF FIRE.
REPLACE FUSE
AS MARKED.
250V, F8.0A - (110-120)
250V, F6.3A - (220-240)

Controls
Description of Controls, Indicators,
and Receptacles
Force 2 Service Manual 3-3
Controls
Standby – Press this button to place the electrosurgical generator in a hold
mode. You cannot activate the generator and all audio alarms are
silenced. The generator’s memory retains the power settings and the
display shows dashes.
Ready – Press this button to place the generator into service with power
outputs, displays, and alarms fully functional.
Monopolar – Press this button to select the monopolar footswitch control for
activating the Accessory receptacle.
Bipolar – Press this button to select the bipolar output when using the
monopolar footswitch.
Power Up –Press this button to increase power in the selected mode.
A single press of the button increases the power setting by one watt.
Continuously pressing the button gradually increases the power to
maximum.
Power Down – Press this button to decrease power in the selected mode.
A single press of the button lowers the power setting by one watt.
Continuously pressing the button gradually decreases the power to
minimum.
Pure Cut – Press this button to select cut with the lowest level of hemostasis.
Blend 1 – Press this button to select cut with minimum hemostasis.
Blend 2 – Press this button to select cut with moderate hemostasis.
Blend 3 – Press this button to select cut with maximum hemostasis.

Indicators
3-4 Force 2 Service Manual
Power Control Pencil Mode – The power control pencil feature does not have a
dedicated button to access this mode. Press the READY button and while
holding it, press the CUT POWER DOWN button. The generator sounds a
single tone and the RMOTE lamp illuminates.
Low Voltage Coag – Low voltage coag does not have a dedicated button to
access this mode. Press the READY button and while holding it, press the
COAG POWER DOWN button. The generator displays an L in the hundreds
digit of the coag power setting display.
Indicators
Standby Indicator – Indicates generator is on, but cannot activate outputs.
Ready Indicator – Indicates generator is ready for use.
Cut Mode Indicators – One of four cut mode indicators illuminates to show
the selected cut mode.
Power Setting Display – The digital power setting display is visible on the
generator in the ready mode. The displayed number indicates the
nominal power in watts. When you activate the mode, the generator
delivers this power to the patient. In the standby mode, the generator
display shows dashes.
Output Power Indicators – The indicator illuminates when that output power
(cut, coag, bipolar) activates. One of the two distinct mode indicator tones
sound in conjunction with the visual output power indicator.
Low Voltage Coag Mode Indicator – An L in the hundreds digit of the coag
power setting display indicates the low voltage coag mode selection.
Monopolar Indicator – This indicator illuminates when you select the
generator's monopolar footswitch for monopolar accessory activation.
Bipolar Indicator – This indicator illuminates when you select the generator’s
monopolar footswitch control to activate the bipolar output.