ConMed sabre 180 Service Manual Download Page 4

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3.5

Controller Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.5.1

RUN Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.5.2

CAL Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3.5.2.1

CAL NOVRAM Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3.5.2.2

CAL Mode Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3.6

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3.6.1

Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3.6.2

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3.7

Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3.7.1

Mains Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3.7.2

Low Voltage Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3.7.3

RF Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

4.0

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.1

General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2

Periodic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2.1

Ground Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2.2

Mains Frequency Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2.3

Aspen Return Monitor (A.R.M.) Calibration Check . . . . . . . . . . . . . . . . . .4-2

4.2.4

RF Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.2.5

RF Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.2.6

RF Leakage from Inactive Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.3

Recalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.3.1

CAL Mode General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.3.2

RF Output Power Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4.3.3

Aspen Return Monitor (A.R.M.) Calibration . . . . . . . . . . . . . . . . . . . . . . .4-8

4.4

Option Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.4.1

Mains Voltage Strapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.4.2

Power-up Default Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4.5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4.5.1

Using and Interpreting HLP Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4.5.2

Diagnostic Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4.5.2.1

Watchdog Timer Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4.5.2.2

Pseudo RUN Diagnostics (dI2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.5.3

Base Voltage Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.5.4

Waveform Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4.5.5

Aspen Return Monitor (A.R.M.) Troubleshooting . . . . . . . . . . . . . . . . . . . .4-14

4.5.6

Power Amplifier Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4.5.7

Continuity Detector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.5.8

RF Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

5.0

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2

Assembly Structure and Parts Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2.1

Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2.2

Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.2.3

A4 Power PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.2.4

A3 Controller PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.2.5

A2 Display PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.2.6

A1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.3

Parts Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

APPENDIX A

HLP Codes and Possible Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Section

Title

Page

Summary of Contents for sabre 180

Page 1: ...Service Manual...

Page 2: ...es other than intended U S Patent Nos 4 569 345 4 617 927 4 848 335 4 961 739 and other patents pending 1996 CONMED Corporation Mailing Address 310 Broad Street Utica New York 13501 Shipping Address 7...

Page 3: ...erating Instructions 2 7 2 5 1 Preliminary Setup 2 7 2 5 2 Operation 2 8 2 6 User Maintenance 2 8 2 6 1 General Maintenance Information 2 8 2 6 2 Cleaning 2 9 2 6 3 Periodic Inspection 2 9 2 6 4 Perio...

Page 4: ...urn Monitor A R M Calibration 4 8 4 4 Option Selection 4 9 4 4 1 Mains Voltage Strapping 4 9 4 4 2 Power up Default Selection 4 10 4 5 Troubleshooting 4 11 4 5 1 Using and Interpreting HLP Codes 4 11...

Page 5: ...er Waveforms 3 10 3 6 Base Voltage Generator Transfer Curve 3 16 3 7 Basic Inverting Break Point Amplifier 3 16 5 1 Access Fastener Locations 5 2 5 2 Major Assembly and Component Locations 5 2 5 3 Fun...

Page 6: ...This page intentionally left blank...

Page 7: ...a time for maximum patient and operator safety Interlocked controls prevent mishaps in the event of conflicting commands POWER ADJUSTABLE WHILE ACTIVAT ED The power settings can be adjusted while the...

Page 8: ...ses is properly grounded and correctly polarized Do not use ground cheater plugs or extension cords Do not place liquid containers on top of the unit Wipe spilled liquids off the unit immediate ly To...

Page 9: ...d or isolated at 60 Hz The risk of burns can be reduced but not eliminated by placing the electrodes of probes as far away as possible from the electrosurgical site and the return electrode Protective...

Page 10: ...be after use An alternative is to wait a few seconds after activation for the tip to cool and then place the accessory into the sup plied holster Electrosurgical currents can produce severe elec trica...

Page 11: ...tion in any other posi tion Consult the factory for advice before making any modifications to the unit Ensure that the RUN RST CAL switch is set to RUN and that the two top cover screws are tight ened...

Page 12: ...Return 2 pin A R M REM capable Bipolar Two 1 4 6 4mm banana jacks Footswitch 4 pin MS connector for Aspen dual treadle footswitch ALARMS Return Electrode 1000 Hz 65 dbA Single Foil acceptance 0 10 oh...

Page 13: ...ch mode while Figures 1 2 1 6 illustrate output power delivered to a range of load resistances for each mode FIGURE 1 1 OUTPUT POWER VS POWER SETTING FIGURE 1 2 PURE CUT LOAD REGULATION 100 75 50 25 0...

Page 14: ...1 4 BLEND 2 CUT LOAD REGULATION POWER OUTPUT WATTS 70 60 50 40 30 20 10 0 0 500 1000 1500 2000 LOAD RESISTANCE OHMS BLEND 1 65W BLEND 1 35W POWER OUTPUT WATTS 70 60 50 40 30 20 10 0 0 500 1000 1500 2...

Page 15: ...LAR COAG REGULATION FIGURE 1 6 BIPOLAR COAG REGULATION POWER OUTPUT WATTS 100 80 60 40 20 0 0 500 1000 1500 2000 LOAD RESISTANCE OHMS 80W 40W POWER OUTPUT WATTS 50 25 0 10 50 100 500 1000 LOAD RESISTA...

Page 16: ...SWITCHED MONOPOLAR ACCESSORIES HIGH VOLTAGE CAUTION EQUIPMENT HAS HIGH VOLTAGE OUTPUT CAPABLE OF CAUSING PHYSIOLOGICAL EFFECTS BIPOLAR OUTPUT CONNECTION FOR BIPOLAR ACCESSORIES FOOTSWITCHED BIPOLAR OU...

Page 17: ...ervice Manual Results of that testing should be compared to the results tabulated on the factory Test Data Sheet that is supplied with each unit This data should be retained for future reference and c...

Page 18: ...ion tone sounds While depressing the Coag treadle turn the Coag Power Control clockwise The power should increase from zero to 5 watts Turn the Coag Power Control coun terclockwise and the power shoul...

Page 19: ...the RESISTANCE bar graph progressively illuminates 2 3 2 Preliminary Performance Testing After the unit passes the Preliminary Functional Tests of Paragraph 2 3 1 preliminary performance testing may...

Page 20: ...or resistance and clears return monitor alarm 6 9 PAD SELECTION Selects whether return monitor is to operate with SINGLE foil non monitoring or DUAL foil contact quality moni toring return electrodes...

Page 21: ...olar cords with 1 4 banana plugs The small hand switch pin is unused Output is delivered only in BIPOLAR COAG mode when coag footswitch is depressed 4 RETURN ELECTRODE JACK Accepts Industry standard A...

Page 22: ...FOOT SWITCH CONNECTOR Accepts Aspen dual treadle foot switch such as Cat No 60 5104 001 See below for connections 4 VOLUME CONTROL Sets volume of acti vation tones over specified range Does not affect...

Page 23: ...ired bipolar accessory to the two blue bipolar banana jacks Although hand switched bipolar accessories and cords may be used with this unit they will be activated only using the foot switch CAUTION Al...

Page 24: ...rmal damage in biopsy samples Monopolar active electrode size and geometry are significant in that a large electrode lacking sharp features e g a ball electrode will have no ten dency to cut independe...

Page 25: ...ions 1 Default settings on power up may be Last used or those power and mode settings when the unit was last activated Factory preset Zero power pure cut and monopolar coag The last used pad selection...

Page 26: ...tive hand switch RETURN MONITOR ALARM PAD mode selection incorrect Monitor SET not pressed in DUAL mode Return electrode not connected Defective return electrode Dual foil electrode placed on poor sit...

Page 27: ...along with further detail regarding the circuitry shown in Fig 5 4 is discussed in Sect 3 7 3 2 RF OUTPUT SECTION Refer to Figure 5 7 for the schematic diagram This section is located on the forward...

Page 28: ...riven from the A3 PWB via the VARM signal line This current feeds into the center tap of T4 primary The voltage on the cen ter tap is the average of the two collector voltages so it appears as a full...

Page 29: ...Cut 50W O C 200V div 1uS div PHOTO 5 Monopolar Blend 1 65W O C 200V div 10uS div PHOTO 2 Monopolar Pure 100W 500 ohm 200V div 1uS div PHOTO 4 Monopolar Pure Cut 50W 500 ohm 100V div 1uS div PHOTO 6 Mo...

Page 30: ...TO 9 Monopolar Coag 80W O C 1000V div 10uS div PHOTO 11 Monopolar Coag 40W O C 1000V div 5uS div PHOTO 8 Monopolar Blend 2 50W 500 ohm 200V div 10uS div PHOTO 10 Monopolar Coag 80W 500 ohm 500V div 10...

Page 31: ...HOTO 15 Bipolar 50W 50 ohm 50V div 10uS div PHOTO 17 Bipolar 25W O C 100V div 10uS div PHOTO 14 Bipolar 50W O C Expanded Scale 100V div 1uS div PHOTO 16 Bipolar 50W 50 ohm Expanded Scale 50V div 1uS d...

Page 32: ...o 2 55 Vdc at U19 16 This voltage is compared to BVARM by comparator U23 to drive ARM COMP at U23 13 Every 12 msec the micro processor reads the ARMCOMP line in response to a sequence of DAC voltages...

Page 33: ...3 7 Q5 C Q6 C T4 1 U2 3 Q10 D Figure 3 2 A R M Oscillator Waveforms RL 50 ohms 2V div 5uS div Figure 3 3 Continuity Detector Waveforms 10V div 2uS div...

Page 34: ...ance is less than about 400 ohms Q14 will draw base current via voltage divider R60 61 The cor responding collector current flows through the LED in optical isolator U5 This produces a beam of light w...

Page 35: ...bing some of the power that could other wise be supplied to Z1 This mode is not as effi cient as saturated operation because Q1 sees simultaneous voltage and current However the current at this point...

Page 36: ...ector bus COLL A4TP16 and the FET GATE A4TP9 500V DIV Q7 C COLL GATE 10V DIV 500nS DIV Figure 3 5a Pure Cut 100W Open Circuit 500V DIV COLL Q7 C GATE 10V DIV 500nS DIV Figure 3 5c Pure Cut 25W 500 ohm...

Page 37: ...polar Coag 40W 500 ohm 200V DIV Q7 C COLL GATE 10V DIV 2uS DIV Figure 3 5g Monopolar Coag 80W 500 ohm 200V DIV Q7 C COLL GATE 10V DIV 2uS DIV Figure 3 5f Monopolar Coag 80W Open Circuit 100V DIV COLL...

Page 38: ...ould a failure occur in the CPU that prevents the detection of a problem thus allowing pro gram execution in a random manner the Sabre 180 is designed so that the WDT detects the problem The WDT shuts...

Page 39: ...will both be high resulting in U6 3 going low and resetting the second stage This causes the same results as the late strobe described above Note that the signal which causes the WDT to latch and ign...

Page 40: ...input for the external interrupt IFAIL generated by the current monitor The Address Decoder U9 is used to select external I O devices for reading and writing High order address to the decoder inputs A...

Page 41: ...differential amplifier 1 4 of U21 an inverting breakpoint summing amplifier 1 4 of U21 and power transistor A8Q1 U20 provides the input voltage selected by the micro processor on the bus AD0 AD7 R25 i...

Page 42: ...Section 3 4 5 for a description of ISENSE is voltage divided and lowpass filtered by R39 R49 and C61 Whenever the resulting voltage exceeds the reference input voltage provided by the DAC U19 a IFAIL...

Page 43: ...er to Figure 5 6b The operation of the Tone Generator is a voltage controlled current source that is switched on and off at the frequency of the desired tone TONE is generated by the micro processor A...

Page 44: ...Watchdog Timer circuit on each pass through the loop Hand control foot switch and return electrode inputs are monitored for changes The validity of the input conditions are checked The following condi...

Page 45: ...bP if any point is adjusted then all other points which have not yet been selected and activated looked at are declared Uncalibrated Uncalibrated points are flagged by flashing target current displays...

Page 46: ...ot return to the CAL Menu Once entered exit is gained only via RST or cycling power Once a CAL Menu selection which produces output power is entered the WDT Diagnostics dI 2 Menu selection is no longe...

Page 47: ...and circuit common to earth This cord should always be connected to a properly grounded AC receptacle to insure that an internal mains to chassis short does not create a serious shock hazard to the us...

Page 48: ...of switchmode control IC known as a Power Factor Controller PFC This device operates to force the low frequency current draw from the 40V source to retain the same sinusoidal waveshape as the 40U inpu...

Page 49: ...d pulled low to the OFF state by the microcontroller via A3U22 14 The microcon troller enables PFCEN only during activation The switcher may be shut down for troubleshoot ing by shorting PFCEN at TP14...

Page 50: ...3 24 This page intentionally left blank...

Page 51: ...structions for cleaning and periodic physical inspection are contained in Sections 2 6 2 and 2 6 3 of this manual Functional testing instruc tions for controls and displays appear in Section 2 3 1 Whe...

Page 52: ...f the resistance read during any of the following tests is above the upper limit repeat the test carefully stopping in each 1 ohm step for at least 1 second Procedure 1 Disconnect all accessories from...

Page 53: ...ed with some loss of accu racy due to load regulation variations See Section 1 3 An RF output power instrument may be con structed using a 500 ohm 100W and 50 ohm 50W non inductive resistors and a set...

Page 54: ...e surface 3 Set the unit for full power in Monopolar Coag and Bipolar Coag Connect the 200 ohm nonin ductive resistor in series with fused RF ammeter and a common earth ground the footswitch con necto...

Page 55: ...led active connector WARNING HAND CONTROL ACTIVATIONS SHOULD BE KEYED USING 3 OR LESS WELL INSULATED JUMPER S USE OF AN INSULATING ROD TO INSERT THE JUMPER IS ADVISED TO PREVENT RF BURNS CAUTION To av...

Page 56: ...nalled by a continuous Lamp Test with all display elements steadily lit 5 Release and press PAD again The CC menu selection will appear in the Coag window and 300 400 or 500 will appear in the Cut Opt...

Page 57: ...lected resistance The lowest Pure Cut and Monopolar Coag calibration target current values in RF Amperes will appear in the power win dows The leading decimal is assumed in the Coag window 5 Use the f...

Page 58: ...is flashing re enter that mode and complete checking any missed flashing targets 20 If desired the ARM Calibration mode Section 4 3 3 below may be entered at this time in lieu of returning to RUN Mode...

Page 59: ...cess instructions 4 4 1 Mains Voltage Strapping The unit is factory configured fused and labeled for 100 115 or 230V 50 60Hz AC operation Field reconfiguration is simple but the unit mains fuses must...

Page 60: ...rightness after deactivation Normal activation indications should operate 16 If the above checks pass close the top cover and secure it with the two rear panel screws 17 The unit may now be returned t...

Page 61: ...e and all mechanical connections are secure Check all fuses Check the operating instructions and see if the suspected problem was actually designed to work that way 4 5 1 Using and Interpreting HLP Co...

Page 62: ...t switch One of the selections places pulses contin uously inside the normal Watchdog Timer win dow while the others are too early and too late It is also possible to set RLYENA to verify opera tion o...

Page 63: ...n allow the fault current to flow for the duration of the activation This may result in damage to other components which had previously been spared by the microproces sor s fast response to overcurren...

Page 64: ...Also check bypass capacitors A4C59 A3C25 and low pass filter capacitor A3C38 If the Resistance Indicator vs resistance test fails check BVARM at A3TP16 with 10 and 150 ohms connected to the Return Ele...

Page 65: ...to its associated circuitry Fault iso lation may proceed most expediently by compar ing voltages in the faulty circuit to those in an operational one The open circuit voltage on the switching lines sh...

Page 66: ...20 ohm 250W power resistor from RFSUP to GROUND The voltage at RFSUP should be in between 68 76V with no more than 6V peak to peak 100Hz 50Hz AC line or 120Hz 60Hz AC line ripple MAINS RFSUP INPUT Vdc...

Page 67: ...d bottom to prevent interference during high power activation from disrupting the display processor and causing a HLP 12 shutdown Refer to Section 1 1 4 for Precautions When Testing or Servicing CAUTI...

Page 68: ...NEL A2 DISPLAY PWB A3 CONTROL PWB A8Q1 POWER UP DEFAULT JUMPER JMP1 A8VR1 A6SP1 A6 BASE ASSY A5 OUTPUT PANEL S1 A6TB1 A6T1 A4 POWER PWB A6R1 A4 HEATSINK MTG SCREWS 4 PLACES Figure 5 1 Access Fastener...

Page 69: ...arnesses aside Lift the A4 heatsink assembly vertically out of the unit While the A4 PWB is out of the unit take advan tage of the opportunity to remove any debris which may have accumulated in the ba...

Page 70: ...the reverse process Place spacer washers on the encoder bushings prior to mount ing on the Control Panel these washers are thick er than the flat washers used under the encoder bushing nuts Install a...

Page 71: ...4LS00 or A3U8 74LS32 4 Watchdog Timer Initialization WDT timing parts incorrect pulse width is Microprocessor frequency incorrect incorrect Faulty A3U7 4538 Faulty A3U3 8031 Faulty A3U6 74LS00 Faulty...

Page 72: ...es 9 Attempted entry to Cal Mode A3S1 set in Cal position Cal mode without Faulty Disconnected control panel PAD button pressed Faulty A2U1 10 Incomplete Cal Cal mode One or more Cal points not calibr...

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