Valleylab Force FX-8C Service Manual Download Page 137

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Correcting Malfunctions

Troubleshooting

Force FX-8C Service Manual

6-9

Abnormal neuromuscular
stimulation (stop surgery
immediately)

Metal-to-metal sparking

Check all connections to the generator, patient return
electrode, and active electrodes.

Can occur during coag

Use a lower power setting for the Fulgurate and Spray
modes or select the Desiccate mode.

Abnormal 50–60 Hz leakage currents

Inside the generator, carefully inspect for damage that
may cause shorting between the AC line voltage and
connected patient components.

Situation

Possible Cause

Recommended Action

Summary of Contents for Force FX-8C

Page 1: ...Service Manual Force FX 8C Electrosurgical Generator with Instant Response Technology...

Page 2: ...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...

Page 3: ...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...

Page 4: ...l 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 Footswit...

Page 5: ...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...

Page 6: ...aces 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 Temperatu...

Page 7: ...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 Re...

Page 8: ...ront 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 Le...

Page 9: ...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 Comp...

Page 10: ...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...

Page 11: ...coag two footswitching instruments 5 9 Figure 5 8 Connections for combined monopolar ultrasonic surgery 5 10 Figure 5 9 Leakage current test circuit per IEC 60601 1 5 21 Figure 7 1 Removing and discon...

Page 12: ...rd schematic page 2 of 2 S 11 Schematic 12 Power supply RF board layout S 12 Schematic 13 Power supply RF board schematic page 1 of 7 S 13 Schematic 14 Power supply RF board schematic page 2 of 7 S 14...

Page 13: ...manual provides instructions for servicing the Valleylab Force FX 8C Electrosurgical Generator with Instant Response Technology This section introduces the features and components of the generator an...

Page 14: ...e monopolar cut modes low pure and blend Three monopolar coag modes desiccate low fulgurate medium and spray high Support for simultaneous coagulation The Valleylab REM Contact Quality Monitoring Syst...

Page 15: ...eraction of the main components and circuit board descriptions refer to Section 4 Principles of Operation Service Personnel Safety Before servicing the generator it is important that you read understa...

Page 16: ...connected to the Bipolar Instrument receptacle only Improper connection may result in inadvertent generator activation or a REM Contact Quality Monitor alarm Set power levels to the lowest setting be...

Page 17: ...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 a...

Page 18: ...calibrating the voltage sense gain for the Low and Pure cut modes Do not activate the generator with any load resistor lower than 2000 ohms while calibrating the voltage sense gain for the Blend mode...

Page 19: ...SECTION 2 Force FX 8C Service Manual 2 1 2Controls Indicators and Receptacles This section describes the front and rear panels including all controls indicators receptacles the fuse drawer and ports...

Page 20: ...Bipolar controls Cut controls Coag controls CEM indicator Bipolar instrument receptacle Monopolar 1 CEM instrument receptacle Monopolar 2 instrument receptacle Power switch This switch supplies power...

Page 21: ...on tone sounds Power buttons Press to increase the power Press to decrease the power Macro mode button Select for macrobipolar output Standard mode button Select for standard bipolar tissue desiccatio...

Page 22: ...acle Connect a footswitching instrument with a two pin connector or Connect a handswitching instrument with a three pin connector Caution Accessories must be connected to the proper receptacle type In...

Page 23: ...one sounds Power buttons Press to increase the power Press to decrease the power Mode indicators Illuminate green when you press the corresponding mode button Blend mode button Select for slower cutti...

Page 24: ...n fulgurate mode Fulgurate mode button Select to fulgurate an area of tissue with a spray of sparks This unit is equipped with an additional fulgurate mode which incorporates a lower crest factor LCF...

Page 25: ...lar instrument to the Monopolar 2 Instrument receptacle A single pin footswitching instrument or a three pin handswitching instrument REM Alarm Indicator This indicator illuminates red until you prope...

Page 26: ...r Panel Figure 2 5 Controls and receptacles on the rear panel Volume control Power entry module Monopolar Footswitch receptacles Option panel Bipolar Footswitch receptacle Equipotential grounding lug...

Page 27: ...e instrument that is connected to the Monopolar 1 CEM Instrument receptacle on the front panel Connect a two pedal monopolar footswitch to the Monopolar 2 Footswitch receptacle The connected footswitc...

Page 28: ...ones that sound when the generator is activated activation tone To ensure that the surgical team is alerted to inadvertent activation these tones cannot be silenced To increase the volume of activatio...

Page 29: ...cations Figure 2 7 The three ports behind the option panel Caution To avoid product damage do not operate the Force FX 8C without an appropriate cover plate in place Expansion port Allows a connected...

Page 30: ...Notes 2 12 Force FX 8C Service Manual...

Page 31: ...C 77 F and a nominal input power voltage Performance Characteristics General Output configuration Isolated output Cooling Natural convection side and rear panel vents fan Display Eight digital seven s...

Page 32: ...millibars Warm up time If transported or stored at temperatures outside the operating temperature range allow one hour for the generator to reach room temperature before use Ambient temperature range...

Page 33: ...o Volume The audio levels stated below are for activation tones bipolar cut and coag and alarm tones REM and system alarms at a distance of one meter Alarm tones meet the requirements for IEC 601 2 2...

Page 34: ...ds the standard range of safe resistance below 5 ohms or above 135 ohms or when the initial measured contact resistance increases by 40 whichever is less the REM Alarm indicator flashes red a tone sou...

Page 35: ...following signals Pin 2 isolated transmit serial data output transmit line Pin 3 isolated receive serial data input receive line Pin 5 isolated ground reference for transmit and receive 15 pin connec...

Page 36: ...e current ground open 300 A Source current patient leads all outputs Normal polarity intact ground 10 A Normal polarity ground open 50 A Reverse polarity ground open 50 A Sink current at high line all...

Page 37: ...lation range 104 132 Vac Input mains voltage full regulation range 208 264 Vac Input mains voltage operating range 85 132 Vac Input mains voltage operating range 170 264 Vac Mains current maximum Idle...

Page 38: ...rator output is floating isolated with respect to ground DANGER Explosion risk if used with flammable anesthetics To reduce the risk of electric shock do not remove the cover Refer servicing to qualif...

Page 39: ...ated Valleylab electrosurgical generator the Force FX 8C generator operates without interference The generator minimizes electromagnetic interference to video equipment used in the operating room Elec...

Page 40: ...rcuit P P Voltage max Rated Load max Power max Crest Factor Bipolar Precise Standard Macro 230 V 170 V 430 V 450 V 320 V 750 V 100 100 100 70 W 70 W 70 W 1 5 1 5 1 5 Monopolar Cut Low Pure Blend 770 V...

Page 41: ...0 31 32 33 34 35 36 37 38 39 40 45 50 55 60 65 70 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 45 50 55 60 65 70 75 80 85 90 95 100 11...

Page 42: ...r followed by constant voltage The maximum output voltage is controlled to reduce capacitive coupling and video interference and to minimize sparking 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20...

Page 43: ...ring at 27 kHz intervals 50 duty cycle Desiccate 1 240 kHz sinusoid repeated at 39 kHz 8 duty cycle Desiccate 2 393 kHz sinusoid Desiccate 3 393 kHz sinusoid Fulgurate 470 kHz damped sinusoidal bursts...

Page 44: ...t specific power settings Bipolar Graphs The insulating surface described in IEC 601 2 2 was used to obtain the bipolar output measurements Figure 3 1 Output power versus impedance for Precise bipolar...

Page 45: ...3 15 Figure 3 3 Output power versus impedance for Standard bipolar mode Figure 3 4 Standard bipolar mode output power vs peak voltage 0 200 400 600 800 1000 80 70 60 50 40 30 20 10 0 70 W 35 W Load R...

Page 46: ...gure 3 5 Output power versus impedance for Macrobipolar mode Figure 3 6 Macrobipolar mode output power vs peak voltage 0 200 400 600 800 1000 80 70 60 50 40 30 20 10 0 70 W 35 W Load Resistance ohms O...

Page 47: ...using short 0 5 meter leads Figure 3 7 Output power versus impedance for Low cut mode Figure 3 8 Low cut mode output power vs peak voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 325 300 275...

Page 48: ...ersus impedance for Pure cut mode Figure 3 10 Pure cut mode output power vs peak voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 325 300 275 250 225 200 175 150 125 100 75 50 25 0 300 W 150 W...

Page 49: ...11 Output power versus impedance for Blend cut mode Figure 3 12 Blend cut mode output power vs peak voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 250 225 200 175 150 125 100 75 50 25 0 200...

Page 50: ...ort 0 5 meter leads Figure 3 13 Output power versus impedance for Desiccate 1 coag mode Figure 3 14 Desiccate 1 coag mode output power vs peak voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 1...

Page 51: ...ons Force FX 8C Service Manual 3 21 Figure 3 15 Desiccate 2 coag mode load resistance vs output power Figure 3 16 Desiccate 2 coag mode output power vs peak voltage Load Resistance ohms Output Power w...

Page 52: ...e FX 8C Service Manual Figure 3 17 Desiccate 3 coag mode load resistance vs output power Figure 3 18 Desiccate 3 coag mode output power vs peak voltage Load Resistance ohms Output Power watts Output P...

Page 53: ...3 19 Output power versus impedance for Fulgurate coag mode Figure 3 20 Fulgurate coag mode output power vs peak voltage 140 120 100 80 60 40 20 0 120 W 60 W 0 200 400 600 800 1000 1200 1400 1600 1800...

Page 54: ...t power versus impedance for LCF Fulgurate mode Figure 3 22 LCF Fulgurate mode output power vs peak voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 140 120 100 80 60 40 20 0 120 W 60 W Load Re...

Page 55: ...gure 3 23 Output power versus impedance for Spray coag mode Figure 3 24 Spray coag mode output power vs peak voltage 0 200 400 600 800 1000 1200 1400 1600 1800 2000 140 120 100 80 60 40 20 0 120 W 60...

Page 56: ...Notes 3 26 Force FX 8C Service Manual...

Page 57: ...l components interact The circuitry resides on four printed circuit boards the Control board the Display board the Footswitch board and the Power Supply RF board This section includes the following in...

Page 58: ...Block Diagram 4 2 Force FX 8C Service Manual Block Diagram...

Page 59: ...works in conjunction with the Valleylab CUSA System 200 and CUSA EXcel for procedures where ultrasonic electrosurgery is desirable When you connect a CUSA handpiece with CEM nosecone to the generator...

Page 60: ...ct resistance baseline resistance between the patient and the patient return electrode If the tissue impedance at the return electrode decreases during electrosurgery the REM system resets the baselin...

Page 61: ...splay board through a 64 pin ribbon cable Microcontrollers Two microcontrollers on the Control board control the Force FX 8C generator These microprocessors communicate with each other through a share...

Page 62: ...power for the 2K x 8 external RAM on the PSD413 device U3 used by the main microcontroller The battery backed RAM stores calibration constants last setup parameters and temporary data Feedback Microco...

Page 63: ...vice incorporates forty individually programmable I O pins divided into five 8 bit ports Twenty four of the general I O pins can alternatively be used as I O for two PLDs featuring a total of 59 input...

Page 64: ...U15 provides 4 channel 8 bit D A capabilities for the feedback microcontroller to output 0 to 5 Vdc analog voltages Waveform Generation T_ON ASIC A dedicated 89C54 microcontroller U9 generates the RF...

Page 65: ...ain microcontroller checks to make sure the T_ON average signal is within 15 counts of the calibrated value During wak control in the coag modes the T_ON average rises an indeterminate amount Due to t...

Page 66: ...ssing this test the feedback mode of the generator is taken into account In current control mode the current calculated by the backup sensors is not allowed to deviate from the current calculated by t...

Page 67: ...ge is held at constant output current according to I P R 1 2 where I is the output current P is the power set by the user and R is the constant current to constant power impedance switchpoint Constant...

Page 68: ...e also contains nine LEDs one for each mode A 25 pin flat ribbon cable connects the membrane keyboard switches and LEDs to the Display board Power Switch A double pole single throw switch snaps into t...

Page 69: ...ator lamps are controlled by the BIP_LMP CUT_LMP and COAG_LMP signals These signals originate from port A of the main microcontroller programmable peripheral U3 on the Control board Buffers in U1 turn...

Page 70: ...atively small capacitance value of 0 1 F to filter higher frequency noise C7 C8 and C9 have a relatively large capacitance value of 47 F to supply the large spikes of current for the LEDs generated by...

Page 71: ...footswitch connector J4 accepts a bipolar footswitch and provides footswitching capability for the Bipolar Instrument receptacle on the front panel Capacitors C39 C46 provide filtering that blocks hig...

Page 72: ...R31 and allowing U6A to oscillate U6A is a relaxation oscillator whose frequencies are determined by the RC time constants of R30 C35 and C18 This design allows the oscillator to produce two distinct...

Page 73: ...fier by C25 to eliminate the need for well controlled input biasing The voltage gain of U7 is set to about 20 by floating its gain select pins Because the U1 output signal is internally biased to Vcc...

Page 74: ...r switch is mounted on the front panel The receptacle filter is mounted on the rear panel of the generator AC line fuses are changeable from the rear of the generator Auto Mains Switching Circuitry Th...

Page 75: ...U5 is used in the voltage mode The output of the regulator is adjustable from approximately zero 0 to 180 Vdc The full bridge consists of four power MOSFETs Q1 Q3 Q4 and Q5 that operate at AC line pot...

Page 76: ...h modulated by comparing ECON with the internal oscillator ramp waveform At the start of an oscillator cycle an output is turned on It turns off when the ramp voltage crosses the ECON level The two ou...

Page 77: ...ng capacitors an RF output L C C filter output directing relays and topology selecting relays Also included in this section are the RF voltage and current sense circuits and a switched damping network...

Page 78: ...er after the last op amp with full scale being 5 Vdc The current sense circuit which uses current transformers T6 and T8 works the same as the voltage sense circuit T6 senses bipolar current and T8 se...

Page 79: ...the advantages of zero voltage switching in the MOSFET The T_ON signal is a continuous pulse train with a 423 ns pulse width Coag Modes In the Fulgurate and Spray coag modes K2 is set so that diode CR...

Page 80: ...moved from tissue The sparking occurs because the RF stage tuning results in a higher natural gain at light loads than at heavy loads Thus during sudden transitions from heavy to light loads the outpu...

Page 81: ...voltage amplitude 80 10 kHz at the REM connector J17 R98 is a temperature compensating thermocouple that cancels temperature drift from the components forming the oscillator The REM transformer T10 p...

Page 82: ...COAG switch closure in a handheld accessory Switch closure is detected by comparing the voltage across the switch to a divider reference with comparators U32 U33 and U34 Current limiting resistors in...

Page 83: ...n the temperature drops to 35 C the circuit reverts to its low temperature state and the cooling fan switches off Thermal Sensing High Temperature Limit A reference voltage is applied to the non inver...

Page 84: ...Notes 4 28 Force FX 8C Service Manual...

Page 85: ...5Setup Tests and Adjustments After unpacking or after servicing the Force FX 8C generator set it up and verify that it functions correctly If the generator does not satisfactorily complete the self t...

Page 86: ...ding lug on the rear panel of the generator Then connect the cable to earth ground 4 Plug the generator power cord into the rear panel receptacle 5 Plug the generator power cord into a grounded recept...

Page 87: ...s performed successfully 7 If the self test is successful a tone sounds Verify the following Indicators above the default mode buttons Standard bipolar Pure cut and Fulgurate coag illuminate green Eac...

Page 88: ...d a handswitching or footswitching instrument Warning Electric Shock Hazard Do not connect wet accessories to the generator Ensure that all accessories and adapters are correctly connected and that no...

Page 89: ...ettings press the Recall button 2 To set the Bipolar mode press the Precise Standard or Macro button The corresponding indicator illuminates green 3 To increase the power for the selected mode press t...

Page 90: ...ent using Monopolar 1 Footswitch receptacle and Monopolar 1 CEM Instrument receptacle Warning Electric Shock Hazard Do not connect wet accessories to the generator Ensure that all accessories and adap...

Page 91: ...ing instrument using Monopolar 2 Footswitch receptacle and Monopolar 2 Instrument receptacle Figure 5 5 Monopolar connection handswitch activation and a monopolar handswitching instrument using either...

Page 92: ...d button and hold for two seconds A tone sounds and the L disappears from the left side of the Coag display 5 To increase the power for the selected coag mode press the blue up arrow button To decreas...

Page 93: ...ators are the same type both are isolated or both are ground referenced However the two Patient return electrode Monopolar instrument Monopolar instrument or CUSA handpiece with CEM nosecone Caution D...

Page 94: ...electrode as close as possible to the site of the surgery to be performed by the generator to which it is connected Ensure that the two patient return electrodes do not touch Connecting the CUSA Handp...

Page 95: ...s available the maximum power is limited to 70 watts Changing the Mode Verify the selected mode with the surgeon You cannot change the mode while the generator is activated To change the mode press th...

Page 96: ...otswitch To reduce the possibility of alternate site burns that may be caused by RF leakage currents avoid unnecessary and prolonged activation of the generator If you use bipolar output when a return...

Page 97: ...current and ground resistance Recommended Test Equipment Digital voltmeter Fluke 77 or 87 or equivalent True RMS voltmeter Fluke 8920 or equivalent Oscilloscope Tektronix 2445 or equivalent Leakage c...

Page 98: ...ctions or damage Check for a secure fit by inserting the monopolar footswitch connector into the receptacle If the connection is loose replace the receptacle Refer to Front Panel Footswitch Receptacle...

Page 99: ...irmly seated 4 Inspect each board for damaged components wires cracks and corrosion If you find evidence of damage on the Control board Display board or Footswitch board replace the board Refer to Con...

Page 100: ...self test is performed successfully 2 If the self test is successful a tone sounds Verify the following Indicators above the default mode buttons Standard bipolar Pure cut and Fulgurate coag illuminat...

Page 101: ...the resistance to 30 ohms and verify that the REM indicator illuminates green 6 Decrease the resistance to 10 ohms and verify that the REM indicator illuminates green 7 Decrease the resistance to 3 o...

Page 102: ...the rear panel 3 Press the Precise button and set the bipolar power to 10 watts 4 Test the output current for the selected Bipolar mode a Press the footswitch pedal and while activating the generator...

Page 103: ...output jacks at the end of the test cables 5 Connect the monopolar footswitch to the Monopolar 1 Footswitch receptacle on the rear panel of the generator C Press the Pure button D Press the Cut up or...

Page 104: ...ed on the voltmeter setting and the current transformer you are using calculate and record the output current E Press the Fulgurate button and repeat step 2 D F Press the Med Fulgurate button and hold...

Page 105: ...olts mV and connect the leakage current test circuit 2 Turn on the generator 3 Measure between all the output receptacles including the Patient Return Electrode receptacle and earth ground Record the...

Page 106: ...nd open the leakage current is less than or equal to 300 A If the leakage current is greater than 300 A call the Valleylab Service Center Output Receptacles and REM Sink Current 1 Set the DVM to AC vo...

Page 107: ...1 Footswitch receptacle on the rear panel 4 Activate the footswitch in each Monopolar mode at the maximum control setting Record the leakage current If using the leakage table leakage current should...

Page 108: ...re not adjustable but must be verified Notice After completing any calibration step proceed to the next step to save the values from the completed calibration step Calibration Step and Description Adj...

Page 109: ...ppears in the Cut and Coag displays You use the Cut and Coag up or down arrow buttons to adjust the displayed values 1 If the generator is off turn it on If you removed and or replaced the battery ala...

Page 110: ...rn off the generator to exit calibration mode or To exit calibration mode without saving the changes for the present calibration step turn off the generator Step 1 Verify the Generator Data In calibra...

Page 111: ...on the Control board A Verify that the Bipolar display shows calibration step number 2 B To select the month press the Coag up or down arrow buttons until the correct value 1 12 appears in the Coag di...

Page 112: ...press the Coag up or down arrow buttons until the correct value 0 23 appears in the Coag display Examples For 2 AM set the hour value to 2 For 2 PM set the value to 14 C To display the minute value p...

Page 113: ...the chassis and sliding it down Install the five screws that secure the cover to the chassis C Open circuit the REM connection Press the Coag up arrow button once Verify that 10 appears in the Coag di...

Page 114: ...wo test cables to the Bipolar Instrument receptacle b Pass one test cable through the current transformer and connect the current transformer to the voltmeter c Connect the 10 ohm resistor across the...

Page 115: ...t receptacle Pass the test cable through the current transformer and connect the current transformer to the voltmeter b Use a test cable to short the two pins on the Patient Return Electrode receptacl...

Page 116: ...go to the next calibration step press the Bipolar up arrow button Next check the voltage sense gain factor as described in Step 6 Check and Adjust the Voltage Sense Gain Step 6 Check and Adjust the Vo...

Page 117: ...the Precise and Macro modes adjusts automatically 3 Disconnect the test cables and remove the 1000 ohm resistor Checking the Voltage Sense Gain for Monopolar Output 1 Connect the test equipment for m...

Page 118: ...If the output current reading was too high raise the V factor by pressing the Coag up arrow button If the reading was too low lower the V factor by pressing the Coag down arrow button Repeat this ste...

Page 119: ...press the Cut up or down arrow buttons Repeat this step until the voltmeter reading is within the stated range The Z factor for the Precise and Macro modes is adjusted automatically 3 Disconnect the t...

Page 120: ...or If the reading was too low raise the Z factor To change the Z factor by ones press the Coag up or down arrow buttons To change it by hundreds press the Cut up or down arrow buttons Repeat this step...

Page 121: ...call the Valleylab Service Center 4 To check the Standard mode press the Standard button and repeat step 3 5 To check the Macro mode press the Macro button and repeat step 3 6 Disconnect the test cab...

Page 122: ...100 ohm resistor from the test cables Checking Monopolar Coag Output 1 Connect the test equipment for monopolar output a Connect one test cable to the left jack in the Monopolar 1 CEM Instrument recep...

Page 123: ...y and a 10 appears in the coag display Repeat step 3 This completes Fulgurate mode calibration 5 To check the Spray mode press the Spray button a Verify that 10 appears in the Coag display b Press the...

Page 124: ...covers the serial port C Connect a standard DB 9 serial cable to your computer and to the serial port Pin 2 is the serial output data line Pin 3 is the serial data input line Pin 5 is the reference l...

Page 125: ...that you enter with specific commands as noted Data Displays Some commands result in the display of data for each mode including CEM The display format is as follows In data displays numbers represen...

Page 126: ...xt lower value FTM Specify the cut mode for enter the number for the desired mode 0 Low 1 Pure 2 Blend FTP Specify the cut power setting 1 2 3 290 300 FTU Increment the cut power setting to the next h...

Page 127: ...bration PSA Total time activated in each mode PSB Number of times activated in each mode PSK Number of times output was activated PSP Average power setting used in each mode PSF List of system errors...

Page 128: ...the DB 9 cable from the generator C Position the panel over the serial port and install the screws that secure it to the rear panel of the generator MC letter where letter may be any of the following...

Page 129: ...ions that may have caused the problem Check the generator for visible signs of physical damage Verify that all accessory cords are properly connected Check the power cord Replace the power cord if you...

Page 130: ...Check the Bipolar Instrument receptacle on the front panel for obstructions or damage Insert the bipolar instrument connector footswitching and handswitching into the appropriate receptacle to verify...

Page 131: ...placement or Footswitch Board Replacement in Section 7 If you find evidence of damage on the Power Supply RF board replace the board only if the damage is severe Refer to Power Supply RF Board Replace...

Page 132: ...tion 7 If a problem persists use a backup generator Loose or disconnected internal cables Check all internal connections Faulty power entry module or connections Check the power entry module and its c...

Page 133: ...ssembly Refer to Front Panel Replacement in Section 7 Alarm number 212 appears in the Cut display during the self test The battery was removed and or replaced but the generator was not calibrated Turn...

Page 134: ...Section 7 Mode buttons do not function correctly when pressed Faulty ribbon cable between Control board and Display board Check connect ribbon cable that connects the Display board to the Control boar...

Page 135: ...efer to Responding to System Alarms later in this section Blown fuse on Power Supply RF board Check the high voltage power supply fuse F1 and replace if necessary Refer to Fuse Replacement in Section...

Page 136: ...ing room Verify that all ground wires are as short as possible and go to the same grounded metal If interference continues when the generator is activated the monitor is responding to radiated frequen...

Page 137: ...generator patient return electrode and active electrodes Can occur during coag Use a lower power setting for the Fulgurate and Spray modes or select the Desiccate mode Abnormal 50 60 Hz leakage curre...

Page 138: ...Refer to Correcting IC U6 Malfunctions in this section 4 Internal diagnostics Main microcontroller CPU test failed Replace the Control board Refer to Control Board Replacement in Section 7 Calibrate t...

Page 139: ...factor Refer to Section 5 for instructions If the alarm number reappears refer to Correcting T_ON ASIC Malfunctions in this section 68 Main microcontroller unable to access GEN_SEM semaphore Refer to...

Page 140: ...oftware malfunction rem_update_state value outside state range Software malfunction rem_pad_state value outside state range Software malfunction rem_state value in re_rem_control outside state range S...

Page 141: ...ble range Repeat the failing calibration step If the alarm number reappears record the number and call the Valleylab Service Center 121 Software malfunction cal_mode value in ca_generator_setup outsid...

Page 142: ...tions in this section 174 Software malfunction which_errors value outside state range Turn off then turn on the generator If the alarm number reappears record the number and call the Valleylab Service...

Page 143: ...switch or Bipolar Footswitch pedal may be stuck 1 Turn off then turn on the generator Do not press buttons or accessory activation devices during the self test 2 If the alarm number reappears disconne...

Page 144: ...alarm number reappears record the number and call the Valleylab Service Center 212 Generator not calibrated Refer to Correcting Battery Backed RAM Malfunctions in this section 213 Internal diagnostic...

Page 145: ...re Refer to Correcting IC U6 Malfunctions in this section 230 231 Software malfunction keyed_state value outside state range Software malfunction key_req_mode value outside state range Turn off then t...

Page 146: ...microcontrollers Software malfunction Delay time out of bounds on feedback microcontroller Software malfunction Data type in me_rtc_get_ outside of the state range Software malfunction Data type in me...

Page 147: ...the components facing the rear panel Fit the edges of the board into the slots on the heat sinks Slide the board down carefully fitting the edge connector into the matching connector on the Power Sup...

Page 148: ...the Control board refer to step 5 8 Recalibrate the generator If the calibration is successful install the cover refer to step 11 9 If the alarm number reappears replace the Control board a Turn off t...

Page 149: ...he Power Supply RF board with the components facing the rear panel Fit the edges of the board into the slots on the heat sinks Slide the board down carefully fitting the edge connector into the matchi...

Page 150: ...he Control board refer to step 5 9 Turn on the generator If the self test completes successfully install the cover refer to step 12 10 If the alarm number reappears replace the Control board a Turn of...

Page 151: ...notch on IC U9 above the notch on the socket and gently press the chip back into the socket 5 Install the Control board a Position the Control board over the Power Supply RF board with the components...

Page 152: ...nto the socket e Install the Control board refer to step 5 8 Turn on the generator If the generator successfully completes the self test install the cover refer to step 11 9 If the alarm number reappe...

Page 153: ...V button cell battery above the socket so that the positive side of the battery is facing out visible c Slide the new battery down into the socket Warning Electric Shock Hazard To allow stored energy...

Page 154: ...Section 5 for instructions If the calibration is successful install the cover refer to step 12 8 If the alarm number reappears replace IC U3 a Turn off the generator Disconnect the power cord from the...

Page 155: ...nents including the REM module and power switch Fuses including two in the fuse drawer and one on the power supply RF board Heat sinks left front left rear and right heat sinks and associated heat sin...

Page 156: ...Interconnect Diagram 7 2 Force FX 8C Service Manual Interconnect Diagram...

Page 157: ...ry is facing out visible b Slide the battery down into the socket until it is firmly seated 6 Position the cover above the chassis and slide it down Install the five screws that secure the cover to th...

Page 158: ...rear panel Fit the edges of the board into the slots on the heat sinks Slide the board down carefully fitting the edge connector into the matching connector on the Power Supply RF board 8 Connect the...

Page 159: ...onnect and remove the front panel assembly 1 Disconnect the power switch from the Power Supply RF board 2 Disconnect the two REM connectors from the Power Supply RF board 3 Remove the four screws that...

Page 160: ...s and install the four screws that secure the board to the front panel B Install the front panel assembly 1 Position the front panel assembly in front of the chassis and carefully slide it into the el...

Page 161: ...sp the seven segment LED and pull it out of the Display board taking care not to bend the pins Note the orientation of pin 1 the corner with the small 45 chamfer 3 Verify that the replacement LED is t...

Page 162: ...d Replacement later in this section Footswitch Board Replacement 1 Remove the Power Supply RF board and attached heat sinks observe all warnings and cautions Refer to Power Supply RF Board Replacement...

Page 163: ...nd Reinstall the Front Panel Components If you are replacing the entire front panel assembly go to Step 3 Install the Front Panel Assembly or If you are replacing only the front panel follow these ins...

Page 164: ...switch with the On switch above the Off O switch Press to snap the switch into place D Install the Display board on the new front panel 1 Connect the membrane keyboard ribbon cable to the Display boa...

Page 165: ...section 2 Remove the two screws that secure the REM module to the front panel and remove the bracket that covers the REM module Set the bracket and screws aside for reinstallation 3 Replace the existi...

Page 166: ...ide a piece of heat shrink tubing 2 54 cm 1 0 in wide 6 35 cm 2 5 in long over the wires 5 Connect the cable to the new power switch assembly using the illustration or the assembly you just removed as...

Page 167: ...ad screwdriver into the slot on the drawer below the power cord receptacle Then slide the drawer out Figure 7 2 Replacing fuses in the fuse drawer 3 Use a fuse puller to remove each blown fuse from th...

Page 168: ...the chassis and slide it down Install the five screws that secure the cover to the chassis Warning Fire Hazard For continued protection against fire hazard replace fuses only with fuses of the same ty...

Page 169: ...eat sinks Save the screws and bracket for reinstallation E On the left side of the chassis remove the two screws that secure the base of the left front heat sink to the rail under the Power Supply RF...

Page 170: ...k A Inspect the assembly for bent pins On the left side of the chassis carefully slide the heat sink down into the matching connectors on the Power Supply RF board B Install the two screws that secure...

Page 171: ...chassis remove the two screws that secure the base of the left rear heat sink to the rail under the Power Supply RF board Save the screws for reinstallation G Lift the left rear heat sink to disconnec...

Page 172: ...cure it to the heat sink Position the new resistor on the heat sink and reinstall the washer and screw To replace one or more of the four HVPS FETs remove the screw and shoulder washer that secure the...

Page 173: ...eft rear heat sink to the rail C Connect the 4 wire heat sink bridge rectifier cable to J8 on the Power Supply RF board D Tighten the screw securing the component clip over the Triac Thermister E Posi...

Page 174: ...e cable from the tank damping resistor on the right heat sink from J12 on the Power Supply RF board F On the right side of the chassis remove the two screws that secure the base of the right heat sink...

Page 175: ...he diode to the heat sink Position the new RF power diode on the heat sink and reinstall the washer and screw To replace the tank damping resistor remove the two screws that secure the top and bottom...

Page 176: ...nks and install the three screws that secure the bracket to the left rear heat sink plastic screw and to the left front and right heat sinks two metal screws E Install the Control board 1 Position the...

Page 177: ...from the low voltage power supply red spade lug and 3 pin connector at the rear 6 pin connector at the front Mark the cables for reinstallation 2 Remove the four screws that secure the low voltage po...

Page 178: ...ct the red spade lug with the green and yellow ground wire to the ground lug on the left rear corner of the low voltage power supply 3 Connect the 6 pin cable to J2 at the front of the low voltage pow...

Page 179: ...e module out the rear panel until you can access the grounding lug post inside the rear panel Then remove the nut and washer that secure the ground wire ring terminal to the grounding lug Save the nut...

Page 180: ...wer entry module C Slide the ground wire ring terminal onto the grounding lug post on the rear panel Then install the washer and nut that secure the ring terminal to the post D Press firmly to snap th...

Page 181: ...er Supply RF board D Disconnect the Footswitch Board ribbon cable from the Power Supply RF board E Disconnect the power entry module from the Power Supply RF board F Remove the four screws that secure...

Page 182: ...crews that secure the base of the left rear heat sink to the rail under the Power Supply RF board Lift the heat sink to disconnect it from the Power Supply RF board 3 Loosen but do not remove the scre...

Page 183: ...ght side of the Power Supply RF board slide the right heat sink components into the matching connectors 2 Install the two screws that secure the heat sink to the rail under the board 3 Connect the rig...

Page 184: ...t the power entry module cable to J6 on the Power Supply RF board C Connect the footswitch board ribbon cable to J5 on the Power Supply RF board D Install the front panel assembly 1 Position the front...

Page 185: ...ormance of the generator only under the following circumstances Installation and setup procedures in this manual are followed Assembly operation readjustments modifications or repairs are carried out...

Page 186: ...ne number Department address city state and zip code Model number Serial number Description of the problem Type of repair to be done Step 2 Clean the Generator A Turn off the generator and unplug the...

Page 187: ...in its original shipping container if available C Ship the generator prepaid to the Valleylab Service Center Returning Circuit Boards Package circuit boards for shipment as follows 1 Place each circui...

Page 188: ...ealthcare Italia SpA Via Gaetano Crespi 12 20134 Milano ITALY Ph 39 02 212181 Fax 39 02 2640059 Tyco Healthcare Spain S L C Fructuos Gelabert 6 8 planta 8a 08970 Saint Joan DESPI Barcelona ESPANA Ph 3...

Page 189: ...and tolerances must be equal to or better than the original Ordering Replacement Parts Parts may be ordered from the Valleylab Service Center for your location When ordering replacement parts include...

Page 190: ...Generator Assembly 9 2 Force FX 8C Service Manual Generator Assembly Figure 9 1 Generator assembly...

Page 191: ...Generator Assembly Service Parts Force FX 8C Service Manual 9 3 Figure 9 2 Generator assembly continued...

Page 192: ...lapsible tray 223 300 054 5 Rubber foot 213 400 082 6 Equipotential ground lug 208 200 141 8 Screw Phillips M4 x 0 7 x 10 237 050 139 9 Sealant loctite 222 232 301 148 10 Screw pnh phh M4 x 0 7 x 8 mm...

Page 193: ...sembly power supply RF board See Power Supply RF Board Assembly and Power Supply RF Board Components in this section 201 482 003 Cover plate 223 301 139 Power cord right angle molded 220V 207 002 033...

Page 194: ...Front Panel Assembly 9 6 Force FX 8C Service Manual Front Panel Assembly Figure 9 3 Front panel assembly...

Page 195: ...Front Panel Assembly Service Parts Force FX 8C Service Manual 9 7 Figure 9 4 Front panel assembly continued...

Page 196: ...ric M3 253 300 044 12 Assembly display board See Display Board Components in this section 201 345 001 13 Screw thread forming 4 20 0 625 237 050 147 14 Display board spacer 223 400 626 15 Cable assemb...

Page 197: ...al 9 9 Control Board Components Reference Designator Description Valleylab Part Number 1 Effect mode controller PCB 207 700 148 BT1 Battery 250 020 028 U3 IC programmed main 210 730 214 U6 IC programm...

Page 198: ...ia 239 750 063 LP1 LP2 LP3 LP4 LP5 LP6 LP7 LP8 LP9 LP10 LP11 LP12 Lamp 215 200 085 Transistors Q1 Q2 Q3 FET N CH 1A 100 V 239 200 027 Resistors R1 R2 R3 R4 16 5 1 2 W 234 014 072 R5 R6 R7 R8 R9 R10 R1...

Page 199: ...pin gold 208 500 055 Socket I C 16 pin 208 121 003 Reference Designator Description Valleylab Part Number Reference Designator Description Valleylab Part Number Capacitors C1 C2 C12 C13 C14 C16 C17 C...

Page 200: ...R23 R26 R29 2 k 5 1 4 W 234 024 070 R11 432 1 1 4 W 234 201 254 R12 Pot 5 k 236 200 103 R13 R16 R20 R24 R27 1 4 k 1 1 8 W 234 201 303 R14 R17 R21 R25 R28 2 15 k 1 1 8 W 234 201 321 R30 19 6 k 1 1 8 W...

Page 201: ...ISO4 ISO5 Optoisolator 4N35 239 750 002 SP1 Speaker miniature 707 241 003 000 Not shown Spacer footswitch 213 110 583 Cable assembly footswitch board 207 500 545 Screw panhead M3 x 0 5 x 8 zinc 237 0...

Page 202: ...Power Supply RF Board Assembly 9 14 Force FX 8C Service Manual Power Supply RF Board Assembly Figure 9 5 Power Supply RF board assembly...

Page 203: ...Power Supply RF Board Assembly Service Parts Force FX 8C Service Manual 9 15 Figure 9 6 Power Supply RF board assembly continued...

Page 204: ...Socket for pins with large lead diameter 208 500 057 7 Socket relay 208 500 089 8 Screw panhead M3 x 0 5 x 8 zinc 237 050 149 9 Washer M3 nylon 253 300 042 10 Screw Phillips M3 x 0 5 x 8 nylon 237 050...

Page 205: ...M3 x 0 5 x 12 zinc Transistor FET N CH 8 A 500 V Diode bridge 35 A 400 V Washer flat M3 0 Washer Lock Internal M3 202 701 886 207 500 212 253 200 061 223 400 633 234 400 251 237 050 135 239 200 022 23...

Page 206: ...em Description Part Number Reference Designator Description Valleylab Part Number Capacitors C1 C90 100 pF 5 100 V 204 200 452 C2 C43 C46 C48 C52 C58 C65 C71 C82 C84 C86 C117 C118 C156 C170 C172 01 F...

Page 207: ...500 V 204 105 022 C28 C36 C37 C38 C45 C47 C51 C53 C55 C56 C57 C59 C62 C64 C66 C67 C72 C74 C76 C78 C80 C83 C85 C88 C89 C92 C95 C100 C101 C103 C106 C109 C110 C114 C115 C116 C121 C123 C125 C128 C131 C13...

Page 208: ...0 485 C105 C108 047 F 20 50 V 204 200 517 C119 C126 C129 6800 pF 5 100 V 204 200 495 C150 C151 C158 C159 3900 pF 5 500 V 204 301 044 C152 3300 pF 5 500 V 204 105 038 C154 C157 0047 F 10 2000 V 204 200...

Page 209: ...39 600 000 Fuses F1 F2 F3 Fuse sub mini 1 2 A 215 100 004 F4 Fuse 5 x 20 mm 6 3 A 215 100 041 Relays K1 K3 K4 K5 K6 K8 K9 K10 K11 12 V 230 013 000 K2 6 pole 230 017 006 K7 Relay 230 017 004 K12 K13 K1...

Page 210: ...R106 R144 R146 R147 R152 R155 1 k 5 1 4 W 234 024 063 R12 R18 R21 R26 R131 R136 R140 51 5 1 4 W 234 024 032 R13 R14 R15 R42 R45 R48 R55 R67 R86 R91 R93 R99 R100 R107 R108 R111 R112 R122 R130 R132 R133...

Page 211: ...005 R35 R52 100 k 1 1 8 W 234 201 481 R36 12 4 k 1 1 8 W 234 201 394 R37 10 5 1 4 W 234 024 015 R40 7 5 5 1 2 W 234 014 065 R43 R104 68 k 5 1 4 W 234 024 107 R44 5 6 M 5 1 4 W 234 024 152 R46 330 5 1...

Page 212: ...8 k 5 1 4 W 234 024 083 R89 5 1 k 5 1 4 W 234 024 080 R90 3 9 k 5 1 4 W 234 024 077 R94 56 2 k 1 1 8 W 234 201 457 R95 R151 R156 R158 R162 R163 R165 10 k 1 1 8 W 234 201 385 R96 Trimpot 5 k 236 200 07...

Page 213: ...ansformers T1 Pulse dual 251 300 014 T2 T6 T8 T16 T17 Inductor current sense 251 300 007 T3 Power switching 251 200 047 T4 RF molded 3F3 core 251 200 070 T7 T10 T11 T12 Square core REM 251 300 027 T13...

Page 214: ...01 U25 U31 Op amp TL052A 210 400 020 U28 Quad analog switch 210 200 041 U29 4081 210 210 081 U30 Inv hex 74HC14 210 230 004 Miscellaneous D1 Thermistor triac AVS 12 CB 239 610 023 J18 J19 Contact mono...

Page 215: ...ice Parts Force FX 8C Service Manual 9 27 TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP15 TP16 TP17 TP18 TP19 Test point 208 200 284 U17 Oscillator precision 250 010 036 Reference Designa...

Page 216: ...Notes 9 28 Force FX 8C Service Manual...

Page 217: ...glect or accident The warranty periods for Valleylab products are as follows Electrosurgical generators or argon units One year from date of shipment Mounting fixtures all models One year from date of...

Page 218: ...strued 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 Bo...

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