Title: From: To

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PROBLEM:

-~~-------------------------------------------~-----------------------Low output wattage RF302 Electrosurgery reading on Analyzer. a Vallejlab SSE2L ESU

Technical Eleazar Technical

E LEe T RON 1 Tip on Valleylab ESU's J. Belen Personnel

C

MAIL Sent:
08/13/92

as:per

If you get a call from a district with the same problem as above, ask them to check the line voltage first (The safety analyzer should give them a fairly accurate reading). Everyone (!) VOLT drop difference from 120V is equivalent to a IO-watt drop on your ESU output. For instance, if the line voltage is 115V instead of 120V, your ESU output will be 50 watts lower.
One interesting situation is when the line voltage in your ben~h is 120V while the district's is lower and you tell them there's nothing wrong with the unit. That's a situation you'd rather not be in(~ut course you know how to handle it now).

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Valleylab. Inc. Caution: Federal (USA) law restricts this device to sale by or on the order of a physician . 1989 PRINTED IN USA All rights reserved. Inc. 1989 Valleylab Part Number: 945 100-11t & Copyright © Valley lab. USA (303) 530-2300 TWX 910-940-2514 . Contents of this publication may not be reproduced in any fonn without the written permission of Valleylab. 5920 Longbow Drive.FORCE 2 SERVICE MANUAL '10V The following service instructions are for use only by qualified personnel to repair and service the equipment described in this manual. Boulder. Colorado 80301..: Effective Date: October. Inc.

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. . .. ... ..TABLE OF CONTENTS SECTION 1 INSTALLATION.. . INTERCONNECT LISTING . . . .. . .... .. AUDIO VOlUM E LINE REGULATION .. .. . .. . . .. 6 REAR PANEL FUNCTIONS.. . . .. .. MONOPOLAR DISPLAY/CONTROL BOARD. . .. ... . .... BIPOLAR DISPLAY BOARD. . .. .... POWER SUPPLY..... . . . .... .. .. . .. ... . . . .. .. .. . SPECIFICATIONS ..... . . .. . .. . .. . ....... .. ... ..... . OUTPUT CHARACTERISTICS LOW FREQUENCY LEAKAGE (50/60 Hz) HIGH FREQUENCY RISK PARAMETERS REMTM CONTACT QUALITY MONITOR...GENERATOR OUTPUT .. . INDICATORS. .. ... . ... . .. . ... WEIGHT... . ... . .... .. .. .. SIZE... . . . 7 SECTION 3 TECHNICAL. .... . ... .. ACCEPTANCE TEST PROCEDURE . S· 8 8 8 9 9 9 9 9 9 14 14 14 14 15 18 20 20 20 20 21 22 OPERATIONAL TESTING . . ... . . .. .. 1 1 1 1 1 1 SECTION 2 DESCRIPTION OF CONTROLS.. . . . .... . .. ... TESTING PROCEDURE . .. . . .. . . .. . . .. INTERFACE BOARD ... .. .. .... .. . .. . .. . .. .. .... ....... ... ... . . . .. . POWER PLUG .. .. . ... .. . . . .. .. . • OUTPUT WAVEFORM. . .. . . LINE FREQUENCY {SO/60 HZ} CURRENT lEAKAGE TEST PROCEDURE . . . . .. . PROCEDURE .. .. . .. . ....... . . .. . .... .. .. .. . .. . ... . .. . 4 INDICATORS 5 ALERTS.. · ••• lIa . .. ... . . ... .. ... .. . . . .. .. RF OUTPUT ..... REMTM TEST PROCEDURE _ . . .. ... . . . .1 INSTALLING THE FORCE 2 POWER FOR THE FORCE 2 . ... . . . 6 RECEPTACLES. . . . . . .. . SECTION 4 CIRCUIT DESCRIPTIONS •..... . ... ROUTINE MAINTENANCE AND INSPECTIONS CLEANING INSTRUCTIONS . .. .. . .. . ..... AND RECEPTACLES 2 CONTROLS.. . .. . .. .... . . ... . ... .. ... . .... . . . . PROPER GROUNDING ..' . .... . .. . .•.. . SECTIONS .. . ... . . . .. ... ... .. .. . . .. . . . . . .. . CALIBRATION PROCEDURE ... . .. . . . . . . .. . . . .. .. ... . ... . 23 29 . . .

PCB ASSEMBLY.. ii .. . . . HEATSINKASSY. .. WARRANTY .. I: " III II III 49 51 51 53 55 55 55 56 57 SECTION 8 .S. PCB ASSEMBL V. ".SECTION 6 ASSEMBLIES SECTION 7 PARTS LIST PCB ASSEMBLY. ... LVPS . . AND SCHEMATICS 31 .... . ... """"."". ... " I " II . MONOPOLAR DISPLAY BIPOLAR DISPLAY INTERFACE POWER SUPPLY RF OUT CLAMP P. 49 . PCB ASSEMBLY. HEATSINK ASSV. III Ii " . a .. HEATSINK ASSV. HEATSINK ASSY. .. I: ill II . .

MONO POLAR CUT MODES OUTPUT POWER VS LOAD .LIST OF ILLUSTRATIONS FIGURE 1 FRONT PANEL REAR PANEL OUTPUT POWER VS LOAD . POWER SUPPLY HEATSINKASSY. RF OUT HEATSINK ASSY. POWER SUPPLY-RF OUTPUT BOARD/SCHEMATIC HEATSINK ASSY. LVPS MONOPOLAR KEYBOARD SCHEMATIC BIPOLAR KEYBOARD SCHEMATIC PAGE 2 3 10 12 13 24 26 27 28 32 34 35 38 40 42 45 45 46 46 47 48 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 iii . CLAMP HEATSINK ASSY.BIPOLAR MONOPOLAR OUTPUT WAVEFORMS RF OUTPUT FET VOLTAGE AND CURRENT RF OUTPUT FET GATE DRIVE WAVEFORMS AT 018 AND 019 DRAINS POWER SUPPLY AND RF CURRENT LIMIT WAVEFORMS COMPONENT/CONNECTOR LOCATIONS-TOP VIEW SYSTEM INTERCONNECT DIAGRAM MONOPOLAR DISPLAY-CONTROL BOARD/SCHEMATIC BIPOLAR DISPLAY BOARD/SCHEMATIC INTERFACE BOARD/SCHEMATIC .MONO POLAR COAG MODES OUTPUT POWER VS LOAD .

its dealers and representatives reserve the right to make changes in equipment built and/or sold by them at any time without incurring any obligation to make the same or similar changes on equipment previously built and/or sold by them.INTRODUCTION This Service Manual covers the installation and basic service instructions for the Force 2 Electrosurgical Generator. Valleylab. Also included are sections covering the Technical Specifications. The reader is directed to the Force Instruction Manual supplied with the generator. Instructions for use and cautions and warnings concerning electrosurgery are beyond the scope of this manual. Circuit Descriptions and the Testing of the generator. iv .

Undesirable 50/60 Hz leakage currents are also affected by the polarization of the input 50/60 Hz power to the generator. Cords should always be grasped by the plug. The ground wire in the power cord is connected to the generator chassis and insures that no dangerous currents will flow from the cabinet of the generator in the event of an internal electrical failure. CLEANING INSTRUCTIONS Use a mild detergent and damp cloth to clean the generator cover. The generator is not sterilizable. or on any convenientand sturdy table or cart. For this reason the Force 2 should not be installed in a closely fitting cabinet or cart which might restrict the free circulation of air. it is normal for the top and rear panel to feel warm to the touch. POWER FOR THE FORCE 2 95 . This Service Manual describes the recommended inspection. PROPER GROUNDING An important consideration in assuring patient safety while using electrical equipment is proper grounding. The generator may be placed on the mounting cart available from Valleylab. If desired. It is the responsibility of the userto assure proper grounding and polarity in the power outlets furnishing power to the Force 2. In case of brownouts or power surges the output of the Force 2 will remain constant. keyboard and cord. DO NOT PULL ON THE CORD ITSELF. 50/60 Hz The Force 2 is designed to operate over a wide range of input voltages within specified output regulation.140 VAC.SECTION 1 INSTALLATION INSTALLING THE FORCE 2 The compact size of the Force 2 system allows a variety of installations. Under continuous use for extended periods of time. ROUTINE MAINTENANCE AND INSPECTIONS We recommend that the Force 2 be inspected by qualified service personnel twice a year. Its purpose should not be defeated by using extension cords or 3-prong to 2-prong adapters. The connector should be periodically inspected by qualified service personnel. For major repairs the Force 2 can be returned to Valleylab. POWER PLUG The Force 2 is shipped with an approved Hospital Grade three-:-prong connector. Do not allow fluids to enter the chassis. testing and calibration procedures. This connector meets all requirements for safe grounding. At high power settings considerable power is dissipated within the generator and it is important that the vents on the bottom and sides remain unobstructed for proper cooling. 1 . ValleyJab will supply any parts or information needed to repair the Force 2.

Figure 1 Front Panel 2 .G iIlI6! ~ ~l - I C3 HICRCStFa. INDICATORS. AND RECEPTACLES / ~ /~ [ ~ ~ r 1lAm. - I (D 1 114m.J!R i \_ . I~ I 1H1~ - IfP fU6'l ~ @J I I~ol I~ol I~ol MFIM!R ~ EJ 8 Frof-SIIIII}j SUl. I ] I I I [ ~ [ STil1Ui' 114m.SECTION 2 DESCRIPTION OF CONTROLS.1IR ~ I~I I~I al'.

/04.RIsk of rtre. flepifJcs fuse "8I1llrksd. o o ~ 0 r?d~!2l V 110rmpOlAR FOOTSIJITCH M Z$OV.VARNIHG. JAG Figure 2 Rear Panel 3 .

Blend 3 . Continuous depression gradually decreases the power to minimum. A two-step procedure is required. Blend 2 . The generator cannot be activated and all audio alarms are Silenced. For a detailed explanation of the Low Voltage Coag mode. displays and alarms fully functional. refer to the Instruction manual. A single depression lowers the power setting by one watt. Up . HONO POLAR w ~ Monopolar . ~ [BL]NO] (BL$ND] [BL)ND J CUT POIIER Blend 1 .Low Voltage Coag does not have a dedicated button to access (illuminate) this mode.Selects pure cut with lowest level of hemostasis. Continuous depression gradually increases the power 10 maximum. Ready .CONTROLS (STDByJ Standby . Down . A two-step procedure is required.Selects monopolar footswitch control for activating ACCESSORY output Bipolar .Depressing this button places the electrosurgical generator in a hold mode.Selects bipolar output when using the monopolar footswitch. A single depression of the key increases the power setting by one watt. Power settings are retained in memory and the display shows "dashes".Decreases power in the selected mode.Selects cut with minimum hemostasis.Selects cut with average hemostasis. 8(YJ COAG POIIER Power Control Pencil Mode . Cut .Selects cut with maximum hemostasis.The Power Control Pencil feature does not have a dedicated button to access (illuminate) this mode.Increases power in the selected mode. 8(y) 4 . Low Voltage Coag .Depressing this button places the generator into service with power outputs.

This indicator is illuminated when the generator's monopolar footswitch is selected for Monopolar Accessory activation. Bipolar Indicator .This lamp will illuminate and the audio alarm will sound once when the remote power change feature is activated. which will be delivered to the patient when the mode is activated. When this indicator is illuminated.An "L" in the hundreds digit of the Coag Power Setting Display indicates that the Low Voltage Coag mode has been selected. One of the two distinct mode indicator tones will sound in conjunction with the visual output power indicator. [888] ( VATTS Power Setting Display.Indicates generator is ready for use. Coag.The digital power setting display is visible on the generator in the Ready mode. power changes can be made using the Power Control handswitching pen~iI.Indicates generator is on. in watts.This indicator is jJluminated when the generator's Monopolar footswitch control is selected to activate the Bipolar output. Ready Indicator . (PURE I I (. 5 . Remote Indicator . In Standby mode "dashes" are displayed. The number displayed indicates the nominal power. [ L BB 1 Low Voltage Coag Mode Indicator . but cannot activate outputs. BL I ) ( BL 2 ) ( BL 2 Cut Mode Indicators .The indicator labeled "Watts" illuminates when that output power (Cut.One of four CUT mode indicators is illuminated to show the selected Cut mode. Monopclar Indicator . ) Output Power Indicators . Bipolar) has been activated by the surgeon.INDICATORS Standby Indicator .

The audio tone will sound twice when the condition is first detected.JW Bipolar Active Receptacle . Power output from this receptacle is activated only by using the handswitch mechanism.ThisreceptacJe. Caution: DO NOT connect more than one device to the ACCESSORY output receptacle.This 2-pin receptacle accepts the patient return electrode connector used in monopolar procedures. Cut and Coag modes may be activated at this receptacle.This receptacle will accept the 3-pin handswitchingactive accessories. No power is available through use of the footswitch. The receptacle will accept both REMTM(cual-section) and conventional patient return electrode connectors. This receptacle will also accept 2-pin bipolar footswitching accessories.This receptacle will accept 3-pin handswitching bipolar accessories.This indicator illuminates when the patient contact quality monitoring system senses that contact between the patient return electrode and the patient is not adequate. The handswitching pencil can be footswitch activated when connected to this output jack. Note: The Power Control pencil is only functional through this jack. These accessories can also be footswitch activated. It will accept 3-pin handswitching active accessories or standard 1-pin accessories which can be activated by the monopolar . o o M! CRCB! Ffl. The generator will not produce output power when this alarm condition exists.. Both output jacks (3-pin and 1-pin) will activate simultaneously. (0 o 0 0 1 HAND-SIJ! TCH Monopolar Active Receptacle (Handswitch) . 0 ACCESSORY Monopolar Active Receptacle (Accessory) . 6 . Cut and Coag modes may be activated at this receptacle.has two output jacks.footswitch.ALERTS REMTMFault Indicator . RECEPTACLES ( 0 a ~OJ PATIENT Patient Return Electrode Receptacle . The alarm condition is cleared when the REMTMsystem senses that the patient/pad contact resistance is within the acceptance range.

This 3-pin receptacle accepts a single-treadle Bipolar footswitch connector.This 4.The volume of the Cut. BIPOLAR FOOTSWITCH [Z:][]JJ ~b]~ MONOPOLAR FOOTSWITCH © Monopolar Footswitch Receptacle .>in receptacle accepts a two-treadle Monopolar footswitch connector. The volume of the audio alarm for alert conditions is not adjustable. and Bipolar mode indicator tones produced when the generator is activated may be adjusted with this control. 7 . Press the toggle upward to turn power on and down to shut power off. Bipolar Footswitch Receptacle .This switch includes a circuit breaker. Audio Volume Control. Coag.REAR PANEL FUNCTIONS ~rn ~[QJ LL ON/OFF Switch .

ground openSink current.S@ 4.0 microamperes 8 . Normal polarity.7 @ 2.7@ 8. ground openReverse polarity. 140V applied. all outputs tied together. Mode Cut Blend 1 Blend 2 Blend 3 Coag LowVoH Coag Bipolar Power readouts agree with actual power into rated load to within± LOW FREQUENCY LEAKAGE (50/60 Hz) Source current. whichever is greater. patient leads.1 @ 3. unmodulated OUTPUT CHARACTERISTICS Maximum (open circuit) p-p Voltage 3000 3500 3700 4000 7000 4000 800 Rated Load (Ohms) 300 300 300 300 300 300 100 Nominal Power Crest Factor (at Rated Load) at Rated Load (Watts) (typical*) 300 250 200 150 120 99 70 2.9@ 4.SECTION 3 TECHNICAL SPECIFICATIONS OUTPUT WAVEFORM Cut Blend 1 Blend 2 Blend 3 Coag Low Volt Coag Bipolar 500 kHz sinusoid 500 kHz bursts of sinusoid at 50% duty cycle recurring at 31 kHz 500 kHz bursts of sinusoid at 37. all inputs Chassis source current: ground open: < 10 microamperes < 100 microamperes < 100 microamperes < 150 microamperes < 11.4@ 3. Normal polarity. intact chassis ground .0@ 100W 100W 100W 100W SOW 100W 40W 15% or 5 watts.5% duty cycle recurring at 31 kHz 500 kHz bursts of sinusoid at 25% duty cycle recurring at 31 kHz 500 kHz damped sinusoidal bursts with a repetition frequency of 31 kHz 500 kHz bursts of sinusoid at 25% duty cycle recurring at 31 kHz 500 kHz sinusoid.

max Coag . REM CONTACT QUALITY MONITOR Measurement Frequency: Measurement Current: 140 kHz + 10 kHz 1. AUDiO VOLUME The mode indicator tones are adjustable to not adjustable. or above 135 ohms. max Cut6 A. 1004 kg SIZE 8 x 13 x 21 inches.5 rnA + 0. 20 x 33 x 53 em Specifications subject to change without notice. output power into nominal load will vary no more than 5% or 5 watts. max Bipolar 180 W.3 A. a REMTMfault condition will occur. if resistance increases by more than 40% above the reference value. WEIGHT 23 Ibs.300 W. max Bipolar .nominally < 20 ohms REMTM. "In this section "typical" refers to a specification that is within 20% of a stated value.I:IIGH FREQUENCY RISK PARAMETERS Bipolar RF leakage current: Monopolar RF leakage current: < 150 milliamperes. In the REMTM mode.1. < 150 milliamperes.50 W. The frequency of the line may vary from 45 to 65 Hz.700W.4 A. max Cut .5 A. max LINE REGULATION Between 90 and 140 volts input.. The alarm tones are Coag . an alarm will be generated.0. Power: Idle .5 rnA Acceptable Resistance Ranges: Single-area Dual-area pad . max VAC. whichever is greater. 9 . max a maximum level of 65 dba at 1 meter. INPUT POWER SOURCE Full regulation range of 95 -140 Current: Idle .nominal range 5 -135 ohms If impedance measured is outside the acceptance range.

~ ... .. I <.... 300 280 c:: 260 ur ~ 240 0 0. I160 ::::l 0 160 140 120 100 80 60 40 20 I . 220 I200 :J 0. I PURE CUT I<.. -.. '\ 1\ \ . 2000 I a 200 400 600 800 1000 1200 1400 1600 1800 IMPEDANCE (OHMS) 400 380 360 ~ 340 en I320 ICl: :...Monopolar Cut Modes 10 ...-.400 360 360 340 (J) l320 ICl: :. 300 260 c:: 260 LU :. I'" -._ -1200 1400 1600 1800 2000 o 200 400 600 800 1000 IMPEDANCE (OHMS] Typical Output Power vs Load .... 240 0 0... I BLEND 1 I 1 I - '" / _'\ \ \ . ~ r-. 220 I200 :J 0..... I I . I -.. .. I160 :J 0 160 140 120 100 80 60 40 20 /" "".... <. -..

280 a:: 260 UJ .3. :--.~ 1000 11 I r-1400 1600 1800 2000 a 200 400 600 BOO 1200 iMPEDANCE (OHMS) (Continued) ..... --..3. <.280 a:: 260 UJ .. / . 220 I-:J 200 n.... I-180 :J 0 160 140 120 100 80 60 40 20 BLEND 2 . ~ ...--_ 1000 1200 1400 1600 .. I l"'<. 240 0 c.. I-180 ::l 0 160 140 120 100 80 60 40 20 ·BLEND 3 I ! ! ! r-..320 I<t: 300 .. 240 0 c. 220 I:J 200 c.400 380 360 340 IJl l320 I-<t: 300 ::... I I . ~ r-. 1800 2000 o 200 400 600 800 IMPEDANCE (OHMS) 400 380 360 340 III I-.3.. <.. ...

. tOO 90 80 70 60 50 40 30 20 10 0 L .. I::J I::l 0 o. " --rI-- I-- o 200 400 600 800 1000 1200 1400 1600 1890 2000 IMPEDANCE (OHMS) Typical Output Power vs Load . 120 UJ ::. I I I I I T 1 I I I I I I I I I I I I I I I I I ·1 - I I 1 1 I ! I I I 400 I I 600 800 I 1000 I 1200 I I a 200 1400 1600 1800· 2000 IMPEDANCE (OHMS) 200 190 180 170 ~ 160 !Jl l150 I¢ 140 :z ~ 130 cr:.. t 10 0 n. <..Monopolar Coag Modes 12 .....'VOLTAGE I I /\ J "- -. I . I::J 0 LO\. -. 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 ! I I I COAG I I I I I I I....... -' I I I I . I::l n.~ r ¢ !Jl I- ::z 0:: UJ ·0 ::z o.

J- ~ J- a.I- ~ tn ~ :z: w 0: 0 -e :z: a.. 0 ~ 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 I I I I I I BIPOLAR 1\ \ I\ I I I \ I\ I 1\ I I I I I I 1 I I I I I I I I I i 2000 \ - ~ I I I I I 1200 I o 200 400 600 800 1000 1400 1600 1800 IMPEDANCE (OHMS) Typical Output Power vs Load .Bipolar 13 ..

Power supply control uses an Op Amp within the 3526 to amplify the difference between a feedback fraction of the DC output and a reference voltage ECON. The drains have 14 . Current limiting and peak voltage limiting circuits prevent damage under extreme load conditions. Volume is controlled by a potentiometer mounted on the rear panel. There is a DC current limit implemented with a comparator and pulse stretcher. The reference is generated by the CPU and scaled as the square root of the front panel power setting. and the latter is generated by signals from the RF circuitry. In the case of an alarm condition the volume pot is bypassed and a full volume alarm is sounded. pulse steering logic and a comparator. A current sampling resistor at the sources provides input to a current limit circuit. Both DC supply and RF current limit levels are calibrated for each mode . the Microprocessor Board.SECTION 4 CIRCUIT DESCRIPTIONS BIPOLAR DISPLAY BOARD The Bipolar Display Board is used as the numeric display for the mode's power set point and to display the bipolar RF lamp. The frequency select for the alarm is done by circuitry on . Duty cycle control is performed by a 3526 Ie regulator with emitter followers to drive the transformers T1 and T2 which switches the power FETs. This circuitry is located on the Monopolar Display/Control Board. capacitor Circuit. The power transformer rectified secondary voltage is filtered by a 0. Eight power FETS act as RF switching elements. The FETs drive the power transformer T3· primary at 320V peak and varying duty cycles. There are no low voltage adjustments. An R-C network on the 3526 pin 7 provides a power-on reset. Gate drive is direct at a 12V level. The error voltage on pin 1 varies from 0. output tuning and transformer turns ratio is different for Cut and Coag waveforms and the selection is done by a relay. Low voltage supplies at +12 and + 5 volts are regulated with 3 pin ICs. WARNING: THE POWER FETS AND OTHER COMPONENTS ON THE SUPPLY HEATSINK ARE AT LINE POTENTIAL. The . Blend 2 and Bipolar.5 volts to change the output duty cycle. rectifier. Input power is supplied by a voltage doubler. Toff to the level required by the front panel power setpoint. The pulse stretcher shuts down the supply's controllCfor about 1/3 of a second and then soft starts the supply. operating at 80 kHz. POWER SUPPLY The generator power supply is located on the mairr PCA. RF OUTPUT This clrcuitry resides on the main circuit board assembly and amplifies the CPU signals Ton. The signals for these indicators are derived from the multiplexed display driver on the Monopolar Display/Control board for the former. Power control is done by varying the supply voltage.Cut. USE EXTREME CAUTION WHEN PROBING THIS CIRCUITRY. Coag.75 mH inductor and two 15 uf capacitors which convert a constant amplitude variable duty cycle input to a variable DC output.5 to 3. The power transformer has snubber networks to limit voltage spikes. The raw DC is generated by a transformer. The IC contains a sawtooth oscillator. two hold-up capacitors and four power FETs in a bridge configuration. An audio alarm is also present on this board. It i5.aIToff~ine DC-DC switching convertor .

the ICM 7218C. When peak voltage limiting occurs comparator is reduced to reduce the output pulse width. change Cut mode. 7 segment decoders. increment power register and. The bipolar control adds an Op Amp to the power supply feedback path. the output resembles a constant voltage source. A peak detector and comparator provide RF lamp control. the current limit circuitry enforces a constant current characteristic.). a single chip microprocessor with 2k of on-board EPROM. The Coag drive waveform is generated by turning on the FETs for two microseconds every 32 microseconds. which is U3. has two major functions in the Force 2.diodes in series to allow the output transformer primary voltage to swing negative in Coag. The FET output. the microprocessor is able to write the display information to this chip in BCD format and the display multiplexer does the rest. Included on the chip is an 8 x 8 static memory array with storage for the displayed information. In performing the first function the CPU card generates the proper RF drive per the mode selected. All eight output FETS must be the same type. This stand alone feature is used for almost all of the required 15 . Check current matching in Coag by clipping a current transformer around the 0.g. The difference is summed with:1he·fedback supply voltage-by injecting current into the feedback divider to reduce the supply under high impedance load conditions. calculates and generates the RF output stage current limit. Consequently. in Cut. The actual software program within the 8749 carries the brunt of the performance requirements of the CPU card.2 ohm strip resistors. The flip-flop is cleared by Toft or by a The current limit reference ICON is supplied by the CPU offset at low powers. The major display requirements of the CPU card are performed using an Intersil Display Multiplexer. The second is to act as an interface between the user inputs and the generator. is rather low impedance and its voltage compliance is limited by the choice of DC supply voltage as the power control parameter. In acting as the interface between user and generator the CPU board receives all operator keyboard inputs and performs the proper functional response (e. MONOPOLAR DISPLAY {CONTROL BOARD The Monopolar Display/Control PCB. This one-shot turns on a FET to load the output and reduce high frequency risk currents. The first is as the main control element of the generator. It is this chip with its host of dedicated peripherals that performs the functional responses required of the CPU board. Above 300 ohms load. The device is a universal eight digit LED driver system. The flip-flop is set by Ton and turns on current limit pulse from the LM306 comparator. and varies as the square root of power with an the reference voltage to the LM306 current limit At high load impedances a one shot is triggered by transformer primary voltages below -100 volts. This amplifies the difference between the RF output peak voltage and the power supply set point voltage. Current injection is enabled only in the Bipolar mode. etc. As this is a hardware description of the card the software program will only be outlined. all the multiplex scan circuitry. Internally it contains all the circuitry necessary to interface a microprocessor to an LED display. and performs adaptive REMtmmonitoring when the generator is not keyed. and the high power digit and segment drivers. RF control uses a set-reset flip-flop toggling at 500 kHz the output FETs. calculates and generates the power supply control voltage. hereafter referred to as the CPU card. Below 300 ohms load. It further accepts all keying signals after they have: been decoded by the Interface PCB and performs the proper algorithm to initiate the desired RF output The main control element on the CPU board is an 8749. The Cut waveform drive is at a 50% duty cycle with a tus on time.display.

This line is activated whenever RF power is being generated by the unit. that is. These two control lines activate an on/off analog gate which either allows audio drive to the speaker or not and a second analog gate which changes (increases) the capacitance of a one gate oscillator. Individual microprocessor port lines are assigned to these two displays. segment H. P13. R14 and R17. A 74LS374. The output of the OSCillator is current boosted by a pair of drivers in U1. R21. several additions have been added to it to clarify the actual audio output. to drive these LED displays. 16 . The falling edge of the ALE. an ULN2803A. P12 and P16 respectively. The audio tone frequency and its enable are both controlled. by port lines of the 8749. The 8749 converses directly with the ICM7218C. For the CPU to be able to communicate with its peripherals. This transistor shorts out the volume control potentiometer and alfows the audio alarm tone to be sounded at full volume. The single gate oscillator. P11 and P10 respectively.display systems. are required to insure that the outputs of the open collector driver pull high when its inputs are low. R31 and CR3 are added to change the duty cycle of the oscillator to fine tune the final audio output. a part of U7. The port line is current boosted by an open collector driver in U1: The lamps are furthercontrolfed by 03. The RF watt lamps and the REMtm and RMOTE lamps are individually driven by microprocessor port lines. The external multiplexing is done by U15 andU29. This transistor must be on for the RF lamps to be lit. The RF lamps are the only other display elements' not controlled by the display driver. line on the CPU indicates that a valid address is present on the data bus. address latch enable. and C8. However. to drive the indicator LED's. There are two ways that 03 can be turned on. has been put on the power input to U7 to completely remove all AC noise that would otherwise be transmitted as amplitude and frequency modulation superimposed on the oscillator output to the speaker creating a "warbling" effect. is used to decode the address information into chip select signals to activate given peripherals. chip selects must be generated external to the CPU to activate that peripheral which is being either written to or read from. the display driver is on the CPU's data bus. the decimal point drive output of the ICM7218C. However. octal D-type latch. The REMtm and HMOTE lamps are not controlled by the ICM7218C. Each of these lamps is driven by an assigned port line of the CPU. the ICM7218C is not capable of driving the mode indicator lamps with sufficient power to make them fully visible through the translucent display windows. Two digit drive lines and seven segment drive lines are bussed from the CPU card to the bjpolar display PWB to control the bipolar display seven segment digits. An additional circuit in parallel with the REMtm LED is transistor 01. The first is by the CPU directly with an assigned port line. which is turned on when the REMtm light is on. The resultant mode lamp drives are current boosted by U14. The pull-up resistors. is the typical R-C type circuitry recommended in the literature. is individually gated with each of the eight digit drives to externally multiplex the mode lamp indicator information. To overcome this deficiency. This is only done at tum on when the generator performs a display test turning all of the display digits and lamps on. A large R-Cfilter. U6. The second way the transistor is activated is by the RF sense line from the PSRF PCB. The resistor R1 in series with the speaker limits the maximum audio output.

output is inverted and drives the clock inputs for the CPU. C29. The actual explanation will be taken up later. in-serial out shift register. The resultant output is then ORed with various peripheral chip select lines to generate the required write pulses for these circuits. mode selection and power UPIDOWN control. The three read locations are used to input the twenty-two user inputs. U23. C41) are used to limit RF interference. the outputs of U6. an eight bit parallel. RF Toft. U 16. U22 performs the nor function. the on drive. The RF on and off drive generation: U28 is used to divide the crystal frequency from 6MHz to 500 kHz. Using the chip selects generated by U6 to control the output enable of these devices makes a convenient way of placing them on the CPU data bus. The selection is controlled by microprocessor port line P15. The fourth write only location is dedicated to US. One of these circuits. . is the inversion of RF Ton. This is decoded whenever either the read or write outputs of the CPU are activated by going low. The. The devices are 74LS240's which are octal inverting data bus drivers with tri-state output capability.used. U26. The clock is then steered to a three input AND gate. an octal D-type latch. The amplifiers are all contained in a Quad Op. U25 is used to generate the RF current limit analog voltage ICON. Integrated circuits. which is used in the keying circuitry. giving the final output range of the two analog signals of 0 to 5 volts. and are each separately addressable. One half of U9 is configured as a toggle flip-flop to further divide the clock to 250kHz. the two signals are negative true. R3&-C6 are required to . . The clock is ANDed with the serial output of the shift register US. The signals are divided logically. Fourteen of these are the keyboard inputs and the remaining eight are decoded keying inputs. the off drive. U11. R35-C29 are used to account for timing skews on the clock generation circuitry. Consequently. and U24 are used to buffer these read Signals onto the CPU data bus. 74LS165. 17 . The write pulse generated by the CPU is not able to meet all of the timing requirements of the various peripheral circuits. The final write location is a 74LS374. The output of TO is internally programmed to be 2 MHz. and the other. How this is done will be explained later. There are eight external memory locations. amplified with a gain of one. The two analog gates of U10 are used to select the onloff drive frequency of the RF drive pulse trains. and amplified again with a gain of two. is used to generate the power supply control voltage. keying inputs. dedicated to RF Ton. is used as a chip select. U27. Two eight bit DACs are on the data bus. the ICM7218C. to insure that only one peripheral is addressed at a time all external memory locations have addresses with all bits high except one. They are configured as write only devices. Three of them are read only and five are write only. To generate the 6MHz clock requirements of the 8749 a crystal is.g. Consequently. U17. Various capacitors (e. ECON. inverted again. A Iowan an address line. stop RF interference from entering the shift register. The other seven locations will now be discussed with the reads covered first.The latch signal is only enabled if external memory is being addressed. whose output is used to gate the prinCipal RF clock frequency to generate the final RF drive waveshape. U13 is used to phase shift and shorten the pulse width with respect to ALE. The outputs of the two DACs are inverted. R2 is used to shift the read enable for the address decoder to ensure that the decoded chip select remains valid during the CPU read of the data bus. One of the write only has already been discussed. Amp chip.

The Q output of this flip-flop is the third input to the enable AND gates for RF drive. a REM fault occurs or the keying input configuration changes. The CPU turns on the relays via BIPOLAR drivers on the Interface PCB. A CPU controlled delay between relay closure and initiation of RF drive reduces contact wear. This assembly· has isolated. When this occurs ALE is no longer generated and port two's tower nibble is configured to show the upper nibble of the CPU address. When ALE is hatted the chip has latched the last port two I/O configuration. increase power and reduce power respectively. normally open. Coag. no keying input and/or a change in keying inputs. output jack selection and return electrode monitoring. are only generated when the CPU is shut Off. This is clocked at power up to allow the CPU to run. The way the latter is done is that the CPU writes to the 74LS374.0047 microfarad capacitors in series with the RFoutput and return. With this knowledge it can be discerned that the auxiliary CPU board keying circuitry has to be able to detect several unique conditions. There are four isolated circuits. high voltage relays. Cut to Coag. Selection of the jack is done by single pole. The 8749 is shutdown by pulling the input single step line to ground.25 KHz. The two bit magnitude comparators constantly compare this keying configuration to the decoded outputs from the interface PWB. To keep the CPU board lIO constant when the CPU is shutdown. Q4 is required to ignore the REMTMfault line when the unit is in bipolar mode. The keying circuits comprise an isolated power source. comparators· to detect switch closure and optical couplers. Two things can reset this flip-flop. These codes for Cut. The remaining keying circuits simply have resistors in. RF drive trains. 18 . The handswitch circuits use three comparators to sense active to Cut. The REMTMcircuitry measures the pad-to-pad resistance of dual-pad patient return electrodes or the wiring resistance of single-pad patient return electrodes. a 74LS374 is used to latch port two information. The power source is two flyback converters and toroid transtorrners. U4. each with its own transformer winding for power. A microswitch in the connector is opened for REMTMpatient return electrodes and selects one of two alarm Signal paths in the alarm logic string. Since the 8 bit shift register is cyclically loading itself while data is being shifted out the drive frequency of modulation is 250/8 = 31. REMTMfault is detected on the interface board and is merely an input line to the CPU board. and therefore RF. If the two are not the same U19 pin 6 will go low. This generator has three possible RF output jacks. active to Coag. with R23-G13 providing time delay and moderate RF filtering to this line. and active to Cut to Coag connections. To avoid RF interference problems with the CPU when the generator is keyed the microprocessor shuts itself off by setting the flip-flop in U9.The output signal of the AND gates are the drive pulses. and component replacement must be done with exact equivalent parts. U17 in combination with U18 and U19 detects a keying input change. U20 is used to detect when there are no keying inputs. Note the 0. Consequently. I" INTERFACE BOARD This circuit assembly is mounted vertically at the front panel shield. It contains the patient circuit generator functions: keying. These are the primary patient protection against electrocution and must be high voltage parts. high voltage. U17.series with the opto couplers to limit current. and REMTMfault. the present keying configuration. patient connected circuitry. This signal is then gated with the no keying signal from U20 and the REMTMfault line from the Interface PWB to generate the reset signal for the CPU single step flip-flop.

The oscillator is tuned to the transformer by a pot. This pulse width is decoded by the CPU to implement the adaptive REMTMfeature for dual pad resistances between 5 and 135 ohms. 19 . The secondary is resonated by two 0.22 microfarad capacitors and the reflected primary load is sensed by a synchronous detector. Two comparators provide hard-wired alarm limits at 5 and 135 ohm alarm limit for REMTMpatient return electrodes. Four clocked CMOS switches perform synchronous detection.Resistance is measured as the load on the REMTMtransformer secondary. The detector output is amplified and input to four comparators. The third comparator provides a hard-wired alarm limit at 20 0Rms-fer-single-paG-eleGtrodes. The fourth comparator generates a pulse width modulated waveform by comparing the REMTMresistance to a triangle wave generated by an oscillator.

Tektronix type P6007 Xl00 Probe. Tektronix typeP6013A High Voltage Probe. NOTE: RF power should be measured with the cover ON. Also. The selection of suitable "ground" points must be made with care to avoid ground-loop errors. When fractional microampere leakage currents are measured. proper test procedures must be adhered to in order to duplicate factory test data. or exceed the specifications of the recommended equipment. 0-250mA. NOTE: The Force 2 is not rated for continuous duty operation. Keep in mind that the meter accuracy of many RF instruments is 5-10% of uncompensated scope probes may cause large errors in the measurement waveforms. Using of high-voltage RF accidental capacitive or values. 0-500 Watts 300 ohm load and 100 ohm load with reactive phase angle of less than 200 at 500 kHz In testing RF equipment. inductance coupling may cause order-of-magnitude errors in the observed CALIBRATION PROCEDURE Note: A Valleylab E3002 Analyzer should not be used to perform the calibration. Tektronix type P6010 Xl0 Probe. it must meet. The lOX or 100X probe to be used should be closely calibrated with the oscilloscope to be used. full scale. In the Acceptance Test Procedure. If substitute equipment is used. proceed directly to step six of the procedure. lead inductance and stray capacitance can affect readings adversely.SECTION 5 TESTING PROCEDURE OPERATIONAL TESTING . If only RF output power needs to be re-caJibrated. all calibrations listed in the procedure are made at the factory before the generator is accepted by QA. Test leads must be kept to the minimum length usable. Special care must be taken in Step 4. The procedure uses equipment listed under "Equipment Needed". measurements are described which accurately determine the condition of the generator. Simpson Model 1339 RMS RF Ammeter.GENERATOR OUTPUT The purpose of an operational test is to quickly determine whether the generator is functioning and generating the necessary electrosurgical waveforms. Wattmeter . ACCEPTANCE TEST PROCEDURE Equipment needed Tektronix type 465 Oscilloscope. The best performance will be obtained if each adjustment is made to the exact setting even if the Performance Check is within the allowable tolerance. (Maximum on time at a power setting of 100 is two minutes). 20 .

a. Turn R89 fully clockwise. Turn R91 to mid-setting With Coag display at 120 watts. Key the generator in Coag. Adjust the High Voltage Clamp: a. e. a.PROCEDURE 1. 21 . 4. The meter should read -4. The meter should read +5 ± . Remove the cover from the Force 2 to expose the internal controls and test points. to midsetting before c. Remove the 300 ohm load. Set R93 to mid-setting. b. d. With Cut display at 300 watts adjust RS9 for 260 ± 40 watts output in Pure Cut. Slowly increase the Coag power display and observe the peak positive . Output power should be 30 ±5 watts.25 volts. b. b. +5 Volt Supply: Connect the digital multimeter between pins 3 or 4 and pins 1 or 2 on the 4Q-pin interconnect cable. + 12 Volt Supply: Connect the digital multimeter between pins 5 or 6 and pins 1 or 2 on the 4O-pin interconnect cable.75 ±. Key generator in Coag. d. Attach a 300 ohm load from the HAND-SWITCH receptacle to the PATIENT receptacle. c. f. b. 5. The meter should read +12 ± . Set the Coag display to 30 watts. 2. Attach an oscilloscope with a 10X or 1 OOX probe between the anode of CR3 and ground. Do not let the peak voltage exceed 425 volts while making this adjustment. Set ECON R9S to mid-setting. Change wattmeter load to 100 ohms. Set Coag display at 120 watts and adjust R9S for 120 watts output in Coag. a. adjust R9i for 100 before proceeding. Set Cut display at 300 watts and adjust R93 tor 300 watts output on Pure Cut.2 volts. Turn R89 counterclockwise proceeding. 3.3 volts. -5 Volt Supply: Connect the digital multimeter between pin 7 and pins 1 or 2 on the 40-pin interconnect cable. Potentiometer R89 and R93 01) the Power Supply/RF Board are the output power adjustments in Pure Cut. c. c. Adjust R29 on the PSRF Board so that the maximum peak voltage is 400 volts. d. ± 20 watts output inCoag. Turn ICON R91 fully clockwise. Potentiometers R91 and R95 on the Power Supply/RF Board ar~ critical to the output power adjustments for Coag: Follow steps a through d using a 300 ohm wattmeter connected to the HAND-SWITCH receptacle and PATIENT receptacle. voltage. Adjust the Coag display 10 1. Follow steps a through dusing a 300 ohm wattmeter as connected in step 4. Change wattmeter load to 100 ohms.

Gradually increase resistance and record value at which REMTMalarm turns on (less than 24 ohms). Set the resistance to 135 ohms and adjust R73 for the highest possible voltage on TP3. a. Adjust R90 for 150 ±50 watts output in Blend 2. Change wattmeter load to 100 ohms. e. d. Decrease the resistance and note that the REMTMalarm again turns off. Then turn R88 clockwise one ± 10 ohms). Decrease the resistance to 50 ohms. Increase the resistance gradually and record the value at which the REMTMalarm turns on (70 until it effects Bipolar output in step b. Set Bipolar display at 70 watts and adjust R92 for 70 watts output in Bipolar with wattmeter load set at 100 ohms. Repeat above test set-up utilizing a non-REMTM type connector. REMTM TEST PROCEDURE Connect a variable resistance across the PATIENT terminals using a REMTM_type connector. to midsetting before c.6. a. Follow steps a through e using a 300 ohm wattmeter. Set Cut power display to 200 watts and adjust R94 to 200 watts output in Blend 2. Turn R90 fully clockwise . . Follow steps a through c using a 100 ohm wattmeter connected across the MICROBIPOLAR output jacks.1 JlS. Potentiometer R90 and R94 on the Power SupplyfRF Board are for the output power adjustments for the Blend modes. Potentiometers R88 and R92 on the Power SuppJy/RF Board are for the output power adjustments for Bipolar. Tum R88 counterclockwise turn. Turn R74 counterclockwise until EREM is below 4 volts. Note that the REWM alarm is off. fine adjust R94 and R90 to bring them on. Turn R90 counterclockwise proceeding. Turn R74clockwise until REMFT (TP1) goes high (5V). 7. Set R92 to mid-setting. b. Set the variable resistance to 5 ohms. c. Set R94 to mid-setting. Monitor REM PW (TP4) and adjust R75'until one period of square wave is 10 milliseconds ±. Without adjusting R94 and R90 confirm that Blend 1 and Blend 3 are within instrument specifications with a 300 ohm load setting on wattmeter. . 22 . Turn R88 fully clockwise. The REMTMalarm should remain off below this value and turn on again if above this value. Decrease the resistance and record the value at which the REMTMalarm again turns on(5 ± 2 ohms). If not. b.

The voltage source should be a 110 volt isolation transformer with a 120k ohm current limiting resistor in series with a secondary. where R =: 1k ohms and E is the voltage measured across the resistor. Third wire leakage current is measured by opening the green grounding wire at the plug and connecting the "1 ohm resistor from cnassls to ground. it is very difficult to make a 50/S0 Hz leakage measurement. This current should be less than 100 microamperes. A 0. In practice. the third wire"leakage should be less than 10 microamps. 10pF 1000n N0:=t 10. The typical value of 50 microamperes is valid for factory installed 15 foot 1S/3 AWG line cords. the 50/60 Hz leakage currents do not change significantly when the generator is keyed.0 microamps leakage is 0. "This capacitor has little effect on the 50/S0 Hz leakage current.LINE FREQUENCY (50/60 HZ) CURRENT LEAKAGE TEST PROCEDURE This test measures potentially dangerous SO/SO Hz leakage currents.10 microfarad capacitor is connected across the 1k ohm resistor to remove any trace of high frequency noise generated by the oscillator inside the generator. The line frequency sink leakage is the current that will pass into the patient leads when a 110 volt. 23 . The maximum voltage across the 1k ohm resistor for 100 k microamps leakage would be 100 millivolts. The current is calculated from the voltage measured across a 1k ohm resistor in series with the AC volt source and the PATIENT or active jacks. The Force 2 is left ON BUT NOT KEYED. ElR. Longer line cords or extension cords will increase the third wire leakage and are not recommended. With the Force 2 turned off. The current is measured indirectly by observing the voltage developed across a 1k ohm resistor to ground from each front panel jack. The maximum acceptable voltage across the 1k ohm resistor for 10. This ratio (110 db) of voltages would require the use of "sophisticated measuring techniques.010 volts (10 millivolts). Leakage current is calculated from I::. INPUJ CIRCUIT: {' O. Commercially available leakage testers may be used for this test. When the generator is activated there can be as much as 7000 volts peak-to-peak of RF compared to 20 millivolts of 50/S0 Hz. 20 NOTE: Because of the extreme difference in magnitude of the 50/S0 Hz leakage current in the RF signals when the generator is activated. SO/SO Hz potential is applied between a PATIENT lead and the chassis.

.Ls/cm VERTICAL SENSITIVITY .500V/cm CUT@300W COAG@ 120W Figure 6 Monopolar Output Waveforms 24 .ALL WAVEFORMS SEEN ACROSS A 300 OHM LOAD HORIZONTAL SENSITIVITY -10J.

BLEND 1 @ 250W BLEND 2 @ 200W BLEND 3 @ 150W LOW VOLTAGE COAG @99W .--- Figure 6 (Continued) 25 . .___.... -.....

1AlOIV HORIZONTAL =1j.LS/OIV COAG@30W t CUT@75W Figure 7 RF Output FET Voltage and Current " 26 .TOP VERTICAL = 100V/OIV BOTTOM VERTICAL".

\ Figure 8 RF Output FE~ Gate Drive Waveforms at Q18 and Q19 Drains 27 .Ton BOTTOM TRACE .VERTICAL = 100V/DIV HORIZONTAL = 1A1DIV COAG TOP TRACE .Toft BLEND 3 TOP TRACE .Toft '.Ton BOTTOM TRACE .

PIN 7. PIN 16 CURRENT IN L2 TOP VERTICAl = 10V/DIV BOTTOM VERTICAL 10V/DIV HORIZONTAL = = O.OV/DIV BOTTOM VERTICAL SA/DIV HORIZONTAL = = 10~S/DIV U7. RF CURRENT LIMIT CONTROL Note: Drive Pulse width shortened from 1J.TOP VERTICAL = .5J.1Sto O.Sj.ls/DIV Q1-8GATES U3.1S Figure 9 Power Supply and RF Current Limit Waveforms 28 .

C. 5 REM RETURN 1 6 REM RETURN 2 P204. 29· HANDSW~TCHCUT 30 HANDSWITCH COAG 31 HANDSWITCH UfO 32 ACCESSORY SWITCH CUT 33 ACCESSORY SWITCH COAG 34 FOOTSWITCH CUT 35 FOOTSWITCH COAG 36 BIPOLAR FOOTSWITCH 37 N.C. 39 Ton 40 Toft J200.C.P1106 1 MONOPOLAR FTSW CUT "0" 2 MONOPOLAR FTSW COAG "A" 3 MONOPOLAR FTSW COMMON "C" 4 BIPOLAR FTSW COMMON "C" 5 BIPOLAR FTSW DESICCATE "A" 6 FOOTSWITCH GROUND "B" P309.J304 1 MONOPOLAR RF 2 N. 19 BIPOLAR ENABLE 20 CUT ENABLE 21 COAG ENABLE 22 BLEND ENABLE 23 BIPOLAR RELAY 24 HANDSWITCH RELAY 25 ACCESSORY RELAY 26 CUT RELAY 27 REM PULSE WIDTH 28 N. 38 N.J1117.C.C.J309 1 +5V FILTER CAP 2 +12V FILTER CAP 3 LO V RETURN 4 +12V 5 +5V 29 . 4 N. P801 1 ACCESSORY ACTIVE 2 ACCESSORY COAG 3 ACCESSORY CUT J202.P802 1 BIPOLAR OUT 1 2 BIPOLAR SWITCH 3 BIPOLAR OUT 2 J202.C.P800 1 HANDSWITCH ACTIVE 2 HANDSWITCH COAG 3 HANDSWITCH CUT J201.J305 1 BIPOLAR RF 1 :2 BIPOLAR RF 2 J206.-5VOLTS 8 ANALOG GROUND 9 ECON VOLTAGE 10 ICON VOLTAGE 11 REM FAULT 12 RF SENSE 13 N. P1116 . 15 VOLUME 16 VOLUME 17 N.P1103 1 REM SWITCH 1 2 REM SWITCH 2 3 N.INTERCONNECT LISTING J208. 18 N.C.C. 3 RF RET J205. 14 N~C. P1108 .J316.C.P1117 1 DIGITAL GROUND 2 DIGITAL-GROUND 3 +5 VOLTS 4 +5 VOLTS 5 +12VOLTS 6 +12VOLTS 7 .

P310.C.C N.P1112 1 2 AC NEUTRAL N.P620 1 2 3 AC HOT N.C.J310 1 J118. J313.J311 1 2 3 4 5 6 7 8 9 10 11 12 13 2 3 4 5 6 LINE LINE LINE N. 17 SPEAKER 2.P1114 1 2 3 4 SV UNREG IN SV UNREG RET 12V UNREG IN 12V UNREG RET 2 3 4 5 6 7 8 9 10' 11 12 13 J315.J419.P521 1 SHIELD 2 DIGITAL GROUND 3 BIPOLAR UP SWITCH 4 . BIPOLAR DOWN SWITCH 30 . P311.P1113 1 16 SPEAKER 2.P1115 1 2 3 +12V . 18 SHIELD. 19 DIGITAL GROUND 20 DIGITAL GROUND J120. SEGMENTF SEGMENTG BIPOLAR UP BIPOLAR DOWN LAMP DRIVE BIPOLAR POWER N. LINE HIGH LOW TRANSFORMER SNUBBER DIGIT 1 DIGIT 2 SEGMENT A SEGMENTB SEGMENTC SEGMENT 0 SEGMENT E . P1118 .. 14 SPEAKER 1 15 SPEAKER 1 J312.C. P1119 SOURCE SOURCE SNUBBER RETURN 1 2 3 4 5 HVDC HVDC HVDC HVDC HVDC pas.C. VOLUME CONTROL SHIELD GROUND J320 1 2 as DRAIN HV CLAMP RESISTOR 14 SHIELD DIGITAL GROUND PURE CUT SWITCH BLEND 1 SWITCH BLEND 2 SWITCH BLEND 3 SWITCH CUT UP SWITCH CUT DOWN SWITCH STANDBY SWITCH BIPOLARFOOTSWITCH SWITCH READY SWITCH MONO POLAR FOOTSWITCH SWITCH COAG UP SWITCH COAG DOWN SWITCH J421 . J314.

ASSEMBLIES AND SCHEMATICS 31 .SECTION 6 / .

32 .I I I I I I I I 1 ~J~:(9-~~ LJ I 1 I I I I I I I D Figure 10 ComponenUConnector Locations .

D 33 .

CNJ FTSW P!OO3 J203 ~ -~ 1P1'1:l6 1P204 I P?05 J:lOS J304 JJOe 1PTT18 8SW.F: H. I Figure 11 EJ I System Interconnect Diagram 34 .!O J1T5 1Pm8 Pn17 MONOPOLAR I DtSFLAY/CrnTROL J1tT P702 J202 PeOi J201 PeOO ..D UNE CCflD 1: I. ~ LO v XFMR I CIRCUIT BRK.REM KANO Sw.. Pm4 ClAMP H..$. KEY BD. SIP o-. I M~POlAR 1 ~ I BIPOlAR KEY BO. P521 J421 BIPOLAR DmAyJ4l9 Pm X20 JI. 1 PJ2 J3~2 4310 J3fI 1'31:1 Pm ..S.. JJI4 M9J20 V ~J2J P320 J3Q9 P309 LOV HEAT SINK ~ '" R.JACK /!CC.1312 Pn12 J3t5 -LE-= . to<.J:1m INTERFJCE J20EI Pt105 r.JtcK SW.HIV HEAT SINK .

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-13 LMPDR 8PPWR ®' 1 -IS . -7 -8 .t .C. -9 .. DGT-2 DGT-1 -2 1.......6 1t6 01 HDSP-7301 02 HDSP-7301 -3 -4 SEG-A SEG-B SEG-C SEG-D SEG-E SEG-F SEG-G AS ABCoEFG CDEFG 101 9 8 5 4 2 3 101 9 8 5 4 2 3 -5 -6 .... 39 .J419 . "IS· J419 -14 SPKRI SPKR2 > N. -10 -II > > > BPUPS BPDNS SHIELD D-GND BPUPS 8PDNS SHIELD D-GND -19 ) -20 < J421-3 < -4 < -2 < J421 -1 t -12 ....".. -IS -17 ..

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47 .J620-14 ~ CGDNS 13»_C_G_U_P_S ~ MONSW 12> 11>~-------------o 9 RDYSW _L 10> > SBYSW o _L CTDNS :~ CTUPS o _L Figure 20 Monopolar Keyboard Schematic .

I :~ > BPDNS BPUPS _L 0 o GND SHIELD J L_l_ :J Figure 21 Bipolar Keyboard Schematic 48 .1-4 ~ J521.J52.

15+24.3k ohm ± 5%. 14.0 flf ±20%.6. 6.33. 1W 3. 17.37 C4.48 R20.25. 100V 100 pf ± 15%. 7 RS R9. 1/4W 1.26 R18 R19.SO RA1+4 CAPACITORS C1.12.26.033 J. 1/4W 4. 7.10. 50V 10 flf ± 20%. 1/4W 24k ohm ± 5%.5.36 R38 R40 R43 R49. 1/4W 100 ohm ± 5%.37 R3. 100V 33 pf ± 15%.22. 1/4W 1 Meg ohm ± 5%.34. 1/4W 33 ohm ± 5%.1f ± 20%.29.12. SOV .13. 25V . 11. 1/2W 330 ohm ± 5%. 42. 1/4W 10k ohm ± 5%. 41.9. 1/2W 51 ohm±5%.47.30. 1/2W 27 ohm±5%. 1/4W 51 ohm±5%. 1/4W 20k ohm ± 5%.3.25.8 Meg ohm ± 5%. 1/2W 18 ohm±5%.34 C31 C33 C35 C36. 1/2W 100k ohm ± 5%.38 100 ohm ±5%.29.16.1 flf ± 20%.7k ohm ± 5%/ 1/4W 510 ohm ±5%.SECTION 7 PARTS LIST PCB ASSEMBLY.27.44+46 R24 R27 R28 R31 R35. 1/4W 33k ohm ± 5%. SOV 0. 13 RiO R1S. 100V 204118014 204118007 204102028 204118004 204118001 204200009 204200007 204200005 204200013 49 . 1k ohm 234022039 234024075 234014086 234014077 234014083 234014073 234024051 234014078 234024111 234024063 234024039 234024087 234024079 234024056 234024135 234024114 234024032 234024099 234024096 234024094 234024141 234100134 1.51.28. 1/2W RESISTOR ARRAY. 32.8 C11 C14. REFERENCE DESIGNATION RESISTORS MONOPOLAR DISPLAY 201 200017 A VALLEYLAB PART NUMBER DESCRIPTION R1 R2. SOV 47 pf ± 15%. 100V 22 pf ± 15%.30. 1/4W 75 ohm±5%.01 mf ± 20%.32 C2. 1/4W 130k ohm ± 5%. 1/4W 1k ohm ± 5%.39. 4.S2 R21 R23.

3.13 012 MISCELLANEOUS Y1 L1.INTEGRATED CIRCUITS U1.7. 19 U20 U21 U22 U25. Programmed ICM7218C 74LS374 74LS165 MC14584B 4001B 4013B 4066 4073B SN7406 4081 74LS240 74LS85 4068B 4071B . PTL 200/12 250010005 251 100090 215200070 HLMP2720 HDSP7031 HLMP2755 HLMP2855 HLMP265~ 239750022 239750029 239750033 239750039 239750042 1N4148 239014000 2N2907A 2N3904 VN10KM 239100012 239015000 239200012 2803A 8749.3.29 U16.14 U2 U3 U4.8 06.3 02. 6. 23.4.17 U5 U7 U8 U9. 4011B DAC0832 LM324N 74LS92 M336 210800.24 U18.2 CRYSTAL.6-10 LED'S 01 D2. 6 MHz EMI FERRITE BEAD LAMP.13 U10 U11 U12 U15.4 05 DIODES CR1.002 210730066 210700001 210520374 210520165 210212106 210210001 210027001 210 200 022 210210073 210500005 210210081 210520240 210520085 210210068 210210071 210210011 210075001 210022000 210520092 210300016 50 .10.26 U27 U28 CR4 TRANSISTORS 01.9.11 05. 2.

205-208. 1/4W 560k ohm ± 5%. 1/4W 10 Meg ohm ± 5%. 1/SW 3.PCB ASSEMBLY. 266 R223. 1/4W . 1/SW 3.224-226.DESIGNATION D1.271 R270 R273 R274 R275 10ohm±5%.261 R229 R230 R231 R232. 1OOkohm.04kohm±1%. 5k ohm. 1/8W 6.203. 1/4W 11k ohm ± 1%.246.1/4W 200k ohm ± 1%. 1/SW TRIMPOT. INTERFACE REFERENCE DESIGNATION RESISTORS R201 R202.2 201 201 003 C· VALLEYLAB PART NUMBER 239750029 241003001 215200071 201 202006 A DESCRIPTION HDSP7301 SPEAKER. 1/SW 51.1/4W DESCRIPTION VALLEYLAB PART NUMBER 1kohm±5%. BIPOLAR DISPLAY REFERENCE .239 R234 R235. 1/4W 3k ohm ± 5%. 1/4W· 5. 100k ohm ± 5%.269 R241 R245 R248 R250 R252 R253 R259 R262 R263 R264.242.254-258 R227 R228.1/4W 4.4k ohm ± 5%. 1/8W 604 ohm ± 1%.251.1k± 1%. 238. 1/4W 10kohm±5%. PTL 6/12 PCB ASSEMBLY. 1/4W 887 ohm ± 1%.237. 20k ohm TRIMPOT. 1/4W 10k ohm ± 1%.1k ohm ± 1%. 8 ohm LAMP. 260 R233.244.210.1/SW 15k ohm ±5%.249. 1/4W 820 ohm ± 5%.6k ohm ± 5%. 272 R236. 1/4W 5. 1/4W 390k ohm ± 5%.265 R268. 212-215. 1/4W 91Okohm ± 5%. #3299X 234024015 234024063 234024078 234024074 2340240S0 234201389 234201453 234024076 234024061 234024118 234024111 234024129 234024134 234024116 234024087· 234024510 234201 364 234024091 234201385 234201268 234024075 234024125 234201 412 234024107 234024104 234024127 234024158 234024099 234024072 234024081 234201 284 236010 DOS 236010006 236010 011 51 . 1/SW 68k ohm ± 5%. #3299X TRIMPOT. 1/4W l60k ohm ± 5%.247 R216 R217 R218-222.3k ohm ± 5%.3k ohm ± 5%. 1/4W 200k ohm ± 5%. 1/4W 33k ohm ± 5%.1k ohm ± 5%.240 R204 R209 R211. 1/4W 2.6k ohm ± 5%. 1/4W 51k ohm± 5%/ 1/4W 470k ohm ± 5%.267. 1/4W 19.

219. 217.011 210300013 210200022 . 235. 216.0 Ilf± 20%. 0047 Ilf ± 20%. 50V 1.202 C203-206 C207-212.258-260 C213.239-246. 6kV 0.010 J..214.232 C221.10300071 210027001 210210. 205.236. 250-256. SOOV 3300 pf .CAPACITORS C201.223-226.208 'U202.220. 100V 10 !If ± 20%.211 U203 U204 U206 U207 U209 TRANSISTORS 0201-203. 234.22 Ilf ± 10%. SOV 204400120 204025050 204118007 204118014 204105011 204200031 204200037 204102028 204121 060 52 . 250V . 21'0. 215.261-264 C218.222 C231.1 Ilf ± 20%. 237 C247-249 INTEGRATED CIRCUITS U201.1f ± 15%.227-229.230.203 MISCELLANEOUS Kl-3 OPT201-206 OPT207-209 REED RELAY.206 0204-205 0207 DIODES CR201-211 CR212-215 TRANSFORMERS T201 T202. 25V . 50V 240 pf ± 5%.8 kV OPTO-ISOLA TOR 12648 GPTO-ISOLA TOR 4N35 230006019 239750019 239750002 TRANSFORMER ASSY TOROID ASSY 202900017 202224·000 1N4148 lN52408 239014000 239600001 2N3904 VN10KM 2N2907A 239015'000 239200012 239100012 LM339AN 40498 I79L05AC 40138 40118 LM3S8AN 4066 210300015 210210049 2.001 111 ± 20%.238 C233.

14. .81 R82. 69. 7. 1/4W 100k ohm ±5%. 96. 75.1/4W 33k ohm ± 5%.110 R36 R37.25.55.85.57.37 R3.6k ohm ±. 1/4W 3. 1/4W 10k ohm ±5%.19. 1/4W 36 ohm ± 5%.32.2 ohm 22 ohm ± 5%.1 ohm ± 3%. 1/4W 30k ohm ± 5%.1/4W 270 ohm ± 5%. 101. 1/4W 47k ohm ± 5%.17. ·86.15.99.1/4W 300 ohm ± 5%.2k ohm ± 5%.4. 111 R49 R51 R52. 1/2W 160k ohm ± 5%. 1/4W 203077 001 234024023 234024063 FOIL lNCONEL.5%. 1/4W 1.7k ohm ± 5%. 1/2W 47k ohm ± 5%.5.67. 1/4W 2. 1/2W 20k ohm ± 5%. 8W . 83 A87 R88-95 R97. 1/4W 470 ohm ± 5%.104.84. 3W 680 ohm ± 5%.53 R45 R48..44. 10k ohm 51 ohm ± 5%.2k ohm ± 5%. .100. 58.1kohm±S.7k ohm ± 5%.72 R34 R35. 1/4W 1. 1k ohm 2kohm±5%. 6.7 ohm ± 5%.Skohm ±5%. 73.98.PCB ASSEMBLY.78 R76. 1J2W TRIMPOT.114 R40.8. 1/4W 150kohm ± 5%. 1/4W 4. 1/4W 1.66.23 R2. 65.9.1/4W 2.20.21.39 R38. 1/4W 51k ohm ± 5%. 1J4W 4. 1/2W 222640001 234014124 234014127 234014115 236200076 234·024070 234024049 234 Of4 048 234024039 234024104 234024079 234024111 234024080 234024050 234024067 234024112 234024057 234024123 234024076· 234024073 234024067 234024099 234024087 234024073 234024084 234024028 234024103 234024098 234024115 234024055 234014060 234000017 234028001 234024059 236200079 234024032 234014041 53 .12.22.59 AS3 R54 R56. 1/4W TRIMPOT.117-119 R13 R26 R27 R28 R29 R30 R31.5k ohm + 5%.105-107 R59 R60 R61 R62 R63 R71 R74. 1/4W 1k ohm ± 5%. 1J4W 110k ohm~5%.16.5k ohm ± 5%.50. 33.46. 1/4W 1.70. 103 R112.04 ohm 120k ohm ± 5%.102.68. 11.113 RESISTOR ASSY.10. 1/4W 330k ohm ± 5%. 1/2W 100 ohm ± 5%. REFERENCE DESIGNATION RESISTORS POWER SUPPLY 201 203005 A DESCRIPTION VALLEYLAB PART NUMBER R1. 1/4W 7. 79.7k ohm ± 5%.77 R80. 1/4W 5.64 R41 R43. 1/4W 560 ohm ± 5%.24.18.

37 C38 C43.18-21 016 022. SOV .45. Ci9 G17 C20 C26.400V 10 uf ± 10%.28 C27 C29 C30 C31 C32 C36. 20V 4050B ICL7660CPA LM306 LM339AN 40238 40118 SG3S26 4066 210210050 210300072 210016002 21Q 300015 210210023 210210011 210300062 210200022 c/ / / / 54 . 35V 151lt ± i0%.012 Ilt ± 10%. 15.0 Ilf ± 20%. 500V .16.34./ 1.39. 100V .22-25.0151lf ± 10%.15.CAPACITORS C1.9 Ci0.24 030 031 VN10KM 2N3904 2N2905A MM3724 IRF531 IRF9533 23920001'2 239015000 239019 000 239 052 000 239200014 239200015 {_. +30 -10%. 100V 2200 pt ± 5%.14.1 I.d ± 20%.33.47-49 C2 C3 C4.11. 200V 6800 Ilt.%.12. 1000V 100 pf ± 15%. 500V illt ± 10.42 C12 C13. +30~10%~ 25V' 4700 ut. 50V 33 pf ± 10%.25 023. 35. 600V 47 pf± 15%.9 TRANSISTORS 010. SOOV 1000 uf 1500 pf 204118014 204085012 204085010 204079059 204200013 204118 007 204200007 204200009 204118004 204200025 204105034 204500 103 204105030 204400138 204105028 2f14500 106 204500105 204400130 204400001 204055002 ± 20%. 250V 1200 pf ± 5%.40.220V 21lf. 200V ± 5%.17. 100V 0.8 C5.44 INTEGRATED CIRCUITS U1 U2 U3 U4 US U6 U7 U8. 6. 500V 1500 pf ± 10%. SOV 1000 pt ± 15%. G14.18..0331lf ± 20%.7.

4 POLE 251 200024 251200029 251 200030 251100077 251 039000 215005039 230007002 MR826 1N4148 1N751A 1N5233B 239066005 239014000 239600011 239600 000 HEATSINK ASSY. 500 ohm ± 5%. PULSE TRANSFORMER. OUTPUT INDUCTOR. REFERENCE DESIGNATION R2 026-29 BR2 202701 069 H DESCRIPTION RES. #T-0403 FUSE. MDA3504 VALLEYLAB PART NUMBER 234003007 239200018 239700003 55 .S. RF OUT REFERENCE DESIGNATION R115/ 01-4 DESCRIPTION RES. CUT INDUCTOR.DIODES CR1-5 CR6-8.6AMPS RELAY. 5W POWER FET SGS BRIDGE RECT. SOW BUZ80A 23400300T 239200020 05-9 HEATSINK ASSY. PWR SWITCHING TRANSFORMER. .15 CR9 CR13 MISCELLANEOUS T1. 50W TRANSISTOR BUZ80A 202701 282 C VALL EYLAB PART NUMBER 234003008 239200020 HEATSINK ASSY. CLAMP REFERENCE DESIGNATION R1 DESCRIPTION RES. 10-12.2 T3 T4 L1 L2 F1 K1 TRANSFORMER. 50 ohm ± 5%.75mH.14. P. 50 ohm TRANSISTOR 202701 283 C VALLEYLAB PART NUMBER ± 5%.

VS247 VALLEYLAB PART NUMBER 234003 005 204118014 204025044 210300073 210300074 239700 034 239006000 H1 C1-4 C5 U1 U2 BR1 BR3.Lf ± 20%. LVPS REFERENCE DESIGNATION 202701 331 A DESCRIPTION RES.0 VOLT. VK648X BRIDGE RECT. 50 ohm ± 3%. LM340K-5.0022 J. 6kV ~ VOLT.HEATSINK ASSY. 50V .0 J.4 56 . REG. 1. SOW CAP. REG.Lf ± 20%. LM340K-12 BRIDGE RECT.

Mounting Fixtures (all models) Footswitches (all models) Return Electrodes Sterile Disposables THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES. or part thereof. which has been repaired or altered outside of Manu. Manufacturer's obligation under this warranty is limited to the repair or replacement. EXPRESS OR IMPLIED. Manufacturer neither assumes nor authorizes any other person to assume for it any other liability in connection with the sale or use of any of Manufacturer's products. and which examination discloses..facturer's factory in a way so as. reserve the. Inc. or which has been subjected to misuse.SECTION a WARRANTY VaUeylab. of any product. shall be construed under and governed by the laws of the State of Colorado.S. U. as stated on packaging. negligence or accid~nt. ANDOFALLOTHEROBLIGATIONSORUABILITIES ON THE PART OF THE MANUFACTURER. its dealers and representatives. The warranty periods for Manufacturer's ELECTROSURGICAL GENERATORS products are as follows: One Year One Year One Year Shelf life only. or part thereof. fig ht 10 make changes in equprnent built and/or sold by them at anytime without incurring any obligation to make the same or similar changes on equipment previously built and/or sold by them. 57 . Sterility only. that the product is defective. at its option. ("Manufacturer") warrants each product manufactured by it to be free from defects in material and workmanship under normal use and service. This warranty does not apply to any product. Valleylab. to affect its stability or reliability. INCLUDING THE WARRANTIESOFMERCHANTABIUTY AND FITNESS. in Manufacturer's judgment.A. This warranty and the rights and obligations hereunder. which has been returned to it or its Distributor within the applicable time period shown below after delivery of the product to the original purchaser. as stated on packaging. There are no warranties which extend beyond the terms hereof. Inc. to Manufacturer's satisfaction.