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Related Manuals for ConMed Hyfrecator 2000
Summary of Contents for ConMed Hyfrecator 2000
- Page 1 Service Manual 2000 Serving the Physician Since 1937...
- Page 2 For Technical Service or Return Authorization Phone: 303-699-7600 / 1-800-552-0138 Extension 5274 Fax 303-699-1628 For Customer Service or to order parts phone: 1-800-448-6506 / 315-797-8375 / Fax 315-735-6235 or contact your CONMED Representative. European Authorized Representative MDSS GmbH Burckhardtstr 1 D - 30163 Hannover...
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Page 3: Table Of Contents
2000 Table of Contents Section Title Page GENERAL INFORMATION ......... . .1 Foreword . - Page 4 2000 Section Title Page 3.3.4.1.4 Power Adjustment ........16 3.3.4.1.5 Setting Storage .
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Page 5: Section Title Page
2000 Section Title Page 4.4.8.3 HV Supply Problems ........45 4.4.8.4 Switch Isolator Problems . - Page 6 2000 This page intentionally left blank.
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Page 7: General Information
Hyfrecator® 2000 Electrosurgical Unit (ESU) up to original factory specifications. CONMED Corporation reserves the right to alter the specifications of the Hyfrecator® 2000. It is important to have access to the Operator’s Manual supplied with each unit in order to restore original specifications. -
Page 8: Warranty
The warranty period for the CONMED HYFRECATOR® 2000 is twelve (12) months to the product’s original owner. NOTE: The warranty card must be returned by the original owner to CONMED within ten (10) days of receipt of the invoice. -
Page 9: Product Description
2000 2.0 PRODUCT DESCRIPTION This Section contains relevant “Quick Start” excerpts of the technical data supplied in the Hyfrecator® 2000 Operator’s Manual, Cat. No. 7-900-OM-ENG. Refer to that document for further details. 2.1 Controls, Displays and Connectors The Hyfrecator® 2000 controls are marked with IEC and ISO symbols which should be familiar to an experienced biomedical technician. -
Page 10: Power Setting Storage
2000 BI: Two 0.25" (6 mm) jacks for connection to a two-conductor bipolar active accessory cord. These connections are not referenced to earth or the P/P connector. 2.1.1 Power Setting Storage Upon each power-up, the power settings for all three modes are returned to the values previously stored. During use, settings are automatically stored to non-volatile memory (EEPROM) each time the following sequence occurs: 1. -
Page 11: Service Precautions
2000 Environmental: Operation: 50 F to 104 F (10 C to 40 C); 10-95% Relative Humidity, non-condensing Storage: -40 F to 158 F (-40 C to 70 C); 0 -95% Relative Humidity, non-condensing Output Ratings: Mode, Power, Load, Voltage, Pulse Rate, Ohms KV(p-p) 1000... - Page 12 • Component Replacement: Replacement components should be as specified in the parts lists in Section 5 of this manual. Consult CONMED Technical Services for custom components or acceptable substitutes. • Housing fasteners: To avoid stripping threads during reassembly, rotate housing screws counterclockwise with light pressure to find the original threads in housing bosses.
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Page 13: Mains Voltage Strapping
2000 2.4 Mains Voltage Strapping This unit may be field-strapped to any of the rated mains voltages shown in Section 2.2 of this manual. Use the following procedure: 1. Unsolder the zero-ohm resistors from the A2 PWB, JP1 through JP5 and reinstall them for the desired mains rating according to Table 1 in Figure 5.8. -
Page 14: Theory Of Operation
2000 3.0 THEORY OF OPERATION The Hyfrecator® 2000’s fault detection and Fault Code displays expedite troubleshooting. However, the biomedical technician must understand more fully how the unit was designed to operate in order to isolate and repair less common problems. This Section is intended to provide that background. 3.1 Overview The Hyfrecator®... -
Page 15: Low Voltage Supplies
2000 The Hyfrecator® 2000 is powered from the 50-60 Hz AC mains at one of four strappable voltage ratings. The factory selection appears on the nameplate on the rear of the enclosure. Mains voltage selection is made on the A2 Power PWB using jumpers JP1-5. See Figure 5.8, Table 2. The procedure for changing the mains voltage is in Section 2.4 of this manual. -
Page 16: Rf Generation
2000 3.2.2 RF Generation Voltage-controlled DC power from the HV regulator is converted to radio frequency (RF) output power by the RF Power Amp and coupled to the RF Output jacks through the patient circuits. The output power of the unit is determined by the gate pulse width and frequency, and the high voltage supply, HV , to the RF Generator. -
Page 17: Tone Generator And Monitor
2000 T2 and Q5 form a self-oscillating power inverter which converts +12 VDC into a 45 KHz AC voltage across the primary of T2. Q5-b is biased into initial conduction by R38 & R39, aided by feedback winding T2-2&3. When T2 primary current rises to about 200 mA, the T2 core saturates, and the feedback winding reverses polarity, switching Q5 off. -
Page 18: Dual-Channel Architecture
2000 Fault Detection: • Stuck activation or power adjust button on power-up. • Incorrect waveform frequency or duty cycle. • Incorrect HV voltage. • Activation tone failure. • Corrupted EEPROM calibration data. • Incorrect LED power display. • Microprocessor malfunction. Fail-Safe RF Shutdown: •... -
Page 19: A1 Signal Descriptions
2000 3.3.2 A1 Signal Descriptions This section describes all signals present on the A1 PWB. 3.3.2.1. Mnemonic Conventions Signal mnemonics use the following conventions: • A leading slant (/) indicates a logic signal which is active low. • A “.C” or “.M” suffix indicates a signal specific to the Control or Monitor microcontroller, respectively. •... -
Page 20: On-Board I/O Signals
2000 3.3.2.6 On-Board I/O Signals • /φ1, /φ2 - Two-bit grey-coded rotary encoder output (power adjust). • SDA, SCL - IIC serial EEPROM data and clock signals (.C & .M) • VCAL - Three-state analog signal representing Service jumper (J2) presence (0.0V), normal run (+5.0V) or Monitor microcontroller fault status (+2.5V) to Control microcontroller. -
Page 21: Run Mode
2000 3.3.4.1 Run Mode Normal operation (Run Mode) occurs when the unit is powered up with the Service Jumper (A1J1) open- circuited such that VCAL is greater than +3.75 Vdc. Entry to Run Mode is accompanied by execution of the Power On Self Test cycle described in Section 3.3.5.3. After the POST cycle completes, the Power display shows the last power setting for the selected Mode as it was read by the Control microcontroller from its EEPROM. -
Page 22: Pset Transfer
2000 3.3.4.1.3 PSET Transfer During the 1 msec LED blanking period, the Control microcontroller turns both Q1 and Q2 off and presents an 8-bit code, PSET, on the PSETO0:7 bus to the Monitor microcontroller. This transfer is necessary because the Monitor microcontroller does not have direct access to user power adjustment inputs. PSET contains data showing the current operating mode and power setting, as well as codes for invalid VMODE voltage and Control-detected fault conditions. -
Page 23: Activation
2000 3.3.4.1.6 Activation Until the unit is activated, the Control microcontroller forces all drive signals to inactive states: HVPWM = low, /GATEPWM = high, /TONE = low. Further, the Monitor microcontroller holds /HVENA inactive (high), so the ACTIVE LED X3 is dark and the HV Regulator is idle. GATENA is held high, however, so that the Monitor can detect activation, valid or otherwise, via the /GATE.M signal. -
Page 24: Gate Waveform Generation
2000 3.3.4.1.7 Gate Waveform Generation The PA gate drive waveforms originate in the Control microcontroller and appear first as /GATEPWM. Each of the three Modes has its own waveform period and ON-time (T ) which do not vary with power setting or calibration adjustments. -
Page 25: Service Mode Menu Diagram
2000 Figure 3.1 Service Mode Menu Diagram This figure presents a flow map of all functions available in Service Mode. -
Page 26: Service Calibrate Mode
2000 Service Mode Mode Switch Display Service Function Output power calibration adjustment. Pseudo-run Normal run without fault detection. Last Fault Last fault code presented from EEPROM. Invalid Invalid Service Mode - “-E” shutdown. The selected mode will be invoked upon removal of the short on J1. Once a Service Mode is entered, the only means of exit is to turn off power to the unit. -
Page 27: Effects Of Offset & Gain Adjustments
2000 Figure 3.2 Effects of Offset & Gain Adjustments Calibration variable selection is done while the unit is deactivated using first the Mode Selector switch to set the Mode to be calibrated, and then by the power buttons or encoder to select between the Offset and Gain variable for that Mode. -
Page 28: Service Pseudo-Run Mode
2000 Figure 3.3 Limits of Calibration Adjustments It is possible to adjust Gain and Offset such that the HVPWM duty cycle hits 100%. Any further increase will force HVPWM to turn off, thus causing RF output to drop to zero. If this occurs, and reducing the CAl variable restores output, then repairs are clearly indicated. -
Page 29: Service Last Fault Recovery Mode
2000 3.3.4.2.4 Service Last Fault Recovery Mode This mode simply pulls up the last Fault Code presented from Monitor EEPROM and displays it. This is a useful troubleshooting aid if the user’s complaint did not note that information. If there was no prior Fault Code stored, “-0”... -
Page 30: Power On Self Test (Post)
2000 Fault codes produced by the Monitor all have a hyphen (-) in the 10’s LED digit, while Control-detected faults show an “E” there. The one’s digit is specific to the fault each detects. A list of fault codes along with a description of the faults they are associated with appears in the Appendix at the end of this manual. -
Page 31: Maintenance
2000 4.0 MAINTENANCE This section describes technical procedures for conducting periodic preventative maintenance, safety and performance testing, along with procedures for calibrating the RF output to ensure that the Hyfrecator® 2000 continues to operate within the original factory specifications. Guidance on troubleshooting and repair are also included to help you return the unit to service quickly in the event a unit fails to pass a test or fails to perform to the physician’s expectations. -
Page 32: Dc Isolation Tests
2000 markings or blur the power display image, so they should be used only when necessary and sparingly. Thoroughly dry the unit and cords with a lint-free cloth before applying power. 4.2.2 DC Isolation Tests This test verifies that the patient output jacks are isolated at DC from earth and from one another. Failure of this isolation will put the patient at risk of electrical shock. -
Page 33: Mains Frequency Leakage
2000 If this normal POST sequence is not observed, or if a Fault Code appears, refer to Section 4.4.3 for corrective action. 5. After a normal POST start up, and BEFORE making any power changes, note the as-delivered position of the Mode Selector switch. Then note the stored power settings in each of the three modes so that they may be restored before returning the unit to the user. -
Page 34: Rf Output Power Testing
2000 These tests are performed most conveniently using any good-quality biomedical electrical safety tester. If you do not possess such a tester, then it is possible to construct your own using a millivoltmeter and a simple RC network constructed according to IEC 60601-1, Clause 19.4 e). NOTE: There should be at least a 3-to-1 difference in measured leakage current between the SFC and NC (earth open and connected). -
Page 35: Rf Leakage Test
2000 ESU Tester Inputs Test Load Mode Power Output (W) Output (mA) Return Active Switch Setting Ω 1000 1000 15.3 18.7 1000 31.5 38.5 11.0 18.0 22.0 BI 1 BI 2 BI 1 BI 2 15.3 18.7 BI 1 BI 2 31.5 38.5 Table 4.1 RF Output Power Test Limits... -
Page 36: Rf Output Power Test Setup
2000 Figure 4.1 RF Output Power Test Setup... -
Page 37: Return To Service
2000 4. Set the unit's controls to 35W BI and connect the test setup per Figure 4.2b. Activate and verify less than 42 mA. Repeat for the other BI output per Figure 4.2b. Low readings from HI are probably due to a shorted capacitor in the RETURN circuit, while high readings point to an open capacitor. -
Page 38: Recalibration Of Rf Output Power
2000 4.3 Recalibration of RF Output Power This Section describes how to adjust RF output power to the original Hyfrecator® 2000 factory specifications. Recalibration need not be performed as part of normal PM checks, but should be done in the following circumstances: •... -
Page 39: Rf Output Calibration Target Currents
2000 Target Rated Load, Ohms Power, W 1000 (HI) 500 (LO, BI) 63 mA 55 mA 77 mA 179 mA 167 mA 237 mA Table 4.2 Target Currents If your unit displays target powers different from those shown above, you may compute target current as: It (mA) = 1000 x √(Pt / Rl) where Pt is displayed power in Watts, and Rl is load resistance in ohms. -
Page 40: Calibration Verification
CONMED. See Section 5.1.3 for ordering information. Of course, a unit may be restored to service far more quickly by exchanging complete printed wiring boards (PWBs). If this method is preferred, spare PWBs may be also be ordered from CONMED. -
Page 41: Using Fault Codes
2000 Expert advice, as well as instructions on returning a unit for factory or warranty service is freely available from the CONMED Technical Services Department. Contact information appears on the inside front cover of this manual. 4.4.1 Using Fault Codes The Hyfrecator®... -
Page 42: Using Pseudo-Run Mode
2000 There are a number of faults which will prevent POST from running, including failure of either microcontroller and shorts on the PSET or LED buses. If the unit powers up with no displays and no tones, first verify that both +5C and +5M are present and correct on the A1 PWB.Then attempt entry to Service Pseudo-Run mode. - Page 43 2000 1. Signal Tracing This method involves injecting a signal at or near the input end of a suspected signal chain and looking for the expected effect farther down the chain. The choice of which chain to investigate is based on the technician’s hypothesis of which part of the system could fail in such a way to explain all of the known symptoms.
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Page 44: A1 Control/Display Pwb Problems
2000 The best method to use on the Hyfrecator® 2000 cannot be prescribed, since it depends upon the technician’s skill, understanding of and experience with the unit. However, if your service organization has service responsibility for about twenty or more Hyfrecator® 2000’s, it may be effective to stock at least one set of spare PWBs to allow for rapid turnaround, and perhaps one known-good Hyfrecator®... -
Page 45: Gate Waveform Problems
2000 If the +5 voltage is incorrect, +12V or +24U may be low or noisy, or the 5V regulator may be faulty; separate +5V regulators are used for each microcontroller. If +5V power exceeds +6.5V , the corresponding regulator has probably failed, and the microcontroller very likely has been permanently damaged. Correct the +5V problem before installing a new microcontroller. -
Page 46: Vgate Problems
2000 If GATE period appears incorrect, then verify that the same period appears on /GATEPWM. If that is incorrect, then check the U1 oscillator frequency (Section 4.4.7.1). If Y1 is running at 4.00 MHz, then U1 is defective; if Y1’s frequency error exceeds 20 KHz, replace Y1. If the GATEMON frequency is different from /GATEPWM, then it is possible that A2U1 is oscillating, so replace it. -
Page 47: Mode Setting Problems
2000 time in a rotating sequence, starting at the top segment and ending with the decimal point. During POST, the blue activation LED is also switched on and off. After POST, the Control microcontroller takes over control of the power display. See Section 3.3.5.3 for a detailed description of POST tests. Careful observation of repeated POST cycles should confirm that each segment can be turned on and off for both digits. -
Page 48: Encoder Problems
2000 With A1 dismounted, the Mode Selector switch is disabled, and, absent electrical faults on the A1, LO Mode will be forced. HI or BI Modes may be selected by connecting a jumper from GND (TP3) to TP1 (HI) or TP2 (LO). -
Page 49: Accessory Push-Button Problems
2000 4.4.7.8 Accessory Push-Button Problems The handswitching accessory supplied with the Hyfrecator® 2000 has three normally-open push-buttons for activation, power increase and power decrease. These buttons share a common return line with the RF output, and thus must be isolated from the internal circuitry. The accessory is subject to flexing and sterilization, and the handswitch isolation circuitry is relatively complex. -
Page 50: A2 Power Pwb Problems
2000 4.4.8 A2 Power PWB Problems The A2 PWB operates with high voltages and currents, and contains a number of heat-producing components. These stresses place it at greater risk for component failure than the A1 PWB. If the symptoms do not include a Fault Code, and the POST display appears normally, then the problem is most likely on the A2 PWB. -
Page 51: Low Voltage Dc Power Problems
2000 If the resistance reads within 5 and 20 Ω, verify that mains voltage strapping jumpers JP1 - JP5 are properly installed and soldered in for the rated mains voltage per Figure 5.8, Table 1. If the jumpers are correct and the resistance reads open circuit, then remove the A2 PWB and test for an open primary in A2T1. - Page 52 2000 If a “-1” (HV Low) is declared, power up and verify that the red LED DS1 lights. If DS1 stays dark, power down immediately to prevent possible damage to A2T1. If DS1 lights, check PRHV at A2TP3. It should be +130 to +170 Vdc with mains voltage set at rated. If PRHV is high, turn the unit OFF (0) and check that the mains voltage and mains straps are correct per Figure 5.8, Table 1.
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Page 53: Switch Isolator Problems
2000 If HV appears correct, and the blue LED is ON continuously, A1U2 may be at fault. See Section 4.4.7.1. If HV is OK, and the blue LED lights ONLY during activation, then a simple recalibration may cure the problem. See Section 4.3. If recalibration fails to correct the problem, check resistance of R1, 2, 17, 19, 27, 31, 33 and 34 and A1R1 and A1R5;... -
Page 54: Tone Generator Problems
2000 If Calibration fails to correct the problem and RF output remains low, Check C19 and D8. If C19 is open, RF output power will be low, and there will be excessive high-frequency noise on HV . If D8 is open, then the waveform at D8-K will “swing freely”... -
Page 55: Technical Data
2000 5.0 TECHNICAL DATA 5.1 General This section contains detailed information about the construction of the Hyfrecator® 2000 necessary for gaining access to internal subassemblies and for component-level troubleshooting and repair. This information is sufficient to guide an experienced technician toward any repair of this unit. Sections 3 and 4 contain additional information which may prove helpful to those who are unfamiliar with this unit or electrosurgical generators in general. -
Page 56: Assembly Breakdown
2000 Figure 5.1 Assembly Breakdown... -
Page 57: Front Panel
2000 5.1.1.1 Front Panel The front and rear panel assemblies may be separated, if necessary, by disconnecting the ribbon harness connector A1P1 from the A1 PWB. This is done most easily with the A1 PWB removed from the front panel. CAUTION: When disconnecting A1P1, pull only on the connector housing, not the ribbon harness. -
Page 58: Connector Plate
2000 The A2 is reinstalled in the reverse order, with regard to the screw thread technique noted in 5.1.1.1 above and the following advice: CAUTION: Excessive torque on the A2T1 power transformer mounting screws will crack the PWB, and too little may allow the transformer to hum during operation or to vibrate during shipment, breaking its connections to the PWB. -
Page 59: A2 Pwb Components
2000 TO-92 devices - All TO-92 devices are installed with the center lead formed about .05" (1.2 mm) toward the flat side of the package. First bend the center lead by hand outward about 30 degrees, then use needle-nose pliers to form a second bend about 1/8" (3 mm) below the package to bring the lead back parallel to the other two. - Page 60 2000 the device leads may be adequately insulated by covering them thoroughly from the device body to the PWB pads with a good grade of silicone sealant. A2J3 - The center pin of this connector is removed from the connector housing to gain adequate clearance between the mains line and neutral circuits.
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Page 61: Parts Ordering Information
CONMED Corp. Replacement parts orders are handled by Customer Services. Contact information is found on the inside front cover of this manual. Be sure to have the CONMED part number(s), unit model, and serial number handy to expedite processing. -
Page 62: Rf Output Waveforms
2000 Figure 5.2 RF Output Waveforms HI Mode, 35W O.C. HI Mode, 35W 1000 Ohm Load 1000 V/div., 5µs/div. 500 V/div., 5µs/div. LO Mode, 20W O.C. LO Mode, 20W 500 Ohm Load 500 V/div., 5µs/div. 200 V/div., 5µs/div. BI Mode, 35W 500 Ohm Load BI Mode, 35W O.C. -
Page 63: A1 Pwb Waveforms
2000 Figure 5.3 A1 PWB Waveforms HVPWM U1-10 VCON HVPWM U2-10 VCON U1 & U2 OSCOUT via 10K Isolation Resistor HVPWM & VCON, 35W & 3W HI 1 V/div., 200 ns/div. 2 V/div., 5µs/div. /TONE GATEMON VGATE TONE-V GATEMON & VGATE, 3W HI /TONE &... -
Page 64: A2 Pwb Waveforms
2000 Figure 5.4 A2 PWB Waveforms /GATE /GATE GATEMON GATEMON /GATE & GATEMON, 35W HI /GATE & GATEMON, 20W LO A1: 2 V/div., A2: 5 V/div., 5µs/div. A1: 2 V/div., A2: 5 V/div. 5µs/div. /TONE /GATE A2Q1-E Maximum Volume GATEMON A2Q1-E Minimum Volume /GATE &... -
Page 65: Nominal Hv Vs. Power Setting
2000 Figure 5.5 Nominal HV vs. Power Setting POWER SETTING, W... - Page 66 2000 This page intentionally left blank.
- Page 67 2000 Appendix Fault Codes See Section 4.4.1 for a discussion of troubleshooting using Fault Codes. Controller-Generated Fault Codes Fault Code Meaning Possible Remedies E1 - E3 Control microprocessor process errors. Replace A1U1 Power adjust overflow. Possible user error. If can't duplicate, and Mode change during power slew.
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Page 68: A1 Control/Display Pwb Parts List, Layout And Schematic
2000 Monitor-generated Fault Codes Fault Code Meaning Possible Remedies In Service Last Fault only: Unit has never declared a fault. No fault code stored. POST detected low HV . HV supply output low. Try Service Pr Mode output checks. If HV low, repair. Otherwise verify HVSENS = VCON x 0.8 to 0.84. -
Page 69: A2 Power Pwb Parts List, Layout And Schematic
2000 Monitor-generated Fault Codes, continued Fault Code Meaning Possible Remedies PSET & LED scan rate incorrect. Check LED1S & LED10S with an oscilloscope. Verify 1S high for 4 msec, then both low, then 10s high 4 msec, then both low in continuous cycle. Verify both swing 0 to +5V . -
Page 70: Top Assembly Parts List, Interconnect And Functional Block Diagrams
2000 REF. DES. CONMED P/N DESCRIPTION Figure 5.6 Top Assembly Parts List, Interconnect and Functional Block Diagrams 61-5710-XXX HYFRECATOR 2000 ASSEMBLY Connector Plate 61-5741-001 ASSY.,PWB, DISPLAY,A1 Assy A3 61-5744-100 ASSY,PWR PWB, A2 100V HYF 2000 Bipolar 61-5744-115 ASSY,PWR PWB, A2 115V HYF 2000... - Page 71 2000 REF. DES. CONMED P/N DESCRIPTION Figure 5.7 A1 Control/Display PWB Parts List, Layout and Schematic C1,3,7,8,10, 62-0267-002 CAP , 0.10 uF 50V 20% CERAMIC 12-16,18,19, 21,22 62-0267-004 CAP , 100pF DIP CER 50V C2,4,5,6,9, 62-0267-001 CAP , 0.01uF, 50V , 20% CER...
- Page 72 2000 REF. DES. CONMED P/N DESCRIPTION REF. DES. CONMED P/N DESCRIPTION Figure 5.8 A2 Power PWB Parts List, Layout and Schematic BR1-2 62-0258-006 BRIDGE RECTIFIER 400V , 1.5A, WO4G 62-0364-012 RES, 7.5, 1/4, 5% C1,10,21, 62-0267-001 CAP , 0.01uF, 50V , 20% CER 62-0961-263 RES, MF, 5.36K 1/4W 1%...
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Hello, my name is Magno Medeiros. I **** an electronics technician and I need to repair a piece of equipment. It shows an error code -1 on the display and the buzzer sounds continuously, preventing the device from working. I would like to ask you to tell me what this error means and if I can fix it... I would be grateful for any help!