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Covidien Force FX Service Manual

Electrosurgical generator c
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Electrosurgical Generator C

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Summary of Contents for Covidien Force FX

  • Page 1 Service Manual Force FX Electrosurgical Generator C...

  • Page 2: Conventions Used In This Guide

    This manual and the equipment it describes are for use only by qualified medical professionals trained in the particular technique and surgical procedure to be performed. It is intended as a guide for servicing the Force FX Electrosurgical Generator C only. Additional users information is available in the Force FX Electrosurgical Generator C User’s Guide.

  • Page 3: Limited Warranty

    County of Boulder, State of Colorado, USA. Covidien reserves the right to make changes in covered products built or sold by it at any time without incurring any obligation to make the same or similar changes to equipment previously built or sold by it.

  • Page 4: Software License

    Customer further acknowledges and agrees that the Software is owned exclusively by COVIDIEN. The Software is licensed to be used on only one computing device or Product, and a valid license must be purchased for each computing device on which the Software is installed.
  • Page 5 Software. COVIDIEN may, in its sole discretion, undertake to incorporate such changes and distribute the Software so modified to all or any of COVIDIEN's customers. All such error corrections, bug fixes, patches, updates or other modifications provided to COVIDIEN shall be the sole property of COVIDIEN.
  • Page 6 (vii) Products or equipment that have been altered, serviced or modified by a party other than COVIDIEN; or (viii) Software that has been subjected to abnormal physical or electrical stress, misuse, negligence or accident by Customer or a third party.

  • Page 7: Table Of Contents

    Transport and Storage ......3-3 Force FX Electrosurgical Generator C Service Manual...
  • Page 8 Electromagnetic Compatibility ..... . 3-17 Cables Used for the Force FX EMC Test ....3-18 Voltage Transients (Emergency Generator Mains Transfer) .
  • Page 9 Setting Up the Generator ......5-2 Force FX Electrosurgical Generator C Service Manual...
  • Page 10 Using the RS-232 Serial Port ......5-42 Establish the Communications Link ....5-42 Force FX Electrosurgical Generator C Service Manual...
  • Page 11 Right Heat Sink and Component Replacement ... . 7-19 Remove the Right Heat Sink ......7-19 Force FX Electrosurgical Generator C Service Manual...
  • Page 12 Parts List ........9-18 Supply/RF Board Components ......9-21 Force FX Electrosurgical Generator C Service Manual...

  • Page 13: Chapter 1. Introduction

    Chapter 1 Introduction This manual provides instructions for servicing the Covidien Force FX Electrosurgical Generator C with Instant Response technology. This chapter introduces the features and components of the generator and reviews the precautions associated with generator repair. Force FX Electrosurgical Generator C Service Manual...

  • Page 14: General Description

    Argon Gas Delivery Unit II system compatibility List of Components The Force FX Electrosurgical Generator C is a self-contained unit, consisting of a main enclosure (cover and base) and power cord. The main components of the generator are the following: •...

  • Page 15: Service Personnel Safety

    Active Accessories Warning Electric Shock Hazard Do not connect wet accessories to the generator. Electric Shock Hazard Ensure that all accessories and adapters are correctly connected and that no metal is exposed. Force FX Electrosurgical Generator C Service Manual...

  • Page 16: Patient Return Electrodes

    Do not connect a wet power cord to the generator or to the wall receptacle. To allow stored energy to dissipate after power is disconnected, wait at least five minutes before replacing parts. Force FX Electrosurgical Generator C Service Manual...

  • Page 17: Servicing

    After completing any calibration step, proceed to the next step to save the values from the completed calibration step. Ω Do not activate the generator with any load resistor higher than 10 ohms (10 ) while calibrating the current sense gain. Otherwise, product damage will result. Force FX Electrosurgical Generator C Service Manual...

  • Page 18: Cleaning

    Calibrate the generator after you install a new Power Supply/RF board. Component differences may affect output waveforms. Cleaning Notice Do not clean the generator with abrasive cleaning or disinfectant compounds, solvents, or other materials that could scratch the panels or damage the generator. Force FX Electrosurgical Generator C Service Manual...

  • Page 19: Chapter 2. Controls, Indicators, And Receptacles

    Chapter 2 Controls, Indicators, and Receptacles This chapter describes the front and rear panels, including all controls, indicators, receptacles, the fuse drawer, and ports. Force FX Electrosurgical Generator C Service Manual...

  • Page 20: Front Panel

    This switch supplies power to the generator. Patient return electrode receptacle For monopolar electrosurgery, To turn on the generator, press (|). connect a patient return To turn off the generator, press ( electrode to this receptacle. Force FX Electrosurgical Generator C Service Manual...

  • Page 21: Bipolar Controls

    Precise mode button Select for fine bipolar Macro mode button tissue desiccation. Select for macrobipolar output. Standard mode button Select for standard bipolar tissue desiccation. This is the default bipolar mode. Force FX Electrosurgical Generator C Service Manual...

  • Page 22: Bipolar Instrument Receptacle

    REM contact quality monitor alarm. You can connect either a footswitching or handswitching bipolar instrument to the Bipolar instrument receptacle. Connect a footswitching instrument with a two-pin connector. Connect a handswitching instrument with a three-pin connector. Force FX Electrosurgical Generator C Service Manual...

  • Page 23: Monopolar Cut Controls

    Blend mode button or no sparking. Select for slower cutting and additional hemostasis. Pure mode button Select for an even cut with little or no hemostasis. This is the default monopolar cut mode. Force FX Electrosurgical Generator C Service Manual...

  • Page 24: Monopolar Coag Controls

    Force FX Electrosurgical Generator C User’s Guide. Fulgurate is the default monopolar coag mode. However, the default coag mode can be changed to either Desiccate or Spray through the serial port on the rear panel. Force FX Electrosurgical Generator C Service Manual...

  • Page 25: Monopolar Instrument Receptacles

    Refer to Connecting the CUSA Handpiece with CEM Nosecone on page 5-11. Connect one monopolar instrument to the Monopolar 2 Instrument receptacle: • A single-pin footswitching instrument or a three-pin handswitching instrument. Force FX Electrosurgical Generator C Service Manual...

  • Page 26: Rem Alarm Indicator

    Rear Panel Controls and receptacles on the rear panel Power entry module Volume control Option panel Bipolar Monopolar Equipotential grounding lug Footswitch Footswitch Use to connect the generator to receptacle receptacles earth ground. Force FX Electrosurgical Generator C Service Manual...

  • Page 27: Footswitch Receptacles

    You must connect a monopolar footswitch if you connect a monopolar footswitching instrument to the generator. Use only a Valleylab monopolar footswitch with the Force FX Electrosurgical Generator C. Use of an incompatible footswitch may cause unexpected output. Connect a two-pedal Valleylab monopolar footswitch to the Monopolar 1 Footswitch receptacle.

  • Page 28: Power Entry Module

    (activation tone). To ensure that the surgical team is alerted to inadvertent activation, these tones cannot be silenced. To increase the volume of activation tones, turn the knob clockwise. To decrease the volume, turn the knob counterclockwise. 2-10 Force FX Electrosurgical Generator C Service Manual...

  • Page 29: Option Panel

    Precaution To avoid product damage, do not operate the Force FX Electrosurgical Generator C without an appropriate cover plate in place. To review the technical specifications for each port, refer to page 3-6 and page 3-7.

  • Page 31: Chapter 3. Technical Specifications

    All specifications are nominal and subject to change without notice. A specification referred to as “typical” is within ± 20% of a stated value at room temperature (77° F/25° C) and a nominal input power voltage. Force FX Electrosurgical Generator C Service Manual...

  • Page 32: Performance Characteristics

    30% to 75%, noncondensing Atmospheric pressure 700 to 1060 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. Force FX Electrosurgical Generator C Service Manual...

  • Page 33: Transport And Storage

    If the internal temperature of the generator is too high, an alarm tone sounds and a number (451) flashes in the Cut display alternately with the power settings. You can activate the generator and change the power settings while this condition exists. Force FX Electrosurgical Generator C Service Manual...

  • Page 34: Internal Memory Audio Volume

    The last 20 error codes detected by the generator The number of times and length of activation for each mode The average power setting used for each mode The total time the generator is on Other service-related information. Force FX Electrosurgical Generator C Service Manual...

  • Page 35: Audio Volume

    REM Polyhesive Patient Return Electrode: 5 to 135 Ω or up to a 40% increase in the initial measured contact resistance (whichever is less). Patient return electrode without the REM safety feature (single section electrode): 0 to 20 Ω. Force FX Electrosurgical Generator C Service Manual...

  • Page 36: Serial Port

    The contacts are closed when the output is energized and open at all other times. This port provides a means to tell other equipment that RF current is being generated. This may be useful when making EEG or ECG measurements. Force FX Electrosurgical Generator C Service Manual...

  • Page 37: Expansion Port

    High Frequency (RF) Leakage Current Bipolar RF leakage < 59.2 mA current Monopolar RF leakage < 150 mA current (additional tolerance)  CEM output modes < 150 mA 50 W Force FX Electrosurgical Generator C Service Manual...

  • Page 38: Input Power

    100-120 VAC Cable - SJT16/3, IEC color code, maximum length 15’ (5 m) Plug - minimum 10 A 125 VAC Unit receptacle - IEC female, minimum 10 A - 125 VAC Force FX Electrosurgical Generator C Service Manual...

  • Page 39: Standards And Iec Classifications

    "ON" (power) IEC 60417-5007 "OFF" (power) IEC 60417-5008 Defibrillation-proof type CF applied part IEC 60417-5336 C= cardiac F= floating applied part Force FX Electrosurgical Generator C Service Manual...
  • Page 40 Pure cutting mode Electrosurgery, blended cutting mode IEC 60417-5781 Blend cutting mode Electrosurgery, coagulation mode IEC 60417-5782 Desiccate coagulation mode Fulgurate coagulation mode Electrosurgery, spray coagulation mode IEC 60417-5783 Spray coagulation mode 3-10 Force FX Electrosurgical Generator C Service Manual...
  • Page 41 Reference Caution ISO 7000-0434A Indicates that caution is necessary when operating the device, or to indicate that the current situation needs operator awareness or operator action in order to avoid undesirable consequences Force FX Electrosurgical Generator C Service Manual 3-11...
  • Page 42 Indicates a serial number so that a specific medical device can be identified Authorized representative in the European community ISO 15223 5.1.2 Indicates the authorized representative in the European community IEC 60417-5016 Fuse 3-12 Force FX Electrosurgical Generator C Service Manual...
  • Page 43 Non-ionizing electromagnetic radiation IEC 60417-5140 General limits IEC 60417-5649 10 sec. To identify the activation time duty cycle (10 seconds ON, 30 sec. 30 seconds OFF) Caution, risk of electric shock IEC 60417-6042 Force FX Electrosurgical Generator C Service Manual 3-13...
  • Page 44 Protective earth ground IEC 60417-5019 Caution, risk of electric shock IEC 60417-6042 3-14 Force FX Electrosurgical Generator C Service Manual...
  • Page 45 Indicates the medical device manufacturer, as defined in European Council Directives 90/385/EEC, 93/42/EEC, and 98/79/EC Catalogue number ISO 7000-2493 Indicates the manufacturer’s catalogue number so that the medical device can be identified Force FX Electrosurgical Generator C Service Manual 3-15...

  • Page 46: Class I Equipment (Iec 60601-1)

    ANSI/AAMI HF18 and IEC 60601-2-2. Liquid Spillage The Force FX Electrosurgical Generator C enclosure is constructed so that liquid spillage in normal use does not wet electrical insulation or other components which when wetted are likely to adversely affect the safety of the equipment.

  • Page 47: Electromagnetic Interference

    IEC 60601-2-2 specifications regarding electromagnetic compatibility. Notice The Force FX Electrosurgical Generator C should not be used adjacent to or stacked with equipment other than specified in the Force FX Electrosurgical Generator C User Guide and Service Manual. If adjacent or stacked use is necessary, the Force FX Electrosurgical Generator C should be observed to verify normal operation in the configuration in which it will be used.

  • Page 48: Cables Used For The Force Fx Emc Test

    5 ft. Rear panel Warning: The use of accessories, other than specified in the Force FX-C User’s Guide and Service Manual, may result in increased emissions or decreased immunity of the Force FX-C generator. Only the use of Covidien-branded monopolar cables and accessories, bipolar cables and accessories, and footswitches are approved for use with the Force FX generator.

  • Page 49: Voltage Transients

    Standards and IEC Classifications Voltage Transients (Emergency Generator Mains Transfer) The Force FX Electrosurgical Generator C operates in a safe manner when the transfer is made between line AC and an emergency generator voltage source. Guidance and manufacturer's declaration - electromagnetic emissions The Force FX Electrosurgical Generator C is intended for use in the electromagnetic environment specified below.
  • Page 50 Guidance and manufacturer's declaration - electromagnetic immunity The Force FX Electrosurgical Generator C is intended for use in the electromagnetic environment specified below. The customer or the user of the Force FX Electrosurgical Generator C should ensure that it is used in such an environment.
  • Page 51 Guidance and manufacturer's declaration - electromagnetic immunity The Force FX Electrosurgical Generator C is intended for use in the electromagnetic environment specified below. The customer or the user of the Force FX Electrosurgical Generator C should ensure that it is used in such an environment.
  • Page 52 RF transmitters, an electromagnetic site survey should be considered. If the measured field strength in the location in which the Force FX Electrosurgical Generator C is used exceeds the applicable RF compliance level above, the Force FX Electrosurgical Generator C should be observed to verify normal operation.

  • Page 53: Output Characteristics

    * Power Efficiency Rating indicates the ability of an electrosurgical generator to deliver the selected power over a wide range of tissue impedances. PER value is approximate. + An indication of a waveform’s ability to coagulate bleeders without a cutting effect Force FX Electrosurgical Generator C Service Manual 3-23...

  • Page 54: Maximum Output For Ultrasonic Electrosurgery

    Desiccate 3500 V 70 W + An indication of a waveform’s ability to coagulate bleeders without a cutting effect Available Power Settings in Watts Bipolar and Macrobipolar Monopolar Cut: Low and Pure 3-24 Force FX Electrosurgical Generator C Service Manual...
  • Page 55 Output Characteristics Monopolar Cut: Blend Monopolar Coag CEM Cut CEM Coag Force FX Electrosurgical Generator C Service Manual 3-25...

  • Page 56: Output Waveforms

    390 kHz sinusoidal bursts with a randomized repetition centered at 28 kHz. Frequencies include 21 kHz < f < 35 kHz. Output is further modulated by a random 250 Hz envelope with a variable duty cycle. 3-26 Force FX Electrosurgical Generator C Service Manual...

  • Page 57: Output Power Vs. Resistance Graphs

    Bipolar Graphs The insulating surface described in IEC 60601-2-2 was used to obtain the bipolar output measurements. Precise Bipolar Mode Output power vs. impedance for Precise bipolar 35W mode Load Resistance (ohms) Force FX Electrosurgical Generator C Service Manual 3-27...
  • Page 58 Output Power vs. Resistance Graphs Output power vs. impedance for Precise bipolar 70W mode Load Resistance (ohms) Open circuit peak voltage vs. output power for Precise bipolar mode Output Power (watts) 3-28 Force FX Electrosurgical Generator C Service Manual...
  • Page 59 Output Power vs. Resistance Graphs Output power vs. generator settings Precise bipolar mode Generator Setting Force FX Electrosurgical Generator C Service Manual 3-29...
  • Page 60 This is a function of the generator, as the software is designed to reduce (switch to Low output) the output power when the impedance exceeds a reference 3-30 Force FX Electrosurgical Generator C Service Manual...
  • Page 61 Open circuit peak voltage vs. output power for Standard bipolar mode Output Power (watts) Open circuit peak voltage vs. output power for Standard bipolar mode Generator Setting Force FX Electrosurgical Generator C Service Manual 3-31...
  • Page 62 Output Power vs. Resistance Graphs Macrobipolar Mode Output power vs. impedance for Macrobipolar 35W mode Load Resistance (ohms) Output power vs. impedance for Macrobipolar 70W mode Load Resistance (ohms) 3-32 Force FX Electrosurgical Generator C Service Manual...
  • Page 63 Output Power vs. Resistance Graphs Open circuit peak voltage vs. output power for Macrobipolar mode Output Power (watts) Output power vs. generator settings Macrobipolar mode Generator Setting Force FX Electrosurgical Generator C Service Manual 3-33...

  • Page 64: Monopolar Cut Graphs

    Output Power vs. Resistance Graphs Monopolar Cut Graphs These measurements were taken using short (< 0.5 meter) leads. Low Cut Mode Output power vs. impedance for Low cut 150W mode Load Resistance (ohms) 3-34 Force FX Electrosurgical Generator C Service Manual...
  • Page 65 Output Power vs. Resistance Graphs Output power vs. impedance for Low cut 300W mode Load Resistance (ohms) Open circuit peak voltage vs. output power for Low cut mode Output Power (watts) Force FX Electrosurgical Generator C Service Manual 3-35...
  • Page 66 Output Power vs. Resistance Graphs Output power vs. generator settings Low cut mode Generator Setting 3-36 Force FX Electrosurgical Generator C Service Manual...
  • Page 67 Output Power vs. Resistance Graphs Pure Cut Mode Output power vs. impedance for Pure cut 150W mode Load Resistance (ohms) Output power vs. impedance for Pure cut 300W mode Load Resistance (ohms) Force FX Electrosurgical Generator C Service Manual 3-37...
  • Page 68 Output Power vs. Resistance Graphs Open circuit peak voltage vs. output power for Pure cut mode Output Power (watts) Output power vs. generator settings Pure cut mode Generator Setting 3-38 Force FX Electrosurgical Generator C Service Manual...
  • Page 69 Output Power vs. Resistance Graphs Blend Cut Mode Output power vs. impedance for Blend cut 100W mode Load Resistance (ohms) Force FX Electrosurgical Generator C Service Manual 3-39...
  • Page 70 Output Power vs. Resistance Graphs Output power vs. impedance for Blend cut 200W mode Load Resistance (ohms) Open circuit peak voltage vs. output power for Blend cut mode Output Power (watts) 3-40 Force FX Electrosurgical Generator C Service Manual...
  • Page 71 Output Power vs. Resistance Graphs Output power vs. generator settings Blend cut mode Generator Setting Force FX Electrosurgical Generator C Service Manual 3-41...

  • Page 72: Monopolar Coag Graphs

    Output Power vs. Resistance Graphs Monopolar Coag Graphs These measurements were taken using short (< 0.5 meter) leads. Desiccate Coag Mode Output power vs. impedance for Desiccate coag 60W mode Load Resistance (ohms) 3-42 Force FX Electrosurgical Generator C Service Manual...
  • Page 73 Output Power vs. Resistance Graphs Output power vs. impedance for Desiccate coag 120W mode Load Resistance (ohms) Open circuit peak voltage vs. output power for Desiccate coag mode Output Power (watts) Force FX Electrosurgical Generator C Service Manual 3-43...
  • Page 74 Output Power vs. Resistance Graphs Output power vs. generator settings Desiccate coag mode Generator Setting 3-44 Force FX Electrosurgical Generator C Service Manual...
  • Page 75 Output Power vs. Resistance Graphs Fulgurate Coag Mode Output power vs. impedance Fulgurate coag 60W mode Load Resistance (ohms) Output power vs. impedance Fulgurate coag 120W mode Load Resistance (ohms) Force FX Electrosurgical Generator C Service Manual 3-45...
  • Page 76 Output Power vs. Resistance Graphs Output power vs. peak voltage Fulgurate coag mode Output Power (watts) Output power vs. generator settings Fulgurate coag mode Generator Setting 3-46 Force FX Electrosurgical Generator C Service Manual...
  • Page 77 Output Power vs. Resistance Graphs LCF Fulgurate Coag Mode Output power vs. impedance LCF Fulgurate coag 60W mode Load Resistance (ohms) Output power vs. impedance LCF Fulgurate coag 120W mode Load Resistance (ohms) Force FX Electrosurgical Generator C Service Manual 3-47...
  • Page 78 Output Power vs. Resistance Graphs Output power vs. peak voltage LCF Fulgurate mode Output Power (watts) Output power vs. generator settings LCF Fulgurate mode Generator Setting 3-48 Force FX Electrosurgical Generator C Service Manual...
  • Page 79 Output Power vs. Resistance Graphs Spray Coag Mode Output power vs. impedance Spray coag 60W mode Load Resistance (ohms) Output power vs. impedance Spray coag 120W mode Load Resistance (ohms) Force FX Electrosurgical Generator C Service Manual 3-49...
  • Page 80 Output Power vs. Resistance Graphs Output power vs. peak voltage Spray coag mode Output Power (watts) Output power vs. generator settings Spray coag mode Generator Setting 3-50 Force FX Electrosurgical Generator C Service Manual...

  • Page 81: Chapter 4. Principles Of Operation

    Chapter 4 Principles of Operation This chapter provides detailed information about how the Force FX Electrosurgical Generator C functions and how the internal 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.

  • Page 82: Block Diagram

    Block Diagram Block Diagram A diagram of generator interconnections Force FX Electrosurgical Generator C Service Manual...

  • Page 83: Functional Overview

    4-12. Ultrasonic Electrosurgery The Force FX Electrosurgical Generator C works in conjunction with the CUSA EXcel for procedures where ultrasonic electrosurgery is desirable. When you connect a CUSA handpiece with CEM nosecone to the generator for ultrasonic electrosurgery, the generator limits the monopolar output power automatically.

  • Page 84: Rem Contact Quality Monitoring System

    Desiccate coag is available; the maximum power setting is 70 W. REM Contact Quality Monitoring System The Force FX Electrosurgical Generator C uses the REM Contact Quality Monitoring System to monitor the quality of electrical contact between the patient return electrode and the patient.
  • Page 85 Then, the red indicator light is extinguished and RF output is enabled. For additional information, refer to REM Circuit on page 4-26. Force FX Electrosurgical Generator C Service Manual...

  • Page 86: Control Board

    • Alarm handling • REM • Audio control • Memory control and storage (system alarms with time stamps; calibration values) • Real-time clock control and interface • Internal self-tests • Communicating with the feedback microcontroller Force FX Electrosurgical Generator C Service Manual...

  • Page 87: Feedback Microcontroller

    • Leakage control (coag) • Constant voltage, current, and power feedback control • ECON initialization • Real-time information update (actual voltage, current, power, impedance, effect mode) • Memory tests • Communicating with the main microcontroller. Force FX Electrosurgical Generator C Service Manual...

  • Page 88: Shared Ram

    Main Microcontroller and eight Keyboard input lines (KBD_D0-KBD_D7). The two Bus Transceiver SN74LVC2T45 (U32-U33) devices receive activation inputs from the IsoBloc decoding circuits on the Power Supply/RF Board. These two devices interface with the FPGA (U16-D). Force FX Electrosurgical Generator C Service Manual...

  • Page 89: Power Supply Supervisor Circuit

    1: Standard and Macro bipolar 2: Low and Pure Cut 3: Blend cut 7: Desiccate coag 8: LCF Fulgurate coag 9: Spray coag 11:Spark-controlled Blend 12:Fulgurate coag Codes 4, 5, 6, 10 and A–F are unused. Force FX Electrosurgical Generator C Service Manual...

  • Page 90: T_On Average Check

    The serial port is configured to 9600 baud, 8 data bits, 1 stop bit, with no parity. This timing is derived from the main microcontroller oscillator frequency of 11.0592 MHz. 4-10 Force FX Electrosurgical Generator C Service Manual...

  • Page 91: Dosage Error Algorithm

    These tests detect stuck or aberrant sensors and improperly delivered power in all modes. The dosage error firmware executes in less than one second. 4-11 Force FX Electrosurgical Generator C Service Manual...

  • Page 92: Instant Response Algorithm

    The feedback loop switches the control function to maintaining the analog to digital converter in the linear operating range. 4-12 Force FX Electrosurgical Generator C Service Manual...

  • Page 93: Front Panel

    Monopolar 1/CEM output jack. When you connect a CUSA handpiece with a CEM nosecone to the Monopolar 1/CEM Instrument receptacle, the arm actuates a small switch that connects to the Display board with a 4-pin connector. 4-13 Force FX Electrosurgical Generator C Service Manual...

  • Page 94: Display Board

    This circuit contains three display drivers for the LEDs and the seven-segment displays. The LEDs indicate modes of operation, and the REM condition. The seven-segment displays indicate bipolar, cut, and coag power settings. 4-14 Force FX Electrosurgical Generator C Service Manual...

  • Page 95: Cem Switch Circuit

    Q1, Q2, and Q3 respectively and become the switch drive signals COM0, COM1, AND COM2. • When COM0 is selected, the power control switches is read. • When COM1 is selected, the Recall Switch and the Bipolar mode select switches are read. 4-15 Force FX Electrosurgical Generator C Service Manual...

  • Page 96: Footswitch Board

    (J3 and J2) accept monopolar footswitches and provide footswitching capability for the Monopolar 1/CEM and Monopolar 2 Instrument receptacles located on the front panel. Use only a Valleylab monopolar footswitch with the Force FX Electrosurgical Generator C. Use of an incompatible footswitch may cause unexpected output. The bipolar footswitch connector (J4) accepts a bipolar footswitch and provides footswitching capability for the Bipolar Instrument receptacle on the front panel.

  • Page 97: Audio Circuit

    U1D output transistor is turned on. The output of U1D creates a voltage divider through R11, R12 (the volume control potentiometer), and R32 to attenuate the audio signal to levels acceptable for input to the audio amplifier. 4-17 Force FX Electrosurgical Generator C Service Manual...

  • Page 98: Power Supply/Rf Board

    • REM impedance monitoring (REM circuit) • Handswitch closure detection (IsoBloc circuit) • RS-232 connector • Expansion connector • EKG contact closure connector • Output high voltage relays • Temperature monitoring and fan control 4-18 Force FX Electrosurgical Generator C Service Manual...

  • Page 99: Power Supply/Rf Board Interfaces

    For 120 Vac operation, the triac is on, which connects the AC neutral to the center of the AC/DC converter capacitor bank (C3, C10, C11, and C22). In this configuration, the circuit acts as a doubler using the right hand half of the bridge rectifier (CR80). 4-19 Force FX Electrosurgical Generator C Service Manual...
  • Page 100 DC flux imbalance in T1. Note: T1 consists of two transformers electrically and magnetically isolated from each other but assembled into the same package. T1A and T1B form one transformer; T1C 4-20 Force FX Electrosurgical Generator C Service Manual...
  • Page 101 CR8. The shut down signal comes from the main microcontroller on the Control board. The resistor divider on the high voltage DC output formed by R52 and R53 is used for dosage error sensing. 4-21 Force FX Electrosurgical Generator C Service Manual...

  • Page 102: Low Voltage Power Supply

    High frequency, high voltage signals that can cause severe burns are present in the RF output stage and in the associated mounting and heat sink hardware described in this manual. Take appropriate precautions when testing and troubleshooting this area of the generator. 4-22 Force FX Electrosurgical Generator C Service Manual...
  • Page 103 DC signal. R119 and C97 provide additional filtering. T17 and the associated circuitry operate the same as the redundant voltage sense circuit. The output is a signal proportional to the output current of the generator. 4-23 Force FX Electrosurgical Generator C Service Manual...
  • Page 104 T4 core. When the MOSFET is turned off, the energy stored in the core rings out with a frequency of 591 kHz. 4-24 Force FX Electrosurgical Generator C Service Manual...

  • Page 105: Spark Control Circuit

    The rectified but unfiltered waveform from the output voltage sense circuit is fed into a peak detector (U23A, CR29, and C104). A high impedance buffer (U23B) maintains the integrity of the peak detected signal. The output of this buffer is divided and fed to a comparator. 4-25 Force FX Electrosurgical Generator C Service Manual...

  • Page 106: Rf Leakage Reduction Circuit

    The REM transformer (T10) provides isolated reflected impedance sensing for tissue impedance across the REM patient return electrode terminals (connected to J17, pins 1 and 2). In addition to tuning the REM circuit, capacitors C155, C156, C169, and C170 4-26 Force FX Electrosurgical Generator C Service Manual...

  • Page 107: Isobloc Circuit

    U32, U33, and U34. Current through the limiting resistors, in series with the LEDs in the optoisolators, cause the LEDs to light. The phototransistor in the optoisolator detects this light. 4-27 Force FX Electrosurgical Generator C Service Manual...

  • Page 108: Temperature Sense Circuits

    Temperature Sense Circuits The Force FX Electrosurgical Generator C features two temperature sense circuits. The first temperature sense circuit measures the air temperature adjacent to the RF output FET heat sink. When the temperature at this location reaches approximately 40°...

  • Page 109: Chapter 5. Setup, Tests, And Adjustment

    Chapter 5 Setup, Tests, and Adjustment After unpacking or after servicing the Force FX Electrosurgical Generator C, set it up and verify that it functions correctly. If the Force FX Electrosurgical Generator C does not satisfactorily complete the self-test, calibrate it to ensure its accuracy.

  • Page 110: Setting Up The Generator

    1. Verify the generator is off by pressing the power switch off (O). 2. Place the generator on a stable flat surface, such as a table, platform, or Covidien cart. Carts with conductive wheels are recommended. For details, refer to the procedures for your institution or to local codes.
  • Page 111 If the self-test is not successful, an alarm tone sounds. A number may momentarily appear in the Cut display and, in most cases, the generator is disabled. Note the number and refer to Responding to System Alarms on page 6-11. Force FX Electrosurgical Generator C Service Manual...

  • Page 112: Connections For Bipolar Or Macrobipolar Surgery

    Bipolar receptacle only. Improper connection may result in inadvertent generator activation or a REM contact quality monitor alarm. Bipolar or macrobipolar connections—footswitch activation and a handswitching or footswitching instrument Bipolar footswitch Footswitching or handswitching instrument Force FX Electrosurgical Generator C Service Manual...

  • Page 113: Setting The Bipolar Output

    3. To increase the power for the selected mode, press the white up arrow (  ) button. To decrease the power, press the white down arrow (  ) button. The maximum power setting is 70 W. Force FX Electrosurgical Generator C Service Manual...

  • Page 114: Connections For Monopolar Surgery

    • Do not connect wet accessories to the generator. • Ensure that all accessories and adapters are correctly connected and that no metal is exposed. Use only a Valleylab monopolar footswitch with the Force FX Electrosurgical Generator C generator. Use on an incompatible footswitch may cause unexpected output.
  • Page 115 Monopolar 2 Footswitch receptacle and Monopolar 2 Instrument receptacle Footswitching or handswitching instrument Valleylab monopolar footswitch Patient return electrode Monopolar connection—handswitch activation and a monopolar handswitching instrument using either Monopolar Instrument receptacle Handswitching instrument Patient return electrode Force FX Electrosurgical Generator C Service Manual...

  • Page 116: Selecting Cut And Coag Modes

    The simultaneous coag tone sounds and coag indicator illuminates blue upon pressing Monopolar 1 Coag and Monopolar 2 Coag handswitch buttons simultaneously, or alternatively pressing Monopolar 1 Coag and Monopolar 2 Coag footswitch pedals simultaneously. Force FX Electrosurgical Generator C Service Manual...
  • Page 117 CUSA handpiece with CEM nosecone Patient return electrode Monopolar instrument Connection for simultaneous coag—two footswitching instruments Monopolar instrument or CUSA handpiece with CEM nosecone Valleylab Patient return electrode monopolar footswitches Monopolar instrument Force FX Electrosurgical Generator C Service Manual...

  • Page 118: Using Two Generators Simultaneously

    Place each patient return 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. 5-10 Force FX Electrosurgical Generator C Service Manual...

  • Page 119: Connecting The Cusa Handpiece With Cem Nosecone

    Valleylab monopolar footswitch and CEM indicator connect it to the Monopolar 1 illuminates green Footswitch receptacle CUSA handpiece Connect to CUSA system with CEM nosecone Patient return electrode 5-11 Force FX Electrosurgical Generator C Service Manual...

  • Page 120: Setting The Output Power

    Pure cut, when you select Blend, the power setting changes to 200 W, the maximum for Blend. If, however, you set the power to 65 W in Desiccate, when you select Fulgurate, the power setting does not change because it falls within that mode’s range. 5-12 Force FX Electrosurgical Generator C Service Manual...

  • Page 121: Changing The Power Setting

    If you use bipolar output when a return electrode is applied to the patient, the return electrode circuit is deactivated automatically to eliminate the possibility of current dispersal. 5-13 Force FX Electrosurgical Generator C Service Manual...

  • Page 122: Periodic Safety Check

    Chapter 6, Troubleshooting. Warning Electric Shock Hazard When taking measurements or troubleshooting the generator, take appropriate precautions, such as using isolated tools and equipment, using the “one hand rule,” etc. 5-14 Force FX Electrosurgical Generator C Service Manual...

  • Page 123: Recommended Test Equipment

    • Leakage current tester—Use UL load device or commercially available leakage tester • Leakage table—per IEC 60601-2-2, Figure 104 • 100, 200, 300, 500 Ω, all 250 watt, 1% tolerance, noninductive (Dale NH-250 or equivalent) 5-15 Force FX Electrosurgical Generator C Service Manual...

  • Page 124: Inspecting The Generator And Accessories

    Front Panel Replacement on page 7-9. Footswitch 1. Disconnect the footswitch from the generator. 2. Disassemble the footswitch connector. Inspect the connector for damage or corrosion. 3. Reassemble the footswitch connector. 4. Inspect the footswitch for damage. 5-16 Force FX Electrosurgical Generator C Service Manual...

  • Page 125: Inspecting The Internal Components

    Refer to Power Supply/RF Board Replacement on page 7-26. 5. Reinstall the cover on the generator. Position the cover above the chassis and slide it down. Tighten the five screws that secure the cover to the chassis. 5-17 Force FX Electrosurgical Generator C Service Manual...

  • Page 126: Testing The Generator

    Responding to System Alarms on page 6-11. If you removed and/or replaced the battery, alarm number 212 may appear in the Cut display when you turn on the generator. If this happens, calibrate the generator. 5-18 Force FX Electrosurgical Generator C Service Manual...

  • Page 127: Verifying Rem Function

    2. Connect the test equipment for bipolar output. a. Connect the two test cables to the Bipolar Instrument receptacle. b. Pass one test cable through the current transformer and connect the current transformer to the voltmeter. 5-19 Force FX Electrosurgical Generator C Service Manual...

  • Page 128: Checking Output For The Monopolar Cut Modes

    If the output is outside the specified range, calibrate the bipolar output as described in Calibrating the Generator on page 5-26. Then repeat this procedure. If the output for one or more modes remains outside the specified range, call the Covidien Service Center.
  • Page 129 If the output is outside the specified range, calibrate the monopolar output as described in Calibrating the Generator on page 5-26. Then repeat this procedure. If the output for one or more cut modes remains outside the specified range, call the Covidien Service Center. 5-21 Force FX Electrosurgical Generator C Service Manual...

  • Page 130: Checking Output For The Monopolar Coag Modes

    If the output is outside the specified range, calibrate the monopolar output as described in Calibrating the Generator on page 5-26. Then repeat this procedure. If the output for one or more coag modes remains outside the specified range, call the Covidien Service Center. 5-22 Force FX Electrosurgical Generator C Service Manual...

  • Page 131: Checking Low Frequency Leakage Current And Ground Resis

    4. Determine the leakage current using the conventional 1 microamp (µA) per 1 mV. 5. Verify under normal conditions (ground closed, normal polarity) the leakage current is less than 10 µA. If the leakage current is greater than 10 µA, call the Covidien Service Center.

  • Page 132: Checking High Frequency Leakage Current

    4. Determine the leakage current using the conventional 1 µA per 1 mV. 5. Verify under normal conditions (ground closed, normal polarity) the leakage current is less than 100 µA. If the leakage current is greater than 100 µA, call the Covidien Service Center.
  • Page 133 Record the leakage current. If using the leakage table, leakage current should not exceed 150 mA for any mode. 5. If the high frequency leakage exceeds 150 mA, call the Covidien Service Center for further instructions. Checking Bipolar High Frequency Leakage Current 1.

  • Page 134: Calibrating The Generator

    Day of the month Year 3. Clock Hour Minute 4. REM oscillator frequency and impedance 5. Current sense gain factor 6. Voltage sense gain factor 7. Reactance gain factor 8. ECON factor 5-26 Force FX Electrosurgical Generator C Service Manual...

  • Page 135: Preparing For Calibration

    If an error occurs during calibration, an alarm number will appear in the Cut display. Note the number and refer to Chapter 6, Troubleshooting. Notice After completing any calibration step, proceed to the next step to save the values from the completed calibration step. 5-27 Force FX Electrosurgical Generator C Service Manual...

  • Page 136: Exiting Calibration Mode

    You cannot adjust these values: • The generator code (model number) for the Force FX Electrosurgical Generator C generator is 4. • The software version number for the main microcontroller may vary among manufacturing lots, but should never be 0.

  • Page 137: Adjusting The Calendar

    8. To save the month, day, and year values and go to the next calibration step, press the Bipolar up arrow () button. Next, check the hour and minute values as described in Adjusting the Clock on page 5- 5-29 Force FX Electrosurgical Generator C Service Manual...

  • Page 138: Adjusting The Clock

    2. Calibrate the REM oscillator frequency: a. Connect an oscilloscope across the Patient Return Electrode receptacle pins. b. Remove the five screws that secure the cover to the chassis and lift the cover off the chassis. 5-30 Force FX Electrosurgical Generator C Service Manual...

  • Page 139: Checking And Adjusting The Current Sense Gain

    Do not activate the generator with any load resistor higher than 10 while calibrating the current sense gain. Otherwise, product damage will result. Do not adjust the current sense gain while the generator is activated. 5-31 Force FX Electrosurgical Generator C Service Manual...
  • Page 140 Verify that the 10 Ω resistor is connected to the test cables through the current transformer for monopolar output. e. Connect a monopolar footswitch to the Monopolar 1 Footswitch receptacle on the rear panel. 5-32 Force FX Electrosurgical Generator C Service Manual...

  • Page 141: Checking And Adjusting The Voltage Sense Gain

    • Current transformer (such as the Pearson Model 411 or equivalent) • True RMS voltmeter (such as the Fluke 8920 or equivalent) • 1000, 2000, and 3000 Ω noninductive power resistors (such as the Dale NH-250) • Bipolar footswitch and monopolar footswitch 5-33 Force FX Electrosurgical Generator C Service Manual...
  • Page 142 Repeat this step until the voltmeter reading is within the stated range. The V factor for the Precise and Macro modes adjusts automatically. 3. Disconnect the test cables and remove the 1000 Ω resistor. 5-34 Force FX Electrosurgical Generator C Service Manual...
  • Page 143 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. 5-35 Force FX Electrosurgical Generator C Service Manual...

  • Page 144: Checking And Adjusting The Reactance Gain

    If the output current reading was too high, lower the Z factor. • 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. 5-36 Force FX Electrosurgical Generator C Service Manual...
  • Page 145 3. Adjust the Z factor for the Blend mode. a. Press the Blend button. b. Press the footswitch cut pedal and check the voltmeter for a reading equivalent to 1000 ± 10 mA rms . 5-37 Force FX Electrosurgical Generator C Service Manual...

  • Page 146: Checking And Adjusting The Econ Factor

    Use the bipolar footswitch to activate bipolar output for between two and five seconds. c. Stop activation. Verify that the Coag display changed to 70. d. Use the bipolar footswitch again to activate bipolar output for between two and five seconds. 5-38 Force FX Electrosurgical Generator C Service Manual...
  • Page 147 Calibrating the Generator e. Stop activation. Verify that the Coag display changed to 30. If the display did not change as described, call the Covidien Service Center. 4. To check the Standard mode, press the Standard button and repeat step 3.
  • Page 148 Calibrating the Generator e. Stop activation. Verify that the Coag display changed to 20. If the display did not change as described, call the Covidien Service Center. 6. Remove the 100 Ω resistor from the test cables. Checking Monopolar Coag Output 1.
  • Page 149 Stop activation. Verify that the Coag display changed to 10. 6. To save the ECON calibration values, press the Bipolar up arrow () button. To leave Calibration mode, refer to Exiting Calibration Mode on page 5-28. 5-41 Force FX Electrosurgical Generator C Service Manual...

  • Page 150: Using The Rs-232 Serial Port

    # is the version number of the software for the listed microcontrollers. Z is a numeric representation of the REM impedance. One of the following messages appears (with the Keying ENABLED message) when you activate the generator: BIPOLAR_REQ MONO1_CUT MONO1_COAG MONO2_CUT MONO2_COAG 5-42 Force FX Electrosurgical Generator C Service Manual...

  • Page 151: Enter The Commands

    Coag Desiccate LCF Fulgurate Coag Spray Coag CEM In data displays, numbers represent the Force FX Electrosurgical Generator C modes. You also use these numbers when you enter commands to select a specific mode. Bipolar Modes 0 Precise 1 Standard...
  • Page 152 Specify the coag power setting (# = 1, 2, 3, … 110, 120). :FGU Increment the coag power setting to the next higher value. :FGD Decrement the coag power setting to the next lower value. Recall the previous front panel settings. 5-44 Force FX Electrosurgical Generator C Service Manual...
  • Page 153 No result is displayed unless a character other than D, F, or S is entered Then the following is displayed: No Change Try Again! To save the new default mode, turn off, then turn on the generator. 5-45 Force FX Electrosurgical Generator C Service Manual...

  • Page 154: Disconnect The Computer From The Generator

    1. Turn off the generator. 2. Disconnect the DB 9 cable from the generator. 3. Position the panel over the serial port and install the screws that secure it to the rear panel of the generator. 5-46 Force FX Electrosurgical Generator C Service Manual...

  • Page 155: Chapter 6. Troubleshooting

    If the generator is not functioning properly, use the information in this section to perform the following tasks: • Identify and correct the malfunction • If a system alarm number was displayed, take the appropriate action to correct the alarm condition Force FX Electrosurgical Generator C Service Manual...

  • Page 156: Inspecting The Generator

    Insert the monopolar instrument connector (footswitching and handswitching) into the appropriate receptacle to verify a secure fit. If any of the connections are loose, replace the front panel. Refer to Front Panel Replacement on page 7-9. Force FX Electrosurgical Generator C Service Manual...

  • Page 157: Inspecting The Internal Components

    Refer to Power Supply/RF Board Replacement on page 7-26. To reinstall the cover, position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. Force FX Electrosurgical Generator C Service Manual...

  • Page 158: Correcting Malfunctions

    Faulty power switch Replace the power switch. Refer to Front Panel Power Switch Replacement on page 7-12. Malfunctioning front panel Replace the front panel assembly. Refer components to Front Panel Replacement on page 7-9. Continued Force FX Electrosurgical Generator C Service Manual...
  • Page 159 Malfunctions on page 6-24. Loss of battery-backed RAM Replace the Control board. Refer to due to faulty component on Control Board Replacement on page 7-4. the Control board (other than the battery) Continued Force FX Electrosurgical Generator C Service Manual...
  • Page 160 Display board to the front Display board panel. Incorrect modes are being Replace the front panel. Refer to Front communicated from the front Panel Replacement on page 7-9. panel Continued Force FX Electrosurgical Generator C Service Manual...
  • Page 161 Board Replacement on page 7-4. High voltage power supply If high voltage is not present at TP3 on malfunction (high voltage is the Power Supply/RF board, troubleshoot not present during activation) the high voltage power supply. Continued Force FX Electrosurgical Generator C Service Manual...
  • Page 162 Plug all electrical equipment into line grounded to different objects power at the same location. rather than a common ground. The generator may respond to the resulting voltage differences between grounded objects. Malfunctioning monitor Replace the monitor. Continued Force FX Electrosurgical Generator C Service Manual...
  • Page 163 Always monitor patients with pacemakers during surgery and keep a defibrillator available. Consult the pacemaker manufacturer or hospital Cardiology Department for further information when use of electrosurgical appliances is planned in patients with cardiac pacemakers. Continued Force FX Electrosurgical Generator C Service Manual...
  • Page 164 Fulgurate and Spray modes or select the Desiccate mode. Abnormal 50–60 Hz leakage Inside the generator, carefully inspect for currents damage that may cause shorting between the AC line voltage and connected patient components. 6-10 Force FX Electrosurgical Generator C Service Manual...

  • Page 165: Responding To System Alarms

    FEEDBACK_SEM If error reappears, replace the Control board. semaphore Refer to Control Board Replacement on page 7-4. Main microcontroller unable to access ECON_SEM semaphore Main microcontroller unable to access KEY_ACTIVE_SEM semaphore 6-11 Force FX Electrosurgical Generator C Service Manual...
  • Page 166 Covidien Service Center. Software malfunction. key_req_mode value outside state range Software malfunction. request+1 value outside state range Software malfunction. *input[i].p_state value outside state range 6-12 Force FX Electrosurgical Generator C Service Manual...
  • Page 167 Software malfunction. rem_led_state value outside state range Software malfunction. cal_state value in ca_generator_setup( ) outside state range Software malfunction. cal_state value in ca_clock_date_setup( ) outside state range 6-13 Force FX Electrosurgical Generator C Service Manual...
  • Page 168 ) outside the Covidien Service Center. state range Open circuit REM sense failure Repeat the failing calibration step. If the alarm number reappears, record the number and call the Covidien Service Center. 6-14 Force FX Electrosurgical Generator C Service Manual...
  • Page 169 Turn the power switch off (O) then on (I) again. Feedback microcontroller If error reappears, replace the Control board. unable to access watchdog Refer to Control Board Replacement on page 7-4. semaphore 6-15 Force FX Electrosurgical Generator C Service Manual...
  • Page 170 Refer to Control Board Replacement on page 7-4. Software malfunction. Turn off, then turn on the generator. If the alarm display_state value outside number reappears, record the number and call state range the Covidien Service Center. 6-16 Force FX Electrosurgical Generator C Service Manual...
  • Page 171 Internal diagnostics. Main and Turn the power switch off (O) then on (I) again. feedback microcontrollers are If error reappears, replace the Control board. not compatible Refer to Control Board Replacement on page 7-4. 6-17 Force FX Electrosurgical Generator C Service Manual...
  • Page 172 Internal diagnostics. Firmware Turn the power switch off (O) then on (I) again. not compatible with hardware If error reappears, replace the Control board. Refer to Control Board Replacement on page 7-4. 6-18 Force FX Electrosurgical Generator C Service Manual...
  • Page 173 CPU test failed Board Replacement on page 7-4. 2. Calibrate the generator. Refer to Calibrating the Generator on page 5-26. If the alarm number reappears, record the number and call the Covidien Service Center. 6-19 Force FX Electrosurgical Generator C Service Manual...
  • Page 174 Turn the power switch off (O) then on (I) again. unable to access If error reappears, replace the Control board. FEEDBACK_SEM semaphore Refer to Control Board Replacement on page 7-4. Feedback microcontroller unable to access ECON_SEM semaphore 6-20 Force FX Electrosurgical Generator C Service Manual...
  • Page 175 Verify that the location of the generator allows was exceeded due to length of for adequate cooling. activation time. Use the lowest power setting that achieves the desired effect. Limit activation times, if possible. 6-21 Force FX Electrosurgical Generator C Service Manual...

  • Page 176: Correcting T_On Asic Malfunctions

    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 connector into the matching connector on the Power Supply/RF board. 6-22 Force FX Electrosurgical Generator C Service Manual...
  • Page 177 Calibrate the generator. Refer to Calibrating the Generator on page 5-26 for instructions. If the alarm number reappears, record the number and call the Covidien Service Center. To install the cover, position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis.

  • Page 178: Correcting Battery-Backed Ram Malfunctions

    Grasp the battery and slide it up and out of the socket. Position the new 3 V button-cell battery above the socket so that the positive side of the battery is facing out (visible). Slide the new battery down into the socket. 6-24 Force FX Electrosurgical Generator C Service Manual...
  • Page 179 Recalibrate the generator. If the alarm number reappears, record the number and call the Covidien Service Center. To install the cover, position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 6-25 Force FX Electrosurgical Generator C Service Manual...

  • Page 181: Chapter 7. Replacement Procedures

    • Power Supply/RF board. For your reference, this section also includes an electrical cable interconnect diagram that illustrates all cable connections. The parts used in these procedures are illustrated in Chapter 9, Service Parts. Force FX Electrosurgical Generator C Service Manual...

  • Page 182: Interconnect Diagram

    Interconnect Diagram Interconnect Diagram A block diagram of generator interconnections BW14 Force FX Electrosurgical Generator C Service Manual...

  • Page 183: Battery Replacement

    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 the chassis. Force FX Electrosurgical Generator C Service Manual...

  • Page 184: Control Board Replacement

    Power Supply/RF board. 5. Verify that the packaging for the new Control board contains the part number for the Force FX Electrosurgical Generator C Control board. Do not install any other Control board. 6. Install the battery in the battery socket (positive side facing up).

  • Page 185: Display Board Replacement

    Remove the four screws that secure the Display board to the front panel. Save the screws for reinstallation. b. Disconnect the CEM switch cable from the Display board. c. Disconnect the membrane keyboard ribbon cable from the Display board. Force FX Electrosurgical Generator C Service Manual...

  • Page 186: Install The Display Board

    Connect the Display board ribbon cable to the Control board and lock the connector. 5. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. Force FX Electrosurgical Generator C Service Manual...

  • Page 187: Display Board Seven-Segment Led Replacement

    5. Connect the fan connector to J4 on the Power Supply/RF board. 6. Reinstall the Power Supply/RF board and attached heat sinks. Refer to Power Supply/ RF Board Replacement on page 7-26. Force FX Electrosurgical Generator C Service Manual...

  • Page 188: Footswitch Board Replacement

    On the rear panel, install the six screws that secure the footswitch receptacles to the rear panel. 4. Reinstall the Power Supply/RF board and attached heat sinks. Refer to Power Supply/ RF Board Replacement on page 7-26. Force FX Electrosurgical Generator C Service Manual...

  • Page 189: Front Panel Replacement

    1. Detach and disconnect the Display board from the front panel. a. Remove the four screws that secure the Display board to the front panel. Save the screws for reinstallation. b. Disconnect the CEM switch cable from the Display board. Force FX Electrosurgical Generator C Service Manual...

  • Page 190: Install The Front Panel Assembly

    5. Connect the Display board ribbon cable to the Control board and lock the connector. 6. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7-10 Force FX Electrosurgical Generator C Service Manual...

  • Page 191: Front Panel Rem Module Replacement

    4. Position the bracket over the new REM module and install the two screws that secure the module to the front panel. 5. Reinstall the front panel assembly. Refer to Front Panel Replacement on page 7-9. 7-11 Force FX Electrosurgical Generator C Service Manual...

  • Page 192: Front Panel Power Switch Replacement

    8. Position the power switch with the On (|) switch above the Off (O) switch. Press to snap the switch into place. 9. Reinstall the front panel assembly. Refer to Front Panel Replacement on page 7-9. 7-12 Force FX Electrosurgical Generator C Service Manual...

  • Page 193: Fuse Replacement

    • For 120 V operation, use 8-amp fuses. • For 240 V operation, use 4-amp fuses. 5. Slide the fuse drawer into its slot until it snaps into place. 6. Connect the power cord to the rear panel. 7-13 Force FX Electrosurgical Generator C Service Manual...

  • Page 194: Replacing The Fuse On The Power Supply/Rf Board

    Use a fuse puller to remove the blown fuse. 4. Replace the blown fuse with a 6.3-amp fuse. 5. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7-14 Force FX Electrosurgical Generator C Service Manual...

  • Page 195: Left Front Heat Sink And Component Replacement

    6. Lift the heat sink to disconnect it from the Power Supply/RF board. If you plan to replace one or more components on the existing heat sink, go to Replace Left Front Heat Sink Components on page 7-16. 7-15 Force FX Electrosurgical Generator C Service Manual...

  • Page 196: Replace Left Front Heat Sink Components

    Connect the Display board ribbon cable to the Control board and lock the connector. 5. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7-16 Force FX Electrosurgical Generator C Service Manual...

  • Page 197: Left Rear Heat Sink And Component Replacement

    If you plan to replace one or more components on the existing heat sink, go to Replace Left Rear Heat Sink Components on page 7-18. If you plan to replace the entire left rear heat sink assembly, go to Install the Left Rear Heat Sink on page 7-18. 7-17 Force FX Electrosurgical Generator C Service Manual...

  • Page 198: Replace Left Rear Heat Sink Components

    (plastic screw) and to the left front and right heat sinks (two metal screws). 6. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7-18 Force FX Electrosurgical Generator C Service Manual...

  • Page 199: Right Heat Sink And Component Replacement

    6. On the right side of the chassis, remove the two screws that secure the base of the right heat sink to the rail under the Power Supply/RF board. Save the screws for reinstallation. 7. Lift the heat sink to disconnect it from the Power Supply/RF board. 7-19 Force FX Electrosurgical Generator C Service Manual...

  • Page 200: Replace Right Heat Sink Components

    • To replace the power MOSFET (under the small circuit board), remove the four screws that secure the small circuit board to the heat sink. Set the board and screws aside for reinstallation. 7-20 Force FX Electrosurgical Generator C Service Manual...

  • Page 201: Install The Right Heat Sink

    Connect the Display board ribbon cable to the Control board and lock the connector. 6. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7-21 Force FX Electrosurgical Generator C Service Manual...

  • Page 202: Low Voltage Power Supply Replacement

    1. Place the new low voltage power supply on the Power Supply/RF board and install the four screws that secure it to the board. 2. Facing the front of the unit, connect the cables from the Power Supply/RF board to the new low voltage power supply. 7-22 Force FX Electrosurgical Generator C Service Manual...
  • Page 203 J2 pin 4 (black wire) to location BW14 pin 4 on Power Supply/RF board • J2 pin 5 (black wire) to location BW14 pin 5 on Power Supply/RF board • J2 pin 6 (blue wire) to location BW14 pin 2 on Power Supply/RF board 7-23 Force FX Electrosurgical Generator C Service Manual...

  • Page 204: Power Entry Module Replacement

    Then, remove the nut and washer that secure the ground wire ring terminal to the grounding lug. Save the nut and washer for reinstallation. 7. Slide the ring terminal off the post and remove the power entry module assembly from the unit. 7-24 Force FX Electrosurgical Generator C Service Manual...

  • Page 205: Install The Power Entry Module

    5. Connect the power entry module cable to J6 on the Power Supply/RF board. 6. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7. Reconnect the power cord to the rear panel. 7-25 Force FX Electrosurgical Generator C Service Manual...

  • Page 206: Power Supply/Rf Board Replacement

    Power Supply/RF board (behind the Control board). Save the screws for reinstallation. 7. Remove the assembly (Power Supply/RF board, heat sinks, Control board, low voltage power supply, fan) from the chassis. 7-26 Force FX Electrosurgical Generator C Service Manual...

  • Page 207: Remove Components From The Old Board

    7. Remove the fan. a. Disconnect the fan control connector from the Power Supply/RF board. b. Remove the four screws and nuts that secure the fan to the underside of the Power Supply/RF board. 7-27 Force FX Electrosurgical Generator C Service Manual...

  • Page 208: Install Components On The New Board

    Control board 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 Supply/RF board. 7-28 Force FX Electrosurgical Generator C Service Manual...

  • Page 209: Install The Power Supply/Rf Board Assembly

    Connect the Display board ribbon cable to the Control board and lock the connector. 5. Position the cover above the chassis and slide it down. Install the five screws that secure the cover to the chassis. 7-29 Force FX Electrosurgical Generator C Service Manual...

  • Page 211: Chapter 8. Repair Policy And Procedures

    Chapter 8 Repair Policy and Procedures This section contains the following information: • The manufacturer’s responsibility • Returning the Force FX Electrosurgical Generator C for service • Returning circuit boards • Service centers Force FX Electrosurgical Generator C Service Manual...

  • Page 212: Responsibility Of The Manufacturer

    Number. Then, clean the generator and ship it to Covidien for service. Obtain a Return Authorization Number Call the Covidien Customer Service Center for your area to obtain a Return Authorization Number. Have the following information ready when you call: •...

  • Page 213: Clean The Generator

    Authorization Number on page 8-2. Ship the circuit board prepaid to the Covidien Service Center. Service Centers For a complete list of service centers worldwide, please refer to the Covidien web site: http://surgical.covidien.com/international-service-centers Force FX Electrosurgical Generator C Service Manual...

  • Page 214: Training/Education

    Training/Education For clinical professionals and service training options, please refer to the Covidien web site: http://www.covidien.com/education Force FX Electrosurgical Generator C Service Manual...

  • Page 215: Chapter 9. Service Parts

    Chapter 9 Service Parts Replacement parts for the Force FX Electrosurgical Generator C are listed in this section. If the part number is not listed for a specific item, a replacement for that item is not available. All components must be replaced with parts of identical construction and value.

  • Page 216: Ordering Replacement Parts

    • Part number (for the part you are ordering) • Modification number, if applicable. If you do not know the part number or if you wish to order spare parts, call the Covidien Service Center for assistance. Force FX Electrosurgical Generator C Service Manual...

  • Page 217: Generator Assembly

    Generator Assembly Generator Assembly Generator assembly Force FX Electrosurgical Generator C Service Manual...
  • Page 218 Generator Assembly Generator assembly–continued Force FX Electrosurgical Generator C Service Manual...

  • Page 219: Parts List

    1081734 / 1080592 See Front Panel Assembly on page 9-7. BCMA / SHMA Assembly, Programmed control board 1081721 See Control Board Components on page 9-10. Cover, upper 1012587 / 1032764 BCMA / SHMA Force FX Electrosurgical Generator C Service Manual...
  • Page 220 Power cord, right angle molded, 110V 207 002 060 Fuse, 8A, 5x20 mm Slow Blow (2) 215 100 070 Washer, flat M4 253 300 005 Tag, receptacle notice 216 151 414 Rubber foot 1005706 Battery 3V 1053105 Force FX Electrosurgical Generator C Service Manual...

  • Page 221: Front Panel Assembly

    Front Panel Assembly Front Panel Assembly Front panel assembly Force FX Electrosurgical Generator C Service Manual...
  • Page 222 Front Panel Assembly Front panel assembly–continue 17, 18 Force FX Electrosurgical Generator C Service Manual...

  • Page 223: Parts List

    Shroud, bipolar 223 100 998 Assembly, CEM switch S1052008 Adhesive, prism 411 232 301 004 Washer, flat M3 253 300 004 Not shown Overlay jack 1049875 Keyboard front 1012634 Control panel 223 200 667 Force FX Electrosurgical Generator C Service Manual...

  • Page 224: Control Board Components

    LEDs and Lamps LED GRN 0.2 DIA 1041644 LP1, LP2, LP3, LP4, LP5, Lamp 1041648 LP6, LP7, LP8, LP9, LP10, LP11, LP12 Transistors Q1, Q2, Q3 XSTR FET N-CHAN 100 V 1A 1042942 9-10 Force FX Electrosurgical Generator C Service Manual...
  • Page 225 L1, L2, L3, L4, L5, L6, L7, FERRITE 3A 100 1206 SMD 1078178 L8, L9, L10, L11, L12, 13, L14, L15, L16, L17, L18, L19, L20, L21, L22 ASSY CABLE DISPLAY FORCEFXC 1043508 CONN PC MALE 2-PINS 1041643 Force FX Electrosurgical Generator C Service Manual 9-11...
  • Page 226 Display Board Components Reference Designator Description Part Number CONN 25 PIN R ANG 1041645 Miscellaneous (not shown) SKT DIP 30 PIN GLD 1042945 SKT IC 16 PIN 1042944 CLIP DISPLAY BOARD 1043507 9-12 Force FX Electrosurgical Generator C Service Manual...

  • Page 227: Footswitch Board Components

    Diodes D1, D2 DIODE SWITCH 100 V 0.15 A SOD 123 1078289 D3, D4, D5 TVS DIODE 5.5 VWM SOT 143 1078192 DIODE ZENER 15 V 500 MW SOD 123 1078193 Transistors Force FX Electrosurgical Generator C Service Manual 9-13...
  • Page 228  RES THICK FILM 1206 1.20 K 1% SMD 1078272  RES 0805 1.00 K 1% 1078273  R44, R46, R49, RES THICK FILM 0603 7.50 K 1% SMD 1078274 R51, R54 9-14 Force FX Electrosurgical Generator C Service Manual...
  • Page 229 CABLE 10-IN TWISTED PAIR 20-WIRE RIBBON 1078514 SCR PNH M3 10 MM 1047291 WSHR FLAT M3.01 1045722 WSHR E.T. M3 STL 1047292 NUT HEX STL ZINC PLD M3X0.5 1047290 W TEF 24 AWG WHT 1047293 Force FX Electrosurgical Generator C Service Manual 9-15...

  • Page 230: Power Supply/Rf Board Assembly

    Power Supply/RF Board Assembly Power Supply/RF Board Assembly Power Supply/RF board assembly Page: 9-19 9-16 Force FX Electrosurgical Generator C Service Manual...
  • Page 231 Power Supply/RF Board Assembly Power Supply/RF board assembly–continued Force FX Electrosurgical Generator C Service Manual 9-17...

  • Page 232: Parts List

    1049723 NUT, M4 x 0.7 1049719 SCREW, PANHEAD PHH M4 x 0.7 x 8 mm 1049730 SCREW, PANHEAD PHILLIPS M4 x 0.7 x 12 ZINC 1049729 LKWASH INTERNAL METRIC m 4.0 1049779 9-18 Force FX Electrosurgical Generator C Service Manual...
  • Page 233 SCREW, PANHEAD PHILLIPS M4 x 0.7 x 8 NYLON 1049727 WIRE, TS, 20 AWG, YELLOW 1049731 SLEEVING, PVC CLEAR 11 AWG 1049733 WIRE, TS, 20 AWG, RED 1049732 WASHER, LOCK INTERNAL M3 1049776 Force FX Electrosurgical Generator C Service Manual 9-19...
  • Page 234 SCREW, PANHEAD PHILLIPS M4 x 0.7 x 12 ZINC 1049729 FUSE HOLDER 1049706 CLIP, RELAY, 6-POLE 1049739 ASSY, CABLE, AUTO BIPOLAR 1049741 TUBING, HEAT SHRINK 3/8 ID 1049734 CABLE ASSEMBLY, 6-WIRE POWER 1049742 CABLE ASSEMBLY, 3-WIRE POWER 1049725 9-20 Force FX Electrosurgical Generator C Service Manual...

  • Page 235: Supply/Rf Board Components

    C18, C19, C20, C21, C23, C181 .22 µF ± 20%, 250 V 1042249 33 µF ± 10%, 35 V 1042308 C58, C98, CAP CER 0.01 µF 100 V 10% X7R SMD 0603 1078283 Force FX Electrosurgical Generator C Service Manual 9-21...
  • Page 236 C31, C87 22 µF ± 20%, 25 V 1042294 1 µF ± 10%, 250 V 1042287 C33, C35 15 µF ± 10%, 200 V 1042275 7500 pF ± 5%, 500 V 1042269 9-22 Force FX Electrosurgical Generator C Service Manual...
  • Page 237 CAP MICA 30 PF 100 V 5% SMD 0805 1078179 C175, C176, C177, C178, C179, C180, C185 CAP CER 22 PF 100 V 5% COG SMD 0603 1078284 CAP CER 33 PF 100 V 5% NPO SMD 0603 1078285 Force FX Electrosurgical Generator C Service Manual 9-23...
  • Page 238 Fuses F1, F2, F3 FUSE, SUB-MINI 1/2 A 1049716 FUSE, 5 x 20 mm, 6.3 A 1042348 Relays K1, K3, K4, 12 V 1042361 K5, K6, K8, K9, K10, K11 6-POLE 1042362 9-24 Force FX Electrosurgical Generator C Service Manual...
  • Page 239 R39, R75, R79, R92, R101, R106, R170  R12, R18, ± 5%, 1/4 W 1042233 R21, R26, R131, R136, R140  R74, R81, RES 0603 1.00 K 1% SMD 1078294 R87, R180, R181 Force FX Electrosurgical Generator C Service Manual 9-25...
  • Page 240 Thermistor 1042367  R35, R52 100 K ± 1%, 1/8 W 1042259  12.4 K ± 1%, 1/8 W 1042268  ± 5%, 1/4 W 1042231  ± 5%, 1/2 W 1042330 9-26 Force FX Electrosurgical Generator C Service Manual...
  • Page 241 ± 5%, 1/2 W 1042310  R59, R60, ± 1%, 1/8 W 1042298 R63, R65  R61, R64 ± 1%, 1/8 W 1042280  ± 1%, 1/8 W 1042315  ± 5%, 1/4 W 1042236 Force FX Electrosurgical Generator C Service Manual 9-27...
  • Page 242 ± 1%, 1/8 W 1042303  R123 270 K ± 5%, 1/4 W 1041641  R124, R144, ± 5%, 1/4 W 1042237 R146, R147, R152, R155  R139 93.1 K ± 1%, 1/4 W 1063247 9-28 Force FX Electrosurgical Generator C Service Manual...
  • Page 243 T7, T10, T11, SQUARE CORE, REM 1051726 VOLTAGE SENSE 1049711 T14, T15 RF CHOKE 1049704 Integrated Circuits U32-U34 DIFF COMPARATOR QUAD 14 SOIC 1049744 AVS1AC 1042976 U2, U9, U20, LM 393 N 1042353 Force FX Electrosurgical Generator C Service Manual 9-29...
  • Page 244 CONNECTOR 90 DEG PCB 9 PIN 1042344 CONNECTOR HEADER VERT 20 POS .100 GOLD 1078290 CONNECTOR PCB 5 CKT 1042357 CONNECTOR PCB 6 CKT 1042358 CONNECTOR PCB 7 CKT 1042366 CONNECTOR PC EDGE 1042340 9-30 Force FX Electrosurgical Generator C Service Manual...
  • Page 245 INDUCTOR, 0.75 MH 1049708 OPT1, OPT2, OPTOISOLATOR, SINGLE 1049745 OPT3, OPT4, OPT5 TP1, TP2, TP3, TEST POINT 1049705 TP4, TP5,TP6, TP7, TP8, TP9, TP10, TP11, TP12, TP13, TP15,TP16, TP17, TP18, TP19 OSCILLATOR, PRECISION 1049736 Force FX Electrosurgical Generator C Service Manual 9-31...

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