Page 1 Service Manual Force FX ™ -8C Electrosurgical Generator with Instant Response ™ Technology...
Page 2 Tyco Healthcare UK Ltd. Gosport, PO130AS, UK For information call: 1-303-530-2300 Made in USA Printed in USA ©2000 Valleylab All rights reserved. Contents of this publication may not be reproduced without the written permission of Valleylab. Force FX-8C Service Manual...
Page 3: Conventions Used In This Guide
Caution Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. Important Indicates an operating tip or Notice maintenance suggestion. Indicates a hazard which may result in product damage. Force FX-8C Service Manual...
Page 4: Table Of Contents
Bipolar Footswitch Receptacle Power Entry Module 2-10 Activation Tone Volume Control 2-10 Option Panel 2-11 Section 3. Technical Specifications Performance Characteristics General Dimensions and Weight Operating Parameters Transport and Storage Duty Cycle Internal Memory Audio Volume Force FX-8C Service Manual...
Page 5 REM Contact Quality Monitoring System Control Board Microcontrollers Main Microcontroller Feedback Microcontroller Shared RAM I/0 Expansion Keyboard Interface and Activation Inputs Power Supply Supervisor Circuit A/D and D/A Conversion Waveform Generation (T_ON ASIC) T_ON Average Check Audio Alarm Force FX-8C Service Manual...
Page 6 Using Two Generators Simultaneously Connecting the CUSA Handpiece with CEM Nosecone 5-10 Setting the Output Power 5-11 Simultaneous Coag with a CUSA System 5-11 Changing the Mode 5-11 Changing the Power Setting 5-11 Activating the Surgical Instrument 5-12 Force FX-8C Service Manual...
Page 7 Inspecting the Internal Components Correcting Malfunctions Responding to System Alarms 6-10 Correcting IC U3 Malfunctions 6-19 Correcting IC U6 Malfunctions 6-21 Correcting T_ON ASIC Malfunctions 6-23 Correcting Battery-Backed RAM Malfunctions 6-25 Section 7. Replacement Procedures Interconnect Diagram Battery Replacement Force FX-8C Service Manual...
Page 8 Install the Power Entry Module 7-26 Power Supply/RF Board Replacement 7-27 Remove the Power Supply/RF Board Assembly 7-27 Remove Components from the Old Board 7-28 Install Components on the New Board 7-29 Install the Power Supply/RF Board Assembly 7-30 viii Force FX-8C Service Manual...
Page 9 Front Panel Assembly Parts List Control Board Components Display Board Components 9-10 Footswitch Board Components 9-11 Power Supply/RF Board Assembly 9-14 Parts List 9-16 Power Supply/RF Board Components 9-18 Appendix A. Warranty Schematics Supplement. Board Drawings and Schematics Force FX-8C Service Manual...
Page 10: List Of Figures
Output power versus impedance for LCF Fulgurate mode 3-24 Figure 3-22. LCF Fulgurate mode—output power vs. peak voltage 3-24 Figure 3-23. Output power versus impedance for Spray coag mode 3-25 Figure 3-24. Spray coag mode—output power vs. peak voltage 3-25 Force FX-8C Service Manual...
Page 11 Schematic 1. Control board layout Schematic 2. Control board schematic, page 1 of 3 Schematic 3. Control board schematic, page 2 of 3 Schematic 4. Control board schematic, page 3 of 3 Schematic 5. Display board layout Force FX-8C Service Manual...
Page 12 Schematic 16. Power supply/RF board schematic, page 4 of 7 S-16 Schematic 17. Power supply/RF board schematic, page 5 of 7 S-17 Schematic 18. Power supply/RF board schematic, page 6 of 7 S-18 Schematic 19. Power supply/RF board schematic, page 7 of 7 S-19 Force FX-8C Service Manual...
Page 13: Section 1. Introduction
SEC TION Introduction This manual provides instructions for servicing the Valleylab Force FX-8C Electrosurgical Generator with Instant Response Technology. This section introduces the features and components of the generator and reviews the precautions associated with generator repair. Force FX-8C Service Manual...
Page 14: General Description
General Description General Description The Valleylab Force FX-8C is an isolated output electrosurgical generator that provides the appropriate power for cutting, desiccating, and fulgurating tissue during bipolar and monopolar surgery. It includes the following features: • Instant Response Technology • Three bipolar modes: precise (low), standard (medium), and macro (macrobipolar) •...
Page 15: List Of Components
List of Components List of Components The Force FX-8C generator 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: • Front panel components—power switch; controls for setting the modes and output power;...
Page 16: Fire/Explosion Hazards
Product damage may occur. Patient Return Electrodes Warning Using a patient return electrode without the REM safety feature will not activate the Valleylab REM Contact Quality Monitoring System. Fire/Explosion Hazards Warning Danger: Explosion Hazard Do not install the generator in the presence of ﬂammable anesthetics, gases, liquids, or objects.
Page 17: Electric Shock Hazards
Handle circuit boards by their nonconductive edges. Use an antistatic container for transport of electrostatic-sensitive components and circuit boards. Notice After installing a new low voltage power supply, verify that the voltages are correct. Force FX-8C Service Manual...
Page 18: Calibration
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-8C Service Manual...
Page 19: Section 2. Controls, Indicators, And Receptacles
SEC TION Controls, Indicators, and Receptacles This section describes the front and rear panels, including all controls, indicators, receptacles, the fuse drawer, and ports. Force FX-8C Service Manual...
Page 20: Front Panel
Patient return electrode This switch supplies power receptacle to the generator. For monopolar electrosurgery, connect a patient return To turn on the generator, press (|). electrode to this receptacle. To turn off the generator, press ( Force FX-8C Service Manual...
Page 21: Bipolar Controls
Press to decrease the power. Precise mode button Select for ﬁne bipolar tissue Macro mode button desiccation. Select for macrobipolar output. Standard mode button Select for standard bipolar tissue desiccation. This is the default bipolar mode. Force FX-8C Service Manual...
Page 22: Bipolar Instrument Receptacle
Improper connection may result in inadvertent generator activation or a 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-8C Service Manual...
Page 23: Monopolar Cut Controls
Select for a cut with little or Blend mode button 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-8C Service Manual...
Page 24: Monopolar Coag Controls
(LCF) than the factory default fulgurate mode. For details about this additional fulgurate mode, LCF Fulgurate, refer to Section 4, Before Surgery, in the Force FX-8C Electrosurgical Generator User’s Guide. Fulgurate is the default monopolar coag mode. However, the default coag mode...
Page 25: Monopolar Instrument Receptacles
• A four-pin CUSA handpiece with CEM nosecone. (The CEM indicator in the upper right of the front panel illuminates green. Refer to Section 4, Connecting the CUSA Handpiece with CEM Nosecone, in the Force FX-8C Electrosurgical Generator User’s Guide. Connect one monopolar instrument to the Monopolar 2 Instrument receptacle: •...
Page 26: Rear Panel
Rear Panel Rear Panel Figure 2-5. Controls and receptacles on the rear panel Power entry module Volume control Monopolar Footswitch Option panel Bipolar Footswitch receptacles receptacle Equipotential grounding lug Use to connect the generator to earth ground. Force FX-8C Service Manual...
Page 27: Footswitch Receptacles
Connect a single-pedal bipolar footswitch to the Bipolar Footswitch receptacle. The connected footswitch activates bipolar output for the instrument that is connected to the Bipolar Instrument receptacle on the front panel. Force FX-8C Service Manual...
Page 28: Power Entry Module
Figure 2-6. Components in the power entry Fuse drawer module The fuse drawer contains two fuses. Refer to the Force FX-8C Electrosurgical Generator Service Manual for instructions on changing the fuses. Power cord receptacle Activation Tone Volume Control Turn to adjust the volume of the tones that sound when the generator is activated (activation tone).
Page 29: Option Panel
After obtaining information or removing a peripheral device, reinstall the original cover plate. Caution To avoid product damage, do not operate the Force FX-8C without an appropriate cover plate in place. To review the technical speciﬁcations for each port, refer to Section 3, Technical Speciﬁcations.
Page 30 Notes 2-12 Force FX-8C Service Manual...
Page 31: Section 3. Technical Specifications
Eight digital seven-segment displays: 1.9 cm (0.75 in.) each Mounting Valleylab cart (E8006, E8008 or UC8009), CUSA EXcel System, CUSA System 200 (using CUSA System 200 optional mounting brackets), a Force GSU unit, a Force Argon unit, or any stable ﬂat surface...
Page 32: Dimensions And Weight
Duration of storage If stored longer than one year, the battery must be replaced and a full checkout, including calibration, must be completed before use. For instructions, refer to Section 5, Calibrating the Generator, in this manual. Force FX-8C Service Manual...
Page 33: Duty Cycle
(REM and system alarms) at a distance of one meter. Alarm tones meet the requirements for IEC 601-2-2. Activation Tone 45 to ≥ 65 dB Volume (adjustable) Frequency Bipolar: 940 Hz Cut: 660 Hz Coag: 940 Hz Duration Continuous while the generator is activated Force FX-8C Service Manual...
Page 34: Rem Contact Quality Monitor
REM Alarm indicator ﬂashes red, a tone sounds twice, and RF output is disabled. The indicator remains illuminated red until you correct the condition causing the alarm. Then, the red indicator is extinguished and RF output is enabled. Force FX-8C Service Manual...
Page 35: Serial Port
• Pin 11 – RF voltage: output signal proportional to active RF voltage. Expansion power (from the + 5 V (pin 6), – 12 V (pin 14), + 12 V (pin 15), and ground low voltage power supply) (pins 12 & 13) Force FX-8C Service Manual...
Page 36: Low Frequency (50-60 Hz) Leakage Current
< 50 µA all inputs High Frequency (RF) Leakage Current Bipolar RF leakage current < 59.2 mA Monopolar RF leakage < 150 mA current (additional tolerance) at ≤ 50 W CEM output modes < 150 mA Force FX-8C Service Manual...
Page 37: Input Power
Mains line frequency range (nominal): Mains line frequency range (nominal): 50 to 60 Hz 50 to 60 Hz Fuses (2): F8 A Fuses (2): T4 A Power cord: 3-prong hospital grade Power cord: 3-prong locally approved connector connector Force FX-8C Service Manual...
Page 38: Standards And Iec Classifications
Type CF Equipment (IEC 601-1)/Deﬁbrillator Proof The Force FX-8C generator provides a high degree of protection against electric shock, particularly regarding allowable leakage currents. It is type CF isolated (ﬂoating) output and may be used for procedures involving the heart.
Page 39: Drip Proof (Iec 601-2-2)
The Force FX-8C generator complies with the appropriate IEC 601-1-2 and IEC 601-2-2 speciﬁcations regarding electromagnetic compatibility. Voltage Transients (Emergency Generator Mains Transfer) The Force FX-8C generator operates in a safe manner when the transfer is made between line AC and an emergency generator voltage source. Force FX-8C Service Manual...
Page 40: Output Characteristics
(max) (max) Factor* Monopolar Cut 300 Ω 1000 V 100 W Monopolar Coag 500 Ω Desiccate 1 3500 V 70 W * An indication of a waveform’s ability to coagulate bleeders without a cutting effect 3-10 Force FX-8C Service Manual...
Page 41: Available Power Settings In Watts
Output Characteristics Available Power Settings in Watts Bipolar and Macrobipolar Monopolar Cut: Low and Pure Monopolar Cut: Blend Force FX-8C Service Manual 3-11...
Page 42: Output Waveforms
As tissue resistance increases from zero, the generator outputs constant current followed by constant power followed by constant voltage. The maximum output voltage is controlled to reduce capacitive coupling and video interference and to minimize sparking. 3-12 Force FX-8C Service Manual...
Page 43 470 kHz damped 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. Force FX-8C Service Manual 3-13...
Page 44: Output Power Vs. Resistance Graphs
The insulating surface described in IEC 601-2-2 was used to obtain the bipolar output measurements. Figure 3-1. Output power versus impedance for Precise bipolar mode Load Resistance (ohms) Figure 3-2. Precise bipolar mode— output power vs. peak voltage Output Power (watts) 3-14 Force FX-8C Service Manual...
Page 45: Figure 3-4. Standard Bipolar Mode-Output Power Vs. Peak Voltage
Output Power vs. Resistance Graphs Figure 3-3. Output power versus impedance for Standard bipolar mode 70 W 35 W 800 1000 Load Resistance (ohms) Figure 3-4. Standard bipolar mode— output power vs. peak voltage Output Power (watts) Force FX-8C Service Manual 3-15...
Page 46: Figure 3-6. Macrobipolar Mode-Output Power Vs. Peak Voltage
Output Power vs. Resistance Graphs Figure 3-5. Output power versus impedance for Macrobipolar mode 70 W 35 W 800 1000 Load Resistance (ohms) Figure 3-6. Macrobipolar mode— output power vs. peak voltage Output Power (watts) 3-16 Force FX-8C Service Manual...
Page 47: Monopolar Cut Graphs
Output power versus impedance for Low cut mode 300 W 150 W 800 1000 1200 1400 1600 1800 2000 Load Resistance (ohms) Figure 3-8. Low cut mode— output power vs. peak voltage Output Power (watts) Force FX-8C Service Manual 3-17...
Page 48: Figure 3-10. Pure Cut Mode-Output Power Vs. Peak Voltage
Output power versus impedance for Pure cut mode 300 W 150 W 800 1000 1200 1400 1600 1800 2000 Load Resistance (ohms) Figure 3-10. Pure cut mode— output power vs. peak voltage Output Power (watts) 3-18 Force FX-8C Service Manual...
Page 49: Figure 3-12. Blend Cut Mode-Output Power Vs. Peak Voltage
Output power versus impedance for Blend cut mode 200 W 100 W 800 1000 1200 1400 1600 1800 2000 Load Resistance (ohms) Figure 3-12. Blend cut mode— output power vs. peak voltage Output Power (watts) Force FX-8C Service Manual 3-19...
Page 50: Monopolar Coag Graphs
Output power versus impedance for Desiccate 1 coag mode 120 W 60 W 800 1000 1200 1400 1600 1800 2000 Load Resistance (ohms) Figure 3-14. Desiccate 1 coag mode— output power vs. peak voltage Output Power (watts) 3-20 Force FX-8C Service Manual...
Page 51: Figure 3-15. Desiccate 2 Coag Mode-Load Resistance Vs. Output Power
Output Power vs. Resistance Graphs Figure 3-15. Desiccate 2 coag mode— load resistance vs. output power Load Resistance (ohms) Figure 3-16. Desiccate 2 coag mode— output power vs. peak voltage Output Power (watts) Force FX-8C Service Manual 3-21...
Page 52: Figure 3-17. Desiccate 3 Coag Mode-Load Resistance Vs. Output Power
Output Power vs. Resistance Graphs Figure 3-17. Desiccate 3 coag mode— load resistance vs. output power Load Resistance (ohms) Figure 3-18. Desiccate 3 coag mode— output power vs. peak voltage Output Power (watts) 3-22 Force FX-8C Service Manual...
Page 53: Figure 3-20. Fulgurate Coag Mode-Output Power Vs. Peak Voltage
Output Power vs. Resistance Graphs Figure 3-19. Output power versus impedance for Fulgurate coag mode Load Resistance (ohms) Figure 3-20. Fulgurate coag mode— output power vs. peak voltage Output Power (watts) Force FX-8C Service Manual 3-23...
Page 54: Figure 3-22. Lcf Fulgurate Mode-Output Power Vs. Peak Voltage
Output power versus impedance for LCF Fulgurate mode 120 W 60 W 800 1000 1200 1400 1600 1800 2000 Load Resistance (ohms) Figure 3-22. LCF Fulgurate mode— output power vs. peak voltage Output Power (watts) 3-24 Force FX-8C Service Manual...
Page 55: Figure 3-24. Spray Coag Mode-Output Power Vs. Peak Voltage
Output power versus impedance for Spray coag mode 120 W 60 W 800 1000 1200 1400 1600 1800 2000 Load Resistance (ohms) Figure 3-24. Spray coag mode— output power vs. peak voltage Output Power (watts) Force FX-8C Service Manual 3-25...
Page 56 Notes 3-26 Force FX-8C Service Manual...
Page 57: Section 4. Principles Of Operation
SEC TION Principles of Operation This section provides detailed information about how the Force FX-8C Electrosurgical Generator 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 58: Block Diagram
Block Diagram Block Diagram Force FX-8C Service Manual...
Page 59: Functional Overview
Functional Overview Functional Overview The Force FX-8C generator is speciﬁcally designed to cut and coagulate (desiccate and fulgurate) tissue during bipolar or monopolar electrosurgery. During electrosurgery, radio frequency (RF) current ﬂows from the generator to an active electrode, which delivers the current to the patient.
Page 60: Rem Contact Quality Monitoring System
Functional Overview REM Contact Quality Monitoring System The Force FX-8C generator uses the Valleylab REM Contact Quality Monitoring System to monitor the quality of electrical contact between the patient return electrode and the patient. The REM system is designed to eliminate the risk of burns at the return electrode site during monopolar electrosurgery.
Page 61: Control Board
96-pin card edge connector. It interfaces with the Display board through a 64-pin ribbon cable. Microcontrollers Two microcontrollers on the Control board control the Force FX-8C generator. These microprocessors communicate with each other through a shared RAM. The main microcontroller (U5) performs all system functions, except the time-critical real time feedback control of generator RF output.
Page 62: Feedback Microcontroller
• T_ON ASIC waveform control • 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-8C Service Manual...
Page 63: Shared Ram
(KBD_D0–KBD_D7) input lines on port A of the expansion port 82C55 (U2). Port B of the expansion port 82C55 reads activation inputs from the IsoBloc decoding circuits on the Power Supply/RF board. Force FX-8C Service Manual...
Page 64: Power Supply Supervisor Circuit
2: Low Cut, Pure Cut, Desiccate 1, and Desiccate 2 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-8C Service Manual...
Page 65: T_On Average Check
The RS-232 serial port is a software-polled interface to the main microcontroller (U5). It is used for diagnostics and calibration. Transmission and receipt of command strings do not stop real time processing, except as single characters are read from or written to the Force FX-8C Service Manual...
Page 66: Dosage Error Algorithm
ECON calculated for the mode. The main microcontroller calculates an ECON that represents 125% of the front panel power setting and veriﬁes that SYS_ECON and HV_SEN do not exceed this value while the generator is activated. 4-10 Force FX-8C Service Manual...
Page 67: Instant Response Algorithm
If the analog to digital converter is saturated, the effect mode feedback loop reduces the output voltage to allow for an unsaturated operating condition. The feedback loop switches the control function to maintaining the analog to digital converter in the linear operating range. Force FX-8C Service Manual 4-11...
Page 68: 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. 4-12 Force FX-8C Service Manual...
Page 69: Display Board
LED and Seven-Segment Display Drivers 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. Force FX-8C Service Manual 4-13...
Page 70: Cem Switch Circuit
(BANK0, BANK1, or BANK2) through port A of programmable peripheral U3 on the Control board. These signals are buffered by Q1, Q2, and Q3 respectively and become the switch drive signals COM0, COM1, and COM2. 4-14 Force FX-8C Service Manual...
Page 71: Footswitch Board
ﬁve comparators. When the voltage at the inverting input exceeds the voltage at the noninverting input, the open collector output of the comparator turns on, causing current to ﬂow in the LED of the corresponding optoisolator. This current generates an IR beam that causes Force FX-8C Service Manual 4-15...
Page 72: Audio Circuit
R32 determines the maximum audio volume and R11 determines the minimum audio volume. R10 determines the audio alert volume level. R34 provides an alternate audio signal path in the event of an open volume control potentiometer. 4-16 Force FX-8C Service Manual...
Page 73: Power Supply/Rf Board
• Spark control circuit • 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. Force FX-8C Service Manual 4-17...
Page 74: Power Supply/Rf Board Interfaces
The control IC (U1) functions as follows: The series circuit (CR1, R1, R2, and C9) provides power for U1. Pin 1 (Vss) is a shunt regulator that provides a –9 V (nominal) output. The divider (R3 and R4) measures the 4-18 Force FX-8C Service Manual...
Page 75 The output of the power transformer is full wave rectiﬁed by a high voltage diode bridge (CR10, CR13, CR19, and CR23). L1, C33, and C35 ﬁlter the rectiﬁed power signal. The regulated DC output from this supply is the input to the RF stage of the generator. Force FX-8C Service Manual 4-19...
Page 76 DC/DC switcher through U6A and 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. 4-20 Force FX-8C Service Manual...
Page 77: Low Voltage Power Supply
The MOSFET gets its gating signal from the T_ON ASIC on the control board. The T_ON ASIC also provides the gating signal for the switched damping network. Force FX-8C Service Manual 4-21...
Page 78 In the Low and Pure cut modes, the T_ON\ signal is a continuous pulse train with a pulse width of 846 ns and a frequency of 390 kHz. In this case, essentially two resonant circuits operate in tandem. The output L-C ﬁlter 4-22 Force FX-8C Service Manual...
Page 79 T_ON\ pulse frequency is randomized over the range of 21.6 kHz to 35.23 kHz. In addition, ampliﬁer U7A randomly varies the output amplitude by 10%. The ECON–GAIN signal from the Control board changes the gain of U7A between 1 and 1.1. Force FX-8C Service Manual 4-23...
Page 80: Spark Control Circuit
The feedback microcontroller waits 100 ms in Pure cut, then re-initiates T_ON\ with a frequency of 470 kHz. The frequency returns to 394 kHz after 1 second of continuous activation or when the generator is reactivated. 4-24 Force FX-8C Service Manual...
Page 81: Rf Leakage Reduction Circuit
The IsoBloc circuit consists of an isolated DC power supply, a comparator to detect switch closure, and an optoisolator link from the output connected circuitry to Force FX-8C Service Manual 4-25...
Page 82: Temperature Sense Circuits
Temperature Sense Circuits The Force FX-8C generator 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 83 (TEMP_HI) and ﬂashes number 451 alternately with the power settings. When the temperature drops to 40° C, the circuit reverts to its low temperature state, and the generator allows activation for an unlimited duration. Force FX-8C Service Manual 4-27...
Page 84 Notes 4-28 Force FX-8C Service Manual...
Page 85: Section 5. Setup, Tests, And Adjustments
SEC TION Setup, Tests, and Adjustments After unpacking or after servicing the Force FX-8C generator, set it up and verify that it functions correctly. If the generator does not satisfactorily complete the self-test, calibrate it to ensure its accuracy. Force FX-8C Service Manual...
Page 86: Setting Up The Generator
Verify the generator is off by pressing the power switch off (O). Place the generator on a stable ﬂat surface, such as a table, platform, or Valleylab cart. Carts with conductive wheels are recommended. For details, refer to the procedures for your institution or to local codes.
Page 87 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 in Section 6. Force FX-8C Service Manual...
Page 88: Connections For Bipolar Or Macrobipolar Surgery
Bipolar receptacle only. Improper connection may result in inadvertent generator activation or a REM Contact Quality Monitor alarm. Figure 5-1. Bipolar or macrobipolar connections—footswitch activation and a handswitching or footswitching instrument Bipolar footswitch Footswitching or handswitching instrument Force FX-8C Service Manual...
Page 89: Setting The Bipolar Output
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 watts. Force FX-8C Service Manual...
Page 90: Connections For Monopolar Surgery
Doing so will cause simultaneous activation of the instruments. Figure 5-3. Monopolar connection—footswitch activation and a footswitching or handswitching instrument using Monopolar 1 Footswitch receptacle and Monopolar 1/CEM Instrument receptacle Footswitching or handswitching instrument Monopolar footswitch Patient return electrode Force FX-8C Service Manual...
Page 91 Monopolar 2 Footswitch receptacle and Monopolar 2 Instrument receptacle Footswitching or handswitching instrument Monopolar footswitch Patient return electrode Figure 5-5. Monopolar connection—handswitch activation and a monopolar handswitching instrument using either Monopolar Instrument receptacle Handswitching instrument Patient return electrode Force FX-8C Service Manual...
Page 92: Selecting Cut And Coag Modes
Generally, the site with lower resistance receives proportionately more power. The combined total output power does not exceed the overall power setting for the coag mode selected. Force FX-8C Service Manual...
Page 93: Using Two Generators Simultaneously
Two generators (and two patient return electrodes) may be used simultaneously on the same patient, provided the generators are the same type (both are isolated or both are ground referenced). However, the two Force FX-8C Service Manual...
Page 94: Connecting The Cusa Handpiece With Cem Nosecone
CEM indicator If you choose to use monopolar/ultrasonic surgery illuminates green a monopolar footswitch, you must connect it to the Monopolar 1 Footswitch Connect to CUSA system CUSA handpiece with CEM nosecone Patient return electrode 5-10 Force FX-8C Service Manual...
Page 95: Setting The Output Power
Verify the power settings for the selected mode with the surgeon. You can change the power setting when the generator is on, including when it is activated. To increase the power, press the up arrow (∆) button for the selected mode. Force FX-8C Service Manual 5-11...
Page 96: Activating The Surgical Instrument
Press Cut or Coag pedal Activation tone sounds – Cut indicator CEM nosecone on CEM nosecone illuminates yellow or Coag indicator illuminates blue – CEM indicator on front panel illuminates green when handpiece is properly connected 5-12 Force FX-8C Service Manual...
Page 97: Periodic Safety Check
• Leakage current tester—Use UL load device or commercially available leakage tester • Leakage table—per IEC 601-2-2, Figure 104 • 100, 200, 300, 500 ohm, all 250 watt, 1% tolerance, noninductive (Dale NH-250 or equivalent). Force FX-8C Service Manual 5-13...
Page 98: Inspecting The Generator And Accessories
Refer to Front Panel Replacement in Section 7. Check the Patient Return Electrode receptacle for a broken pin or an obstruction. If the receptacle is damaged or obstructed, replace the front panel assembly. Refer to Front Panel Replacement in Section 7. 5-14 Force FX-8C Service Manual...
Page 99: Inspecting The Internal Components
Refer to Power Supply/RF Board Replacement in Section 7. 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. Force FX-8C Service Manual 5-15...
Page 100: Testing The Generator
Note the number and refer to Responding to System Alarms in Section 6. 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. 5-16 Force FX-8C Service Manual...
Page 101: Verifying Rem Function
• Two small test cables (less than 61 cm [24 in.] long) with banana plugs • Current transformer • True RMS voltmeter (such as the Fluke 8920 or equivalent) • 100, 300, and 500 ohm 1% noninductive power resistors • Bipolar footswitch and monopolar footswitch. Force FX-8C Service Manual 5-17...
Page 102 If the output is outside the speciﬁed range, calibrate the bipolar output as described in calibration steps 5, 6, 7, and 8. Then repeat this procedure. If the output for one or more modes remains outside the speciﬁed range, call the Valleylab Service Center. 5-18 Force FX-8C Service Manual...
Page 103: Check The Output For The Cut Modes
If the output is outside the speciﬁed range, calibrate the monopolar output as described in calibration steps 5, 6, 7, and 8. Then repeat this procedure. If the output for one or more cut modes remains outside the speciﬁed range, call the Valleylab Service Center. Force FX-8C Service Manual 5-19...
Page 104: Check The Output For The Coag Modes
If the output is outside the speciﬁed range, calibrate the monopolar output as described in calibration steps 5, 6, 7, and 8. Then repeat this procedure. If the output for one or more coag modes remains outside the speciﬁed range, call the Valleylab Service Center. 5-20 Force FX-8C Service Manual...
Page 105: Checking Low Frequency Leakage Current And Ground Resistance
Periodic Safety Check Checking Low Frequency Leakage Current and Ground Resistance Check the low frequency leakage current and ground resistance before returning the Force FX-8C generator to clinical use. Equipment required: • DVM • Leakage current tester. Figure 5-9. Leakage current test circuit per...
Page 106 Determine the leakage current using the conventional 1 µA per 1 mV. Verify the leakage current is less than or equal to 20 µA. If the leakage current is greater than 20 µA, call the Valleylab Service Center. 5-22 Force FX-8C Service Manual...
Page 107: Checking High Frequency Leakage Current
Periodic Safety Check Checking High Frequency Leakage Current Check the high frequency leakage current and ground resistance before returning the Force FX-8C generator to clinical use. Check the leakage current • After calibrating the generator • Every six months. Equipment required: •...
Page 108: Calibrating The Generator
After completing any calibration step, proceed to the next step to save the values from the completed calibration step. Calibration Step and Description Adjustable? 1 Force FX-8C generator data Generator model number No (verify value) Master microcontroller software version No (verify value)
Page 109: Preparing For Calibration
Cut display. Note the number and refer to Responding to System Alarms in Section 6. Notice After completing any calibration step, proceed to the next step to save the values from the completed calibration step. Force FX-8C Service Manual 5-25...
Page 110: Exiting Calibration Mode
You cannot adjust these values. • The generator code (model number) for the Force FX-8C generator is 4. • The software version number for the main microcontroller may vary among manufacturing lots, but should never be 0.
Page 111: Adjust The Calendar
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 Step 3 – Adjust the Clock. Force FX-8C Service Manual 5-27...
Page 112: Adjust The Clock
To save the hour and minute values and go to the next calibration step, press the Bipolar up arrow ( ∆ ) button. Next, check the REM impedance as described in Step 4 – Check and Adjust the REM Oscillator Frequency and Impedance. 5-28 Force FX-8C Service Manual...
Page 113: Check And Adjust The Rem Oscillator Frequency And Impedance
To save the REM calibration values and go to the next calibration step, press the Bipolar up arrow (∆) button. Next, check the current sense gain factor as described in Step 5 – Check and Adjust the Current Sense Gain Factor. Force FX-8C Service Manual 5-29...
Page 114: Check And Adjust The Current Sense Gain
Pass one test cable through the current transformer and connect the current transformer to the voltmeter. Connect the 10 ohm resistor across the output jacks at the end of the test cables. Connect the bipolar footswitch to the Bipolar Footswitch receptacle on the rear panel. 5-30 Force FX-8C Service Manual...
Page 115 I factor by pressing the Coag down arrow (∇) button. Repeat this step until the voltmeter reading is within the stated range. The I factor for the Low cut mode is adjusted automatically. Force FX-8C Service Manual 5-31...
Page 116: Check And Adjust The Voltage Sense Gain
Verify that the Bipolar display shows calibration step 6. The Cut and Coag displays show the V (output voltage) factor. If it is four or more digits, the most signiﬁcant digits are in the Cut display. 5-32 Force FX-8C Service Manual...
Page 117 Electrode receptacle. Connect the second test cable from the voltmeter to both pins of the Patient Return Electrode receptacle. Connect the 3000 ohm resistor to the test cables through the current transformer for monopolar output. Force FX-8C Service Manual 5-33...
Page 118: Check And Adjust The Reactance Gain
Verify that the Bipolar display shows calibration step 7. The Cut and Coag displays show the Z (reactance) factor. If it is four or more digits, the most signiﬁcant digits are shown in the Cut display. 5-34 Force FX-8C Service Manual...
Page 119 Adjust the Z factor for the Low and Pure cut modes. Press the Pure button. Press the footswitch cut pedal and check the voltmeter for a reading equivalent to 949 ± 3 mA rms. Force FX-8C Service Manual 5-35...
Page 120: Check And Adjust The Econ Factor
• Bipolar footswitch and monopolar footswitch • Current transformer (such as the Pearson Model 411 or equivalent) • True RMS voltmeter (such as the Fluke 8920 or equivalent). Verify that the Bipolar display shows calibration step 8. 5-36 Force FX-8C Service Manual...
Page 121 Use the bipolar footswitch again to activate bipolar output for between two and ﬁve seconds. Stop activation. Verify that the Coag display changed to 30. If the display did not change as described, call the Valleylab Service Center. To check the Standard mode, press the Standard button and repeat step 3.
Page 122 ﬁve seconds. Stop activation. Verify that the Coag display changed to 30. If the display did not change as described, call the Valleylab Service Center. To check the Pure mode, press the Pure button and repeat step 3.
Page 123 Coag display. Stop activation. Verify that the Coag display changed to 10. To save the ECON calibration values, press the Bipolar up arrow (∆) button. To leave Calibration mode, refer to Exiting Calibration Mode. Force FX-8C Service Manual 5-39...
Page 124: 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 is displayed (with the Keying ENABLED message) when you activate the generator: BIPOLAR_REQ MONO1_CUT MONO1_COAG MONO2_CUT MONO2_COAG keying ENABLED 5-40 Force FX-8C Service Manual...
Page 125: Enter The Commands
Cut CEM Coag Desiccate Coag Spray Coag CEM LCF Fulgurate In data displays, numbers represent the Force FX-8C modes. You also use these numbers when you enter commands to select a speciﬁc mode. Bipolar Modes 0 Precise 1 Standard 2 Macro...
Page 126 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. 5-42 Force FX-8C Service Manual...
Page 127 List of system errors 11 through 20 with time and date stamp :PSE# Number of times speciﬁed error has occurred (# represents an alarm number listed in Section 6) Generator model and ﬁrmware version numbers Force FX-8C Service Manual 5-43...
Page 128: Disconnect The Computer From The Generator
Step 3 – Disconnect the Computer from the Generator Turn off the generator. Disconnect the DB 9 cable from the generator. Position the panel over the serial port and install the screws that secure it to the rear panel of the generator. 5-44 Force FX-8C Service Manual...
Page 129: Section 6. Troubleshooting
• If a system alarm number was displayed, take the appropriate action to correct the alarm condition. Inspecting the Generator If the Force FX-8C generator malfunctions, check for obvious conditions that may have caused the problem: • Check the generator for visible signs of physical damage.
Page 130: Inspecting The Receptacles
Front Panel Replacement in Section 7. Check the Patient Return Electrode receptacle for a broken pin or an obstruction. If the receptacle is damaged or obstructed, replace the REM module. Refer to Front Panel REM Module Replacement in Section 7. Force FX-8C Service Manual...
Page 131: Inspecting The Internal Components
Refer to Power Supply/RF Board Replacement in Section 7. 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-8C Service Manual...
Page 132: Correcting Malfunctions
RF board disconnects. Faulty power switch Replace the power switch. Refer to Front Panel Power Switch Replacement in Section 7. Malfunctioning front panel components Replace the front panel assembly. Refer to Front Panel Replacement in Section 7. Force FX-8C Service Manual...
Page 133 Faulty connections or speaker on Replace the Footswitch board. Refer to Footswitch Board Footswitch board Replacement in Section 7. Audio signal malfunction on Control board Replace the Control board. Refer to Control Board Replacement in Section 7. Force FX-8C Service Manual...
Page 134 Check/connect the ribbon cable that connects the panel and the Display board Display board to the front panel. Incorrect modes are being communicated Replace the front panel. Refer to Front Panel from the front panel Replacement in Section 7. Force FX-8C Service Manual...
Page 135 Check the power MOSFET at J9 for failure (typically fail shorted). Check all output relays to verify that they are toggling during operation. If they are not, check the relay drivers (U15 and U16). Check for shorting of the output tuning inductors (T14 and T15). Force FX-8C Service Manual...
Page 136 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. Force FX-8C Service Manual...
Page 137 Use a lower power setting for the Fulgurate and Spray modes or select the Desiccate mode. Abnormal 50–60 Hz leakage currents Inside the generator, carefully inspect for damage that may cause shorting between the AC line voltage and connected patient components. Force FX-8C Service Manual...
Page 138: Responding To System Alarms
KEY_ACTIVE_SEM semaphore Software malfunction. Invalid alarm Turn off, then turn on the generator. If the alarm number number (number shown on terminal using reappears, record the number and call the Valleylab Service serial port) Center. Internal diagnostics. Invalid activated Refer to Correcting IC U6 Malfunctions (steps 1–7) and Correcting power, function, mode, or key request IC U3 Malfunctions (steps 4–11) in this section.
Page 139 GEN_SEM semaphore Software malfunction. ﬂash_power_state Turn off, then turn on the generator. If the alarm number value outside state range reappears, record the number and call the Valleylab Service Center. Software malfunction. key_req_mode value outside state range Software malfunction. request+1 value outside state range Software malfunction.
Page 140 Software malfunction. rem_update_state Turn off, then turn on the generator. If the alarm number value outside state range reappears, record the number and call the Valleylab Service Center. Software malfunction. rem_pad_state value outside state range Software malfunction. rem_state value in re_rem_control( ) outside state range Software malfunction.
Page 141 Recommended Action Software malfunction. cal_mode value in Turn off, then turn on the generator. If the alarm number ca_clock_date_setup( ) outside state reappears, record the number and call the Valleylab Service range Center. Software malfunction. cal_state value in ca_clock_time_setup( ) outside state range Software malfunction.
Page 142 Software malfunction. which_errors value Turn off, then turn on the generator. If the alarm number outside state range reappears, record the number and call the Valleylab Service Center. Internal diagnostics. Main microcontroller Refer to Correcting IC U3 Malfunctions in this section.
Page 143 Valleylab Service Center. Internal diagnostics. Main microcontroller Refer to Correcting IC U3 Malfunctions in this section. watchdog test failed Internal diagnostics. Feedback Refer to Correcting IC U6 Malfunctions in this section. microcontroller watchdog test failed Force FX-8C Service Manual 6-15...
Page 144 Valleylab Service Center. Software malfunction. data_type value Turn off, then turn on the generator. If the alarm number outside state range reappears, record the number and call the Valleylab Service Center Software malfunction. which_data value outside state range Generator not calibrated Refer to Correcting Battery-Backed RAM Malfunctions in this section.
Page 145 FEEDBACK_SEM semaphore Software malfunction. keyed_state value Turn off, then turn on the generator. If the alarm number outside state range reappears, record the number and call the Valleylab Service Center. Software malfunction. key_req_mode value outside state range Feedback microcontroller unable to access Refer to Correcting IC U6 Malfunctions in this section.
Page 146 Software malfunction. Delay time out of Turn off, then turn on the generator. If the alarm number bounds on main microcontrollers reappears, record the number and call the Valleylab Service Center. Software malfunction. Delay time out of bounds on feedback microcontroller Software malfunction.
Page 147: Correcting Ic U3 Malfunctions
Connect the display board ribbon cable to the Control board and lock the connector. Calibrate the generator. Refer to Section 5, Setup, Tests, and Adjustments for instructions. If the calibration is successful, install the cover (refer to step 11). Force FX-8C Service Manual 6-19...
Page 148 Install the new Control board (refer to step 5). Recalibrate the generator. If the alarm number reappears, record the number and call the Valleylab 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 149: Correcting Ic U6 Malfunctions
ﬁtting the edge connector into the matching connector on the Power Supply/RF board. Connect the display board ribbon cable to the Control board and lock the connector. Turn on the generator. If the self-test completes successfully, install the cover (refer to step 12). Force FX-8C Service Manual 6-21...
Page 150 Install the new Control board (refer to step 5). Calibrate the generator. If the alarm number reappears, record the number and call the Valleylab 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 151: Correcting T_On Asic Malfunctions
Slide the board down, carefully ﬁtting the edge connector into the matching connector on the Power Supply/RF board. Connect the display board ribbon cable to the Control board and lock the connector. Force FX-8C Service Manual 6-23...
Page 152 Calibrate the generator. Refer to Calibrating the Generator in Section 5 for instructions. If the alarm number reappears, record the number and call the Valleylab Service Center. To install the cover, position the cover above the chassis and slide it down.
Page 153: Correcting Battery-Backed Ram Malfunctions
Memory) is lost when the battery is removed. 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. Force FX-8C Service Manual 6-25...
Page 154 Install the new Control board (refer to step 6). Recalibrate the generator. If the alarm number reappears, record the number and call the Valleylab 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 155: Section 7. Replacement Procedures
• Power entry module • 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 Section 9, Service Parts. Force FX-8C Service Manual...
Page 156: Interconnect Diagram
Interconnect Diagram Interconnect Diagram Force FX-8C Service Manual...
Page 157: Battery Replacement
(visible). Slide the battery down into the socket until it is ﬁrmly seated. Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. Force FX-8C Service Manual...
Page 158: Control Board Replacement
Power Supply/RF board. Verify that the packaging for the new Control board contains the part number for the Force FX-8C Control board. Do not install any other Control board. Install the battery in the battery socket (positive side facing up).
Page 159: Display Board Replacement
RF board. Remove the four screws that secure the front panel to the chassis. Save the screws for reinstallation. Slide the front panel assembly forward, carefully disengaging it from the electrical contacts on the Power Supply/RF board. Force FX-8C Service Manual...
Page 160: Install The Display Board
Power Supply/RF board. Connect the Display board ribbon cable to the Control board and lock the connector. Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. Force FX-8C Service Manual...
Page 161: Display Board Seven-Segment Led Replacement
Install the new seven-segment LED, making sure that the orientation of pin 1 (designated by the small 45° chamfer) is the same as that of the LED you removed. Reinstall the Display board. Refer to Display Board Replacement earlier in this section. Force FX-8C Service Manual...
Page 162: Fan Replacement
On the rear panel, install the six screws that secure the footswitch receptacles to the rear panel. Reinstall the Power Supply/RF board and attached heat sinks. Refer to Power Supply/RF Board Replacement later in this section. Force FX-8C Service Manual...
Page 163: Front Panel Replacement
Detach and disconnect the Display board from the front panel. Remove the four screws that secure the Display board to the front panel. Save the screws for reinstallation. Disconnect the CEM switch cable from the Display board. Force FX-8C Service Manual...
Page 164: Install The Front Panel Assembly
Connect the Display board ribbon cable to the Control board and lock the connector. 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-8C Service Manual...
Page 165: Front Panel Rem Module Replacement
Position the bracket over the new REM module and install the two screws that secure the module to the front panel. Reinstall the front panel assembly. Refer to Front Panel Replacement earlier in this section. Force FX-8C Service Manual 7-11...
Page 166: Front Panel Power Switch Replacement
Position the power switch with the On (|) switch above the Off (O) switch. Press to snap the switch into place. Reinstall the front panel assembly. Refer to Front Panel Replacement earlier in this section. 7-12 Force FX-8C Service Manual...
Page 167: Fuse Replacement
• For 120 V operation, use 8-amp fuses. • For 240 V operation, use 4-amp fuses. Slide the fuse drawer into its slot until it snaps into place. Connect the power cord to the rear panel. Force FX-8C Service Manual 7-13...
Page 168: Replacing The Fuse On The Power Supply/Rf Board
Use a fuse puller to remove the blown fuse. Replace the blown fuse with a 6.3-amp fuse. 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-8C Service Manual...
Page 169: Left Front Heat Sink And Component Replacement
On the left side of the chassis, remove the two screws that secure the base of the left front heat sink to the rail under the Power Supply/ RF board. Save the screws for reinstallation. Lift the heat sink to disconnect it from the Power Supply/RF board. Force FX-8C Service Manual 7-15...
Page 170: Replace Left Front Heat Sink Components
Connect the display board ribbon cable to the Control board and lock the connector. 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-8C Service Manual...
Page 171: Left Rear Heat Sink And Component Replacement
Power Supply/ RF board. Save the screws for reinstallation. Lift the left rear heat sink to disconnect it from the Power Supply/ RF board. Force FX-8C Service Manual 7-17...
Page 172: Replace Left Rear Heat Sink Components
Remove the screw that secures the rectiﬁer to the heat sink. Position the new bridge rectiﬁer on the heat sink and reinstall the screw. Connect the four wires to the appropriate terminal on the rectiﬁer. 7-18 Force FX-8C Service Manual...
Page 173: Install The Left Rear Heat Sink
(plastic screw) and to the left front and right heat sinks (two metal screws). Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. Force FX-8C Service Manual 7-19...
Page 174: Right Heat Sink And Component Replacement
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. Lift the heat sink to disconnect it from the Power Supply/RF board. 7-20 Force FX-8C Service Manual...
Page 175: Replace Right Heat Sink Components
Position the new power MOSFET on the heat sink and reinstall the two screws. Position the small circuit board over the power MOSFET and reinstall the four screws that secure the board to the heat sink. Force FX-8C Service Manual 7-21...
Page 176: Install The Right Heat Sink
Connect the Display board ribbon cable to the Control board and lock the connector. Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. 7-22 Force FX-8C Service Manual...
Page 177: Low Voltage Power Supply Replacement
6-pin connector at the front). Mark the cables for reinstallation. Remove the four screws that secure the low voltage power supply to the Power Supply/RF board. Save them for reinstallation. Lift the low voltage power supply off the Power Supply/RF board. Force FX-8C Service Manual 7-23...
Page 178: Install The Low Voltage Power Supply
(plastic screw) and to the left front and right heat sinks (two metal screws). Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. 7-24 Force FX-8C Service Manual...
Page 179: 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. Slide the ring terminal off the post and remove the power entry module assembly from the unit. Force FX-8C Service Manual 7-25...
Page 180: Install The Power Entry Module
Connect the power entry module cable to J6 on the Power Supply/ RF board. Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. Reconnect the power cord to the rear panel. 7-26 Force FX-8C Service Manual...
Page 181: Power Supply/Rf Board Replacement
Power Supply/RF board (behind the Control board). Save the screws for reinstallation. Remove the assembly (Power Supply/RF board, heat sinks, Control board, low voltage power supply, fan) from the chassis. Force FX-8C Service Manual 7-27...
Page 182: Remove Components From The Old Board
Power Supply/RF board. Remove the low voltage power supply. Remove the fan. Disconnect the fan control connector from the Power Supply/ RF board. Remove the four screws and nuts that secure the fan to the underside of the Power Supply/RF board. 7-28 Force FX-8C Service Manual...
Page 183: Install Components On The New Board
Position the support bracket over the heat sinks and install the three screws that secure the bracket to the left rear heat sink (plastic screw) and to the left front and right heat sinks (two metal screws). Force FX-8C Service Manual 7-29...
Page 184: Install The Power Supply/Rf Board Assembly
Connect the display board ribbon cable to the Control board and lock the connector. Position the cover above the chassis and slide it down. Install the ﬁve screws that secure the cover to the chassis. 7-30 Force FX-8C Service Manual...
Page 185: Section 8. Repair Policy And Procedures
• Returning circuit boards • Service centers. Responsibility of the Manufacturer Valleylab is responsible for the safety, reliability, and performance of the generator only under the following circumstances: • Installation and setup procedures in this manual are followed. • Assembly operation, readjustments, modiﬁcations, or repairs are carried out by persons authorized by Valleylab.
Page 186: Returning The Generator For Service
Returning the Generator for Service Before you return the generator, call your Valleylab Representative for assistance. If you are instructed to send the generator to Valleylab, ﬁrst obtain a Return Authorization Number. Then, clean the generator and ship it to Valleylab for service.
Page 187: Ship The Generator
Attach a tag to the container that includes the Return Authorization Number and the information (hospital, phone number, etc.) listed previously in Obtain a Return Authorization Number. Ship the circuit board prepaid to the Valleylab Service Center. Force FX-8C Service Manual...
Page 188: Service Centers
Tyco Healthcare Italia SpA Via Gaetano Crespi, 12 Auto Suture Company, Canada 20134 Milano, ITALY 4490 Garand Street Ph: 39 02 212181 Ville St. Laurent Fax: 39 02 2640059 Quebec, CANADA H4R 2A2 Ph: 514-334 -7602 Fax: 514-331-5983 Force FX-8C Service Manual...
Page 189: Section 9. Service Parts
SEC TION Service Parts Replacement parts for the Force FX-8C generator 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 190: Generator Assembly
Generator Assembly Generator Assembly Figure 9-1. Generator assembly Force FX-8C Service Manual...
Page 191 Generator Assembly Figure 9-2. Generator assembly – continued Force FX-8C Service Manual...
Page 192: Parts List
Nut, hex M6 x 10 brass nickel plated 224 300 000 Assembly, front panel 202 701 978 See Front Panel Assembly in this section. Assembly, control board 201 500 011 See Control Board Components in this section. Cover, upper 223 200 610 Force FX-8C Service Manual...
Page 193 Cover plate 223 301 139 Power cord, right angle molded, 220V 207 002 033 Fuse, 8A, 5x20 mm Slow Blow (2) 215 100 074 Washer, ﬂat M4 253 300 005 Tag, receptacle notice Label, serial number Force FX-8C Service Manual...
Page 194: Front Panel Assembly
Front Panel Assembly Front Panel Assembly Figure 9-3. Front panel assembly Force FX-8C Service Manual...
Page 195 Front Panel Assembly Figure 9-4. Front panel assembly – continued Force FX-8C Service Manual...
Page 196: Parts List
Assembly, cable switch CEM 202 701 867 Adhesive, prism 405 232 301 149 Washer, ﬂat M3 253 300 004 Not shown: Overlay jack 216 150 613 Keyboard front 207 500 597 Control panel 223 100 978 Force FX-8C Service Manual...
Page 197: Control Board Components
Reference Valleylab Part Designator Description Number Effect mode controller PCB 207 700 148 Battery 250 020 028 IC, programmed main 210 730 214 IC, programmed feedback 210 730 213 IC, programmed T_ON ASIC 210 730 216 Force FX-8C Service Manual...
Page 198: Display Board Components
234 100 134 R19, R20, R21 270 kΩ ± 5%, 1/4 W 234 024 121 Integrated Circuits 2803A 210 800 002 U2, U3 Bicolor display 239 750 076 U6, U10 Display driver 7218A 210 800 025 9-10 Force FX-8C Service Manual...
Page 199: Footswitch Board Components
1 µF ± 20%, 50 V 204 200 464 .022 µF ± 10%, 100 V 204 200 501 C38, C39, C40, .01 µF ± 10%, 500 V 204 200 547 C41, C42, C43, C44, C45, C46 Force FX-8C Service Manual 9-11...
Page 200 5.11 kΩ ± 1%, 1/8 W 234 201 357 56 kΩ ± 5%, 1/4 W 234 024 105 100 kΩ ± 5%, 1/4 W 234 024 111 Integrated Circuits LM339AN 210 300 015 DC/DC converter HPR107 210 750 007 9-12 Force FX-8C Service Manual...
Page 201 Washer, ﬂat M3.0 253 300 004 Washer, ext. tooth, M3, steel 253 300 022 Nut, hex M3 x 0.5 stl zinc pld 224 300 004 ® Wire, Teﬂon , 24 awg wht 255 120 140 Force FX-8C Service Manual 9-13...
Page 202: Power Supply/Rf Board Assembly
Power Supply/RF Board Assembly Power Supply/RF Board Assembly Figure 9-5. Power Supply/RF board assembly 9-14 Force FX-8C Service Manual...
Page 203 Power Supply/RF Board Assembly Figure 9-6. Power Supply/RF board assembly – continued Force FX-8C Service Manual 9-15...
Page 204: Parts List
224 300 034 Screw, panhead PHH M4 x 0.7 x 8 mm 237 050 113 Screw, panhead Phillips M4 x 0.7 x 12 zinc 237 050 141 Washer, lock internal metric M4 253 300 045 9-16 Force FX-8C Service Manual...
Page 205 Wire, TS, 20 awg, yellow 255 058 006 Sleeving, PVC clear 11 awg 249 014 012 Wire, TS, 20 awg, red 255 058 008 Washer, lock internal M3 253 300 044 Tie wire 222 004 007 Force FX-8C Service Manual 9-17...
Page 206: Power Supply/Rf Board Components
C97, C98, C99, C102, C132, C134, C137, C139, C140, C141, C144, C145, C146, C148 C5, C6, C7, 1000 pF ± 5%, 100 V 204 200 454 C14, C15, C16, C17, C18, C19, C20, C21, C23 9-18 Force FX-8C Service Manual...
Page 207 22 µF ± 20%, 25 V 204 600 063 1 µF ± 10%, 250 V 204 400 153 C33, C35 15 µF ± 10%, 200 V 204 400 150 12000 pF ± 5%, 500 V 204 300 130 Force FX-8C Service Manual 9-19...
Page 208 470 pF ± 5%, 100 V 204 200 481 Diodes 1N4007 239 500 013 CR3, CR4, 1N4148 239 014 000 CR5, CR6, CR7, CR8, CR12, CR15, CR17, CR18, CR25, CR26, CR27, CR28, CR34, CR37, CR39, CR41, CR47, CR48, CR49, CR50 9-20 Force FX-8C Service Manual...
Page 209 FET VN0808L 239 200 039 Resistors R1, R2 9.1 kΩ, 1 W 234 204 003 R3, R38, R69 1 MΩ ± 5%, 1/4 W 234 024 135 18.2 kΩ ± 1%, 1/8 W 234 201 410 Force FX-8C Service Manual 9-21...
Page 210 R113, R114, 234 024 061 R115, 4.75 kΩ ± 1%, 1/8 W 234 201 354 R19, R109 Thermistor, 10 kΩ, 25 C 240 003 006 10 Ω ± 5%, 1/2 W R22, R23 234 014 068 9-22 Force FX-8C Service Manual...
Page 211 110 kΩ ± 5%, 1/4 W 234 024 112 39 kΩ ± 5%, 1/2 W 234 014 113 R59, R60, 2 kΩ ± 1%, 1/8 W 234 201 318 R63, R65, R71, R72, R73, R85 Force FX-8C Service Manual 9-23...
Page 212 2.15 kΩ ± 1%, 1/8 W 234 201 321 R120 3.16 kΩ ± 1%, 1/8 W 234 201 337 R123 270 kΩ ± 5%, 1/4 W 234 024 121 750 Ω ± 5%, 1/4 W R124 234 024 060 9-24 Force FX-8C Service Manual...
Page 213 210 800 018 U2, U9, U20, LM 393 N 210 300 011 U26, U32, U33, U34 U3, U13, U19 MOSFET driver TSC1427 210 800 012 MOSFET driver 210 800 031 PWM controller, high speed 210 720 019 Force FX-8C Service Manual 9-25...
Page 214 J27, J28 FB1, FB2, FB3, Ferrite bead 251 100 116 FB4, FB5, FB6, FB7, FB8, FB9, FB10, FB11, FB12 Inductor, 0.75 MH 251 100 107 OPT1, OPT2, Optoisolator, single 239 750 073 OPT3, OPT4, OPT5 9-26 Force FX-8C Service Manual...
Page 215 Power Supply/RF Board Components Reference Valleylab Designator Description Part Number TP1, TP2, TP3, Test point 208 200 284 TP4, TP5,TP6, TP7, TP8, TP9, TP10, TP11, TP12, TP13, TP15,TP16, TP17, TP18, TP19 Oscillator, precision 250 010 036 Force FX-8C Service Manual 9-27...
Page 216 Notes 9-28 Force FX-8C Service Manual...
Page 217 Valleylab’s satisfaction, that the product is defective. This warranty does not apply to any product, or part thereof, which has been repaired or altered outside Valleylab’s factory in a way so as, in Valleylab’s judgment, to affect its stability or reliability, or which has been subjected to misuse, neglect, or accident.
Page 218 Valleylab disclaims any liability hereunder or elsewhere in connection with the sale of this product, for indirect or consequential damages. This warranty and the rights and obligations hereunder shall be construed under and governed by the laws of the State of Colorado, USA. The sole...

Valleylab Force FX-8C Service Manual

Section 1. Introduction

Section 2. Controls, Indicators, and Receptacles

Section 3. Technical Specifications

Section 4. Principles of Operation

Section 5. Setup, Tests, and Adjustments

Section 6. Troubleshooting

Section 7. Replacement Procedures

Section 8. Repair Policy and Procedures

Section 9. Service Parts

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Summary of Contents for Valleylab Force FX-8C