Valleylab Force 2-2 PCH Service Manual
Valleylab Force 2-2 PCH Service Manual

Valleylab Force 2-2 PCH Service Manual

Electrosurgical generator
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Summary of Contents for Valleylab Force 2-2 PCH

  • Page 1 Service Manual Force ™ Electrosurgical Generator...
  • Page 2 945 103 106 (1 of 2) Valleylab part number: October 2004 Effective date: Force™ 2 and REM™ are trademarks of Valleylab. The Force 2 generator is protected by one or more of the following U.S. patents and their foreign counterparts: 4,632,109, 4,658,819, 4,658,820, 4,827,927, 5,190,517.
  • Page 3: Conventions Used In This Guide

    Conventions Used in this Guide Warning Indicates a potentially hazardous situation, which if not avoided, could result in death or serious injury. Caution Indicates a hazardous situation, which if not avoided, may result in minor or moderate injury. Important Indicates an operating tip or Notice maintenance suggestion.
  • Page 4: Valleylab Service Centers

    Valleylab Service Centers Valleylab Tyco Healthcare Belgium B.V. Boulder, Colorado, 80301-3299 Generaal De Wittelaan 9/5 B-2800 Mechelen Ph: 303-530-2300 BELGIUM Toll Free: 800-255-8522 Ph: 32-15-298111 Fax: 32-15-217987 Tyco Healthcare Nederland B.V. Technical Service Center Tyco Healthcare Austria GmbH De Beverspijken 37 Jochen Rindt Str.
  • Page 5: Table Of Contents

    Operating Parameters Storage and Shipping Output Waveform PCH Generator Output Characteristics Output Configuration Input Power Source Force 2-2 PCH Generator Force 2-8 PCH Generator Line Regulation Force 2-2 PCH Generator Force 2-8 PCH Generator High Frequency Risk Parameters Force 2 Service Manual...
  • Page 6 Low Frequency Leakage (50-60 Hz) Force 2-2 PCH Generator Force 2-8 PCH Generator (per VDE 0750 (IEC601-1), Section 19 for Class 1 Equipment) REM Contact Quality Monitor Audio Volume Approximate Weight Size Classification Type CF Equipment per IEC 601-1 Drip Proof per IEC 601-1 Output Power vs.
  • Page 7 Section 7. Manufacturer Service Returning the Equipment for Service Returning the Force 2 Generator Returning Circuit Boards and Other Subassemblies Section 8. Service Parts List Ordering Replacement Parts Monopolar Control/Display Board Bipolar Display Board Interface Board Power Supply RF Board Heatsink Assembly 8-13 RF Out...
  • Page 8: List Of Figures

    List of Figures Figure 3-1. PCH Generator Front View Figure 3-2. PCH Generator Rear View Figure 4-1. PCH Generator Typical Output Power vs Load—Monopolar Cut Modes Figure 4-2. PCH Generator Typical Output Power vs Load—Monopolar Cut Modes (continued) Figure 4-3. PCH Generator Typical Output Power vs Load—Monopolar Coag Modes Figure 4-4.
  • Page 9 Schematic 12. Power Supply board layout, page 1 of 2 S-15 Schematic 13. Power Supply board layout, page 2 of 2 S-16 Schematic 14. Power Supply board, page 1 of 6 S-17 Schematic 15. Power Supply board, page 2 of 6 S-18 Schematic 16.
  • Page 10 Notes Force 2 Service Manual...
  • Page 11: Section 1. Service Warnings And Cautions

    SECTION Service Warnings and Cautions Danger Explosion Hazard Do not install the Force 2 generator in the presence of flammable anesthetics, gases, liquids, or objects. For continued protection against fire hazard, replace the fuse with those having the same type and rating as the original fuse. Warning Electric Shock Hazard Always unplug the generator before cleaning.
  • Page 12 Caution This generator contains electrostatic sensitive components. When repairing the generator, work at a static control workstation. Wear a grounding strap when handling electrostatic sensitive components. Handle the circuit boards by their nonconductive edges. Use an antistatic container for transport of electrostatic sensitive components and circuit boards.
  • Page 13: Section 2. Unpacking And Installation

    SECTION Unpacking and Installation Unpacking the Force 2 Generator Notify Valleylab to arrange for repair or replacement of any parts damaged from shipping. All returns must have approval from the Valleylab Customer Service Department. The return authorization number must be displayed on the package label. Refer to Section 7, Manufacturer Service, for further information.
  • Page 14: Preparing The Generator For Use

    Preparing the Generator for Use The electrosurgical generator may be placed on a mounting cart available from Valleylab or any sturdy table or platform. It is recommended that carts have conductive wheels. Refer to hospital procedures or local codes for detailed information.
  • Page 15: Ensure Proper Grounding

    Ensure Proper Grounding Ensure Proper Grounding To ensure patient safety, the Force 2 generator must be properly grounded. Important It is the user's responsibility to The ground wire in the power cord connects to the unit chassis and ensure that the electrical installation ensures that no dangerous currents flow from the cabinet in the event of of the relevant room complies with internal electrical failure.
  • Page 16 Notes Force 2 Service Manual...
  • Page 17: Section 3. Description Of Controls, Indicators, And Receptacles

    SECTION Description of Controls, Indicators, and Receptacles This section describes the controls, indicators, and receptacles for accessories located on the front panel of the Force 2 generator. Force 2 Service Manual...
  • Page 18 Figure 3-1. PCH Generator Front View Figure 3-2. PCH Generator Rear View MONOPOLAR FOOTSWITCH 250V, F8.0A - (110-120) FOREIGN EQUIVALENTS AND BIPOLAR 250V, F6.3A - (220-240) U.S. PATENTS: 4416276, 4416277, FOOTSWITCH 4632109, 4658819, 4658820, WARNING: RISK OF FIRE. 4827927 REPLACE FUSE AS MARKED.
  • Page 19: Controls

    Controls Controls – Press this button to place the electrosurgical generator in a hold Standby mode. You cannot activate the generator and all audio alarms are silenced. The generator’s memory retains the power settings and the display shows dashes. – Press this button to place the generator into service with power Ready outputs, displays, and alarms fully functional.
  • Page 20: Indicators

    Indicators – The power control pencil feature does not have a Power Control Pencil Mode dedicated button to access this mode. Press the button and while READY holding it, press the button. The generator sounds a CUT POWER DOWN single tone and the lamp illuminates.
  • Page 21: Alarms

    – This receptacle accepts the three-pin Monopolar Active Receptacle (Handswitch) handswitching active accessories and the Valleylab power control pencil. You can only activate the power output from this receptacle by using the handswitch mechanism. No power is available through use of the footswitch.
  • Page 22: Rear Panel Functions

    Rear Panel Functions Rear Panel Functions – Press the toggle up to turn power on and down to shut On/Off Switch power off. The Force 2 generator uses a universal type power entry module but is not voltage selectable. Line fuse replacement is the following: 250V 110-120V generators (-2 PCH) 250V...
  • Page 23: Section 4. Technical Specifications

    SECTION Technical Specifications In this section “typical” refers to a specification that is within 20% of a stated value. Specifications subject to change without notice. Standard Conditions of Measurement Unless otherwise specified, all measurements are specified at an ambient temperature of 21° C (70° F) and 760 torr. Operating Parameters Temperature Range 10°...
  • Page 24: Output Waveform

    Output Waveform Output Waveform 510 kHz sinusoid Blend 1 510 kHz bursts of sinusoid at 50% duty cycle recurring at 31 kHz Blend 2 510 kHz bursts of sinusoid at 37.5% duty cycle recurring at 31 kHz Blend 3 510 kHz bursts of sinusoid at 25% duty cycle recurring at 31 kHz Coag 510 kHz damped sinusoidal bursts with a...
  • Page 25: Input Power Source

    Input Power Source Input Power Source Force 2-2 PCH Generator Maximum Operating Range 85-135 Vac Nominal Operating Range 110-120 Vac The line frequency may vary between 45 and 65 Hz Current: Idle - 0.7A, max Power: Idle - 60W, max Cut - 7.0A, max...
  • Page 26: High Frequency Risk Parameters

    < 150 mA, per IEC 601-2-2. Monopolar RF leakage current < 150 mA, per IEC 601-2-2. Low Frequency Leakage (50-60 Hz) Force 2-2 PCH Generator All patient connected terminals tied together: Source current normal polarity, intact chassis ground < 10 µA Source current normal polarity, ground open <...
  • Page 27: Rem Contact Quality Monitor

    REM Contact Quality Monitor REM Contact Quality Monitor Measurement Frequency 140 kHz ± 20 kHz Measurement Current 3.0 mA, maximum Acceptable Resistance Single area pad - nominally < 24 ohms Ranges Dual area REM - nominal range 5 - 135 ohms If impedance measured is outside the acceptance range, a REM alarm will occur.
  • Page 28: Output Power Vs. Impedance Graphs

    Output Power vs. Impedance Graphs Output Power vs. Impedance Graphs All monopolar output measurements are made using the setup referred to in IEC 601-2-2, Figure 104. Figure 4-1. Pure Cut PCH Generator Typical Output Power vs Load—Monopolar Cut Modes Generator Power Setting 300 W...
  • Page 29 Output Power vs. Impedance Graphs Figure 4-2. Blend 2 PCH Generator Typical Output Power vs Load—Monopolar Cut Modes Generator (continued) Power Setting 200 W 100 W Impedance (ohms) Blend 3 Generator Power Setting 150 W 75 W Impedance (ohms) Force 2 Service Manual...
  • Page 30 Output Power vs. Impedance Graphs Figure 4-3. Coag PCH Generator Typical Output Power vs Load—Monopolar Coag Modes Generator Power Setting 120 W 60 W Impedance (ohms) Low Voltage Coag Generator Power Setting 99 W 55 W Impedance (ohms) Force 2 Service Manual...
  • Page 31 Output Power vs. Impedance Graphs Bipolar measurements are made using bipolar forceps on the insulating surface referred to in IEC 601-2-2, Figure 104. Figure 4-4. Bipolar PCH Generator Typical Output Power vs Load—Bipolar Mode Generator Power Setting 70 W 35 W 15 W Impedance (ohms) Force 2 Service Manual...
  • Page 32 Notes 4-10 Force 2 Service Manual...
  • Page 33: Section 5. Circuit Descriptions

    SECTION Circuit Descriptions Bipolar Display The Bipolar Display board is the numeric display for the mode's power set point, and the signals for these indicators derive from the multiplexed display driver on the Monopolar Control/Display board. The Bipolar Display board displays the bipolar RF indicator and the RF circuitry generates the signals.
  • Page 34: Mode Indicators

    Monopolar Control/Display When functioning as the main control element of the generator, the Monopolar Control/Display board produces the proper RF drive according to the mode selected. It calculates and generates the required power supply control voltage. It also calculates and sets the current limit for the RF output stage.
  • Page 35: Rem And Rmote Indicators

    Monopolar Control/Display REM and RMOTE Indicators The ICM7218C does not control the REM and RMOTE indicators. Microcontroller port lines P12 and P16, buffered by U5B and U5A, drive the REM and RMOTE indicators directly. Pull-up resistors R45 and R47 ensure that the outputs of the open collector driver pull high when its inputs are low.
  • Page 36: External Memory

    Monopolar Control/Display External Memory There are eight external memory locations. To ensure accessing only one peripheral at a time, all external memory locations have addresses with all bits high except one. The address latch, U9, is continuously active with addresses on the address/data bus latched with every negative transition of ALE.
  • Page 37: Interface

    Interface deactivate the RF output and to begin to respond to the new activation (or de-activation) input. R27 and C29 provide time delay and moderate RF filtering to this line. An 8.192 MHz crystal oscillator generates the required clock signal for 89C54.
  • Page 38: Power Supply

    Power Supply simply have resistors in series with the opto couplers to limit current. There are four isolated circuits, each with its own transformer winding for power. This generator has three possible RF output receptacles. Single pole, normally open, high voltage relays make the selection of the receptacle. The CPU turns on the relays through bipolar drivers on the Interface board.
  • Page 39: Rf Output

    RF Output stretcher shuts down the supply's control IC for about 1/3 of a second and then soft starts the supply. The R-C network on the 3526 pin 7 provides a power on reset. A separate switching power supply on the rear of the chassis supplies the low voltages.
  • Page 40 RF Output load impedances a one shot triggers by transformer primary voltages below -100V. This one shot places a resistive load across the output and reduces high frequency risk currents. The FET output is rather low impedance, and the choice of DC supply voltage as the power control parameter limits its voltage compliance.
  • Page 41: Section 6. Maintenance Procedures

    SECTION Maintenance Procedures Routine Maintenance and Inspections Valleylab recommends that qualified service personnel inspect the Force 2 generator every six months. Check the power cord assembly periodically for damaged insulation or connectors. This service manual describes the recommended maintenance, inspection, testing, and calibration procedures.
  • Page 42: General Testing Information

    General Testing Information General Testing Information Warning Take appropriate precautions (such as use of isolated tools and equipment; use of the “one hand rule,” etc.) when taking measurements or troubleshooting the generator. Electric Shock Hazard Do not touch any exposed wiring or conductive surface while the generator is disassembled and energized.
  • Page 43: Recommended Test Equipment

    Recommended Test Equipment Recommended Test Equipment You will need the following equipment to perform the checks and calibration described in this section. If you use substitute equipment, it must meet or exceed the specifications of the recommended equipment. • Tektronix type 465 Oscilloscope, or equivalent, with 50 MHz or greater band width •...
  • Page 44: Calibration

    floating at potentially harmful voltage potentials. Use the footswitching ACCESSORY receptacle for generator output on the Force 2-8 PCH and Force 2-2 PCH generators. Adjust the High Voltage Clamp Set the coag power setting display to 30 W.
  • Page 45 Calibration Procedure Adjust the Pure Cut Output Calibration Attach a 300 ohm load to the generator output. Set cut power setting display at 300 W and adjust R74 for 300 W output. Attach a 100 ohm load to the generator output. Verify that cut output is 290 W - 325 W.
  • Page 46 Calibration Procedure High Impedance Power Attach a 4000 ohm load between the ACCESSORY PATIENT receptacles. Activate cut at maximum power setting and adjust R61 to achieve approximately 35 W (93 mA). Verify the 3000 ohm output is above 170 W (238 mA). Attach a 4000 ohm load between the ACCESSORY PATIENT...
  • Page 47: Rem Test Procedure

    REM Test Procedure Monopolar Patient Return RF Leakage Connect the 200 ohm load and RMS voltmeter in series from PATIENT receptacle to chassis ground, connect a 30 pF capacitor between active accessory and chassis ground. Activate cut at 15 W and note leakage current. Increment the setting by 5 W until 25 W is reached and ensure that the hot spot between the incremental settings is less than 150 mA.
  • Page 48: Line Frequency (50-60 Hz) Current Leakage Test Procedure

    Line Frequency (50-60 Hz) Current Leakage Test Procedure Line Frequency (50-60 Hz) Current Leakage Test Procedure This test measures potentially dangerous 50-60 Hz leakage currents. The Force 2 generator is left on but not active. To indirectly measure the current, observe the voltage across a 1k ohm resistor to ground from each front panel receptacle.
  • Page 49: Bipolar And Monopolar Output Rf Leakage Test Procedures

    Bipolar and Monopolar Output RF Leakage Test Procedures Bipolar and Monopolar Output RF Leakage Test Procedures Important The following procedure is meant to Test Setup approximate the test procedure Place the Force 2 generator on a wooden table with no exposed metal found in the IEC Standard 601-2-2 on the surface or within one meter of the table surface.
  • Page 50: Typical Output Waveforms

    Typical Output Waveforms Typical Output Waveforms Figure 6-1. 300 Ω Load Pure Cut 100 Ω Load Bipolar Figure 6-2. 300 Ω Load Blend 1 6-10 Force 2 Service Manual...
  • Page 51 Typical Output Waveforms Figure 6-3. 300 Ω Load Blend 2 Figure 6-4. 300 Ω Load Blend 3 Low Voltage Coag 300 Ω Load Force 2 Service Manual 6-11...
  • Page 52 Typical Output Waveforms Figure 6-5. 300 Ω Load Coag 6-12 Force 2 Service Manual...
  • Page 53: Tt-On Waveforms At Tp12 On Psrf Board

    TT-on Waveforms at TP12 on PSRF Board TT-on Waveforms at TP12 on PSRF Board Figure 6-6. 1-Cut/Bipolar 2-Blend 1 3-Blend 2 4-Blend 3/LV Coag 5-Coag RF Drive Waveforms at TP7-10 on PSRF Board Figure 6-7. 1-Cut/Bipolar 2-Blend 1 3-Blend 2 4-Blend 3/LV Coag 5-Coag Force 2 Service Manual...
  • Page 54: Clamp Waveform At Tp11 On Psrf Board

    Clamp Waveform at TP11 on PSRF Board Clamp Waveform at TP11 on PSRF Board Figure 6-8. Open Circuit 120W Coag 6-14 Force 2 Service Manual...
  • Page 55: Components Replacement Guidelines

    Components Replacement Guidelines Components Replacement Guidelines Follow these guidelines when installing and mounting components on circuit boards. Install all nonpolarized components so that the value, tolerance, and part number are visible. Install polarized components correctly so that the positive symbol (+), negative symbol (-), or other polarization markings are visible.
  • Page 56 Notes 6-16 Force 2 Service Manual...
  • Page 57: Section 7. Manufacturer Service

    SECTION Manufacturer Service Returning the Equipment for Service Before you return the generator to Valleylab, call the Valleylab Service Department for a Return Authorization Number, or call your Valleylab representative for assistance. Have the following information ready: • Hospital/clinic name/customer number •...
  • Page 58: Returning The Force 2 Generator

    Returning the Force 2 Generator Returning the Force 2 Generator Package the generator in the original packaging container, if available. If the original packaging is not available, use the following guidelines for packaging: • Remove and retain the footswitch. • Use a packing container with double wall construction. •...
  • Page 59: Section 8. Service Parts List

    • Model number (located on the rear of the generator) • Serial number (located on the rear of the generator) • Valleylab part number. All components must be replaced with parts of identical construction and value. Replacement part ratings and tolerances must be equal or better than original.
  • Page 60: Monopolar Control/Display Board

    Monopolar Control/Display Board Monopolar Control/Display Board 201 496 000 Valleylab Reference Designator Description Part Number Resistors 10k Ω ± 5%, 1/4W R24, 27, 39, 44 234 024 087 100k Ω ± 5%, 1/4W R2, 8, 22 234 024 111 1k Ω ± 5%, 1/4W...
  • Page 61 Monopolar Control/Display Board Valleylab Reference Designator Description Part Number C7, 11 100 pF ± 5%, 100V 204 200 454 68 µF ± 20%, 20V 204 600 068 0.033 µF ± 20%, 50V 204 200 459 C34, 38, 39, 43, 44 0.01 µF ±...
  • Page 62: Bipolar Display Board

    Bipolar Display Board Valleylab Reference Designator Description Part Number Transistors 2N2907A 239 100 012 Q2, 3, 7 VN10KM FET 239 200 012 2N3904 239 015 000 MPS6651 239 300 039 Diodes CR1-6, 8 1N4148 239 014 000 CR12, 13 LM336...
  • Page 63: Interface Board

    Interface Board Interface Board 201 304 002 Valleylab Reference Designator Description Part Number Resistors 1k Ω ± 5%, 1/4W R1, 4, 6, 8, 9, 12, 14, 18 19, 29, 32,39, 234 024 063 58, 59, 61 10 Ω ± 5%, 1/4W 234 024 015 4.3k Ω...
  • Page 64 Interface Board Valleylab Reference Designator Description Part Number 5k Ω trimpot 236 010 006 68k Ω ± 5%, 1/4W 234 024 107 560k Ω ± 5%, 1/4W 234 024 129 100k Ω trimpot 236 010 011 910k Ω ± 5%, 1/4W 234 024 134 200k Ω...
  • Page 65 Interface Board Valleylab Reference Designator Description Part Number C22, 44 0.01 µF ± 10%, 100V 204 600 457 10 µF ± 10%, 20V 204 600 064 Integrated Circuits U6, 7, 9, 10 4049B 210 210 049 U1, 8 LM339AN 210 300 015...
  • Page 66: Power Supply Rf Board

    Power Supply RF Board Valleylab Reference Designator Description Part Number K1, 2 Reed Relay, 10kV 230 007 007 Double Pole Relay 230 012 000 Power Supply RF Board (-8 PCH) 202 701 918 (-2 PCH) 202 701 917 Valleylab Reference Designator...
  • Page 67 Power Supply RF Board Valleylab Reference Designator Description Part Number 3k Ω ± 5%, 1/4W 234 024 074 3.3k Ω ± 5%, 1/4W R33, 34, 37, 39 234 024 075 3.6k Ω ± 5%, 1/4W R111 234 024 076 3.9k Ω ± 5%, 1/4W 234 024 077 4.7k Ω...
  • Page 68 20k Ω ± 5%, 1/4W 234 024 094 0 Ω jumper J11, 13 234 300 080 0 Ω jumper J6 (Force 2-2 PCH only) 234 300 080 0 Ω jumper J7 (Force 2-8 PCH only) 234 300 080 Capacitors C13, 34 100 pF ±...
  • Page 69 Power Supply RF Board Valleylab Reference Designator Description Part Number 2 µF ± 10%, 400V 204 400 001 1 µF ± 10%, 250V 204 400 138 C30, 31 15 µF ± 10%, 200V 204 400 150 C63, 75 1000 µF ± 20%, 200V...
  • Page 70 239 600 000 CR12 LM336-5 210 300 018 CR14 LM336-2.5 210 300 016 Miscellaneous F1 (Force 2-2 PCH) Fuse 6A, 250V 215 005 039 F1 (Force 2-8 PCH) Fuse 6.3A, 250V 215 100 041 4 pole relay 230 007 002 Thermistor 5 Ω, 6A...
  • Page 71: Heatsink Assembly

    Heatsink Assembly Heatsink Assembly RF Out 202 701 789 Valleylab Reference Designator Description Part Number Q1-4 Transistor FET BUZ80A 239 200 020 500 Ω, 500W TO-220 234 400 271 HVDC 202 701 790 Valleylab Reference Designator Description Part Number CR21-24...
  • Page 72: Generator Base Assembly

    Generator Base Assembly Generator Base Assembly 202 701 448 Valleylab Reference Designator Description Part Number REM Adapter 202 701 063 Monopolar Keyboard 207 500 147 Bipolar Keyboard 207 500 148 8-14 Force 2 Service Manual...
  • Page 73 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 74 District Court for the County of Boulder, State of Colorado. Valleylab, its dealers and representatives, reserve the right to make changes in equipment built and/or sold by them at any time without incurring any obligation to make the same or similar changes on equipment previously built and/or sold by them.

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