Page 1 Service Manual Force FX Electrosurgical Generator C...
Page 4: 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 5: Limited Warranty
Covidien’s liability with respect to this limited warranty and the products sold hereunder shall be limited to the aggregate purchase price for the products sold to the customer. This limited warranty is non-transferable and runs only to the original purchaser of the Force FX Electrosurgical Generator C Service Manual...
Page 6 EXPRESSLY PROVIDED HEREIN, COVIDIEN DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, ORAL OR WRITTEN, WITH RESPECT TO PRODUCTS, INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Force FX Electrosurgical Generator C Service Manual...
Page 7: Table Of Contents
Duty Cycle ........3-3 Force FX Electrosurgical Generator C Service Manual...
Page 8 Shared RAM ........4-8 Force FX Electrosurgical Generator C Service Manual...
Page 9 Setting the Bipolar Output ......5-5 Connections for Monopolar Surgery ....5-6 Force FX Electrosurgical Generator C Service Manual...
Page 10 Enter the Commands ......5-43 Disconnect the Computer from the Generator ..5-46 viii Force FX Electrosurgical Generator C Service Manual...
Page 11 Replace Right Heat Sink Components ....7-20 Install the Right Heat Sink ......7-21 Force FX Electrosurgical Generator C Service Manual...
Page 12 Parts List ........9-17 Power Supply/RF Board Components ....9-19 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. 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
Caution 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 3-5 and page 3-6.
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
• 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 34: Audio Volume
REM Polyhesive Patient Return Electrode: 5 to 135 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 . Force FX Electrosurgical Generator C Service Manual...
Page 35: 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 36: Expansion Port
< 50 µA line, all inputs 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 37: Input Power
220VAC CEE7/7 power cord. Should the AC power cord need to be replaced to match another plug configuration, the replacement plug/cable/receptacle configuration must meet or exceed the following specifications: Force FX Electrosurgical Generator C Service Manual...
Page 38: Standards And Iec Classifications
Plug - minimum 6 A - 250 VAC Unit receptacle - IEC female, minimum 6 A - 250 VAC Standards and IEC Classifications The Force FX Electrosurgical Generator C meets all pertinent clauses of the IEC 60601-1 second edition and IEC 60601-2-2 third edition. ATTENTION Consult accompanying documents.
Page 39: Class I Equipment (Iec 60601-1)
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 40: Voltage Transients
Ensure adequate separation of electronic medical equipment based on observed reactions. The use of accessories, other than those specified in the Force FX Electrosurgical Generator C User Guide and Service Manual, may result in increased emissions or decreased immunity of the Force FX Electrosurgical Generator C.
Page 41 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 42 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 43 The Force FX Electrosurgical Generator C is intended for use in an electromagnetic environment in which radiated RF disturbances are controlled. The Customer or the user of the Force FX Electrosurgical Generator C can help prevent electromagnetic interferences by maintaining a...
Page 44: 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 3-14 Force FX Electrosurgical Generator C Service Manual...
Page 45: Maximum Output For Ultrasonic Electrosurgery
Monopolar Coag 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 Force FX Electrosurgical Generator C Service Manual 3-15...
Page 46 Output Characteristics Monopolar Cut: Blend Monopolar Coag CEM Cut CEM Coag 3-16 Force FX Electrosurgical Generator C Service Manual...
Page 47: Output Waveforms
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 Electrosurgical Generator C Service Manual 3-17...
Page 48: 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) 3-18 Force FX Electrosurgical Generator C Service Manual...
Page 49 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) Force FX Electrosurgical Generator C Service Manual 3-19...
Page 50 Output Power vs. Resistance Graphs Output power vs. generator settings Precise bipolar mode Generator Setting 3-20 Force FX Electrosurgical Generator C Service Manual...
Page 51 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 Force FX Electrosurgical Generator C Service Manual 3-21...
Page 52 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 3-22 Force FX Electrosurgical Generator C Service Manual...
Page 53 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) Force FX Electrosurgical Generator C Service Manual 3-23...
Page 54 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 3-24 Force FX Electrosurgical Generator C Service Manual...
Page 55: 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) Force FX Electrosurgical Generator C Service Manual 3-25...
Page 56 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) 3-26 Force FX Electrosurgical Generator C Service Manual...
Page 57 Output Power vs. Resistance Graphs Output power vs. generator settings Low cut mode Generator Setting Force FX Electrosurgical Generator C Service Manual 3-27...
Page 58 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) 3-28 Force FX Electrosurgical Generator C Service Manual...
Page 59 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 Force FX Electrosurgical Generator C Service Manual 3-29...
Page 60 Output Power vs. Resistance Graphs Blend Cut Mode Output power vs. impedance for Blend cut 100W mode Load Resistance (ohms) 3-30 Force FX Electrosurgical Generator C Service Manual...
Page 61 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) Force FX Electrosurgical Generator C Service Manual 3-31...
Page 62 Output Power vs. Resistance Graphs Output power vs. generator settings Blend cut mode Generator Setting 3-32 Force FX Electrosurgical Generator C Service Manual...
Page 63: 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) Force FX Electrosurgical Generator C Service Manual 3-33...
Page 64 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) 3-34 Force FX Electrosurgical Generator C Service Manual...
Page 65 Output Power vs. Resistance Graphs Output power vs. generator settings Desiccate coag mode Generator Setting Force FX Electrosurgical Generator C Service Manual 3-35...
Page 66 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) 3-36 Force FX Electrosurgical Generator C Service Manual...
Page 67 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 Force FX Electrosurgical Generator C Service Manual 3-37...
Page 68 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) 3-38 Force FX Electrosurgical Generator C Service Manual...
Page 69 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 Force FX Electrosurgical Generator C Service Manual 3-39...
Page 70 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) 3-40 Force FX Electrosurgical Generator C Service Manual...
Page 71 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 Force FX Electrosurgical Generator C Service Manual 3-41...
Page 73: 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 74: Block Diagram
Block Diagram Block Diagram A diagram of generator interconnections Force FX Electrosurgical Generator C Service Manual...
Page 75: 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 76: 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 77 Then, the red indicator light is extinguished and RF output is enabled. For additional information, refer to REM Circuit on page 4-28. Force FX Electrosurgical Generator C Service Manual...
Page 78: 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 79: Feedback Microcontroller
(512K x 8 external flash memory) and data memory (2K x 8 external static RAM) for the feedback microcontroller. Additional data memory is available from these sources: • 256K x 8 microcontroller internal RAM • 4K x 8 external static RAM (U4) shared with the main microcontroller. Force FX Electrosurgical Generator C Service Manual...
Page 80: 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 Electrosurgical Generator C Service Manual...
Page 81: Power Supply Supervisor Circuit
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 82: 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 83: 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. Force FX Electrosurgical Generator C Service Manual 4-11...
Page 84: 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 85: 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. Force FX Electrosurgical Generator C Service Manual 4-13...
Page 86: 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 87: Cem Switch Circuit
• When COM1 is selected, the recall switch and the bipolar mode select switches may be read. • When COM2 is selected, the cut and coag mode select switches may be read. Force FX Electrosurgical Generator C Service Manual 4-15...
Page 88 To read the switches, the main microcontroller asserts the desired BANK select line and reads the state of the keyboard switch return lines KBD_D0 through KBD_D7. These lines are read through port A of the I/O expansion port (U2) on the Control board. 4-16 Force FX Electrosurgical Generator C Service Manual...
Page 89: 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 90: Audio Circuit
U1D floats. When the U1C output transistor is on, R10 is pulled to ground and creates a fixed voltage divider with R32 to produce the alarm volume level at the input to audio amplifier U7. 4-18 Force FX Electrosurgical Generator C Service Manual...
Page 91 The voltage gain of U7 is set to about 20 by floating its gain select pins. Because the U1 output signal is internally biased to Vcc/2, it is necessary to AC couple the speaker through C27 to prevent the amplifier from DC biasing the speaker. Force FX Electrosurgical Generator C Service Manual 4-19...
Page 92: Power Supply/Rf Board
A series of fuse clips connect the RF outputs and other front panel interfaces (i.e., REM and handswitching signals). The fuse clips mate to lugs located in the output portion of the front panel. 4-20 Force FX Electrosurgical Generator C Service Manual...
Page 93: High Voltage Power Supply
In either case, an unregulated nominal 300 Vdc is provided to the DC/ DC switching regulator. Thermistors R32 and R33 provide inrush current limiting, and fuse F4 provides protection against faults in the DC/DC switcher. Force FX Electrosurgical Generator C Service Manual 4-21...
Page 94 L-C filter. Note: U7A is used for random gain switching in the Spray mode and is configured for unity gain in all other modes. 4-22 Force FX Electrosurgical Generator C Service Manual...
Page 95: Low Voltage Power Supply
±12 Vdc output. This power supply automatically adjusts for both input voltage ranges. It also has internal current limiting. The pinouts between the low voltage power supply and the Power Supply/RF board are listed below: Voltage Test Point +5 Vdc -12 Vdc +12 Vdc GROUND Force FX Electrosurgical Generator C Service Manual 4-23...
Page 96: Rf Output Stage
U11B is a high input impedance follower to prevent the rectifier circuit from loading down the resistive divider. U11A is a follower that adds phase delay, which improves balance in the rectified waveform between positive and negative half cycles of the input signal. 4-24 Force FX Electrosurgical Generator C Service Manual...
Page 97 Pure or Low. To minimize ringing at the beginning of the off period of the Blend waveform envelope, the damping resistor is switched on just before switching ends and stays on for part of the off period. Force FX Electrosurgical Generator C Service Manual 4-25...
Page 98 In all monopolar modes, K13 is closed and routes patient return current through the Patient Return Electrode receptacle. K15 routes active current through the Monopolar 1/CEM Instrument receptacle. K16 routes the active current through the Monopolar 2 Instrument receptacle. 4-26 Force FX Electrosurgical Generator C Service Manual...
Page 99: Spark Control Circuit
The VSENSE signal is obtained from the divider (R58, R25) located on the primary side of T4. VSENSE is input to a negative peak detector (U24A) that generates the analog signal (VPEAK–). Then U25A amplifies and inverts the signal. Force FX Electrosurgical Generator C Service Manual 4-27...
Page 100: Rem Circuit
The oscillator circuit consists of a chain of 74HC14 inverters. The output of the oscillator yields a 67.5 kHz square wave that is applied to the input of three 4081 buffers (U29). 4-28 Force FX Electrosurgical Generator C Service Manual...
Page 101: 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.
Page 102 (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. 4-30 Force FX Electrosurgical Generator C Service Manual...
Page 103: 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 104: Setting Up The Generator
Then, connect the cable to earth ground. 4. Plug the generator power cord into the rear panel receptacle. 5. Plug the generator power cord into a grounded receptacle. Force FX Electrosurgical Generator C Service Manual...
Page 105 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 106: 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 107: 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 108: 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 109 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 110: 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 Electrosurgical Generator C Service Manual...
Page 111 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 112: 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 113: 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 Force FX Electrosurgical Generator C Service Manual 5-11...
Page 114: 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 115: 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. Force FX Electrosurgical Generator C Service Manual 5-13...
Page 116: Periodic Safety Check
“one hand rule,” etc. Electric Shock Hazard Do not touch any exposed wiring or conductive surfaces while the generator is disassembled and energized. Never wear a grounding strap when working on an energized generator. 5-14 Force FX Electrosurgical Generator C Service Manual...
Page 117: 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 , all 250 watt, 1% tolerance, noninductive (Dale NH-250 or equivalent) Force FX Electrosurgical Generator C Service Manual 5-15...
Page 118: Inspecting The Generator And Accessories
Refer to 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. 5-16 Force FX Electrosurgical Generator C Service Manual...
Page 119: 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. Force FX Electrosurgical Generator C Service Manual 5-17...
Page 120: 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 121: 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. Force FX Electrosurgical Generator C Service Manual 5-19...
Page 122: Checking Output For The Monopolar Cut Modes
4. Press the Cut up ( ) or down ( ) arrow buttons to set the cut power to 75 W. 5. Test the monopolar cut output. a. Press the footswitch cut pedal and, while activating the generator, note the output on the voltmeter. 5-20 Force FX Electrosurgical Generator C Service Manual...
Page 123 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. Force FX Electrosurgical Generator C Service Manual 5-21...
Page 124: 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 125: Checking Low Frequency Leakage Current And Ground Resistance
6. Verify single fault conditions (ground open) the leakage current is less than or equal to 50 µA. If the leakage current is greater than 50 µA, call the Covidien Service Center. Force FX Electrosurgical Generator C Service Manual 5-23...
Page 126: Checking High Frequency Leakage Current
• 200 , 250 watt, noninductive resistor • Current transformer • True RMS voltmeter (Fluke 8920 or equivalent) • Bipolar and monopolar footswitches • Leakage table - per IEC 60601-2-2, Figure 104. 5-24 Force FX Electrosurgical Generator C Service Manual...
Page 127 It should not exceed 60 mA for any mode using either the leakage table or short lead configuration. 5. If the high frequency leakage exceeds 60 mA, call the Covidien Service Center for further instructions. Force FX Electrosurgical Generator C Service Manual 5-25...
Page 128: 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 129: 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. Force FX Electrosurgical Generator C Service Manual 5-27...
Page 130: 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 131: 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- Force FX Electrosurgical Generator C Service Manual 5-29...
Page 132: 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 133: 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. Force FX Electrosurgical Generator C Service Manual 5-31...
Page 134 Verify that the 10 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 135: 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 noninductive power resistors (such as the Dale NH-250) • Bipolar footswitch and monopolar footswitch Force FX Electrosurgical Generator C Service Manual 5-33...
Page 136 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 resistor. 5-34 Force FX Electrosurgical Generator C Service Manual...
Page 137 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. Force FX Electrosurgical Generator C Service Manual 5-35...
Page 138: Checking And Adjusting The Reactance Gain
2. Adjust the Z factor for bipolar output. a. Press the Standard button. b. Press the bipolar footswitch pedal and check the voltmeter for a reading equivalent to 1250 ± 12 mA 5-36 Force FX Electrosurgical Generator C Service Manual...
Page 139 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 Force FX Electrosurgical Generator C Service Manual 5-37...
Page 140: 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 141 Press the cut pedal to activate monopolar output for between two and five seconds. c. Stop activation. Verify that the Coag display changed to 200. d. Press the cut pedal again to activate monopolar output for between two and five seconds. Force FX Electrosurgical Generator C Service Manual 5-39...
Page 142 Press the coag pedal and, while activating the generator, press the Coag up ( ) or down ( ) arrow buttons until the voltmeter reading is equivalent to 141 ± 13 mA . Ignore changes to the Coag display. 5-40 Force FX Electrosurgical Generator C Service Manual...
Page 143 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. Force FX Electrosurgical Generator C Service Manual 5-41...
Page 144: 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 145: 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 146 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 147 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. Force FX Electrosurgical Generator C Service Manual 5-45...
Page 148: 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 149: 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 150: 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 151: 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 152: 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 153 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 154 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 155 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 Continued not present during activation) the high voltage power supply. Force FX Electrosurgical Generator C Service Manual...
Page 156 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 157 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 158 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 159: 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 Force FX Electrosurgical Generator C Service Manual 6-11...
Page 160 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 161 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 Force FX Electrosurgical Generator C Service Manual 6-13...
Page 162 ) 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 163 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 Force FX Electrosurgical Generator C Service Manual 6-15...
Page 164 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 165 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. Force FX Electrosurgical Generator C Service Manual 6-17...
Page 166 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 167 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. Force FX Electrosurgical Generator C Service Manual 6-19...
Page 168 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 169 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. Force FX Electrosurgical Generator C Service Manual 6-21...
Page 170: Correcting T_On Asic Malfunctions
Grip IC U9 with the chip extractor and lift it out of its socket. Align the notch on IC U9 above the notch on the socket and gently press the chip back into the socket. Install the Control board. 6-22 Force FX Electrosurgical Generator C Service Manual...
Page 171 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. Force FX Electrosurgical Generator C Service Manual 6-23...
Page 172: 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 173 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. Force FX Electrosurgical Generator C Service Manual 6-25...
Page 175: 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 176: Interconnect Diagram
Interconnect Diagram Interconnect Diagram A block diagram of generator interconnections BW14 Force FX Electrosurgical Generator C Service Manual...
Page 177: Battery Replacement
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 Electrosurgical Generator C Service Manual...
Page 178: Control Board Replacement
Power Supply/RF board. 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. Install the battery in the battery socket (positive side facing up).
Page 179: Display Board Replacement
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. Disconnect the membrane keyboard ribbon cable from the Display board. Force FX Electrosurgical Generator C Service Manual...
Page 180: Install The Display 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 Electrosurgical Generator C Service Manual...
Page 181: Display Board Seven-Segment Led Replacement
Connect the fan connector to J4 on the Power Supply/RF board. 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 182: Footswitch Board 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 on page 7-26. Force FX Electrosurgical Generator C Service Manual...
Page 183: 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 Electrosurgical Generator C Service Manual...
Page 184: 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 Electrosurgical Generator C Service Manual...
Page 185: 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 on page 7-9. Force FX Electrosurgical Generator C Service Manual 7-11...
Page 186: 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 on page 7-9. 7-12 Force FX Electrosurgical Generator C Service Manual...
Page 187: 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 Electrosurgical Generator C Service Manual 7-13...
Page 188: 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 Electrosurgical Generator C Service Manual...
Page 189: Left Front Heat Sink And Component Replacement
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. Force FX Electrosurgical Generator C Service Manual 7-15...
Page 190: 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 Electrosurgical Generator C Service Manual...
Page 191: 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. Force FX Electrosurgical Generator C Service Manual 7-17...
Page 192: Replace Left Rear Heat Sink Components
(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. 7-18 Force FX Electrosurgical Generator C Service Manual...
Page 193: 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. Force FX Electrosurgical Generator C Service Manual 7-19...
Page 194: 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 195: 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. Force FX Electrosurgical Generator C Service Manual 7-21...
Page 196: Low Voltage Power Supply Replacement
Place the new low voltage power supply on the Power Supply/RF board and install the four screws that secure it to the board. 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 197 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 2 (blue wire) to location BW14 pin 3 on Power Supply/RF board Force FX Electrosurgical Generator C Service Manual 7-23...
Page 198: 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. 7-24 Force FX Electrosurgical Generator C Service Manual...
Page 199: 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. Force FX Electrosurgical Generator C Service Manual 7-25...
Page 200: 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. 7-26 Force FX Electrosurgical Generator C Service Manual...
Page 201: Remove Components From The Old Board
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. Force FX Electrosurgical Generator C Service Manual 7-27...
Page 202: 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 203: 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. Force FX Electrosurgical Generator C Service Manual 7-29...
Page 205: 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 206: Responsibility Of The Manufacturer
Number. Have the following information ready when you call: • Hospital/clinic name/customer number • Telephone number • Department/address, city, state, and zip code • Model number • Serial number • Description of the problem • Type of repair to be done Force FX Electrosurgical Generator C Service Manual...
Page 207: 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://www.valleylab.com/valleylab/international/service-world.html Force FX Electrosurgical Generator C Service Manual...
Page 209: 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 210: Ordering Replacement Parts
Ordering Replacement Parts Ordering Replacement Parts You can order parts for the Force FX Electrosurgical Generator C from the Covidien Service Center for your location. When ordering replacement parts, include this information: • Model number (located on the rear panel of the generator) •...
Page 211: Generator Assembly
Generator Assembly Generator Assembly Generator assembly Force FX Electrosurgical Generator C Service Manual...
Page 212 Generator Assembly Generator assembly–continued Force FX Electrosurgical Generator C Service Manual...
Page 213: Parts List
Nut, hex M6 x 10 brass nickel plated 224 300 000 Assembly, front panel 202 701 892 See Front Panel Assembly on page 9-7. Assembly, Control board 1004056 See Control Board Components on page 9-10. Force FX Electrosurgical Generator C Service Manual...
Page 214 223 301 139 Power cord, right angle molded, 110V 207 002 060 Fuse, 4A, 5x20 mm Slow Blow (2) 215 100 074 Washer, flat M4 253 300 005 Tag, receptacle notice 216 151 414 Force FX Electrosurgical Generator C Service Manual...
Page 215: Front Panel Assembly
Front Panel Assembly Front Panel Assembly Front panel assembly Force FX Electrosurgical Generator C Service Manual...
Page 216 Front Panel Assembly Front panel assembly–continue 17, 18 Force FX Electrosurgical Generator C Service Manual...
Page 217: Parts List
223 500 076 Assembly, cable switch CEM 202 701 867 Adhesive, prism 411 232 301 213 Washer, flat M3 253 300 004 Not shown: Overlay jack 1020029 Keyboard front 1012634 Control panel 223 200 667 Force FX Electrosurgical Generator C Service Manual...
Page 218: Control Board Components
LP4, LP5, LP6, LP7, LP8, LP9, LP10, LP11, LP12 Transistors Q1, Q2, Q3 FET N-CH 1A, 100 V 239 200 027 Resistors R1, R2, R3, ± 5%, 1/2 W 234 014 072 9-10 Force FX Electrosurgical Generator C Service Manual...
Page 219 U8, U9, U11, U12, U13 Miscellaneous (not shown) Clip, display board 213 130 033 Socket, dip 20-pin gold 208 500 054 Socket, dip 30-pin gold 208 500 055 Socket, I.C. 16-pin 208 121 003 Force FX Electrosurgical Generator C Service Manual 9-11...
Page 220: Footswitch Board Components
C42, C43, C44, C45, Diodes D1, D2 1N4148 239 014 000 Transistors FET TN2404KL 239 200 097 Resistors R1, R2, R3, 10 k ± 5%, 1/4 W 234 024 087 R4, R7, R9 9-12 Force FX Electrosurgical Generator C Service Manual...
Page 221 234 024 111 Integrated Circuits LM339AN 210 300 015 DC/DC converter HPR107 210 750 007 U3, U4, U5 LM 393 N 210 300 011 LM358AN 210 300 013 Audio amp LM386 210 400 019 Force FX Electrosurgical Generator C Service Manual 9-13...
Page 222 253 300 004 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 9-14 Force FX Electrosurgical Generator C Service Manual...
Page 223: Power Supply/Rf Board Assembly
Power Supply/RF Board Assembly Power Supply/RF Board Assembly Power Supply/RF board assembly Force FX Electrosurgical Generator C Service Manual 9-15...
Page 224 Power Supply/RF Board Assembly Power Supply/RF board assembly–continued 9-16 Force FX Electrosurgical Generator C Service Manual...
Page 225: Parts List
224 300 040 Screw, panhead PHH M4 x 0.7 x 8 mm 1030418 Screw, panhead Phillips M4 x 0.7 x 12 zinc 237 050 141 Washer, lock internal metric M4 253 300 045 Force FX Electrosurgical Generator C Service Manual 9-17...
Page 226 237 050 143 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 9-18 Force FX Electrosurgical Generator C Service Manual...
Page 227: Power Supply/Rf Board Components
.01 µF ± 20%, 50 V 204 200 456 C46, C48, C52, C58, C65, C71, C82, C84, C86, C117, C118, C156, C170, C172 C3, C10, 680 µF, 400 V 204 500 178 C11, C22 Force FX Electrosurgical Generator C Service Manual 9-19...
Page 228 C61, C70, C113, C120, C122, C124, C127, C130, C136, C142, C147, C149, C160, C161, C162, C163, C164, C165, C166, C167, C168 C27, C49 680 pF ± 5%, 500 V 204 105 022 9-20 Force FX Electrosurgical Generator C Service Manual...
Page 229 1500 pF ± 5%, 100 V 204 200 487 C54, C81, .47 µF ± 20%, 50 V 204 200 463 C104 C63, C68 22 pF ± 5%, 100 V 204 200 450 Force FX Electrosurgical Generator C Service Manual 9-21...
Page 230 CR12, CR15, CR17, CR18, CR25, CR26, CR27, CR28, CR34, CR37, CR39, CR41, CR47, CR48, CR49, CR50 LED, green.2 dia. 239 750 063 CR14, CR16, Schottky.6 A, 40 V 239 700 066 CR29 9-22 Force FX Electrosurgical Generator C Service Manual...
Page 231 234 024 135 18.2 k ± 1%, 1/8 W 234 201 410 R5, R6 30 k ± 5%, 3 W 234 100 180 91 k ± 5%, 1/4 W 234 024 110 Force FX Electrosurgical Generator C Service Manual 9-23...
Page 232 240 003 006 R22, R23 ± 5%, 1/2 W 234 014 068 R24, R34, ± 5%, 1/4 W 234 024 039 R102, R117, R121, R135 ± 1%, 1/8 W 234 201 234 9-24 Force FX Electrosurgical Generator C Service Manual...
Page 233 110 k ± 5%, 1/4 W 234 024 112 39 k ± 5%, 1/2 W 234 014 113 R59, R60, ± 1%, 1/8 W 234 201 318 R63, R65, R71, R72, R73, R85 Force FX Electrosurgical Generator C Service Manual 9-25...
Page 234 234 024 111 R141 R110 2.15 k ± 1%, 1/8 W 234 201 321 R113, R114, ± 5%, 1/4 W 234 024 061 R115, R120 3.40 k ± 1%, 1/8 W 234 201 340 9-26 Force FX Electrosurgical Generator C Service Manual...
Page 235 RF choke 251 100 174 Integrated Circuits AVS1AC 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 Force FX Electrosurgical Generator C Service Manual 9-27...
Page 236 223 500 078 J21, J22, J23, Fuse clip 215 100 078 J24, J25, J26, J27, J28 FB1, FB2, FB3, Ferrite bead 251 100 116 FB4, FB5, FB6, FB7, FB8, FB9, FB10, FB11, FB12 9-28 Force FX Electrosurgical Generator C Service Manual...
Page 237 239 750 073 OPT3, OPT4, OPT5 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 Electrosurgical Generator C Service Manual 9-29...
Page 239 Schematics Supplement Force FX Electrosurgical Generator C...
Page 241 Schematics Supplement This supplement contains the assembly drawings and schematics for the printed circuit board assemblies listed below: • Control board • Display board • Footswitch board • Power Supply/RF board Force FX Electrosurgical Generator C Service Manual Schematics page 1...
Page 243 Control Board Layout Force FX Electrosurgical Generator C Service Manual Schematics page 3...
Page 245 Control Board Schematic - Sheet 1 of 2 Force FX Electrosurgical Generator C Service Manual Schematics page 5...
Page 246 Control Board Schematic - Sheet 2 of 2 Schematics page 6 Force FX Electrosurgical Generator C Service Manual...
Page 247 Display Board Layout Force FX Electrosurgical Generator C Service Manual Schematics page 7...
Page 249 Display Board Schematic - Sheet 1 of 3 Force FX Electrosurgical Generator C Service Manual Schematics page 9...
Page 250 Display Board Schematic - Sheet 2 of 3 Schematics page 10 Force FX Electrosurgical Generator C Service Manual...
Page 251 Display Board Schematic - Sheet 3 of 3 Force FX Electrosurgical Generator C Service Manual Schematics page 11...
Page 253 Footswitch Board Layout Force FX Electrosurgical Generator C Service Manual Schematics page 13...
Page 255 Footswitch Board Schematic - Sheet 1 of 2 Force FX Electrosurgical Generator C Service Manual Schematics page 15...
Page 256 Footswitch Board Schematic - Sheet 2 of 2 Schematics page 16 Force FX Electrosurgical Generator C Service Manual...
Page 257 Power Supply/RF Board Assembly 1* Item 37 - Installed on Force FX- 8CA model only. Force FX Electrosurgical Generator C Service Manual Schematics page 17...
Page 259 .22UF +12V LINE U6-A R169 +5.1V 250V,20% FILTER AC (LINE) +5.1V -12V 4093 HV_ENABLE C173 +12V .1UF -12V GRN/YEL CR11 DO NOT STUFF LOW VOLTAGE BOARD MNT SUPPLY CABLE ASSY Force FX Electrosurgical Generator C Service Manual Schematics page 19...
Page 260 4081 LM393 1427 U6-C U21-B 74HC14 LF412 DG445 U30-F U13-B U31-B U9-B 4093 U2-B U28-D TL052 LM393 U6-D 74221 LM393 1427 74HC14 U20-B U25-B DG445 U26-B 4093 TL052 LM393 LM393 Schematics page 20 Force FX Electrosurgical Generator C Service Manual...
Page 261 4093 LM393 R109 1/8W 1% 10K/25C/5% R125 R110 4.7K 2.15K 5.1K 1K/25C/5% .01UF .01UF 1/8W 1% 100V 10% 100V 10% 1/8W 1% .1UF 3.9K FAN CONTROL 100V 10% REM OSCILLATOR Force FX Electrosurgical Generator C Service Manual Schematics page 21...
Page 262 TRACES INSIDE DASHED LINES NEED R120 1N5233B .1UF .01UF 100V 10% TO BE A MINIMUM OF .100" WIDE 3.40K 1/8W 1% PATIENT OUTPUT -12V -V_ISO_3 REM_CLK REM_DRV REM DETECTION BIPOLAR KEYING-OUTPUT RELAYS Schematics page 22 Force FX Electrosurgical Generator C Service Manual...
Page 263 HV_ENABLE .5A 125V +12V ISO_TST KEY_INH T_ON SYS_I_OUT SYS_V_OUT [ T_ON_EN] ECON_GAIN AUTOBIPOLAR BOARD TNK_DMP_OUT .5A 125V -12V CONN96 CONN16X2/V +12V .5A 125V -12V MICROPROCESSOR RS232 EXPANSION BOARD PORT PORT Force FX Electrosurgical Generator C Service Manual Schematics page 23...
Page 266 Part No. 1012637 COVIDIEN, COVIDIEN with logo and Covidien logo are U.S. and internationally registered trademarks of Covidien AG. CUSA, CUSA EXcel and CEM are trademarks of Integra LifeSciences Corporation or its subsidiary. Other brands are trademarks of a Covidien company. U.S.
Page 268 Part No. 1012637 COVIDIEN, COVIDIEN with logo and Covidien logo are U.S. and internationally registered trademarks of Covidien AG. CUSA, CUSA EXcel and CEM are trademarks of Integra LifeSciences Corporation or its subsidiary. Other brands are trademarks of a Covidien company. U.S.

Coviden Force FX Service Manual

Chapter 1. Introduction

Chapter 2. Controls, Indicators, and Receptacles

Chapter 3. Technical Specifications

Chapter 4. Principles of Operation

Chapter 5. Setup, Tests, and Adjustment

Chapter 6. Troubleshooting

Chapter 7. Replacement Procedures

Chapter 8. Repair Policy and Procedures

Chapter 9. Service Parts

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Summary of Contents for Coviden Force FX