SERVICE MANUAL

Force FXTM-C
Electrosurgical Generator
with Instant Response™ Technology
Service Manual

Force FXTM-C
Electrosurgical Generator
with Instant Response™ Technology
Preface
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
Valleylab Force FXTM_C Electrosurgical Generator only. Additional
information about using the generator is available in the Force FXTM-C
Electrosurgical Generator User's Guide.

Equipment covered in this manual:

Valleylab Force FX™-C Electrosurgical Generator vvith Instant Response™
Technology-
110-120 V ~ Nominal, 220-240 V ~ Nominal (auto selected)

The Force FX-C Electrosurgical Generator Service Manual consists of h-vo

parts-the text (part 1 of 2) and a Schematics Supplement (part 2 of 2)
which contains the schematics.
Valleylab Part Number: 945 103 064 (1 of 2)
Effective Date: September 2000
Patent Information: Protected by U.S. Pat. Nos. 4,416,276; 4,416,277; 4,658,820;
5,599,344; and 5,628,745.
Trademark Acknowledgments:
CUSATM, CUSA EXceFM, Force GSUTM, PolyHesiveT!l.1, REMTM, CEMTM,
Force ArgonTM, Force FXTM, and Instant Response™ are trademarks of
Valleylab; Teflon® is a registered trademark of E.I. DuPont de Nemours
and Co., Inc.
Manufactured by:
Valleylab
Boulder, Colorado 80301-3299 USA
For information call:
1-800-255-8522/1-303-530-2300

Made in USA
Printed in USA
©1999, 2000 Valleylab All rights reserved.

ii Force F)(TM -C Service Manual

Conventions Used in this Guide
Warning
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.

Indicates a hazardous situation which, if not avoided, may result in minor or

moderate injury.

"'Important
Indicates an operating tip or
Notice
maintenance suggestion.
Indicates a hazard which may result in product damage.

Force FXTM-C Service Manual iii

Table of Contents
Preface ji
Conventions Used in this Guide iii
List of Figures x

Section 1. Introduction
General Description 1·2
List of Components 1·3
Service Personnel Safety 1·3
General 1·3
Fire/Explosion Hazards 1·4
Electric Shock Hazards 1-5
Servicing 1-5
Calibration 1·6
Cleaning 1·6

Section 2. Controls, Indicators, and Receptacles

Front Panel 2·2
Bipolar Controls 2·3
Bipolar Instrument Receptacle 2·4
Monopolar Cut Controls 2·5
Monopolar Coag Controls 2·6
Monopolar Instrument Receptacles 2·7
REM Alarm Indicator 2·8
Rear Panel 2·9
Footswitch Receptacles 2·10
Monopolar Footswitch Receptacles 2·10
Bipolar Footswitch Receptacle 2·10
Power Entry Module 2·11
Activation Tone Volume Control 2·11
Option Panel 2·12

Section 3. Technical Specifications

Performance Characteristics 3·1
General 3-1
Dimensions and Weight 3·2
Operating Parameters 3·2
Transport and Storage 3·2
Duty Cycle 3-3
Internal Memory 3·3
Audio Volume 3-3

IV Force FXTM·C Service Manual

 REM Contact Quality Monitor 3-4
Serial Port 3-5
RF Activation Port 3-5
Expansion Port 3-5
Low Frequency (50-60 Hz) Leakage Current 3-5
High Frequency (RF) Leakage Current 3-6
Input Power 3-6
Standards and IEC Classifications 3-7
Class I Equipment(IEC 601-1) 3-7
Type CF Equipment (IEC 601-1)/Defibriliator Proof 3-7
Drip Proof (IEC 601-2-2) 3-7
Electromagnetic Interference 3-8
Electromagnetic Compatibility (IEC 601-1-2 and IEC 601-2-2) 3-8
Voltage Transients (Emergency Generator Mains Transfer) 3-8
Output Characteristics 3-9
Maximum Output for Bipolar and Monopolar Modes 3-9
Maximum Output for Ultrasonic Electrosurgery 3-9
Available Power Settings in Watts 3-10
Output Waveforms 3-11
Output Power vs. Resistance Graphs 3-13
Bipolar Graphs 3-13
Monopolar Cut Graphs 3·15
Monopolar Coag Graphs 3-16

Sec"lion 4. Principles of Operation

Block Diagram 4-2
Functional Overview 4-3
Instant Response Technology 4·3
Ultrasonic Electrosurgery 4-3
Simultaneous Coag 4·3
REM Contact Quality Monitoring System 4-4
Control Board 4-5
Microcontrollers 4-5
Main Microcontroller 4-5
Feedback Microcontroller 4-6
Shared RAM 4-7
I/O Expansion 4-7
Keyboard Interface and Activation Inputs 4-7
Power Supply Supervisor Circuit 4-8
AID and D/A Conversion 4-8
Waveform Generation (T_ON ASIC) 4-8
T_ON Average Check 4-9
Audio Alarm 4-9

Force FXTM-C Service Manual v

 Serial Interface 4-9
Dosage Error Algorithm 4-10
Instant Response Algorithm 4-11
Front Panel 4-12
Membrane Keyboard 4-12
Power Switch 4-12
REM Connector/Switch 4-12
CEM Mechanism Switch 4-12
Display Board 4-13
RF Indicator Lamps 4-13
REM Indicators 4-13
LED and Seven-Segment Display Drivers 4-13
CEM Switch Circuit 4-14
Mode Selection and Power Control Switches 4-14
Footswitch Board 4-15
Footswitch Decode Circuit 4-15
Audio Circuit 4-16
Power Supply/RF Board 4-17
Power Supply/RF Board Interfaces 4-18
High Voltage Power Supply 4-18
Low Voltage Power Supply 4-21
RF Output Stage 4-21
Spark Control Circuit 4-24
RF Leakage Reduction Circuit 4-25
REM Circuit 4-25
Iso Bloc Circuit 4-25
Temperature Sense Circuits 4-26

Section 5. Setup, Tests, and Adjustments

Setting Up the Generator 5-2
Connections for Bipolar or Macrobipolar Surgery 5-4
Setting the Bipolar Output 5-5
Connections for Monopolar Surgery 5-6
Selecting Cut and Coag Modes 5-8
Simultaneous Coag 5-8
Using Two Generators Simultaneously 5-9
Connecting the CUSA Handpiece with CEM Nosecone 5-10
Setting the Output Power 5-11
Simultaneous Coag with a CUSA System 5-11
Changing the Mode 5-11
Changing the Power Setting 5-11
Activating the Surgical Instrument 5-12

vi Force F)(TM-C Service Manual

 Periodic Safety Check 5-13
Recommended Test Equipment 5-13
Inspecting the Generator and Accessories 5-14
Inspecting the Internal Components 5-15
Testing the Generator 5-16
Verifying REM Function 5-17
Confirming Outputs 5-17
Check the Output for the Cut Modes 5-19
Check the Output for the Coag Modes 5-20
Checking Low Frequency Leakage Current 5-21
Checking High Frequency Leakage Current 5-23
Calibrating the Force FX-C Generator 5-24
Preparing for Calibration 5-25
Entering Calibration Mode 5-25
Exiting Calibration Mode 5-26
Verify the Force FX-C Generator Data 5-26
Adjust the Calendar 5-27
Adjust the Clock 5-28
Check and Adjust the REM Oscillator Frequency and Impedance 5-29
Check and Adjust the Current Sense Gain 5-30
Check and Adjust the Voltage Sense Gain 5-32
Check and Adjust the Reactance Gain 5-34
Check and Adjust the ECON Factor 5-36
Using the RS-232 Serial Port 5-40
Establish the Communications Link 5-40
Enter the Commands 5-41
Disconnect the Computer from the Generator 5-44

Section 6. Troubleshooting
Inspecting the Generator 6-1
Inspecting the Receptacles 6-2
Inspecting the Internal Components 6-3
Correcting Malfunctions 6-4
Responding to System Alarms 6-10
Correcting IC U3 Malfunctions 6-20
Correcting IC U6 Malfunctions 6-22
Correcting T__ ON ASIC Malfunctions 6-24
Correcting Battery-Backed RAM Malfunctions 6-26

Force FXTM-C Service Manual vii

 Section 7. Replacement Procedures
Interconnect Diagram 7-2
Battery Replacement 7-3
Control Board Replacement 7-4
Display Board Replacement 7·5
Remove the Display Board 7·5
Install the Display Board 7-6
Display Board Seven-Segment LED Replacement 7-7
Fan Replacement 7·8
Footswitch Board Replacement 7-8
Front Panel Replacement 7-9
Remove the Front Panel Assembly 7-9
Remove and Reinsta" the Front Panel Components 7·9
Insta" the Front Panel Assembly 7·10
Front Panel REM Module Replacement 7-11
Front Panel Power Switch Replacement 7-12
Fuse Replacement 7-13
Replacing Fuses in the Fuse Drawer 7·13
Replacing the Fuse on the Power Supply/RF Board 7-14
Left Front Heat Sink and Component Replacement 7·15
Remove the Left Front Heat Sink 7-15
Replace Left Front Heat Sink Components 7-16
Install the Left Front Heat Sink 7·16
Left Rear Heat Sink and Component Replacement 7-17
Remove the Left Rear Heat Sink 7·17
Replace Left Rear Heat Sink Components 7-18
Install the Left Rear Heat Sink 7-19
Right Heat Sink and Component Replacement 7·20
Remove the Right Heat Sink 7-20
Replace Right Heat Sink Components 7-21
Install the Right Heat Sink 7·22
Low Voltage Power Supply Replacement 7·23
Remove the Low Voltage Power Supply 7·23
Install the Low Voltage Power Supply 7-24
Power Entry Module Replacement 7-25
Remove the Power Entry Module 7·25
Install the Power Entry Module 7-26

viii Force F)(TM-C Service Manual

 which extend beyond the terms hereof. Valleylab disclaims any liability
hereunder or elsewhere in connection with the sale of this product, for
indirect or consequential damages.
This warranty and the rights and obligations hereunder shall be construed
under and governed by the laws of the State of Colorado, USA. The sole
forum for resolving disputes arising under or relating in any way to this
warranty is the District Court of the County of Boulder, State of Colorado,
USA.
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.

A-2 Force FXTM-C Service Manual

 which extend beyond the terms hereof. Valleylab disclaims any liability
hereunder or elsewhere in connection with the sale of this product, for
indirect or consequential damages.
This warranty and the rights and obligations hereunder shall be construed
under and governed by the laws of the State of Colorado, USA. The sole
forum for resolving disputes arising under or relating in any way to this
warranty is the District Court of the County of Boulder, State of Colorado,
USA.
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.

A-2 Force FXTM-C Service Manual