Force FX Electrosurgical Generator C Service Manual

Service Manual
Force FX
TM
Electrosurgical Generator C
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 Force FX Electrosurgical Generator C only.
Additional users information is available in the Force FX Electrosurgical Generator C
Users Guide.
Equipment covered in this manual:
Covidien Force FX Electrosurgical Generator C
110 V ~ Nominal / 230 V ~ Nominal (auto selected)
The Force FX Electrosurgical Generator C Service Manual consists of two parts: the text
(part 1 of 2) and a Schematics Supplement (part 2 of 2) which contains the schematics.
Device is compliant with the European Communities Council Directive 93/42/EEC,
Medical Device Directive.
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.
Notice
Indicates a hazard which may result in product damage.
Important
Indicates an operating tip or maintenance suggestion.
ii Force FX Electrosurgical Generator C Service Manual

Limited Warranty
Covidien warrants each covered product listed below to be free from defects in material
and workmanship for normal use and service for the period(s) set forth below. Covidiens
obligation under this warranty is limited to the repair or replacement, at its sole option,
of any product, or part thereof, which has been returned to it (or its authorized
distributor) within the applicable time period shown below after delivery of the product
to the original purchaser, and which examination discloses, to Covidiens satisfaction, that
the product is defective. This limited warranty does not apply to any product, or part
thereof, which has been repaired or altered in a way so as, in Covidiens judgment, to
affect its stability or reliability, or which has been subjected to misuse, neglect, or
accident.
The warranty periods for Covidien products are as follows:
ForceTriadTM Energy Platform One year from date of shipment
Electrosurgical Generators One year from date of shipment
Cool-tipTM RFA Generator One year from date of shipment
EvidentTM MWA Generator One year from date of shipment
RFG-3CTM Plus Lesion Generator One year from date of shipment
LigaSureTM Vessel Sealing System One year from date of shipment
LigaSureTM Reusable Instruments One year from date of shipment
Mounting Fixtures (all models) One year from date of shipment
Footswitches (all models) One year from date of shipment
ValleylabTM Argon Gas Delivery Unit II One year from date of shipment
RapidVacTM Smoke Evacuator One year from date of shipment
LigaSureTM Sterile Single Use Items Sterility only as stated on packaging
Cool-tipTM Sterile Single Use Items Sterility only as stated on packaging
Sterile Single Use Items Sterility only as stated on packaging
Patient Return Electrodes Shelf life only as stated on packaging
Notwithstanding any other provision herein or in any other document or communication,

Covidiens 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 iii

covered product(s). There are no warranties which extend beyond the terms hereof.
Covidien disclaims any liability hereunder or elsewhere in connection with the sale of
products and for any form of indirect, tort, or consequential damages.
This limited 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 limited warranty is the District Court
of the County of Boulder, State of Colorado, USA.
Covidien reserves the right to make changes in covered products built or sold by it at any
time without incurring any obligation to make the same or similar changes to equipment
previously built or sold by it.
THE OBLICATION TO REPAIR OR REPLACE A DEFECTIVE OR NONPERFORMING PRODUCT
IS THE SOLE REMEDY OF THE CUSTOMER UNDER THIS LIMITED WARRANTY. EXCEPT AS
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.
iv Force FX Electrosurgical Generator C Service Manual

Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Conventions Used in this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Chapter 1. Introduction
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
List of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Service Personnel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Active Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Patient Return Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Fire/Explosion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electric Shock Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Chapter 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Footswitch Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Monopolar Footswitch Receptacles . . . . . . . . . . . . . . . . . . . 2-9
Bipolar Footswitch Receptacle . . . . . . . . . . . . . . . . . . . . . . . 2-9
Power Entry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Activation Tone Volume Control . . . . . . . . . . . . . . . . . . . . . . . 2-10
Option Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Chapter 3. Technical Specifications
Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Force FX Electrosurgical Generator C Service Manual v

Internal Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Audio Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
REM Contact Quality Monitor. . . . . . . . . . . . . . . . . . . . . . . . 3-4
Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
RF Activation Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Expansion Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Low Frequency (5060 Hz) Leakage Current . . . . . . . . . . . . 3-6
High Frequency (RF) Leakage Current . . . . . . . . . . . . . . . . . 3-6
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Power Cord Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Standards and IEC Classifications . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Class I Equipment (IEC 60601-1) . . . . . . . . . . . . . . . . . . . . . . 3-9
Type CF Equipment (IEC 60601-1)/Defibrillator Proof . . . . . 3-9
Liquid Spillage (IEC 60601-2-2 Clause 44.3) . . . . . . . . . . . . . 3-9
Electromagnetic Interference . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Electromagnetic Compatibility (IEC 60601-1-2 and
IEC 60601-2-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Voltage Transients (Emergency Generator Mains
Transfer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Maximum Output for Bipolar and Monopolar Modes . . . 3-14
Maximum Output for Ultrasonic Electrosurgery . . . . . . . . 3-15
Available Power Settings in Watts . . . . . . . . . . . . . . . . . . . 3-15
Output Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Output Power vs. Resistance Graphs. . . . . . . . . . . . . . . . . . . . . 3-18
Bipolar Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Monopolar Cut Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Monopolar Coag Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Chapter 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Microcontrollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Main Microcontroller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Feedback Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Shared RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
vi Force FX Electrosurgical Generator C Service Manual

I/0 Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Keyboard Interface and Activation Inputs. . . . . . . . . . . . . . 4-8
Power Supply Supervisor Circuit . . . . . . . . . . . . . . . . . . . . . . 4-9
A/D and D/A Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Waveform Generation (T_ON ASIC) . . . . . . . . . . . . . . . . . . . 4-9
T_ON Average Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Audio Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Serial Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Dosage Error Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Instant Response Algorithm . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Membrane Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
REM Connector/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
CEM Mechanism Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
RF Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
REM Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
LED and Seven-Segment Display Drivers . . . . . . . . . . . . . . 4-14
CEM Switch Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Mode Selection and Power Control Switches . . . . . . . . . . 4-15
Footswitch Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Footswitch Decode Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Audio Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Power Supply/RF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Power Supply/RF Board Interfaces . . . . . . . . . . . . . . . . . . . 4-20
High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
RF Output Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Spark Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
RF Leakage Reduction Circuit . . . . . . . . . . . . . . . . . . . . . . . 4-27
REM Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
IsoBloc Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Temperature Sense Circuits. . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Chapter 5. Setup, Tests, and Adjustment
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
Force FX Electrosurgical Generator C Service Manual vii

Selecting Cut and Coag Modes . . . . . . . . . . . . . . . . . . . . . . . 5-8
Simultaneous Coag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Using Two Generators Simultaneously. . . . . . . . . . . . . . . . 5-10
Connecting the CUSA Handpiece with CEM Nosecone . . . 5-11
Setting the Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Simultaneous Coag with a CUSA System . . . . . . . . . . . . . . 5-12
Changing the Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Changing the Power Setting . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Activating the Surgical Instrument . . . . . . . . . . . . . . . . . . . 5-13
Periodic Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . 5-15
Inspecting the Generator and Accessories . . . . . . . . . . . . . 5-16
Inspecting the Internal Components . . . . . . . . . . . . . . . . . 5-17
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Verifying REM Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Confirming Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Checking the Bipolar Output . . . . . . . . . . . . . . . . . . . . . . . 5-19
Checking Output for the Monopolar Cut Modes . . . . . . . 5-20
Checking Output for the Monopolar Coag Modes . . . . . . 5-22
Checking Low Frequency Leakage Current and
Ground Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Checking High Frequency Leakage Current . . . . . . . . . . . . 5-24
Calibrating the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Entering Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Exiting Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Verifying the Generator Data . . . . . . . . . . . . . . . . . . . . . . . 5-28
Adjusting the Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Checking and Adjusting the REM Oscillator Frequency
and Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Checking and Adjusting the Current Sense Gain. . . . . . . . 5-31
Checking and Adjusting the Voltage Sense Gain . . . . . . . 5-33
Checking and Adjusting the Reactance Gain . . . . . . . . . . . 5-36
Checking and Adjusting the ECON Factor . . . . . . . . . . . . . 5-38
Using the RS-232 Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Establish the Communications Link . . . . . . . . . . . . . . . . . . 5-42
Enter the Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Disconnect the Computer from the Generator . . . . . . . . . 5-46
viii Force FX Electrosurgical Generator C Service Manual

Chapter 6. Troubleshooting
Inspecting the Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Inspecting the Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Inspecting the Internal Components . . . . . . . . . . . . . . . . . . 6-3
Correcting Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Responding to System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Correcting T_ON ASIC Malfunctions . . . . . . . . . . . . . . . . . . . . . 6-22
Correcting Battery-Backed RAM Malfunctions . . . . . . . . . . . . 6-24
Chapter 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Footswitch Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Front Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Remove the Front Panel Assembly . . . . . . . . . . . . . . . . . . . . 7-9
Remove and Reinstall the Front Panel Components . . . . . . 7-9
Install 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 . . . . . . . . . . . . . . . . . . . . . . 7-18
Right Heat Sink and Component Replacement . . . . . . . . . . . . 7-19
Remove the Right Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Replace Right Heat Sink Components . . . . . . . . . . . . . . . . 7-20
Install the Right Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Force FX Electrosurgical Generator C Service Manual ix

Low Voltage Power Supply Replacement . . . . . . . . . . . . . . . . . 7-22
Remove the Low Voltage Power Supply . . . . . . . . . . . . . . 7-22
Install the Low Voltage Power Supply . . . . . . . . . . . . . . . . 7-22
Power Entry Module Replacement . . . . . . . . . . . . . . . . . . . . . . 7-24
Remove the Power Entry Module . . . . . . . . . . . . . . . . . . . . 7-24
Install the Power Entry Module . . . . . . . . . . . . . . . . . . . . . 7-25
Power Supply/RF Board Replacement . . . . . . . . . . . . . . . . . . . . 7-26
Remove the Power Supply/RF Board Assembly . . . . . . . . . 7-26
Remove Components from the Old Board . . . . . . . . . . . . . 7-27
Install Components on the New Board. . . . . . . . . . . . . . . . 7-28
Install the Power Supply/RF Board Assembly . . . . . . . . . . . 7-29
Chapter 8. Repair Policy and Procedures
Responsibility of the Manufacturer . . . . . . . . . . . . . . . . . . . . . . 8-2
Returning the Generator for Service. . . . . . . . . . . . . . . . . . . . . . 8-2
Obtain a Return Authorization Number . . . . . . . . . . . . . . . 8-2
Clean the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Ship the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Returning Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Chapter 9. Service Parts
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Control Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Display Board Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Footswitch Board Components . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Power Supply/RF Board Assembly . . . . . . . . . . . . . . . . . . . . . . . 9-15
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Power Supply/RF Board Components . . . . . . . . . . . . . . . . . . . . 9-19
x Force FX Electrosurgical Generator C Service Manual

Chapter 1
Introduction
This manual provides instructions for servicing the Covidien Force FX

Electrosurgical Generator C with Instant ResponseTM 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 1-1

General Description
General Description
The Covidien Force FX Electrosurgical Generator C is an isolated output electrosurgical
generator that provides the appropriate power for cutting, desiccating, and fulgurating
tissue during bipolar and monopolar surgery.
It includes the following features:
Instant Response technology
Three bipolar modes: precise (low), standard (medium), and macro (macrobipolar)
Three monopolar cut modes: low, pure, and blend
Three monopolar coag modes: desiccate (low), fulgurate (medium), and spray (high)
Support for simultaneous coagulation
The REMTM Contact Quality Monitoring System
Support for ultrasonic electrosurgery using the CUSA EXcelTM system and a CUSATM
handpiece with a CUSA electrosurgical module (CEMTM) nosecone
Handswitch or footswitch activation
Recall of most recently used mode and power settings
Adjustable activation tone volume
An RF activation port, RS-232 serial port, and expansion port
ValleylabTM 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:
Front panel componentspower switch; controls for setting the modes and output
power; a button for recalling the power settings and modes that were used last;
receptacles for connecting electrosurgical accessories; and indicators that alert you to
the current settings and patient return electrode status.
Rear panel componentsvolume control; three footswitch receptacles; power entry
module; equipotential grounding lug; and three ports (serial port, RF activation port,
and expansion port).
Internal componentsControl (microcontroller) board; Display board; Footswitch
board; Power Supply/Radio Frequency (RF) board; low voltage power supply; fan; and
heat sinks.
A handle is located on the underside of the chassis.
For details about the interaction of the main components and circuit board descriptions,
refer to Chapter 4, Principles of Operation.
1-2 Force FX Electrosurgical Generator C Service Manual

Service Personnel Safety
Introduction
Before servicing the generator, it is important that you read, understand, and follow the
instructions supplied with it and with any other equipment used to install, test, adjust, or
repair the generator.
General
Warning
Use the generator only if the self-test has been completed as described. Otherwise, inaccurate
power outputs may result.
The instrument receptacles on this generator are designed to accept only one instrument at a
time. Do not attempt to connect more than one instrument at a time into a given receptacle.
Doing so will cause simultaneous activation of the instruments.
Caution
Do not stack equipment on top of the generator or place the generator on top of electrical
equipment (except a Valleylab Argon Gas Delivery Unit II or a CUSA EXcel unit). These
configurations are unstable and/or do not allow for adequate cooling.
Provide as much distance as possible between the electrosurgical generator and other electronic
equipment (such as monitors). An activated electrosurgical generator may cause interference with
them.
Do not turn the activation tone down to an inaudible level. The activation tone alerts the surgical
team when an accessory is active.
Notice
If required by local codes, connect the generator to the hospital equalization connector with an
equipotential cable.
Connect the power cord to a wall receptacle having the correct voltage. Otherwise, product
damage may result.
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.

Caution
Accessories must be connected to the proper receptacle type. In particular, bipolar accessories
must be connected to the Bipolar Instrument receptacle only. Improper connection may result in
inadvertent generator activation or a REM contact quality monitor alarm.
Set power levels to the lowest setting before testing an accessory.
Notice
During bipolar electrosurgery, do not activate the generator until the forceps have made contact
with the patient. Product damage may occur.
Patient Return Electrodes

Warning
Using a patient return electrode without the REM safety feature will not activate the REM Contact
Quality Monitoring System.
Fire/Explosion Hazards
Warning
Danger: Explosion Hazard Do not install the generator in the presence of flammable
anesthetics, gases, liquids, or objects.
Fire Hazard Do not place active accessories near or in contact with flammable materials (such
as gauze or surgical drapes). Electrosurgical accessories that are activated or hot from use can
cause a fire. Use a holster to hold electrosurgical accessories safely away from personnel and
flammable materials.
Fire Hazard Do not use extension cords.
Fire Hazard For continued protection against fire hazard, replace fuses only with fuses of the
same type and rating as the original fuse.
Electric Shock Hazards

Warning
Connect the generator power cord to a properly grounded receptacle. Do not use power plug
adapters.
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.

Introduction
Warning
Always turn off and unplug the generator before cleaning.
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.
When taking measurements or troubleshooting the generator, take appropriate precautions, such
as using isolated tools and equipment, using the one hand rule, etc.
Potentially lethal AC and DC voltages are present in the AC line circuitry, high voltage DC circuitry,
and associated mounting and heat sink hardware described in this manual. They are not isolated
from the AC line. Take appropriate precautions when testing and troubleshooting this area of the
generator.
High frequency, high voltage signals that can cause severe burns are present in the RF output
stage and in the associated mounting and heat sink hardware described in this manual. Take
appropriate precautions when testing and troubleshooting this area of the generator.
Servicing
Caution
Read all warnings, cautions, and instructions provided with this generator before servicing.
The generator contains electrostatic-sensitive components. When repairing the generator, work at
a static-control workstation. Wear a grounding strap when handling electrostatic-sensitive
components, except when working on an energized generator. Handle circuit boards by their
nonconductive edges. Use an antistatic container for transport of electrostatic-sensitive
components and circuit boards.
Notice
After installing a new low voltage power supply, verify that the voltages are correct.
Calibration
Caution
To avoid inadvertent coupling and/or shunting of RF currents around the resistor elements, keep
the resistors at least 4"(10.2 cm) away from any metal surface including tabletops and other
resistors. This is especially true if several resistors are connected in series or parallel to obtain a
specified value. Do not allow the resistor bodies to touch each other.
Notice
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.

Notice
Do not activate the generator with any load resistor lower than 1000 while calibrating the
voltage sense gain for bipolar output. Otherwise, product damage will result.
voltage sense gain for the Low and Pure cut modes. Do not activate the generator with any load
resistor lower than 2000 while calibrating the voltage sense gain for the Blend mode.
Otherwise, product damage will result.
Do not adjust the current sense gain (I factor), the voltage sense gain (V factor), or the reactance
gain (Z factor) while the generator is activated.
After calibration, the generator will be ready to use only after you initiate the internal self-test by
turning the generator off, then on.
Calibrate the generator after you install a new battery. Calibration values are lost when the
battery is replaced.
Calibrate the generator after you install a new Control board. Otherwise, the default calibration
values are used.
Calibrate the generator after you install a new heat sink or replace components on the heat sink.
Component differences may affect output waveforms.
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.

Chapter 2
Controls, Indicators, and Receptacles
This chapter describes the front and rear panels, including all controls, indicators,
receptacles, the fuse drawer, and ports.

Front Panel
Front Panel
Layout of controls and indicators on the front panel
Recall button
Pressing this button sets the REM alarm indicator
generator to the most recently
CEM
used mode and power settings.
indicator
Bipolar controls Cut controls Coag controls
Bipolar Monopolar 1/CEM Monopolar 2

instrument instrument instrument
receptacle receptacle receptacle
Power switch
This switch supplies power
to the generator. Patient return electrode
receptacle
To turn on the generator, press (|). For monopolar electrosurgery,
connect a patient return
To turn off the generator, press (O).
electrode to this receptacle.

Bipolar Controls
Bipolar Controls
Buttons and indicators for bipolar controls
Bipolar indicator
Bipolar display When you activate bipolar, this
Shows the power setting, indicator illuminates blue and
in watts, for the selected an activation tone sounds.
mode.
Controls, Indicators,
Mode indicators
and Receptacles
Illuminate green when
you press the Power buttons
corresponding mode Press to increase the power.
button. Press to decrease the power.
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.

Bipolar Instrument Receptacle
Bipolar Instrument Receptacle

Caution
Connect accessories to the proper receptacle type. In particular, bipolar accessories
must be connected to the Bipolar Instrument receptacle only. Improper connection
may result in inadvertent generator activation or a REM contact quality monitor
alarm.
You can connect either a footswitching or handswitching bipolar instrument to the

Bipolar instrument receptacle.
Connect a footswitching instrument with a two-pin connector.
or
Connect a handswitching instrument with a three-pin connector.

Monopolar Cut Controls
Monopolar Cut Controls

Buttons and indicators for cut controls (monopolar)
Cut indicator
Cut display When you activate cut, this
Shows the power indicator illuminates yellow and
setting, in watts, for the an activation tone sounds.
selected mode.
and Receptacles
Mode indicators
Illuminate green when Power buttons
you press the Press to increase the power.
corresponding mode
button. Press to decrease the power.
Low mode button

Select for a cut with little
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.

Monopolar Coag Controls
Monopolar Coag Controls

Buttons and indicators for coag controls (monopolar)
Coag display Coag indicator
Shows the power When you activate coag, this
setting, in watts, for indicator illuminates blue and
the selected mode. an activation tone sounds.
Mode indicators
Illuminate green when
you press the
corresponding mode Power buttons
button. Press to increase the power.
Press to decrease the power.
Spray mode button

Desiccate mode button Select to evenly coagulate a wide
Select to desiccate the area area of tissue with a spray of
of tissue that is in direct sparks; penetration is shallower
contact with the active and tissue area is larger than in
electrode. fulgurate mode.
Fulgurate mode button

Select to fulgurate an area of tissue with a
spray of sparks.
This unit is equipped with an additional
fulgurate mode which incorporates a lower
crest factor (LCF) than the factory default
fulgurate mode. For details about this
additional fulgurate mode, LCF Fulgurate,
refer to Chapter 4, Before Surgery, in the
Force FX Electrosurgical Generator C Users
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.

Monopolar Instrument Receptacles
Monopolar Instrument Receptacles

Warning
You can connect a footswitching or handswitching monopolar instrument to the

monopolar receptacles. Some footswitching instruments may require a single-pin adapter
(E0502 Series or E0017), available from Covidien.
Connect one monopolar instrument to the Monopolar 1/CEM Instrument receptacle:
and Receptacles
A single-pin footswitching instrument or a three-pin handswitching instrument
or
A four-pin CUSA handpiece with CEM nosecone. (The CEM indicator in the upper
right of the front panel illuminates green.) 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.

REM Alarm Indicator
REM Alarm Indicator

This indicator illuminates red until you properly apply a REM PolyhesiveTM Patient Return
Electrode to the patient and connect it to the generator. Then the indicator illuminates
green. (When you connect an electrode without the REM safety feature, the indicator
does not illuminate.)
If the REM system senses an alarm condition, the indicator flashes red until you correct
the alarm conditionthen the indicator illuminates green. (If you are using a return
electrode without the REM safety feature, the red indicator light is extinguished when
you correct the alarm condition.)
Rear Panel
Controls and receptacles on the rear panel
Power entry module

Volume control
Option panel
Monopolar Bipolar
Equipotential grounding lug
Footswitch Footswitch
Use to connect the generator to
receptacles receptacle
earth ground.

Footswitch Receptacles
Footswitch Receptacles
The rear panel contains three footswitch receptacles: two for monopolar and one for
bipolar.
Monopolar 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.
and Receptacles
Use of an incompatible footswitch may cause unexpected output.
Connect a two-pedal Valleylab monopolar footswitch to the Monopolar 1 Footswitch
receptacle.
1
The connected footswitch activates monopolar output for the instrument that is
connected to the Monopolar 1/CEM Instrument receptacle on the front panel.
Connect a two-pedal monopolar footswitch to the Monopolar 2 Footswitch receptacle.
2
The connected footswitch activates monopolar output for the instrument that is
connected to the Monopolar 2 Instrument receptacle on the front panel.
Bipolar Footswitch Receptacle

You must connect a bipolar footswitch if you connect a bipolar footswitching instrument
to the generator.
Connect a single-pedal bipolar footswitch to the Bipolar Footswitch receptacle.
The connected footswitch activates bipolar output for the instrument that is connected
to the Bipolar Instrument receptacle on the front panel.

Power Entry Module
Power Entry Module

The power entry module consists of a power cord receptacle and a fuse drawer.
Components in the power entry module
Fuse drawer
The fuse drawer contains two fuses. Refer
to Fuse Replacement on page 7-13 for
instructions on changing the fuses.
Power cord receptacle
Activation Tone Volume Control

Turn to adjust the volume of the tones that sound when the generator is activated
(activation tone). 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.

Option Panel
Option Panel
A removable plate on the rear panel covers a serial port, an expansion port, and a radio
frequency (RF) activation port. Remove this plate to obtain information through the RS-
232 port or to install a peripheral device such as a Bipolar Current Monitor, but retain the
original cover plate. After obtaining information or removing a peripheral device, reinstall
the original cover plate.
Caution
To avoid product damage, do not operate the Force FX Electrosurgical Generator C without an
appropriate cover plate in place.
and Receptacles
To review the technical specifications for each port, refer to page 3-5 and page 3-6.
The three ports behind the option panel
Expansion port
Allows a connected device to receive
information about the RF voltage and
current being generated as well as signal
the generator to halt RF output.
Serial port
Allows connection of a computer to the
RF Activation port
generator. You can obtain information
Allows a connected device to
about the generator using RS-232
receive information during RF
communications protocol or change the
activation of the generator,
default coag mode from Fulgurate to
which will then generate a
Desiccate or Spray. Refer to Using the RS-
response in the device.
232 Serial Port on page 5-42, for
instructions.

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.

Performance Characteristics
General
Output configuration Isolated output
Cooling Natural convection; side and rear panel vents; fan
Display Eight digital seven-segment displays: 0.75" (1.9 cm)

each
Mounting Universal cart (UC8009), CUSA EXcel System, a

Valleylab Argon Gas Delivery Unit II, or any stable flat
surface
Dimensions and Weight
Width 14" (35.6 cm)
Depth 18" (45.7 cm)
Height 4 3/8" (11.1 cm)
Weight <18 lb (< 8.2 kg)
Operating Parameters
Ambient temperature 50 to 104 F (10 to 40 C)

range
Relative humidity 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.

Transport and Storage
Ambient temperature -40 to 158 F (-40 to 70 C)

range
Relative humidity 25% to 85%, noncondensing
Atmospheric pressure 500 to 1060 millibars
Duration of storage If stored longer than one year, the battery must be
replaced (Refer to Battery Replacement on page 7-3)
and a full checkout, including calibration, must be
completed before use. For instructions, refer to
Chapter 5, Setup, Tests, and Adjustment.
Duty Cycle
Under maximum power settings and rated load conditions (Pure cut, 300 watt setting,
300 load) the generator is suitable for activation times of 10 seconds on, 30 seconds
off for one hour.
If the internal temperature of the generator is too high, an alarm tone sounds and a
number (451) flashes in the Cut display alternately with the power settings. You can
activate the generator and change the power settings while this condition exists.
Internal Memory
Nonvolatile, battery- Battery type: 3 V lithium button cell

backed RAM
Battery life: 5 years
Storage capacity One configuration, including three power settings

and three mode settings
The last 20 error codes detected by the generator
The number of times and length of activation for
each mode
The average power setting used for each mode
The total time the generator is on
Other service-related information.

Audio Volume
The audio levels stated below are for activation tones (bipolar, cut, and coag) and alarm
tones (REM and system alarms) at a distance of one meter. Alarm tones meet the
requirements for IEC 60601-2-2.
Activation Tone
Volume (adjustable) 45 to 65 dBA
Frequency Bipolar: 940 Hz

Cut: 660 Hz
Coag: 940 Hz
Duration Continuous while the generator is activated
Alarm Tone
Volume (not 65 dBA

adjustable)
Frequency 660 Hz
Duration 250 to 500 ms
REM Contact Quality Monitor

REM current is measured according to IEC 60601-1, Ed. 1988, Figure 15.
Measurement 80 kHz 10 kHz

frequency
Measurement current < 10 A
Acceptable Resistance Range

REM resistance measurements are 10% during RF activation and 5% when RF output
is not activated.
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 .

If the measured resistance is outside the acceptable range(s) noted above, a REM fault
condition occurs.
REM Alarm Activation

REM Polyhesive Patient Return Electrode: When the measured resistance exceeds the
standard range of safe resistance (below 5 or above 135 ) or when the initial
measured contact resistance increases by 40% (whichever is less), the REM Alarm
indicator flashes red, a tone sounds twice, and RF output is disabled. The indicator
remains illuminated red until you correct the condition causing the alarm. Then, the
indicator illuminates green and RF output is enabled.
Patient return electrode without the REM safety feature: When the measured
resistance between the patient return electrode pins exceeds 20 , the REM Alarm
indicator flashes red, a tone sounds twice, and RF output is disabled. The indicator
remains illuminated red until you correct the condition causing the alarm. Then, the red
indicator is extinguished and RF output is enabled.
Serial Port
RS-232 compatible; 9600 baud, 8 data bits, 1 stop bit, no parity
9-pin connector Pin 2isolated transmit

supports the (serial data output transmit line)
following signals
Pin 3isolated receive
(serial data input receive line)
Pin 5isolated ground
(reference for transmit and receive).
RF Activation Port
The RF activation port is a subminiature telephone jack attached to the contacts of a
small relay. 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.

Expansion Port
15-pin connector; Pin 2isolated transmit

supports the (serial data output transmit line)
following signals
Pin 3isolated receive
(serial data input receive line)
Pin 5isolated ground
(reference for transmit and receive)
Pin 9RF disable: input signal which, when activated
by an external device, disables active RF output
Pin 10RF current: output signal proportional to
active RF current
Pin 11RF voltage: output signal proportional to
active RF voltage.
Expansion power + 5 V (pin 6),-12 V (pin 14), + 12 V (pin 15), and

(from the low voltage ground (pins 12 & 13)
power supply)
Low Frequency (5060 Hz) Leakage Current
Enclosure source < 300 A

current, ground open
Source current, Normal polarity, intact ground: < 10 A

patient leads, all
Normal polarity, ground open: < 50 A
outputs
Reverse polarity, ground open: < 50 A
Sink current at high < 50 A

line, all inputs
High Frequency (RF) Leakage Current
Bipolar RF leakage < 59.2 mA rms

current
Monopolar RF leakage < 150 mArms

current
(additional tolerance)
CEM output modes < 150 mArms at 50 W

Input Power
100120 Volt 220240 Volt
Maximum VA at nominal line Voltage: Maximum VA at nominal line Voltage:

Idle: 52 VA Idle: 52 VA
Bipolar: 450 VA Bipolar: 450 VA
Cut: 924 VA Cut: 924 VA
Coag: 530 VA Coag: 530 VA
Input mains voltage, full regulation Input mains voltage, full regulation
range: 104132 Vac range: 208264 Vac
Input mains voltage, operating range: Input mains voltage, operating range:
85132 Vac 170264 Vac
Mains current (maximum): Mains current (maximum):

Idle: 0.4 A Idle: 0.2 A
Bipolar: 2.0 A Bipolar: 1.0 A
Cut: 7.0 A Cut: 3.5 A
Coag: 4.0 A Coag: 2.0 A
Mains line frequency range (nominal): Mains line frequency range (nominal):
50 to 60 Hz 50 to 60 Hz
Fuses (2): F8 A Fuses (2): T4 A
Power cord: 3-prong hospital grade Power cord: 3-prong locally approved
connector connector
Power Cord Specification

This unit was equipped from the factory with either a 110VAC hospital grade NEMA 5-15
power cord or a 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:

Standards and IEC Classifications
100-120 VAC
Cable - SJT16/3, IEC color code, maximum length 15 (5 m)
Plug - minimum 10 A 125 VAC
Unit receptacle - IEC female, minimum 10 A - 125 VAC
220-240 VAC
Cable - H05VVF3G1.0 VDE, maximum length 15 (5 meters)
Plug - minimum 6 A - 250 VAC
Unit receptacle - IEC female, minimum 6 A - 250 VAC

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.
The generator output is floating (isolated) with respect to

F ground.
DANGER
Explosion risk if used with flammable anesthetics.
To reduce the risk of electric shock, do not remove the

cover. Refer servicing to qualified service personnel.
Non-Ionizing Radiation
Classified with respect to electrical shock, fire, and

mechanical hazards only in accordance with UL60601-1
and CAN/CSA C22.2 No. 601.1.

Class I Equipment (IEC 60601-1)

Accessible conductive parts cannot become live in the event of a basic insulation failure
because of the way in which they are connected to the protective earth conductor.
Type CF Equipment (IEC 60601-1)/Defibrillator Proof

The Force FX Electrosurgical Generator C provides a high
degree of protection against electric shock, particularly
regarding allowable leakage currents.It is type CF isolated
(floating) output and may be used for procedures involving
the heart.
The Force FX Electrosurgical Generator C patient return
electrode terminal is protected from defibrillator discharge
according to ANSI/AAMI HF18 and IEC 60601-2-2.
Liquid Spillage (IEC 60601-2-2 Clause 44.3)

The Force FX Electrosurgical Generator C enclosure is constructed so that liquid spillage in
normal use des not wet electrical insulation or other components which when wetted are
likely to adversely affect the safety of the equipment.
Electromagnetic Interference
When placed on or beneath an activated Valleylab electrosurgical generator, the Force FX
Electrosurgical Generator C operates without interference. The generator minimizes
electromagnetic interference to video equipment used in the operating room.
Electromagnetic Compatibility (IEC 60601-1-2 and

IEC 60601-2-2)
The Force FX Electrosurgical Generator C complies with the appropriate IEC 60601-1-2
and 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.

Notice
The Force FX Electrosurgical Generator C intentionally applies RF energy for diagnosis or
treatment during activation. Observe other electronic medical equipment in the vicinity during the
Force FX Electrosurgical Generator C activation for any possible adverse electromagnetic effects.
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.
Voltage Transients (Emergency Generator Mains Transfer)

The Force FX Electrosurgical Generator C operates in a safe manner when the transfer is
made between line AC and an emergency generator voltage source.
Guidance and manufacturer's declaration - electromagnetic emissions
The Force FX Electrosurgical Generator C is intended for use in the electromagnetic environment
specified below. The customer or the user of the Force FX Electrosurgical Generator C should
ensure that it is used in such an environment.
Emissions test Compliance Electromagnetic

environment - guidance
RF emissions Group 1 The Force FX Electrosurgical

CISPR 11 Generator C uses RF energy
only for its internal function.
Therefore, its RF emissions are
very low and are not likely to
cause any interference in
nearby electronic equipment.
RF emissions Class B The Force FX Electrosurgical

CISPR 11 Generator C is suitable for use
in all establishments other
Harmonic emissions Class A than domestic and those
IEC 61000-3-2 directly connected to the
public low-voltage power
Voltage fluctuations/ flicker Complies supply network that supplies
emissions IEC61000-3-3 buildings used for domestic
purposes.

Guidance and manufacturer's declaration - electromagnetic immunity
Immunity test IEC 60601 test Compliance Electromagnetic environment -

level level guidance
Electrostatic +/-6 kV contact +/-6 kV contact Floors should be wood, concrete

discharge (ESD) or ceramic tile. If floors are covered
+/-8 kV air +/-8 kV air
IEC 61000-4-2 with synthetic material, the relative
humidity should be at least 30%.
Electrical fast +/-2 kV for +/-2 kV for Mains power quality should be
transient/burst power supply power supply that of a typical commercial or
IEC 61000-4-4 lines lines hospital environment.
+/-1 kV for +/-1 kV for
input/output input/output
lines lines
Surge +/-1 kV +/-1 kV Mains power quality should be

IEC 61000-4-5 differential differential that of a typical commercial or
mode mode hospital environment.
+/-2 kV +/-2 kV
common mode common mode
Voltage dips, <5% Ut <5% Ut Mains power quality should be

short (>95% dip in (>95% dip in that of a typical commercial or
interruptions and Ut) for 0,5 cycle Ut) for 0,5 cycle hospital environment. If the user of
voltage variations the Force FX Electrosurgical
40% Ut 40% Ut
on power supply Generator C requires continued
(>60% dip in (>60% dip in
input lines operation during power mains
Ut) for 5 cycles Ut) for 5 cycles
IEC 61000-4-11 interruptions, it is recommended
70% Ut 70% Ut that the Force FX Electrosurgical
(>30% dip in (>30% dip in Generator C be powered from an
Ut) for 25 cycles Ut) for 25 cycles uninterruptible power supply or a
battery.
<5% Ut <5% Ut
(>95% dip in (>95% dip in
Ut) for 5 sec Ut) for 5 sec
Power frequency 3 A/m 3 A/m Power frequency magnetic fields

(50/60 Hz) should be at levels characteristic of
magnetic field a typical location in a typical
IEC 61000-4-8 commercial or hospital
environment.
NOTE: Ut is the a.c. mains voltage prior to the application of the test level.

Guidance and manufacturer's declaration - electromagnetic immunity
Immunity IEC 60601 Compliance Electromagnetic environment - guidance

test test level level
Portable and mobile RF communications

equipment should be used no closer to any
part of the Force FX Electrosurgical
Generator C, including cables, than the
recommended separation distance
calculated from the equation applicable to
the frequency of the transmitter.
Recommended separation distance
Conducted RF 3 Vrms 7V d=0.5P

IEC 61000-4-6 150KHz to d=0.5P 80MHz to 800MHz
80MHz d=P 800MHz to 2.5GHz
Radiated RF 7 V/m
IEC 61000-4-3 3 V/m Where P is the maximum output power
80MHz to rating of the transmitter in watts (W)
2.5GHz according to the transmitter manufacturer
and d is the recommended separation
distance in meters (m).
Field strengths from fixed RF transmitters, as
determined by an electromagnetic site
survey, should be less than the compliance
level in each frequency range.
Interference may occur in the vicinity of
equipment marked with the following
symbol:
NOTE 1 At a 80MHz and 800MHz, the higher frequency range applies.

NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is
affected by absorption and reflection from structures, objects and people.
a. Field strengths from fixed transmitters, such as base stations for radio (cellular/cordless)
telephones and land mobile radios, amateur radio, AM and FM radio broadcast and TV
broadcast cannot be predicted theoretically with accuracy. To assess the electromagnetic
environment due to fixed 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. If abnormal performance is observed, additional
measures may be necessary, such as reorienting or relocating the Force FX Electrosurgical
Generator C.
b. Over the frequency range 150kHz to 80MHz, field strengths should be less than 7V/m.

Recommended separation distances between portable and mobile RF communication

equipment and the Force FX Electrosurgical Generator C
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
minimum distance between portable and mobile RF communications equipment (transmitters)
and the Force FX Electrosurgical Generator C as recommended below, according to the
maximum output power of the communications equipment.
Separation distance according to frequency of transmitter (m)

Rated maximum
150 kHz to 80MHz 80MHz to 800MHz 800MHz to 2.5GHz
output power of
d=0.5P d=0.5P d=P
transmitter (W)
0.01 0.05 m 0.05 m 0.1 m
0.1 0.16 m 0.16 m 0.32 m
1 0.5 m 0.5 m 1m
10 1.6 m 1.6 m 3.2 m
100 5m 5m 10 m
For transmitters rated at a maximum output power not listed above, the recommended
separation distance d in meters (m) can be estimated using the equation applicable to the
frequency of the transmitter, where P is the maximum output power rating of the transmitter in
watts (W) according to the transmitter manufacturer.
NOTE 1 At a 80MHz and 800MHz, the separation distance for the higher frequency range
applies.
NOTE 2 These guidelines may not apply in all situations. Electromagnetic propagation is
affected by absorption and reflection from structures, objects and people.

Output Characteristics
Maximum Output for Bipolar and Monopolar Modes

Power readouts agree with actual power into rated load to within 15% or 5 W,
whichever is greater.
Open Circuit P-P Rated Load Power Crest

Mode Voltage (max) (max) (max) Factor+
Bipolar
Precise 450 V 100 70 W 1.5
Standard 320 V 100 70 W 1.5
Macro 750 V 100 70 W 1.5
Monopolar Cut
Low
1350 V 300 300 W 1.5
Pure
2300 V 300 300 W 1.5
Blend
3300 V 300 200 W 2.5
Monopolar
Coag
Desiccate 3500 V 500 120 W 5.0
Fulgurate 8500 V 500 120 W 7.0
LCF Fulgurate 6900 V 500 120 W 5.5
Spray 9000 V 500 120 W 8.0
* 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 waveforms ability to coagulate bleeders without a cutting effect

Maximum Output for Ultrasonic Electrosurgery
Open Circuit P-P Rated Load Power (max) Crest Factor+

Mode Voltage (max) (max)
Monopolar Cut
Low 1000 V 300 100 W 1.5
Monopolar Coag
Desiccate 3500 V 500 70 W 5.0
+
An indication of a waveforms ability to coagulate bleeders without a cutting effect
Available Power Settings in Watts
Bipolar and Macrobipolar
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
45 50 55 60 65 70
Monopolar Cut: Low and Pure
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
45 50 55 60 65 70 75 80 85 90
95 100 110 120 130 140 150 160 170 180
190 200 210 220 230 240 250 260 270 280
290 300

Monopolar Cut: Blend
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
45 50 55 60 65 70 75 80 85 90
95 100 110 120 130 140 150 160 170 180
190 200
Monopolar Coag
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
45 50 55 60 65 70 75 80 85 90
95 100 110 120
CEM Cut
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
45 50 55 60 65 70 75 80 85 90
95 100
CEM Coag
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
45 50 55 60 65 70

Output Waveforms
Instant Response technology, an automatic adjustment, controls all bipolar modes and all
cut modes. It does not control the coag modes because of their fulguration capabilities.
For more information, refer to Chapter 4, Instant Response Technology and Instant
Response Algorithm.
Bipolar
Precise 470 kHz sinusoid
Standard 470 kHz sinusoid
Macro 470 kHz sinusoid
Monopolar Cut
Low 390 kHz sinusoid. Similar to the Pure cut mode except
the maximum voltage is limited to a lower value.
Pure 390 kHz sinusoid
Blend 390 kHz bursts of sinusoid, recurring at 27 kHz

intervals. 50% duty cycle.
Monopolar Coag
Desiccate 240 kHz sinusoid repeated at 39 kHz. 8% duty cycle
Fulgurate 470 kHz damped sinusoidal bursts with a repetition

frequency of 30 kHz into 500
LCF Fulgurate 470 kHz damped sinusoidal bursts with a repetition

frequency of 57 kHz into 500
Spray 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.

Output Power vs. Resistance Graphs

The graphs that follow depict the changes for each mode at specific power settings.
Note: These curves represent the lower and upper limits of output power with tolerance
included. The normal output power will be halfway between these two curves.
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

Output Power (watts)
Load Resistance (ohms)

Output power vs. impedance for Precise bipolar 70W mode

Open circuit peak voltage vs. output power for Precise bipolar mode
Open Circuit Peak Voltage (volts)

Output power vs. generator settings Precise bipolar mode
Generator Setting

Standard Bipolar Mode

Output power vs. impedance for Standard bipolar 35W mode
Output power vs. impedance for Standard bipolar 70W mode
Note: In the Bipolar Standard mode only, the power curve will reflect both High and Low
output values between the impedance range of 475-600 ohms. This is based on the
sensed impedance value the generator calculates, and the tolerances of the sensing
circuits. 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

(475-600 ohms impedance) level. Clinically, above 475 ohms the tissue is almost
completely desiccated. By dropping to lower output power levels, we allow the surgeon
sufficient time to deactivate the output before tissue sticking occurs.
Open circuit peak voltage vs. output power for Standard bipolar mode
Open circuit peak voltage vs. output power for Standard bipolar mode
Generator Setting

Macrobipolar Mode
Output power vs. impedance for Macrobipolar 35W mode
Output power vs. impedance for Macrobipolar 70W mode

Open circuit peak voltage vs. output power for Macrobipolar mode
Output power vs. generator settings Macrobipolar mode

Generator Setting

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

Output power vs. impedance for Low cut 300W mode
Open circuit peak voltage vs. output power for Low cut mode

Output power vs. generator settings Low cut mode

Generator Setting

Pure Cut Mode

Output power vs. impedance for Pure cut 150W mode
Output power vs. impedance for Pure cut 300W mode


Open circuit peak voltage vs. output power for Pure cut mode
Output power vs. generator settings Pure cut mode
Generator Setting

Blend Cut Mode

Output power vs. impedance for Blend cut 100W mode

Output power vs. impedance for Blend cut 200W mode
Open circuit peak voltage vs. output power for Blend cut mode

Output power vs. generator settings Blend cut mode

Generator Setting

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

Output power vs. impedance for Desiccate coag 120W mode
Open circuit peak voltage vs. output power for Desiccate coag mode

Output power vs. generator settings Desiccate coag mode

Generator Setting

Fulgurate Coag Mode

Output power vs. impedance Fulgurate coag 60W mode
Output power vs. impedance Fulgurate coag 120W mode


Output power vs. peak voltage Fulgurate coag mode
Output power vs. generator settings Fulgurate coag mode
Generator Setting

LCF Fulgurate Coag Mode

Output power vs. impedance LCF Fulgurate coag 60W mode
Output power vs. impedance LCF Fulgurate coag 120W mode


Output power vs. peak voltage LCF Fulgurate mode

Output power vs. generator settings LCF Fulgurate mode
Generator Setting

Spray Coag Mode

Output power vs. impedance Spray coag 60W mode
Output power vs. impedance Spray coag 120W mode


Output power vs. peak voltage Spray coag mode

Output power vs. generator settings Spray coag mode
Generator Setting

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.
This chapter includes the following information:
A block diagram that illustrates how the generator functions

A general description of how the generator works
Detailed descriptions of the circuitry for each printed circuit board

Block Diagram
Block Diagram
A diagram of generator interconnections

Functional Overview
Functional Overview
The Force FX Electrosurgical Generator C is specifically designed to cut and coagulate
(desiccate and fulgurate) tissue during bipolar or monopolar electrosurgery.
During electrosurgery, radio frequency (RF) current flows from the generator to an active
electrode, which delivers the current to the patient. The resistance to the current,
provided by the patients tissue and/or the air between the active electrode and the
tissue, produces the heat that is necessary for the surgical effect. The RF current flows
from the active electrode, through the patients body tissue to the return electrode,
which recovers the current and returns it to the generator.
Instant Response Technology

The Force FXFX Electrosurgical Generator C automatically senses resistance and adjusts
the output voltage to maintain a consistent tissue effect across different tissue density.
This adjustment is based on the selected mode (bipolar or cut modes only), the power
setting, and the level of tissue resistance. For details, refer to Instant Response Algorithm
on page 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.
The maximum power setting for monopolar cut is 100 W.
The maximum power setting for monopolar coag is 70 W.
When you activate the handpiece for cut or coag output, the Low cut mode or the
Desiccate coag mode is in effect automatically. The remaining cut modes and coag
modes are not available.
For more information, refer to CEM Mechanism Switch on page 4-13 and CEM Switch
Circuit on page 4-15.
Simultaneous Coag
When you simultaneously activate two monopolar instruments for coag output, each
receives a percentage of the coag power setting set for the selected mode. The amount
of power each instrument receives depends on the tissue resistance sensed by the
generator at each surgical site. Generally, the site with lower resistance receives
proportionately more power. The combined total output power does not exceed the
coag power setting.

Functional Overview
You can also use a CUSA handpiece with a CEM nosecone for simultaneous coag when
you connect a monopolar instrument to the Monopolar 2 Instrument receptacle. Only
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. The REM system is designed to eliminate the risk of burns at the return
electrode site during monopolar electrosurgery.
When you connect a REM Polyhesive Patient Return Electrode to the Patient Return
Electrode receptacle, you activate the REM system. When you activate monopolar
output, the FX Electrosurgical Generator C connects the patient return electrode path. If
you activate bipolar output while a return electrode is connected to the patient, the
return electrode circuit is deactivated automatically to eliminate the possibility of current
dispersal.
The REM system continuously measures resistance at the return electrode site and
compares it to a standard range of safe resistance (between 5 and 135 ), thus
eliminating intermittent false alarms that could result from small changes in resistance.
The REM system also adapts to individual patients by measuring the initial contact
resistance (baseline resistance) between the patient and the patient return electrode. If
the tissue impedance at the return electrode decreases during electrosurgery, the REM
system resets the baseline resistance.
REM Alarm Activation

The REM Alarm indicator flashes red, a tone sounds, and the generator stops producing
output power when either of the following occurs:
The measured resistance is below 5 or above 135 , the limits of the standard
range of safe resistance.
An increase in contact resistance is greater than 40% from the initial measurement
(baseline resistance).
The REM Alarm indicator remains illuminated red until you correct the condition causing
the alarm. Then, the indicator illuminates green and RF output is enabled.
Electrodes Without the REM Safety Feature

When you use a patient return electrode that does not have the REM safety feature, the
REM system does not monitor the patient contact area. The REM system can monitor
only the pin-to-pin resistance at the connector and can detect broken wires or connectors
in the return electrode cord.

Functional Overview
The REM Alarm indicator does not illuminate green when you connect a non-REM
patient return electrode. Instead, the indicator light is extinguished. If the generator
detects a break in continuity between the electrode and the generator, the indicator
illuminates red.
When resistance between the Patient Return Electrode receptacle pins exceeds 20 , the
REM Alarm indicator flashes red, a tone sounds twice, and RF output is disabled. The
indicator remains illuminated red until you correct the condition causing the alarm. Then,
the red indicator light is extinguished and RF output is enabled.
For additional information, refer to REM Circuit on page 4-28.

Control Board
Control Board
Refer to Chapter 9, Service Parts, for components and the Schematics Supplement for
board drawings and schematics.
The Control board contains the circuitry that controls the generator, including the
indicators and switches on the Display board and the RF output stage on the Power
Supply/RF board. Firmware on the Control board performs many diagnostic and
initialization routines. Errors are reported as alarm numbers on the front panel.
The Control board interfaces with the Power Supply/RF board through a 96-pin card edge
connector. It interfaces with the Display board through a 64-pin ribbon cable.
Microcontrollers
Two microcontrollers on the Control board control the generator. These microprocessors
communicate with each other through a shared RAM. The main microcontroller (U5)
performs all system functions, except the time-critical real time feedback control of
generator RF output. The feedback microcontroller (U11), which is a separate, dedicated
microcontroller, handles the time-critical real time feedback control of generator RF
output. All system analog signals are available to these microcontrollers.
A third microcontroller (U9) functions as an application-specific integrated circuit, or
ASIC. It generates the RF drive waveforms (T_ON\) for the RF output stage.
Main Microcontroller
The main microcontroller (U5) is an 80C562 that incorporates an 8-input multiplexed
8-bit A/D converter. The main microcontroller is responsible for overall system control. It
monitors all dosage error functions and safety circuits. It implements the user interface,
including activation control. It is primarily responsible for these functions:
Segment display drivers and LED update
Power control buttons, mode buttons, and the activation interface
Serial port interface
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.

Control Board
Main Microcontroller Memory

An ST microelectronics PSD835G2 programmable systems device (U3) provides program
memory (512K x 8 external flash memory) and data memory (2K x 8 external battery-
backed static RAM) for the main 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 feedback microcontroller
Battery-Backed RAM
A socket on the Control board contains a 3.0 V lithium button cell battery (BT1) that
provides backup power for the 2K x 8 external RAM on the PSD835G2 device (U3) used
by the main microcontroller. The battery-backed RAM stores calibration constants, last
setup parameters, and temporary data.
Feedback Microcontroller
The feedback microcontroller (U11), like the main microcontroller, is an 80C562. It
receives commands from the main microcontroller and, when the generator is activated,
establishes the appropriate relay closures and activates RF output. It continually adjusts
the output signal of the generator by controlling the high voltage DC power supply and
the RF clock circuitry. It is primarily responsible for these functions:
Scaling relay control and output relay control
T_ON ASIC waveform control
Leakage control (coag)
Constant voltage, current, and power feedback control
ECON initialization
Real-time information update (actual voltage, current, power, impedance, effect
mode)
Memory tests
Communicating with the main microcontroller
Feedback Microcontroller Memory

An ST microelectronics PSD835G2 programmable systems device (U6) provides program
memory (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.

Control Board
Shared RAM
The 4K x 8 external shared static RAM is provided by an IDT 713425A device (U4) with
semaphore flags. The shared RAM allows the main microcontroller (U5) and the feedback
microcontroller (U11) to share common variables. It functions as a communications
interface between the main and feedback microcontrollers. It also provides additional
general purpose RAM to these microcontrollers.
I/0 Expansion
Three devices provide I/O expansion capabilities:
One ST microelectronics PSD835G2 programmable systems device
One ST microelectronics PSD835G2 programmable systems device
One 82C55 expansion port (U2).
The ST Microelectronics PSD835G2 incorporates 52 individually programmable I/O pins
divided into 6 ports of 8-bits each and 1 port of 4-bits. Of the general I/O pins, 24 can be
alternatively utilized for 24 PLD outputs.
The PSD835G2 also contains 512K x 8 main flash memory, 32K x 8 boot flash memory,
2K x 8 of SRAM, and a power management unit for battery backup. The power
management unit for battery backup is not used by the feedback microcontroller. The I/O
expansion capabilities of the feedback PSD835G2 has a built-in IEEE 1149.1 compliant
JTAG serial port to allow full-chip in-system programmability (ISP).
The main PSD835G2 is #1 on the JTAG chain and the feedback PSD835G2 with the
exception that the 512K x 8 flash memory for the main PSD835G2 is accessed in a bank
switching methodology and the I/O expansion capabilities are configured as outputs for
lamp control, keyboard scanning, and chip selects.
The 82C55 is configured as all inputs, and is used to read the keyboard, keying signals,
accessory switches, and system status flags.
Keyboard Interface and Activation Inputs

The keyboard interface is a simple row and column matrix between three bank select
output lines (BANK0BANK2) on port A of the PSD835G2 (U3) used by the main
microcontroller and eight keyboard (KBD_D0KBD_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.

Control Board
Power Supply Supervisor Circuit

The power supply supervisor circuit (U14), a MAX691, generates a Reset signal and a
Reset\ signal for the main microcontroller (U5) if the power supply voltage to the Control
board drops below 4.65 V. It also generates a voltage sensitive chip select for the
PSD835G2 (U6) and the PSD835G2 (U3). The low voltage threshold (4.65 V) places U3
and U6 in sleep mode and disables the 2K x 8 external static RAM.
A/D and D/A Conversion

Each 80C562 microcontroller (U5 and U11) contains an 8-channel multiplexed 8-bit A/D
converter. Resolution of voltage and current sense inputs is enhanced by incorporating
gain scaling relays in the sense circuits on the Power Supply/RF board and prescaling
based on the expected input voltage or current values.
An MP7226 quad D/A converter (U15) provides 4-channel 8-bit D/A capabilities for the
feedback microcontroller to output 0 to 5 Vdc analog voltages.
Waveform Generation (T_ON ASIC)

A dedicated 89C54 microcontroller (U9) generates the RF drive waveforms (T_ON\) for
the RF output amplifier on the Power Supply/RF board. The microcontroller functions as
an application-specific integrated circuit, or ASIC, performing an endless series of
repetitive tasks while enabled.
The feedback microcontroller (U11) holds the T_ON ASIC (U9) in a reset state until the
feedback microcontroller detects a valid activation request. After validating the request,
the feedback microcontroller releases the T_ON ASIC from reset and communicates a
4-bit code that represents the generator mode to be activated. The acceptable activation
codes are listed below:
0: Precise bipolar
1: Standard and Macro bipolar
2: Low and Pure Cut
3: Blend cut
7: Desiccate coag
8: LCF Fulgurate coag

9: Spray coag
11: Spark-controlled Blend
12: Fulgurate coag
Codes 4, 5, 6, 10 and AF are unused.

Control Board
Each code generates a unique waveform pattern to be delivered to the RF output stage
of the generator. The T_ON ASIC reads and evaluates the code and, if the code value is
acceptable, repetitively generates the appropriate waveform until the activation request
ends. After the request ends, the feedback microcontroller places the T_ON ASIC back
into reset.
If the code received by the T_ON ASIC is not valid, the internal program sets an error flag,
deactivates all output signals, and remains in an error state until the system is reset.
T_ON Average Check

The T_ON waveform generator output waveform is integrated in hardware and returned
to the main microcontroller as an analog value called T_ON average. The T_ON average is
different for each distinct output mode of the T_ON waveform generator. The main
microcontroller continually checks the T_ON average for compliance with the calibrated
value to ensure that the T_ON waveform generator is operating properly.
The T_ON average signal rests at 5 V when the generator is not activated and drops to
the calibrated value when activation occurs. The main microcontroller checks to make
sure the T_ON average signal is within 15 counts of the calibrated value.
During wak control in the coag modes, the T_ON average rises an indeterminate amount.
Due to this unknown, the T_ON average is allowed to rise to 253 counts, which
guarantees the T_ON waveform generator is still operating. The T_ON average is still not
allowed to drop below the lower limit of 15 counts mentioned above.
Audio Alarm
The audio alarm circuit is located on the Footswitch board. The audio alarm is controlled
by software and hardware.
Software control is provided by the UP_TONE\ (microcontroller tone) and LO_TONE
signals generated by the main microcontroller in response to activation inputs, alarms,
and at power-up. These signals connect from the Control board to the Power Supply/
RF board through the 96-pin connector and then from the Power Supply/RF board to
the Footswitch board through the 16-pin footswitch ribbon connector.
Hardware control is provided by the RF_TONE\ signal generated in the RF output
stage by RF sensing circuitry on the Power Supply/RF board.
Serial Interface
The RS-232 serial port is a software-polled interface to the main microcontroller (U5). It is
used for diagnostics and calibration. Transmission and receipt of command strings do not
stop real time processing, except as single characters are read from or written to the serial
port. 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.

Control Board
The Control board serial port signals connect to the Power Supply/RF board through the
96-pin connector. The signals are then connected to the 9-pin serial port connector on
the Power Supply/RF board.
Dosage Error Algorithm
Dosage Error Algorithm for Closed-Loop Modes

The dosage error algorithm for the closed-loop modes (bipolar and cut) is based on a
comparison between the actual power as calculated by the main microcontroller (U5)
using the backup sensors and the maximum allowed power.
While the feedback microcontroller is operating the generator output, the main
microcontroller calculates and checks the values to make sure the feedback
microcontroller is operating the generator properly.
In a closed loop mode, there is a 500 ms delay before the dosage error algorithm
monitors the RMS output of the generator. After the delay, the algorithm first checks to
see that the voltage, current, and power calculated by the backup sensors are less than
125% of the value calculated by the primary sensors.
On passing this test, the feedback mode of the generator is taken into account.
In current control mode, the current calculated by the backup sensors is not allowed
to deviate from the current calculated by the primary sensors by more than 50% of
the value calculated by the primary sensors.
In voltage control mode, the voltage calculated by the backup sensors is not allowed
to deviate from the voltage calculated by the primary sensors by more than 50% of
the value calculated by the primary sensors.
During closed loop activation, the main microcontroller continually checks for broken
backup sensors. The current and voltage sensor analog values are compared to the
previous readings to ensure that the sensor values are not constant or falling while ECON
is rising.
When the generator drops into spark control, the software makes allowances for the
shift in frequency. The voltage sensor returns a value that is approximately 2025% high,
and the rms value calculated for the voltage sensor is reduced by 25%. The current
sensor returns a value that is approximately 1015% low, and the rms value calculated
for the current sensor is increased by 12.5%.
The dosage error algorithm for the open loop modes (coag) is based on the ECON
calculated for the mode. The main microcontroller calculates an ECON that represents
125% of the front panel power setting and verifies that SYS_ECON and HV_SEN do not
exceed this value while the generator is activated.
These tests detect stuck or aberrant sensors and improperly delivered power in all modes.
The dosage error firmware executes in less than one second.

Control Board
Instant Response Algorithm

This mode is a closed loop control algorithm implemented in microcontroller firmware. It
is applied to the bipolar modes and the cut modes. It is not applied to the coag modes.
As tissue impedance increases from short circuit to open circuit, the algorithm
implements first constant current, then constant power, and finally, constant voltage. The
maximum output voltage is controlled to reduce capacitive coupling, reduce video
interference, and eliminate sparking. At low impedances, constant current protects
output circuitry. At high impedances, constant voltage control limits arcing and
electromagnetic interference.
Constant current: output voltage is held at constant output current according to
I = (P/R) (1/2)
where I is the output current, P is the power set by the user, and R is the constant current
to constant power impedance switchpoint.
Constant power: the power set by the user is maintained.
Constant voltage: the output voltage is maintained according to
V = (P*R) (1/2)
where V is the output voltage, P is the power set by the user, and R is the constant power
to constant voltage impedance switchpoint.
High Impedance Operation

The firmware algorithm clamps the output voltage to specific levels for high impedance
conditions. The clamp level is a function of the mode that is activated. This helps prevent
arcing and electromagnetic interference.
Analog to Digital Saturation

Analog to digital saturation works in conjunction with RF leakage current limiting. If the
analog to digital converter is saturated, the effect mode feedback loop reduces the
output voltage to allow for an unsaturated operating condition. The feedback loop
switches the control function to maintaining the analog to digital converter in the linear
operating range.

Front Panel
Front Panel
The front panel consists of an injection molded plastic bezel with a membrane keyboard,
power switch, CEM mechanism switch, and REM connector with switch. These front
panel components interface with the Display board and the Power Supply/RF board.
Membrane Keyboard
The membrane keyboard is attached to the bezel with a high strength adhesive. It is not
removable. The membrane contains 16 metal dome push-button switches. Six of these
switches control the up and down sequencing of the power seven-segment LEDs (light-
emitting diodes). One switch controls the previous settings Recall function and nine
switches control each of the nine output modes of the generator.
The membrane also contains nine LEDs, one for each mode. A 25-pin flat ribbon cable
connects the membrane keyboard switches and LEDs to the Display board.
Power Switch
A double pole single throw switch snaps into the front of the bezel. This switch supplies
the AC mains current to the generator.
REM Connector/Switch
An internal REM connector and sense switch connects to the inside of the bezel with two
screws. Two cables leave this assembly. One cable is the actual REM connector; the other
cable is the output of the internal switch that senses the presence or absence of the
center pin on the REM plug.
CEM Mechanism Switch

A small plastic lever arm mechanism is attached to the inner wall of the front panel bezel
on the 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.

Display Board
Display Board
The Display board is located in the front panel assembly. It contains RF indicator lamps,
seven-segment LED power setting displays, REM alarm LEDs, and a CEM indicator LED.
The Display board switch circuitry includes the LED and lamp driver circuitry, power
selection switches, mode selection switches, the REM switch circuit, and the CEM switch
circuit.
RF Indicator Lamps
The RF indicator lamps illuminate during RF activation to visually indicate the presence of
RF power. Each of the three indicator bars (Bipolar, Cut, and Coag) on the front panel is
illuminated by four incandescent bulbs (LP1LP12).
LP1LP4 illuminate the blue Bipolar bar, indicating bipolar activation.
LP5LP8 illuminate the yellow Cut bar, indicating cut activation.
LP9LP12 illuminate the blue Coag bar, indicating coag activation.
The RF indicator lamps are controlled by the BIP_LMP, CUT_LMP, and COAG_LMP signals.
These signals originate from port A of the main microcontroller programmable peripheral
(U3) on the Control board.
Buffers in U1 turn the RF indicator lamps on and off. Resistors R1R12 set the amount of
current flowing through the lamps when they are turned on. The value of these resistors
varies for each indicator bar, depending on the color of the bar, to make the different
colors of the bars illuminate with equal intensities.
REM Indicators
The REM indicator consists of two bicolor LED arrays incorporating one red and four
green LEDs per array. The LEDs are controlled by the REM_RED and REM_GREEN signals
originating from port A of the main microcontroller programmable peripheral (U3) on the
Control board. The signals are buffered on the Display board by driver U1. Both the red
and green LEDs are current limited by 100 resistors (R13, R14, R15, and R16).
LED and Seven-Segment Display Drivers

This circuit contains three display drivers for the LEDs and the seven-segment displays.
The LEDs indicate modes of operation, and the REM condition. The seven-segment
displays indicate bipolar, cut, and coag power settings.

Display Board
Each display driver (U6, U10, and U14) can drive up to eight banks of eight LEDs by
multiplexing the time that each bank is turned on. The banks can be wired together to
increase the time that a group of LEDs is on, effectively increasing the brightness of that
group.
U10 drives the discrete LEDs and the CEM LED. These include green indicators for the
bipolar modes (Precise, Standard, and Macro), the cut modes (Low, Pure, and Blend), and
the coag modes (Desiccate, Fulgurate, and Spray). The anode of the mode selection LEDs
are tied to driver U10. By using pairs of the driver digit lines, the duty ratio for these LEDs
is effectively 1/4.
U6 drives the seven-segment displays that indicate power settings. U4 and U5 indicate
the bipolar power setting, U7U9 indicate the cut power setting, and U11U13 indicate
the coag power setting. The anodes of these displays are each tied to only one digit line
of the driver. The effective duty cycle is 1/8 for each seven-segment display.
Some filtering components are associated with U6, U10, and U14. Bypass capacitors C3,
C4, C7, C8, C9, and C10 are connected between + 5V and DGND. C3, C4, and C10
have a relatively small capacitance value of 0.1 F to filter higher frequency noise. C7,
C8, and C9 have a relatively large capacitance value of 47 F to supply the large spikes of
current for the LEDs generated by the multiplexing action of the drivers, which typically
occurs at 250 Hz.
Resistor array R18 reduces the input impedance of the display driver inputs as seen by the
main microcontroller on the Control board. This rounds off the edges of these digital
signals, reducing high frequency emissions. The lowered impedance also reduces the
susceptibility of the circuit to noise from other circuits.
CEM Switch Circuit

When you plug a CUSA handpiece with a CEM nosecone into the Monopolar 1/CEM
Instrument receptacle, the small nonconductive pin in the plug pushes a spring-loaded
plastic lever arm mounted inside the front panel. This lever arm activates a small switch
that plugs into the Display board. The switch signal tells the microcontroller to limit the
power.
Mode Selection and Power Control Switches

The mode selection and power control switches are arranged in a matrix. The main
microcontroller selects a bank of switches to read by asserting a bank select signal

(BANK0, BANK1, or BANK2) through port A of programmable peripheral U3 on the
Control board. These signals are buffered by Q1, Q2, and Q3 respectively and become
the switch drive signals COM0, COM1, and COM2.
When COM0 is selected, the power control switches may be read.
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.

Display Board
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.

Footswitch Board
Footswitch Board
The Footswitch board is mounted inside the rear panel. It contains circuitry accepting and
decoding footswitch keying inputs and an audio circuit for announcing generator keying
and various alarm tones. The Footswitch board interfaces with the Power Supply/RF
board.
Footswitch Decode Circuit

Two monopolar footswitch connectors and a bipolar footswitch connector are mounted
on the Footswitch board and extend through the rear panel. The monopolar footswitch
connectors (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. Capacitors C39C46 provide filtering
that blocks high frequency noise from exiting the generator on the footswitch cables.
As required by the IEC, the footswitch circuit is isolated from patient connected and
ground referenced circuits and is able to withstand a potential of 500 Vrms (50/60 Hz). To
obtain this isolation, the footswitch connected circuitry is powered from an isolated
power supply (U2). The isolated power supply, an HPR-107, operates from the ground
referenced +12 V power supply and supplies an isolated 12 V.
Resistors R18 and R19 form a voltage divider that yields a signal (Vref2) of approximately
6 V. This reference voltage is applied to the noninverting inputs of comparators U3A,
U3B, U4A, U4B, and U5A.
The common terminal of each footswitch is connected to the +12 V isolated power
source. Footswitch activation causes this voltage to be applied to a resistor divider. The
values of the resistors comprising the input divider are selected to provide a switching
threshold of approximately 750 .
The divided voltage is then applied to the inverting input of one of the five comparators.
When the voltage at the inverting input exceeds the voltage at the noninverting input,
the open collector output of the comparator turns on, causing current to flow in the LED
of the corresponding optoisolator. This current generates an IR beam that causes the
associated photo-transistor to conduct. The collectors of the transistors are connected to
input pins of an I/O port on the microcontroller where they activate the desired mode of
operation.

Footswitch Board
Audio Circuit
The audio system consists of an audio oscillator, tone control signals, a volume control
potentiometer, an audio amplifier, and a speaker. A reference voltage (Vref) is used
throughout the audio circuit and is generated by dividing the +12 V power supply down
to about 2 V by R9 and R8.
The audio circuit annunciates the presence of RF output and provides an auditory
indication of alarm conditions. A potentiometer adjusts the volume of RF output
activation tones. The speaker volume cannot be turned off entirely. The volume of the
tone issued during alarm conditions is not adjustable.
The audio oscillator is enabled when UP_TONE\ or RF_TONE\ is pulled low. Diodes D1 and
D2 provide a wired OR function for the two signals. Because UP_TONE\ and RF_TONE\
are +5 V (logic level) signals, resistors R4 and R6 divide the +12 V audio power supply
down to about 4.85 V to prevent D1 and D2 from sourcing current into the output pin of
U3 on the Control board.
When either UP_TONE\ or RF_TONE\ is enabled low, the voltage at the noninverting input
of U1B is pulled below the Vref threshold present at U1B inverting input, the open
collector output of U1B is turned on, grounding R31 and allowing U6A to oscillate.
U6A is a relaxation oscillator whose frequencies are determined by the RC time constants
of R30, C35, and C18. This design allows the oscillator to produce two distinct
frequencies that can be selected by the state of the LO_TONE signal.
When LO_TONE is not asserted, R30 and C35 determine the frequency of operation
of the oscillator (approximately 900 Hz).
When LO_TONE is asserted (+5 V), the voltage at the noninverting input of U1A
exceeds the 2 V Vref signal at the inverting input, turning on its output transistor. This
effectively connects C18 in parallel with C35 to produce a higher RC time constant
for the oscillator, which results in a lower audio frequency of approximately 700 Hz.
The ALARM signal selects the user-controlled audio volume or the fixed alarm level
volume. U1C and U1D are configured in an exclusive OR arrangement in which the state
of the output transistors of U1C or U1D is complementary. In other words, the output
transistor of one of these two devices is always on, but both cannot be on
simultaneously.
Under normal operating conditions, the ALARM signal is low, allowing the U1C output to
float while the U1D output transistor is turned on. The output of U1D creates a voltage
divider through R11, R12 (the volume control potentiometer), and R32 to attenuate the
audio signal to levels acceptable for input to the audio amplifier.
R32 determines the maximum audio volume and R11 determines the minimum audio
volume. R10 determines the audio alert volume level. R34 provides an alternate audio
signal path in the event of an open volume control potentiometer.
When the ALARM signal is high, the U1C output transistor is turned on while the output
of 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.

Footswitch Board
Meanwhile, the output of U1D is allowed to float, thus removing the variable resistor
divider from the circuit. In this case, the volume control potentiometer becomes a small
resistance in series with the high impedance input from the audio amplifier, negating the
effect of the volume setting.
Audio amplifier U7 and speaker SP1 comprise the final stage in the audio system. The
audio signal is AC coupled to the amplifier by C25 to eliminate the need for well-
controlled input biasing. 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.

Power Supply/RF Board

board drawing and schematics.
The Power Supply/RF board is the main board of the generator. It contains the high
voltage power supply and the RF output stage. Circuitry on this board performs several
other functions:
Output voltage monitoring
Output current monitoring
Leakage current sensing (RF leakage sensing and reduction circuits)
Spark control circuit
REM impedance monitoring (REM circuit)
Handswitch closure detection (IsoBloc circuit)
RS-232 connector
Expansion connector
EKG contact closure connector
Output high voltage relays
Temperature monitoring and fan control
Power Supply/RF Board Interfaces

The Power Supply/RF board interfaces to other boards and components as follows:
AC input line filter
Control board
Footswitch board
Heat sink components (RF damping resistor, RF MOSFET, and high voltage power
supply MOSFETs)
Single-wire attachment points for connecting the sense transformers
Low voltage power supply (AC input and DC output)
Low noise fan
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.

High Voltage Power Supply

Warning
Potentially lethal AC and DC voltages are present in the AC line circuitry, high voltage DC circuitry,
and associated mounting and heat sink hardware described in this manual. They are not isolated
from the AC line. Take appropriate precautions when testing and troubleshooting this area of the
generator.
The high voltage power supply section contains the power entry circuitry, auto mains
switching circuitry, AC/DC conversion circuitry, and a DC/DC switching regulator.
Power Entry Circuit

The power entry circuit consists of an integral three wire power cord receptacle, fuse
drawer, EMI filter, and a separate power switch. The power switch is mounted on the
front panel. The receptacle/filter is mounted on the rear panel of the generator. AC line
fuses are changeable from the rear of the generator.
Auto Mains Switching Circuitry

The auto mains switching circuit detects the AC line voltage level and controls the triac
(D1). This triac controls the topology of the AC/DC converter.
For 120 Vac operation, the triac is on, which connects the AC neutral to the center of the
AC/DC converter capacitor bank (C3, C10, C11, and C22). In this configuration, the
circuit acts as a doubler using the right hand half of the bridge rectifier (CR80).
For 240 Vac operation the triac is off and CR80 is used as a full wave rectifier.
The control IC (U1) functions as follows: The series circuit (CR1, R1, R2, and C9) provides
power for U1. Pin 1 (Vss) is a shunt regulator that provides a -9 V (nominal) output.
The divider (R3 and R4) measures the input line voltage. Because the voltage at pin 8
varies with the line, it can sense the line voltage zero crossing as well as the peak voltage.
Pins 2 and 3 are inputs to an oscillator used for triac triggering timing. R7 and C1 set the
oscillator frequency.
Pin 7 is tied to Vss, which places the circuit in the fail-safe mode. Thus, once the circuit
enters full bridge mode, it remains in that mode until input power is recycled. A power
dropout cannot cause the circuit to accidentally act as a doubler when the higher input
voltage range is used.
AC/DC Converter
The AC/DC converter uses CR80 as either a doubler or full wave rectifier, depending on
the input voltage. 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.

Capacitors C3, C10, C11, and C22 are an energy storage reservoir for the DC/DC
switcher. C29 is a high frequency bypass filter. Bleeder resistors R5 and R6 discharge the
capacitors when the AC line is disconnected or the power switch is turned off.
DC/DC Switching Regulator

The DC/DC switching regulator is a buck derived, pulse width modulated (PWM)
transformer. It is an isolated, fixed frequency, full bridge converter. The PWM IC (U5) is
used in the voltage mode. The output of the regulator is adjustable from approximately
zero (0) to 180 Vdc.
The full bridge consists of four power MOSFETs (Q1, Q3, Q4, and Q5) that operate at AC
line potential. Transistors Q3 and Q5 are on while Q1 and Q4 are off, and the reverse. In
this manner, power signals to the power transformer are bidirectional, or push-pull.
This allows full utilization of the transformer core magnetization capability. Regulation is
achieved by modulating the time that each MOSFET pair is on. Capacitor C32 in series
with the power transformer T3 primary prevents DC flux imbalance.
A snubber circuit (C27 and R31) absorbs leakage energy spikes. Another snubber circuit
(C49 and R51) reduces spikes due to reverse recovery of the output bridge rectifier.
The gate driver circuitry for each MOSFET is transformer-coupled through T1 to provide
AC line isolation. It consists of a dual MOSFET driver (U3) and various damping resistors.
Resistors R12, R18, R21, and R26 minimize turn-off oscillations. Resistors R22 and R23
damp ringing due to parasitic inductances in T1. Blocking capacitors C24 and C25
prevent DC flux imbalance in T1.
Note: T1 consists of two transformers electrically and magnetically isolated from each
other but assembled into the same package. T1A and T1B form one transformer; T1C
and T1D form the other.
The output of the power transformer is full wave rectified by a high voltage diode bridge
(CR10, CR13, CR19, and CR23). L1, C33, and C35 filter the rectified power signal. The
regulated DC output from this supply is the input to the RF stage of the generator.
The SYS_ECON signal from the microcontroller controls the output voltage level. This 0 to
5 Vdc signal sets the reference for the PWM control loop.
An external op-amp (U7B) is used for gain and integration, because common mode
voltage limitations in U5s internal op-amp preclude its use over the full range of 0 to 5 V.
The internal op-amp is connected as a follower.
SYS_ECON is compared to the feedback voltage from the output divider (R34, R35, and
R49), and an error signal (ECON) is sent to the PWM microcontroller. In addition to the
error signal, U7B and the associated R-C networks provide lead-lag loop compensation to
increase the bandwidth of the regulator beyond that of the output 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.

The output of U5 is a pair of 180 out-of-phase signals that are pulse width modulated
by comparing ECON with the internal oscillator ramp waveform. At the start of an
oscillator cycle, an output is turned on. It turns off when the ramp voltage crosses the
ECON level. The two output signals from U5 (pins 11 and 14) feed the MOSFET drivers
(U3A and U3B).
R36 and C42 set the U5 oscillator frequency to approximately 170 kHz. C45 controls the
ramp-up of the pulse width at power on for slow start control. Transformer T2 limits the
power transformer primary current, protecting against faults in the DC/DC switcher
power stage and faults in circuitry downstream of the switcher.
The output of T2 is rectified (CR3CR6), filtered (R30 and C30), and fed to the current
limit pin (pin 9 of U5). During an overcurrent condition the U5 current limit function
resets the slow start circuit, resulting in the output cycling from on to off until the current
falls.
Pin 9 of U5 is also used for remote shut down of the DC/DC switcher through U6A and
CR8. The shut down signal comes from the main microcontroller on the Control board.
The resistor divider on the high voltage DC output formed by R52 and R53 is used for
dosage error sensing.
Low Voltage Power Supply

The low voltage power supply is rated for 40 W. It delivers a regulated +5 Vdc and
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:
PIN Voltage Test Point
1 +5 Vdc TP8
2 -12 Vdc TP5
3 +12 Vdc TP6
4 GROUND TP9

The low voltage power supply specifications are as follows:
Output Voltage Output Current Output Power*
+5 Vdc 4000 mA 20.0 W
-12 Vdc 400 mA 4.8 W
+12 Vdc 2000 mA 24.0 W
*Total output power cannot exceed 40 W.
RF Output Stage
Warning
High frequency, high voltage signals that can cause severe burns are present in the RF output
stage and in the associated mounting and heat sink hardware described in this manual. Take
appropriate precautions when testing and troubleshooting this area of the generator.
The RF stage consists of a single MOSFET power switch with associated gate drive
circuitry, an RF power transformer, tuning capacitors, an RF output L-C-C filter, output
directing relays, and topology selecting relays. Also included in this section are the RF
voltage and current sense circuits and a switched damping network for certain
operational modes.
The MOSFET gets its gating signal from the T_ON ASIC on the Control board. The T_ON
ASIC also provides the gating signal for the switched damping network.
When the topology selecting relays (K2 and K14) are unenergized, the RF stage is in the
Fulgurate and Spray coag modes; when both are energized, the RF stage is in the cut and
bipolar modes. For the Desiccate coag mode, K2 is unenergized and K14 is energized.
Primary Sense Circuits

The primary voltage and current sense circuits provide feedback information to the
feedback microcontroller in the bipolar and cut modes.
For voltage sensing, the two 10 k resistors (R148 and R149) in series with the primary
of T13 work with the 100 resistor across the secondary to divide the output voltage
down.
Depending on the front panel power setting, one of the four relays (K3 to K6) is switched
in to give optimum scaling. The four AD827 high speed op-amps, along with the
associated resistors, capacitors, and diodes, form a precision full wave rectifier circuit.
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.

The actual rectification is done with U8A and U8B. The rectified waveform is converted to
DC by the R-C filter after the last op-amp, with full scale being 5 Vdc.
The current sense circuit, which uses current transformers T6 and T8, works the same as
the voltage sense circuit. T6 senses bipolar current and T8 senses monopolar current.
Relay K7 selects the appropriate current. Note that the current scaling relays (K8 to K11)
switch at different power settings than the voltage scaling relays.
Redundant Sense Circuits

Redundant voltage and current sense circuits provide dosage error monitoring.
T16 monitors the current through the output capacitors (C150, C152, and C158). This
current is proportional to the output voltage of the generator. A full bridge rectifier is
formed by CR25CR28. The rectifier output is filtered by R118 and C96. Op-amp U18
buffers the DC signal. R119 and C97 provide additional filtering.
T17 and the associated circuitry operate the same as the redundant voltage sense circuit.
The output is a signal proportional to the output current of the generator.
Cut Modes
In the cut modes, K2 is set so that diode CR2 is in parallel with the MOSFET body drain
diode, C34 and C41 are across the MOSFET, and the transformer primary consists of
windings 1-2 and 3-4 in series. K14 is closed so the series capacitor bank (C150C152,
C158, and C159) is across the output.
In the Low and Pure cut modes, the T_ON\ signal is a continuous pulse train with a pulse
width of 846 ns and a frequency of 390 kHz. In this case, essentially two resonant circuits
operate in tandem.
The output L-C filter is tuned just slightly higher than the RF switching frequency,
achieving a high degree of filtering. The output is very sinusoidal over the full range of
load impedances.
Capacitors C34 and C41 are tuned with the RF transformer primary so that the flyback
voltage appearing across the MOSFET at turn off is a half sine pulse and returns to zero
volts before the next cycle begins. The T_ON\ pulse width is chosen to support this
tuning. This zero voltage switching improves the efficiency of the RF stage and is effective
over a wide range of load impedances.
The circuit topology of the Blend cut mode is the same as the Pure cut mode. In Blend mode,
however, the T_ON\ signal is an interrupted pulse train with a 50% duty cycle and a pulse
train repetition rate of 27 kHz.

For a given power setting, Blend gives a higher peak current, providing better hemostasis
than 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.

Bipolar Modes
The circuit topology for the bipolar modes is essentially the same as the cut modes,
except the output voltage is tapped off C152 and the switching frequency is 470 kHz.
These differences allow for the higher currents and lower voltages required in bipolar
surgery while still maintaining the advantages of zero voltage switching in the MOSFET.
The T_ON\ signal is a continuous pulse train with a 423 ns pulse width.
Coag Modes
In the Fulgurate and Spray coag modes, K2 is set so that diode CR2 blocks reverse current
in the power MOSFET, C40 as well as C34 and C41 are across the MOSFET, and the
transformer primary consists of winding 1-2 only. K14 is open, keeping the series
capacitor bank (C150C152, C158, and C159) out of the circuit.
In the LCF Fulgurate coag mode, the T_ON\ signal is a continuous pulse train with a pulse
width of 1.69 s and a repetition frequency of 57 kHz. When the MOSFET turns on,
some energy is delivered to the output and some is stored in the T4 core. When the
MOSFET is turned off, the energy stored in the core rings out with a frequency of
591 kHz.
The frequency is set by C34, C40, C41, and the inductance of winding 1-2 of T4. CR2
blocks reverse current in the body drain diode of the MOSFET so that the power
waveform can ring negative. This allows high peak voltages to be achieved at the output.
In most cases, all the energy stored in the transformer core during one switching cycle is
delivered to the load before the next cycle begins. The Fulgurate mode works the same
as the LCF Fulgurate mode, except the T_ON\ signal is a continuous pulse train with a
pulse width of 1.69 s and a repetition frequency of 30 kHz.
The Spray mode works essentially the same as the Fulgurate mode, except the T_ON\
pulse frequency is randomized over the range of 21.6 kHz to 35.23 kHz. In addition,
amplifier U7A randomly varies the output amplitude by 10%. The ECONGAIN signal
from the Control board changes the gain of U7A between 1 and 1.1.
To minimize ringing on the output voltage waveform at light loads, transistor Q7
switches in the 50 watt, 150 heat sink mounted resistor in series with the transformer
primary for part of the RF switching cycle.
In the Desiccate coag mode, K2 is closed and K14 is open. The T_ON\ signal is a
continuous pulse train with a pulse width of 2 s and a frequency of 39 kHz. The output
resonates with a frequency of 308 kHz.
Output Relays
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.

In bipolar mode, the Patient Return Electrode receptacle relay is open. Relays K12 and
K17 route bipolar current to the Bipolar Instrument receptacle.
All output relays are open when the generator is not being activated.
Spark Control Circuit

The spark control uses the voltage sense circuit to monitor the output voltage. It
interrupts the delivery of power if the output voltage exceeds a preset threshold. This
greatly reduces sparking when an activated accessory is removed from tissue.
Sparking occurs because the RF stage tuning results in a higher natural gain at light loads
than at heavy loads. Thus, during sudden transitions from heavy to light loads, the output
voltage rises faster than the microcontroller can respond. This analog circuit works
outside the microcontroller loop at a much greater speed.
The rectified but unfiltered waveform from the output voltage sense circuit is fed into a
peak detector (U23A, CR29, and C104). A high impedance buffer (U23B) maintains the
integrity of the peak detected signal. The output of this buffer is divided and fed to a
comparator.
The other input to the comparator is an analog threshold level (VMAX_CLP) that is set by
the main microcontroller on the Control board and depends on the mode and power
setting.
When the peak detected sample of the output voltage exceeds the threshold, one-shot
U14A is fired and generates a 3 ms pulse (SPARK_CON) that is sent to the T_ON ASIC on
the Control board. This pulse is ignored if it occurs during the first 0.2 seconds of
activation. Otherwise, SPARK_CON causes the T_ON\ signal to stop.
The feedback microcontroller on the Control board senses this and realizes that a spark
has been suppressed. The feedback microcontroller waits 100 ms in Pure cut, then re-
initiates T_ON\ with a frequency of 470 kHz. The frequency returns to 394 kHz after
1 second of continuous activation or when the generator is reactivated.
RF Leakage Reduction Circuit
Fulgurate and Spray Coag Modes

For the Fulgurate and Spray coag modes, the high voltage RF output pulse repetition
period varies with changes in spark and patient tissue impedance to limit the RF leakage
current to a desired level.
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.

The averaged signal (now called VPK+) is input to the feedback microcontroller on the
Control board and added to the ECON value at the selected power setting. The sum of
these signals, with the proper gain factors, varies linearly with load impedance at the
patient site.
This sum is input into a pulse width modulator that sends its output (WAK\) to a NAND
gate. Thus, the T_ON\ signal is inhibited for up to four consecutive cycles. Without the
leakage control, the pulse repetition period is 17 s. With the leakage control fully
activated, the total pulse train repeats every 84 s with a maximum dead time of 60% or
51 s.
REM Circuit
Components U17 along with R95, R96, R97, and C79 form a precision oscillator. R96 is
adjusted for the frequency that will produce maximum voltage amplitude (80 10 kHz)
at the REM connector (J17). R98 is a temperature compensating thermocouple that
cancels temperature drift from the components forming the oscillator.
The REM transformer (T10) provides isolated reflected impedance sensing for tissue
impedance across the REM patient return electrode terminals (connected to J17, pins 1
and 2). In addition to tuning the REM circuit, capacitors C155, C156, C169, and C170
provide a return path for high frequency RF signals through C157 to the RF output
transformer. The REM transformer (T10) and capacitors C155, C156, C169, and C170
form a resonant circuit with a nominal operating frequency of 80 kHz.
Pin 1 of T10 clocks the active synchronous rectifier formed by CMOS switch U28A. This
device is closed during the positive period of the REM_AC signal and open during the
negative period. When the switch is closed, C122 is charged to the peak positive value of
REM_AC. Then, U31B amplifies, filters and buffers the charge on C122 to produce the
R_SEN signal. The microcontrollers monitor the R_SEN signal (which is a DC voltage
proportional to impedance) to determine the patient return electrode status.
IsoBloc Circuit
The IsoBloc circuit provides a means of detecting a switch closure in an output accessory
while maintaining electrical isolation between the generator output and ground
referenced circuitry.
The IsoBloc circuit consists of an isolated DC power supply, a comparator to detect switch
closure, and an optoisolator link from the output connected circuitry to the ground
referenced low voltage circuitry. Each handswitching output of the generator is
associated with its own IsoBloc power source and isolated signal paths.
Oscillator
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).

Power Supply
The three 4081 buffers (U29) drive three TN2404KL FETs connected to transformers
which are operated in a quasi-resonant flyback mode with their associated 6800 pF
capacitors. The voltages at the secondaries of the three transformers are half-wave
rectified and referenced to three separate isolated grounds to provide -8 V for operating
the isolated activation circuitry.
Optoisolators
The isolated power supply voltages produced by the IsoBloc power supplies are
connected to the active output terminals of the generator. Handswitch activation is
accomplished by sensing active to CUT or active to COAG switch closure in a handheld
accessory.
Switch closure is detected by comparing the voltage across the switch to a divider
reference with comparators U32, U33, and U34. Current limiting resistors, in series with
the LEDs in the optoisolators, cause the LEDs to light. The phototransistor in the
optoisolator detects this light.
The phototransistor, which is connected to an input on the 82C55 expansion port in the
main microcontroller circuit, turns on, pulling the associated input low. This is interpreted
by the software as an activation request, and the generator is activated accordingly.
Temperature Sense Circuits

The Force FX Electrosurgical Generator C features two temperature sense circuits.
The first temperature sense circuit measures the air temperature adjacent to the RF
output FET heat sink. When the temperature at this location reaches approximately
40 C, a cooling fan switches on to minimize heat buildup. The fan switches off when
the temperature drops below approximately 35 C.
The second temperature sense circuit measures the air temperature near the Control
board, which is located in the forward third of the generator enclosure. When this
temperature reaches approximately 50 C, the main microcontroller flashes number 451
alternately with the power settings to indicate that the generator is too hot. Generator
operation reverts to normal when the temperature decreases to below 40 C.
Thermal Sensing (Fan Control)

A reference voltage is applied to the noninverting input of comparator U2A. Resistors

R15 and R16 determine the reference voltage. When the temperature of NTC thermistor
R19 is 40 C, the reference voltage is set to be equal to the voltage at the inverting input
of U2A. Resistor R10 provides positive feedback causing approximately 5 C of hysteresis.

At temperatures below 40 C, the output of U2A is low. When the thermistor exceeds
the threshold, the voltage comparator changes state causing the output at U2A to go
high, turning on FET Q2. This applies 12 V to the cooling fan. When the temperature
drops to 35 C, the circuit reverts to its low temperature state, and the cooling fan
switches off.
Thermal Sensing (High Temperature Limit)

A reference voltage is applied to the non-inverting input of comparator U26A. Resistors
R111 and R110 determine the reference voltage. When the temperature of NTC
thermistor R109 is 50 C, the reference voltage is set to be equal to the voltage at the
inverting input of U26A. Resistor R94 provides positive feedback causing approximately
10 C of hysteresis.
When the thermistor exceeds the threshold, the voltage comparator changes state,
causing the output at U26A to go high. The main microcontroller reads this signal
(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.

Setup, Tests, and Adjustment
Chapter 5
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.

Setting Up the Generator

Warning
Electric Shock Hazard Connect the generator power cord to a properly grounded receptacle.
Do not use power plug adapters.
Fire Hazard Do not use extension cords.
Caution
equipment (except a Valleylab Argon Gas Delivery Unit II or a CUSA EXcel unit). These
configurations are unstable and/or do not allow adequate cooling.
Provide as much distance as possible between the electrosurgical generator and other electronic
equipment (such as monitors). An activated electrosurgical generator may cause interference with
them.
Notice
If required by local codes, connect the generator to the hospital equalization connector with an
equipotential cable.
Connect the power cord to a wall outlet having the correct voltage. Otherwise product damage
may result.
1. Verify the generator is off by pressing the power switch off (O).
2. Place the generator on a stable flat surface, such as a table, platform, or Covidien
cart. Carts with conductive wheels are recommended. For details, refer to the
procedures for your institution or to local codes.
Provide at least four to six inches of space from the sides and top of the generator for
cooling. Normally, the top, sides, and rear panel are warm when the generator is used
continuously for extended periods of time.
Ensure that the generator rests securely on the cart or platform. The underside of the
generator contains four rubber feet and additional holes that allow you to reposition
the feet to ensure stability. Use a Phillips screwdriver to remove the rubber feet from
the generator. Then, reinstall the feet in the preferred location.
3. According to the procedures used by your institution, connect an equipotential
grounding cable to the grounding lug on the rear panel of 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.


6. Turn on the generator by pressing the power switch on (|). Verify the following:
All visual indicators and displays on the front panel illuminate.
Activation tones sound to verify that the speaker is working properly.
Important
If the coag mode has been optionally changed to default to Desiccate or Spray, that
corresponding indicator illuminates after the self-test is performed successfully.
7. If the self-test is successful, a tone sounds. Verify the following:

Indicators above the default mode buttons (Standard bipolar, Pure cut, and
Fulgurate coag) illuminate green.
Each display shows a power setting of one watt.
The REM Alarm indicator illuminates red.
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.

Connections for Bipolar or Macrobipolar Surgery

If you plan to use a footswitching bipolar instrument, you must connect a bipolar
footswitch. You may also use a footswitch to activate a handswitching instrument. Refer
to the figures on this page and page 5-5.
Warning
Electric Shock Hazard
Do not connect wet accessories to the generator.
Ensure that all accessories and adapters are correctly connected and that no metal is exposed.
Caution
Accessories must be connected to the proper receptacle type. In particular, bipolar accessories
must be connected to the Bipolar receptacle only. Improper connection may result in inadvertent
generator activation or a REM contact quality monitor alarm.
Bipolar or macrobipolar connectionsfootswitch activation and a handswitching or

footswitching instrument
Bipolar
footswitch
Footswitching or handswitching
instrument


Bipolar or macrobipolar connectionhandswitching instrument
Handswitching instrument
Setting the Bipolar Output

Caution
1. (Optional) To display the previous settings, press the Recall button.

2. To set the Bipolar mode, press the Precise, Standard, or Macro button. The
corresponding indicator illuminates green.
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.

Connections for Monopolar Surgery

If you plan to use a footswitching monopolar instrument, you must connect a Valleylab
monopolar footswitch. You may also use a footswitch to activate a handswitching
instrument or a CUSA handpiece with CEM nosecone. Refer to the figures on this page
and page 5-7.
Warning
Use only a Valleylab monopolar footswitch with the Force FX Electrosurgical Generator C
generator. Use on an incompatible footswitch may cause unexpected output.
Monopolar connectionfootswitch activation and a footswitching or handswitching

instrument using Monopolar 1 Footswitch receptacle and Monopolar 1/CEM Instrument
receptacle
Footswitching or
handswitching
instrument
Valleylab monopolar
footswitch
Patient return electrode


Monopolar connectionfootswitch activation and a footswitching or handswitching
instrument using Monopolar 2 Footswitch receptacle and Monopolar 2 Instrument
receptacle
Footswitching
or handswitching
instrument
Valleylab monopolar
footswitch
Monopolar connectionhandswitch activation and a monopolar handswitching

instrument using either Monopolar Instrument receptacle
Handswitching
instrument

Selecting Cut and Coag Modes

Caution
1. (Optional) To display the previous settings, press the Recall button.

2. To select a cut mode, press the Low, Pure, or Blend button. The corresponding
indicator illuminates green.
3. To increase the power for the cut mode you selected, press the yellow up arrow ( )
button. To decrease the power, press the yellow down arrow ( ) button. The
maximum power setting for Low and Pure is 300 W. The maximum power setting for
Blend is 200 W.
4. To select a coag mode, press the Low (Desiccate), Med (Fulgurate), or High (Spray)
button. The corresponding indicator illuminates green.
To select the LCF Fulgurate mode, press the Med button and hold for two seconds. A
tone sounds and an L appears on the left side of the Coag display. To return to the
standard Fulgurate mode, press the Med button and hold for two seconds. A tone
sounds and the L disappears from the left side of the Coag display.
5. To increase the power for the selected coag mode, press the blue up arrow ( )
button. To decrease the power, press the blue down arrow ( ) button. The
maximum power setting for each coag mode is 120 W.
In the LCF Fulgurate mode, an L appears on the left side of the Coag display. When
the LCF Fulgurate power setting is above 95 W, the power setting display alternates
between the power setting (for example, 110 W) and L--.
Simultaneous Coag
Connect two monopolar instruments for simultaneous coag. Each receives a percentage
of the overall power setting. The amount of power provided to each instrument depends
on the tissue resistance sensed by the generator at each surgical site. 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.


Connections for simultaneous coagtwo handswitching instruments
Monopolar
instrument or
CUSA
handpiece with
CEM nosecone
Monopolar
instrument
Connection for simultaneous coagtwo footswitching instruments
Monopolar
instrument or
CUSA
handpiece with
CEM nosecone
Valleylab
Patient return electrode monopolar
footswitches
Monopolar
instrument

Using Two Generators Simultaneously

Caution
equipment (except a Valleylab Argon Gas Deliver Unit II or a CUSA EXcel unit). These
configurations are unstable and/or do not allow adequate cooling.
Two generators (and two patient return electrodes) may be used simultaneously on the
same patient, provided the generators are the same type (both are isolated or both are
ground referenced).
However, the two generators are not synchronized. One return electrode frequently
acquires a high positive voltage while the other acquires an opposite negative voltage.
When this occurs, the potential voltage difference between them may cause the current
to flow from one patient return electrode to the other. The current causes no harm if it
produces no sparks or high current densities on the patient.
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.


Connecting the CUSA Handpiece with CEM Nosecone
Warning
Connections for combined monopolar/ultrasonic surgery

If you choose to use a monopolar
footswitch, you must use a only
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

Setting the Output Power

Caution
When you use the CUSA handpiece with CEM nosecone for ultrasonic electrosurgery,
only Low cut or Desiccate coag are available when you activate the handpiece.
To verify or change the Low cut power setting:

To increase the power, press the yellow up arrow ( ) button. To decrease the power,
press the yellow down arrow ( ) button. The maximum cut power is 100 W.
To verify or change the Desiccate coag power setting:

To increase the power, press the blue up arrow ( ) button. To decrease the power,
press the blue down arrow ( ) button. The maximum coag power is 70 W.
Simultaneous Coag with a CUSA System

To use a CUSA handpiece with CEM nosecone for simultaneous coag, connect the
handpiece to the Monopolar 1/CEM Instrument receptacle. Then connect a monopolar
instrument to the Monopolar 2 Instrument receptacle. During simultaneous coag, only
Desiccate coag is available; the maximum power is limited to 70 W.
Changing the Mode

Verify the selected mode with the surgeon. You cannot change the mode while the
generator is activated.
To change the mode, press the desired bipolar, cut, or coag mode button. The indicator
above that button illuminates green. You can activate only one mode at a time.
When you change modes within a function (bipolar, cut, coag), the power setting
remains the same unless it exceeds the maximum for the new mode. In that case, it
reverts to the maximum for the new mode. For example, if you set the power to 250 W
for 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 modes range.


Changing the Power Setting
Verify the power settings for the selected mode with the surgeon. You can change the
power setting when the generator is on, including when it is activated.
To increase the power, press the up arrow () button for the selected mode.
To decrease the power, press the down arrow () button for the selected mode.
When you press and release the power button, the power changes by one setting (1, 5,
or 10 W), based on the settings available for the selected mode. The available power
settings are listed in Chapter 3, Technical Specifications.
To reach the maximum or minimum power setting for the selected mode, press and hold
the up arrow () or down arrow () button. The setting changes slowly at first, then
more rapidly. Release the button when the desired setting is displayed. If you try to set
the power above the maximum setting or below the minimum setting for the selected
mode, a tone sounds.
Activating the Surgical Instrument

Notice
Do not activate the generator until the forceps have made contact with the patient. Product
damage may occur.
To activate a handswitching instrument, use the controls on the instrument or on the

appropriate footswitch. To activate a footswitching instrument, you must use a
footswitch.
To reduce the possibility of alternate site burns that may be caused by RF leakage
currents, avoid unnecessary and prolonged activation of the generator.
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.

Periodic Safety Check
Activation Indicators
Handswitching Footswitching Activation Indicator
Bipolar Close forceps tines Press pedal Activation tone sounds

firmly Bipolar indicator illuminates
blue
Monopolar Press Cut or Coag Press Cut or Coag Activation tone sounds Cut
button or Close pedal indicator illuminates yellow
forceps tines firmly or Coag indicator illuminates
blue
CUSA handpiece Press Cut or Coag Press Cut or Coag Activation tone sounds Cut
with CEM button on CEM pedal indicator illuminates yellow
nosecone nosecone or Coag indicator illuminates
blue CEM indicator on
front panel illuminates green
when handpiece is properly
connected

Important
When testing RF equipment, follow these test procedures to duplicate manufacturer test data.
Keep test leads to the minimum length usable; lead inductance and stray capacitance can
adversely affect readings. Carefully select suitable ground points to avoid ground loop error in
measurements.
The accuracy of most RF instruments is approximately 15% of full scale. Using uncompensated
scope probes causes large errors when measuring high voltage RF waveforms.
Perform the following safety check every six months to verify that the generator is
functioning properly. Record the test results for reference in future tests. If the generator
fails to meet any of the checks, refer to Chapter 6, Troubleshooting.
Warning
Electric Shock Hazard When taking measurements or troubleshooting the generator, take
appropriate precautions, such as using isolated tools and equipment, using the one hand rule,
etc.
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.


Caution
Here is a summary of safety checks:

Inspect the generator and accessories
Inspect the internal components
Test the generator
Verify REM function
Confirm outputs
Check leakage current and ground resistance
Recommended Test Equipment

Digital voltmeterFluke 77 or 87, or equivalent
True RMS voltmeterFluke 8920, or equivalent
OscilloscopeTektronix 2445, or equivalent
Leakage current testerUse UL load device or commercially available leakage tester
Leakage tableper IEC 60601-2-2, Figure 104
100, 200, 300, 500 , all 250 watt, 1% tolerance, noninductive (Dale NH-250 or
equivalent)

Inspecting the Generator and Accessories

Equipment required
Bipolar footswitch or monopolar footswitch
Bipolar instrument cords (handswitching and footswitching)
Monopolar instrument cords (handswitching and footswitching)
Turn off the generator, and disconnect the power cord from the wall receptacle.
Rear Panel
1. Check the rear panel footswitch receptacles for obstructions or damage. Check for a
secure fit by inserting the bipolar footswitch or monopolar footswitch connector into
the appropriate receptacle.
2. Remove the fuse and verify correct voltage and current rating. Refer to Performance
Characteristics on page 3-2.
If either connection is loose, replace the Footswitch board assembly. Refer to Footswitch
Board Replacement on page 7-8.
Front Panel
1. Check the Bipolar Instrument receptacle for obstructions or damage. Insert the bipolar
instrument connector (footswitching and handswitching) into the appropriate
receptacle to verify a secure fit.
If the connection is loose, replace the front panel assembly. Refer to Front Panel
Replacement on page 7-9.
2. Check the monopolar instrument receptacles for obstructions or damage. 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 assembly. Refer to Front
Panel Replacement on page 7-9.
3. Check the Patient Return Electrode receptacle for a broken pin or an obstruction. If
the receptacle is damaged or obstructed, replace the front panel assembly. Refer to
Front Panel Replacement on page 7-9.
Footswitch
1. Disconnect the footswitch from the generator.
2. Disassemble the footswitch connector. Inspect the connector for damage or
corrosion.
3. Reassemble the footswitch connector.


4. Inspect the footswitch for damage.
5. Reconnect the footswitch to the generator.
Power Cord
1. Disconnect the power cord from the unit and ensure that it is unplugged from the
wall receptacle.
2. Inspect the power cord for damage.
3. Reconnect the power cord to the generator and wall receptacle.
Inspecting the Internal Components

Equipment required
Phillips screwdriver
Caution
1. Turn off the generator.

2. Loosen the five screws that secure the cover to the chassis. Lift the cover off the
chassis. Set the cover aside for reinstallation.
3. Verify that all connectors are firmly seated.
4. Inspect each board for damaged components, wires, cracks, and corrosion.
If you find evidence of damage on the Control board, Display board, or Footswitch
board, replace the board. Refer to Control Board Replacement on page 7-4,
Display Board Replacement on page 7-5, or Footswitch Board Replacement on
page 7-8.
If you find evidence of damage on the Power Supply/RF board, replace the board
only if the damage is severe. 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.

Testing the Generator

Turning on the generator initiates an internal self-test to verify the calibration. The self-
test also checks the operation of the speaker, all indicators, and the displays.
Warning
Use the generator only if the self-test has been completed as described. Otherwise, inaccurate
power outputs may result.
Generator Self-test
1. Turn on the generator by pressing the front panel On (|) switch. Verify the following:
All visual indicators and displays on the front panel illuminate.
Activation tones sound to verify that the speaker is working properly.
Important
If the coag mode has been optionally changed to default to Desiccate or Spray, that
corresponding indicator illuminates after the self-test is performed successfully.
2. If the self-test is successful, a tone sounds. Verify the following:

Indicators above the default mode buttons (Standard bipolar, Pure cut, and
Fulgurate coag) illuminate green.
Each display shows a power setting of one watt.
The REM Alarm indicator illuminates red.
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.
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.

Confirming Outputs

Verifying REM Function
Equipment required
REM plug and resistance substitution box.
1. Set the resistance substitution box to 120 . Connect the resistance box to the
generator and confirm that the REM indicator illuminates green.
2. Slowly increase the resistance and verify that the REM alarm sounds at 135 5 .
3. Decrease the resistance to 60 and verify that the REM indicator illuminates green.
4. Increase the resistance to 100 and verify that the REM alarm sounds.
7. Decrease the resistance to 3 and verify that the REM alarm sounds.
8. Switch to a connector without the pin, and increase the resistance from 3 to 24 .
Verify that the REM alarm sounds.
Confirming Outputs
Use this procedure to ensure the accuracy of the generator. Always confirm the output:
After calibrating the generator
Every six months
Equipment required
Two small test cables (less than 24" [61 cm] long) with banana plugs
Current transformer
True RMS voltmeter (such as the Fluke 8920 or equivalent)
100, 300, and 500 1% noninductive power resistors
Bipolar footswitch and monopolar footswitch
Checking the Bipolar Output

1. Verify that the generator successfully completes the self-test as described in
Generator Self-test on page 5-18 in this section.
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.

Confirming Outputs
c. Connect the 100 power resistor across the output jacks at the end of the test
cables.
d. Connect the bipolar footswitch to the Bipolar Footswitch receptacle on the rear
panel.
3. Press the Precise button and set the bipolar power to 10 W.
4. Test the output current for the selected Bipolar mode.
a. Press the footswitch pedal and, while activating the generator, note the output on
the voltmeter.
b. Release the footswitch pedal.
c. Based on the voltmeter setting and the current transformer you are using,
calculate and record the output current.
5. Press the Standard button and repeat step 4 (above).
6. Press the Macro button and repeat step 4 (above).
7. Verify that the generator output for each mode is 315 24 mArms.
If the output is outside the specified range, calibrate the bipolar output as described
in Calibrating the Generator on page 5-26. Then repeat this procedure. If the output
for one or more modes remains outside the specified range, call the Covidien Service
Center.
Checking Output for the Monopolar Cut Modes

1. Verify that the generator successfully completes the self-test as described in
Generator Self-test on page 5-18.
2. Connect the test equipment for monopolar output.
a. Connect one test cable to the left jack in the Monopolar 1/CEM Instrument
receptacle. Pass the test cable through the current transformer and connect the
current transformer to the voltmeter.
b. Use a test cable to short the two pins on the Patient Return Electrode receptacle.
c. Connect the second test cable from the voltmeter to both pins of the Patient
Return Electrode receptacle.
d. Connect the 300 resistor across the output jacks at the end of the test cables.
e. Connect the monopolar footswitch to the Monopolar 1 Footswitch receptacle on
the rear panel of the generator.
3. Press the Pure button.
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.

Confirming Outputs

6. Press the Low cut button and repeat step 5 (above).
7. Press the Blend button and repeat step 5 (above).
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.

Confirming Outputs
Checking Output for the Monopolar Coag Modes

1. Complete steps 1 and 2 of Checking Output for the Monopolar Cut Modes on
page 5-20, replacing 300 resistor with 500 resistor in item 2d.
2. Press the Low (Desiccate) button.
3. Press the Coag up () or down () arrow buttons to set the coag power to 30 W.
4. Test the monopolar coag output.
a. Press the footswitch coag pedal and, while activating the generator, note the
output on the voltmeter.
5. Press the Med (Fulgurate) button and repeat step 4 (above).
6. Press the Med (Fulgurate) button and hold for two seconds. After the tone sounds
and the L appears on the left side of the Coag display, repeat step 4 (above).
7. Press the High (Spray) button and repeat step 4 (above).
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.

Confirming Outputs

Checking Low Frequency Leakage Current and Ground
Resistance
Check the low frequency leakage current and ground resistance before returning the
generator to clinical use.
Equipment required
DVM
Leakage current tester
Leakage current test circuit per IEC 60601-1
Output Receptacles and REM Source Current

1. Set the DVM to AC volts (200 millivolts [mV]) and connect the leakage current test
circuit.
2. Turn on the generator.
3. Measure between all the output receptacles (including the Patient Return Electrode
receptacle) and earth ground. Record the largest reading.
4. Determine the leakage current using the conventional 1 microamp (A) per 1 mV.
5. Verify under normal conditions (ground closed, normal polarity) the leakage current is
less than 10 A. If the leakage current is greater than 10 A, call the Covidien Service
Center.
6. Verify single fault conditions (ground open) the leakage current is less than or equal
to 50 A. If the leakage current is greater than 50 A, call the Covidien Service
Center.

Confirming Outputs
Chassis or Earth Leakage

1. Set the DVM to AC volts (200 mV) and connect the leakage current test circuit.
2. Turn on the generator.
3. Measure between the chassis and earth ground.
4. Determine the leakage current using the conventional 1 A per 1 mV.
5. Verify under normal conditions (ground closed, normal polarity) the leakage current is
less than 100 A. If the leakage current is greater than 100 A, call the Covidien
Service Center.
6. Verify single fault conditions (ground open) the leakage current is less than or equal
to 300 A. If the leakage current is greater than 300 A, call the Covidien Service
Center.
Output Receptacles and REM Sink Current

1. Set the DVM to AC volts (200 mV) and connect the leakage current test circuit.
2. Turn on the generator and connect the end of the leakage current test circuit to
mains voltage through a 120 k resistor.
3. Connect the other side of the IEC leakage load to all of the output receptacles
(including the Patient Return Electrode receptacle).
4. Determine the leakage current using the conventional 1 A per 1 mV.
5. Verify the leakage current is less than or equal to 20 A. If the leakage current is
greater than 20 A, call the Covidien Service Center.
Checking High Frequency Leakage Current

Check the high frequency leakage current and ground resistance before returning the
generator to clinical use. Check the leakage current:
After calibrating the generator
Every six months
Equipment required
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.

Confirming Outputs

Checking Monopolar High Frequency Leakage Current
1. Connect the 200 load from the active accessory through the current transformer to
the equipotential ground lug on the rear of the generator.
2. Connect the current transformer to a true RMS voltmeter.
3. Connect a monopolar footswitch to the Monopolar 1 Footswitch receptacle on the
rear panel.
4. Activate the footswitch in each Monopolar mode at the maximum control setting.
Record the leakage current. If using the leakage table, leakage current should not
exceed 150 mA for any mode.
5. If the high frequency leakage exceeds 150 mA, call the Covidien Service Center for
further instructions.
Checking Bipolar High Frequency Leakage Current

1. Remove the monopolar accessories, and connect the 200 load from one side of the
bipolar output through the current transformer to the equipotential ground lug on
the rear of the generator.
2. Connect the current transformer to the true RMS voltmeter.
3. Connect a bipolar footswitch to the Bipolar Footswitch receptacle on the rear panel.
4. Activate the footswitch in each mode at maximum control setting. Record the
leakage current. 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.

Calibrating the Generator

There are eight calibration steps. During calibration you verify information specific to the
generator, adjust the date, and adjust the clock. You also adjust the REM circuit and
several values, or factors, that ensure the proper operation of the generator.
The calibration steps and the values you can adjust are summarized below. Certain values
are not adjustable but must be verified.
Notice
Calibration Step and Description Adjustable?
1. Generator data
Generator model number No (verify value)
Master microcontroller software version No (verify value)
Feedback microcontroller software version No (verify value)
2. Calendar
Month Yes
Day of the month Yes
Year Yes
3. Clock
Hour Yes
Minute Yes
4. REM oscillator frequency and impedance Yes
5. Current sense gain factor Yes
6. Voltage sense gain factor Yes
7. Reactance gain factor Yes
8. ECON factor Yes


Preparing for Calibration
Equipment required
Two small test cables (less than 24" [61 cm] long) with banana plugs
REM plug (modified)
Resistor substitution box
Oscilloscope
True RMS voltmeter (such as the Fluke 8920A or equivalent)
Current transformer (such as the Pearson Model 411 or equivalent)
Noninductive power resistors (such as a Dale NH-250) with these values (in ): 10,
20, 30, 100, 200, 500, 1000, 1500, 1800, 2000, 2200, and 3000
If these exact values are not available, you may substitute series or parallel
combinations of other values.
Entering Calibration Mode

When you are in calibration mode, the calibration step number appears in the Bipolar
display. The value(s) associated with each calibration step appears in the Cut and Coag
displays. You use the Cut and Coag up () or down () arrow buttons to adjust the
displayed values.
1. If the generator is off, turn it on.
If you removed and/or replaced the battery, alarm number 212 will appear in the Cut
display the first time you turn on the generator. Turn off, then turn on the generator
to clear the number. Then calibrate the generator.
If any other number appears, calibrate the generator before taking the appropriate
action to respond to the number.
2. To enter calibration mode, simultaneously press the Recall, Pure, and Low (Desiccate)
buttons.
The first calibration step number (C1) appears in the Bipolar display. For instructions
on completing this step, refer to the first calibration step, Verifying the Generator
Data on page 5-28.
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

Exiting Calibration Mode

You can exit calibration mode at any time. If you want to save the new values for a
particular calibration step, press the Bipolar up arrow () button at the end of that step
before exiting calibration mode. Calibration values are saved one step at a time.
For example, if you only want to adjust the clock, first enter calibration mode and press
the Bipolar up arrow () button until the generator displays calibration step 3 (C3). Next,
change the hour and/or minute values. Then press the Bipolar up arrow () button. This
saves the changes for calibration step 3 (C3) and displays the next calibration step (C4).
After saving the changes, turn off the generator to exit calibration mode.
If you do not want to save the changes you make for a particular calibration step, turn off
the generator [do not press the Bipolar up arrow () button at the end of the step]. The
values that were in effect before you started that step remain in effect.
Notice
After calibration, the generator will be ready to use only after you initiate the internal self-test by
turning the generator off, then on.
To save the changes for the present calibration step, press the bipolar up arrow () button
to display the next calibration step number. Then, turn off the generator to exit
calibration mode.
or
To exit calibration mode without saving the changes for the present calibration step, turn
off the generator.
Verifying the Generator Data

In calibration step 1 (C1), you verify the generator model number and the software
version numbers for the main and feedback microcontrollers. 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.
The software version number for the feedback microcontroller may vary among
manufacturing lots, but should never be 0.
If one or more of the values that appear as you complete this calibration step are not
correct, call the Covidien Service Center.
1. In the Bipolar display, verify that the calibration step number is C1.
2. In the Cut display, verify that the generator model number is 4.
3. In the Coag display, verify that the main microcontroller version number is a value
other than 0.


4. To display the feedback microcontroller version number, press the Med (Fulgurate)
button. Verify that the version number in the Coag display is a value other than 0.
5. To proceed to the next calibration step, press the Bipolar up arrow () button.
At the end of each calibration step, press the Bipolar up arrow () button to advance
to the next step. If you need to return to a previous calibration step, press the Bipolar
down arrow () button.
The Bipolar up arrow () button cycles through the calibration steps. For example,
when you reach step C10 and press the Bipolar up arrow () button, the generator
returns to step C1.
Next, check the month, day, and year values as described in Adjust the Calendar.
Adjusting the Calendar

The month, day of the month, and year values are stored in the real-time clock on the
Control board.
1. Verify that the Bipolar display shows calibration step number C2.
2. To select the month, press the Coag up () or down () arrow buttons until the
correct value (112) appears in the Coag display.
3. To display the day value, press the Med (Fulgurate) button.
4. To select the day, press the Coag up () or down () arrow buttons until the correct
value (131) appears in the Coag display.
5. To display the year value, press the High (Spray) button. Initially, the Coag display may
show a value outside the normal range of 0 to 99. Ignore the displayed value.
6. To select the year, press the Coag up () or down () arrow buttons until the correct
value (099) appears in the Coag display.
7. Examples:
For 1997, set the year value to 97.
For 2001, set the value to 1.
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-
30.

Adjusting the Clock

The hour and minute values are stored in the real-time clock on the Control board. The
clock was originally set for Mountain Standard Time. The clock is configured to the
24-hour (i.e., military time) format.
1. Verify that the Bipolar display shows calibration step number C3.
2. To select the hour, press the Coag up ( ) or down ( ) arrow buttons until the
correct value (023) appears in the Coag display.
Examples:
For 2 AM, set the hour value to 2.
For 2 PM, set the value to 14.
3. To display the minute value, press the Med (Fulgurate) button.
4. To select the minute value, press the Coag up ( ) or down ( ) arrow buttons until
the correct value (059) appears in the Coag display.
5. To save the hour and minute values and go to the next calibration step, press the
Bipolar up arrow ( ) button.
Next, check the REM impedance as described in Check and Adjust the REM Oscillator
Frequency and Impedance.
Checking and Adjusting the REM Oscillator Frequency

and Impedance
Equipment required
Oscilloscope
REM plug (modified) or two small (24" [< 61 cm]) test cables
Resistor substitution box
Warning
1. Verify the following:

The Bipolar display shows calibration step number C4.
The Coag display shows the letters OP (open circuit).
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.


c. On the Power Supply/RF board, adjust potentiometer R96 for maximum amplitude
of the voltage waveform across the Patient Return Electrode receptacle pins. The
frequency of this waveform should be approximately 82 kHz.
d. Remove the oscilloscope.
e. Install the cover by positioning it above the chassis and sliding it down. Install the
five screws that secure the cover to the chassis.
3. Open circuit the REM connection. Press the Coag up arrow () button once. Verify
that 10 appears in the Coag display.
4. Connect the resistor substitution box across the two terminals in the Patient Return
Electrode receptacle using a modified REM plug or two test cables.
5. Set the resistor substitution box to 10 . Press the Coag up arrow () button once.
Verify that 70 appears in the Coag display.
6. Set the resistor substitution box to 70 . Press the Coag up arrow () button once.
Verify that 135 appears in the Coag display.
7. Set the resistor substitution box to 135 .
8. To save the REM calibration values and go to the next calibration step, press the
Next, check the current sense gain factor as described in Check and Adjust the Current
Sense Gain Factor.
Checking and Adjusting the Current Sense Gain

Equipment required
Two short test cables (less than 24" [61 cm] long) with banana plugs
10 noninductive power resistor (such as the Dale NH-250)
Caution
To avoid inadvertent coupling and/or shunting of RF currents around the resistor elements, keep
the resistors at least 4" (10.2 cm) away from any metal surface including tabletops and other
resistors. This is especially true if several resistors are connected in series or parallel to obtain a
specified value. Do not allow the resistor bodies to touch each other.
Notice
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.

Verify that the Bipolar display shows calibration step number C5. The Cut and Coag
displays show the I (current) factor. If it is four or more digits, the most significant digits
appear in the Cut display.
Checking the Current Sense Gain for Bipolar Output

c. Connect the 10 resistor across the output jacks at the end of the test cables.
panel.
2. Check and adjust the I factor for bipolar output.
a. Press the Med (Standard) button.
b. Press the bipolar footswitch pedal and check the voltmeter for a reading
equivalent to 1790 20 mArms.
c. Stop activation. Do one of the following:
If the output current reading was too high, raise the I factor by pressing the
Coag up arrow ( ) button.
If the reading was too low, lower the I factor by pressing the Coag down
arrow ( ) button.
Repeat this step until the voltmeter reading is within the stated range. The I factor for
the Precise and Macro modes is adjusted automatically.
3. Disconnect the test cables from bipolar output.
Checking the Current Sense Gain for Monopolar Output

d. 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.


2. Check and adjust the I factor for the Low and Pure cut modes.
a. Press the Pure button.
b. Press the footswitch cut pedal and check the voltmeter for a reading equivalent to
1250 8 mArms.
Coag up () arrow button.
arrow () button.
Repeat this step until the voltmeter reading is within the stated range. The I factor for
the Low cut mode is adjusted automatically.
3. Check and adjust the I factor for the Blend mode.
a. Press the Blend button.
1000 8 mArms.
Coag up arrow () button.
arrow () button.
Repeat this step until the voltmeter reading is within the stated range.
4. Disconnect the test cables and remove the 10 resistor.
5. To save the current sense gain calibration and go to the next calibration step, press
the Bipolar up arrow () button.
Next, check the voltage sense gain factor as described in Check and Adjust the Voltage
Sense Gain.
Checking and Adjusting the Voltage Sense Gain

Equipment required
1000, 2000, and 3000 noninductive power resistors (such as the Dale NH-250)

Notice
Do not adjust the voltage sense gain while the generator is activated.
Verify that the Bipolar display shows calibration step C6. The Cut and Coag displays show
the V (output voltage) factor. If it is four or more digits, the most significant digits are in
the Cut display.
Checking the Voltage Sense Gain for Bipolar Output

Notice
voltage sense gain for bipolar output. Otherwise, product damage will result.

panel.
2. Check and adjust the V factor for bipolar output.
a. Press the Standard button.
If the output current reading was too high, raise the V factor by pressing the
If the reading was too low, lower the V factor by pressing the Coag down
arrow () button.
Repeat this step until the voltmeter reading is within the stated range. The V factor
for the Precise and Macro modes adjusts automatically.


Checking the Voltage Sense Gain for Monopolar Output
Notice
Do not activate the generator with any load resistor lower than 3000 while calibrating the voltage
sense gain for the Low and Pure cut modes. Do not activate the generator with any load resistor
lower than 2000 while calibrating the voltage sense gain for the Blend mode. Otherwise, product
damage will result.

d. Connect the 3000 resistor to the test cables through the current transformer
for monopolar output.
the rear panel.
2. Check and adjust the V factor for the Low and Pure cut modes.
a. Press the Pure button.
216 3 mArms.
If the reading was too low, lower the V factor by pressing the Coag down
arrow () button.
Repeat this step until the voltmeter reading is within the stated range. The V factor
for the Low cut mode is adjusted automatically.
3. Replace the 3000 resistor with the 2000 resistor.
4. Check and adjust the V factor for the Blend mode.
300 3 mArms.
If the reading was too low, lower the V factor by pressing the Coag down arrow
() button.

6. To save the voltage sense gain calibration and go to the next calibration step, press
the Bipolar up arrow () button.
Next, go to Check and Adjust the Reactance Gain
Checking and Adjusting the Reactance Gain

Equipment required
30 and 200 noninductive power resistors (such as the Dale NH-250)
Notice
Do not adjust the reactance gain while the generator is activated.
Verify that the Bipolar display shows calibration step C7. The Cut and Coag displays show
the Z (reactance) factor. If it is four or more digits, the most significant digits are shown in
the Cut display.
Checking the Reactance Gain for Bipolar Output

a. Connect the two test cables to the Bipolar receptacle.
d. Connect the bipolar footswitch to the Bipolar Footswitch receptacle.
2. Adjust the Z factor for bipolar output.
a. Press the Standard button.


If the output current reading was too high, lower the Z factor.
If the reading was too low, raise the Z factor.
To change the Z factor by ones, press the Coag up () or down () arrow buttons.
To change it by hundreds, press the Cut up () or down () arrow buttons.
Repeat this step until the voltmeter reading is within the stated range. The Z factor for
the Precise and Macro modes is adjusted automatically.
3. Disconnect the test cable and remove the 30 resistor.
Checking the Reactance Gain for Monopolar Output

d. Connect the 200 resistor to the test cables through the current transformer for
monopolar output.
the rear panel.
2. Adjust the Z factor for the Low and Pure cut modes. Press the Pure button.
a. Press the footswitch cut pedal and check the voltmeter for a reading equivalent to
949 3 mArms.
b. Stop activation. Do one of the following:
Repeat this step until the voltmeter reading is within the stated range. The Z factor for
the Low cut mode is adjusted automatically.
3. Adjust the Z factor for the Blend mode.
1000 10 mArms.


4. Disconnect the test cables and remove 200 resistor.
5. To save the reactance gain calibration and go to the next calibration step, press the
Next, go to Check and Adjust the ECON Factor.
Checking and Adjusting the ECON Factor

Equipment required
30, 100, and 500 noninductive power resistors (such as the Dale NH-250)
Verify that the Bipolar display shows calibration step C8.
Checking Bipolar Output

b. Connect the 30 resistor across the output jacks at the end of the test cables.
c. Connect the bipolar footswitch to the Bipolar Footswitch receptacle.
2. Press the Precise button.
3. Check the ECON for the selected bipolar mode.
a. Verify that the Coag display shows 30.
b. 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.


e. Stop activation. Verify that the Coag display changed to 30.
If the display did not change as described, call the Covidien Service Center.
4. To check the Standard mode, press the Standard button and repeat step 3.
5. To check the Macro mode, press the Macro button and repeat step 3.
Checking Monopolar Cut Output

d. Connect the 100 resistor to the test cables.
the rear panel.
2. Press the Low button.
3. Check the ECON for the selected cut mode.
a. Verify that the Coag display shows 30.
b. Press the footswitch cut pedal to activate monopolar output for between two and
five seconds.
d. Press the cut pedal again to activate monopolar output for between two and five
seconds.
4. To check the Pure mode, press the Pure button and repeat step 3 (above).
5. Check the Blend mode.
a. Press the Blend button. The Coag display changes to 20.
b. Press the cut pedal to activate monopolar output for between two and five
seconds.
d. Press the cut pedal again to activate monopolar output for between two and five
seconds.


6. Remove the 100 resistor from the test cables.
Checking Monopolar Coag Output

d. Verify that the monopolar footswitch is connected to the Monopolar 1 Footswitch
receptacle on the rear panel.
e. Connect the 500 resistor across the output jacks at the end of the test cables.
2. Press the Desiccate button.
3. Check the ECON for the selected coag mode.
a. Verify that "10" appears in the Coag display.
b. Press the footswitch coag pedal and, while activating the generator, press the
Coag up () or down () arrow buttons until the voltmeter reading is equivalent
to 141 9 mArms. Ignore changes to the Coag display.
d. Press the coag pedal again and, while activating the generator, press the Coag up
() or down () arrow buttons until the voltmeter reading is equivalent to
489 5 mArms. Ignore changes to the Coag display.
4. To check the Fulgurate mode, press the Fulgurate button and repeat step 3 (above).
a. If a 0 (zero) appears in the Cut display and a 10 appears in the coag display,
repeat step 3. This completes LCF Fulgurate mode calibration.
b. Press the Med (Fulgurate) button. Verify that an H appears in the Cut display
and a 10 appears in the coag display. Repeat step 3. This completes Fulgurate
mode calibration.
5. To check the Spray mode, press the Spray button.
a. Verify that C10 appears in the Coag display.
b. Press the coag pedal and, while activating the generator, press the Coag up () or
down () arrow buttons until the voltmeter reading is equivalent to


d. Press the coag pedal again and, while activating the generator, press the Coag up
() or down () arrow buttons until the voltmeter reading is equivalent to
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.

Using the RS-232 Serial Port

The RS-232 serial port allows communication between an attached computer or terminal
and the main microcontroller of the generator. This communication link lets you obtain
information regarding calibration values, power and mode settings, and the alarm
number history of the generator. You can also use the link when calibrating the
generator.
Equipment required
Establish the Communications Link

2. On the rear panel of the generator, remove the screws that secure the metal plate
that covers the serial port.
3. Connect a standard DB 9 serial cable to your computer and to the serial port.
Pin 2 is the serial output data line.
Pin 3 is the serial data input line.
Pin 5 is the reference line.
4. On your computer, enter your communication program. Configure your computer for
9600 baud, 8 data bits, 1 stop bit, and no parity.
5. Turn on the generator. Information similar to the following is displayed on your
computer:
FX Main
(c) 1995 Valleylab
Gen Model: Force FX
Main F/W Version: #
Feedback F/W Version: #
REM Impedance = Z
where # 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


keying ENABLED
When activation ceases, the following message appears:
key request removed
Enter the Commands

You can enter commands to change settings or display data about the generator. Each
command should begin with a colon (:) and end with Enter. The # symbol represents a
numeric value that you enter with specific commands as noted.
Data Displays
Some commands result in the display of data for each mode, including CEM. The display
format is as follows:
Default
Bipolar Precise Bipolar Standard Bipolar Macro Fulgurate
Cut Low Cut Pure Cut Blend Cut CEM
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
2 Macro
Cut Modes
0 Low
1 Pure
2 Blend
Coag Modes
0 Desiccate
1 Fulgurate
2 Spray

Commands for Selecting Modes and Power Settings
Command Action
:FBM# Specify the bipolar mode (for #, enter the number for the
desired mode):
0 = Precise
1 = Standard
2 = Macro
:FBP# Specify the bipolar power setting (# = 1, 2, 3, 65, 70).
:FBU Increment the bipolar power setting to the next higher value.
:FBD Decrement the bipolar power setting to the next lower value.
:FTM# Specify the cut mode (for #, enter the number for the desired
mode):
0 = Low
1 = Pure
2 = Blend
:FTP# Specify the cut power setting(# = 1, 2, 3, 290, 300).
:FTU Increment the cut power setting to the next higher value.
:FTD Decrement the cut power setting to the next lower value.
:FGM# Specify the coag mode (for #, enter the number for the desired
mode):
0 = Desiccate
1 = Fulgurate
2 = Spray
:FGP# 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.
:FR Recall the previous front panel settings.


Commands for Displaying Data on a Computer
Command Result Displayed on Computer
:PP Front panel values
:PT Current real-time clock values
:PSC Date of last calibration
:PSA Total time activated in each mode
:PSB Number of times activated in each mode
:PSK Number of times output was activated
:PSP Average power setting used in each mode
:PSF List of system errors 1 through 10 with time and date stamp
:PSL List of system errors 11 through 20 with time and date stamp
:PSE# Number of times specified error has occurred

(# represents an alarm number listed in Chapter 6,
Troubleshooting)
:PG Generator model and firmware version numbers
Commands for Changing the Default Coag Mode
Command Action
:MC <letter> where <letter> may be any of the following:

D sets default coag mode to desiccate
F sets default coag mode to fulgurate
S sets default coag mode to spray
:MF <value> Modifies the selected Fulgurate mode setting, where <value>
represents a selection as follows:
0
1 LCF Fulgurate
Fulgurate
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.

Disconnect the Computer from 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.

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

Inspecting the Generator

If the generator malfunctions, check for obvious conditions that may have caused the
problem:
Check the generator for visible signs of physical damage
Verify that all accessory cords are properly connected
Check the power cord. Replace the power cord if you find exposed wires, cracks,
frayed insulation, or a damaged connector
Open the fuse drawer and inspect the fuse housing and fuses for damage and
corrosion. Verify that the fuses are firmly seated
An internal component malfunction in the generator can damage the fuses. You may
need to replace the fuses if the generator fails the self-test or stops functioning. Refer to
Fuse Replacement on page 7-13.
Inspecting the Receptacles

Equipment required
Bipolar footswitch
Monopolar footswitch
Bipolar instrument cords (handswitching and footswitching)
Monopolar instrument cords (handswitching and footswitching)
2. Disconnect the power cord from the wall receptacle.

3. Check the three Footswitch receptacles on the rear panel for obstructions or damage.
Check for a secure fit by inserting the bipolar footswitch or monopolar footswitch
connector into the appropriate receptacle.
If any connection is loose, replace the Footswitch board assembly. Refer to Footswitch
4. Check the Bipolar Instrument receptacle on the front panel for obstructions or
damage. Insert the bipolar instrument connector (footswitching and handswitching)
into the appropriate receptacle to verify a secure fit.
If the connection is loose, replace the front panel. Refer to Front Panel Replacement
on page 7-9.
5. Check the Monopolar 1/CEM and Monopolar 2 Instrument receptacles on the front
panel for obstructions or damage. 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

6. Check the Patient Return Electrode receptacle for a broken pin or an obstruction. If the
receptacle is damaged or obstructed, replace the REM module. Refer to Front Panel
REM Module Replacement on page 7-11.
Inspecting the Internal Components

Equipment required
Caution
Troubleshooting
1. Remove the five screws that secure the cover to the chassis. Lift the cover off the
chassis. Save the cover and screws for reinstallation.
2. Verify that all connectors are firmly seated.
3. Inspect each board for damaged components, wires, cracks, and corrosion.
If you find evidence of damage on the Control board, Display board, or Footswitch
board, replace the board. Refer to Control Board Replacement on page 7-4,
Display Board Replacement on page 7-5, or Footswitch Board Replacement on
page 7-8.
If you find evidence of damage on the Power Supply/RF board, replace the board
only if the damage is severe. Refer to Power Supply/RF Board Replacement on
page 7-26.
4. To reinstall the cover, position the cover above the chassis and slide it down. Install the

Correcting Malfunctions
If a solution is not readily apparent, use the table below to help identify and correct
specific malfunctions. After you correct the malfunction, verify that the generator
completes the self-test as described in Chapter 5, Setup, Tests, and Adjustment.
Generator does Disconnected power cord, Check power cord connections

not respond faulty wall receptacle, or (generator and wall receptacle). Connect
when turned on faulty power cord the power cord to a functional wall
receptacle. If necessary, replace the
power cord.
Fuse drawer is open or fuses Close the fuse drawer. If necessary,

are blown replace the fuse(s). Refer to Fuse
Replacement on page 7-13. If a problem
persists, use a backup generator.
Loose or disconnected internal Check all internal connections.

cables
Faulty power entry module or Check the power entry module and its
connections cable connections.
Faulty low voltage power Check the low voltage power supply.
supply
Damaged Control board Remove the Control board and inspect

connectors and/or the connectors to the Power Supply/RF
malfunctioning Control board board and to the Display board for
damage, poor seating, etc.
If the problem persists, replace the
Control board. For instructions, refer to
Control Board Replacement on page 7-4.
Shorts or disconnects on Check the Power Supply/RF board for

Power Supply/RF board shorts or disconnects.
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

Generator is on, An alarm condition exists Check the display for an alarm number.
but did not Note the number and refer to
complete the self- Responding to System Alarms on
test page 6-11.
Software malfunction Turn off, then turn on the generator.
Loose or disconnected internal Check and correct all internal

cables connections.
Faulty low voltage power Check the low voltage power supply.
supply
Troubleshooting
Damaged Control board Remove the Control board and inspect
connectors the connectors to the Power Supply/RF
and/or malfunctioning Control board and to the Display board for
board damage, poor seating, etc. If the
problem persists, replace the Control
board. For instructions, refer to Control
Shorts or disconnects on Check the Power Supply/RF board for

Power Supply/RF board shorts or disconnects.
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.
Alarm number The battery was removed and/ Turn off, then turn on the generator to
212 appears in or replaced, but the generator clear the number. Calibrate the
the Cut display was not calibrated generator. For instructions, refer to
during the self- Calibrating the Generator on page 5-26.
test
Faulty battery on Control Replace the battery and check the
board causing loss of battery- battery-backed RAM device. Refer to
backed memory Correcting Battery-Backed RAM
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

Activation and/or Poor connection or damaged Check/correct connection. If indicated,

alarm tones do Footswitch board ribbon cable replace the Footswitch board. Refer to
not sound; Footswitch Board Replacement on
speaker is page 7-8.
malfunctioning
Faulty connections or speaker Replace the Footswitch board. Refer to
on Footswitch board Footswitch Board Replacement on
page 7-8.
Audio signal malfunction on Replace the Control board. Refer to

Control board Control Board Replacement on page 7-4.
Blank or Faulty ribbon cable between Check/connect ribbon cable that

confusing LED Control board and Display connects the Display board to the
display board Control board.
Incorrect display modes Replace the Control board. Refer to

communicated through the Control Board Replacement on page 7-4.
Control board
Display board malfunction Replace the Display board. Refer to

Display Board Replacement on page 7-5.
Mode buttons do Faulty ribbon cable between Check/connect ribbon cable that
not function Control board and Display connects the Display board to the
correctly when board Control board.
pressed
Incorrect modes Replace the Control board. Refer to
communicated through the Control Board Replacement on page 7-4.
Control board
Faulty ribbon cable between Check/connect the ribbon cable that

the front panel and the connects the 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

Situation Possible Cause Recommended Action
Generator is on Malfunctioning footswitch or Turn off the generator. Check and

and accessory is handswitching instrument correct all accessory connections.
activated, but
Turn on the generator. Replace the
generator does
accessory if it continues to malfunction.
not deliver output
Incompatible footswitch Use only a Covidien footswitch with the
Force FX Electrosurgical Generator C
generator.
Troubleshooting
Footswitch connected to Connect the footswitch to the
Monopolar 1 Footswitch Monopolar 2 Footswitch receptacle.
receptacle is being used for or
instrument connected to Connect the instrument to the
Monopolar 2 Instrument Monopolar 1/CEM Instrument
receptacle receptacle.
Footswitch connected to Connect the footswitch to the

Monopolar 2 Footswitch Monopolar 1 Footswitch receptacle.
receptacle is being used for or
instrument connected to Connect the instrument to the
Monopolar 1/CEM Instrument Monopolar 2 Instrument receptacle.
receptacle
Power set too low Increase the power setting.
An alarm condition exists Check the Cut display for an alarm

number. Note the number and refer to
Responding to System Alarms on
page 6-11.
Blown fuse on Power Supply/ Check the high voltage power supply
RF board fuse (F1) and replace if necessary. Refer
to Fuse Replacement on page 7-13.
Control board malfunction If the indicator bar does not illuminate

and the tone does not sound, replace
the Control board. Refer to Control
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.

(Continued) RF output stage malfunction Troubleshoot the RF output stage as

(high voltage is present during described below:
Generator is on
activation)
and accessory is On the Power Supply/RF board, verify
activated, but T_ON\ pulses at U4 during activation.
generator does
If pulses are not present before U4,
not deliver output
replace the Control board. Refer to
Control Board Replacement on
page 7-4.
If pulses are present at U4 but not
after U4, replace U4.
Check the power MOSFET at J9 for
failure (typically fail shorted).
Check all output relays to verify that they
are toggling during operation. If they are
not, check the relay drivers (U15 and
U16).
Check for shorting of the output tuning
inductors (T14 and T15).
Footswitch will Malfunctioning or damaged Replace the Footswitch board. Refer to

not activate footswitch receptacle Footswitch Board Replacement on
output page 7-8.
Footswitch activation signal Replace the Control board. Refer to

lost on Control board Control Board Replacement on page 7-4.
Continuous Faulty chassis-to-ground Check and correct the chassis ground

monitor connections connections for the monitor and, if
interference applicable, for the generator.
Check other electrical equipment in
the room for defective grounds.
Electrical equipment is 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

Interference with Metal-to-metal sparking Check all connections to the generator,

other devices only patient return electrode, and accessories.
when generator is
activated High settings used for Use lower power settings for fulguration
fulguration or select the Desiccate mode.
Electrically inconsistent Verify that all ground wires are as short

ground wires in the operating as possible and go to the same grounded
room metal.
If interference continues when Check with the manufacturer of the
Troubleshooting
the generator is activated, the monitor.
monitor is responding to
Some manufacturers offer RF choke
radiated frequencies.
filters for use in monitor leads. The filters
reduce interference when the generator
is activated and minimize the potential
for an electrosurgical burn at the site of
the monitor electrode.
Pacemaker Intermittent connections or Check all connections to the generator.

interference metal-to-metal sparking
It may be necessary to reprogram the
pacemaker.
Current traveling from active Use bipolar instruments, if possible. If

to return electrode during you must use a monopolar instrument,
monopolar electrosurgery is place the patient return electrode as
passing too close to close as possible to the surgical site.
pacemaker. Make sure the current path from the
surgical site to the patient return
electrode does not pass through the
vicinity of the heart or the site where the
pacemaker is implanted.
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

Abnormal Metal-to-metal sparking Check all connections to the generator,

neuromuscular patient return electrode, and active
stimulation (stop electrodes.
surgery
immediately) Can occur during coag Use a lower power setting for the
Fulgurate and Spray modes or select the
Desiccate mode.
Abnormal 5060 Hz leakage Inside the generator, carefully inspect for

currents damage that may cause shorting
between the AC line voltage and
connected patient components.

Responding to System Alarms

When a system alarm condition exists, an alarm tone sounds and a number flashes in the
Cut display. The generator is disabled until the condition is cleared.
Most system alarms require some action on your part to correct the condition; however,
some are corrected automatically. Use the following table to determine how to correct an
alarm condition.
After correcting the alarm condition, verify that the generator completes the self-test as
described in Chapter 5, Setup, Tests, and Adjustment.
Troubleshooting
Number Description Recommended Action
0 Main microcontroller failed to Turn the power switch off (O) then on (I) again.
hold feedback microcontroller If error reappears, replace the Control board.
in reset Refer to Control Board Replacement on page 7-4.
1
Main microcontroller failed to
power up feedback
microcontroller
2 Feedback microcontroller Turn the power switch off (O) then on (I) again.
failed to power up and If error reappears, replace the Control board.
initialize RAM in time allotted Refer to Control Board Replacement on page 7-4.
3
Feedback microcontrolled
failed to checksum battery-
backed RAM data in dual-port
RAM in time allotted
4 Internal diagnostics Replace the Control board. Refer to Control Board

Main microcontroller CPU test
failed 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.
5 Main microcontroller unable Turn the power switch off (O) then on (I) again.
to access FEEDBACK_SEM If error reappears, replace the Control board.
semaphore Refer to Control Board Replacement on page 7-4.
6
Main microcontroller unable
to access ECON_SEM
7 semaphore

to access KEY_ACTIVE_SEM
semaphore

10 Software malfunction. Invalid Turn off, then turn on the generator. If the alarm
alarm number (number shown number reappears, record the number and call
on terminal using serial port) the Covidien Service Center.
11 Internal diagnostics. Invalid Turn the power switch off (O) then on (I) again.
activated power, function, If error reappears, replace the Control board.
mode, or key request mode Refer to Control Board Replacement on page 7-4.
echoed by feedback
microcontroller
12 Diagnostics/microcontroller Turn the power switch off (O) then on (I) again.
malfunction. T_ON_ERR test If error reappears, replace the Control board.
failed Refer to Control Board Replacement on page 7-4.
to access GEN_SEM If error reappears, replace the Control board.
14 Internal diagnostics. Turn the power switch off (O) then on (I) again.
Calibration data checksum If error reappears, replace the Control board.
error on main microcontroller Refer to Control Board Replacement on page 7-4.
(data in error shown on
terminal using serial port)
16 Diagnostics/microcontroller Calibrate the ECON factor. Refer to Calibrating

malfunction. T_ON average the Generator on page 5-26.
test failed
If the alarm number reappears, refer to Correcting
T_ON ASIC Malfunctions on page 6-22.
69 Software malfunction. Turn off, then turn on the generator. If the alarm
flash_power_state value number reappears, record the number and call
outside state range the Covidien Service Center.
70
Software malfunction.
key_req_mode value outside
71
state range
80
request+1 value outside state
range
*input[i].p_state value outside
state range

81 Internal component Do not attempt to use the generator. Record the

malfunction. Optoisolator test number and call the Covidien Service Center.
failed
90 Generator model number in Turn the power switch off (O) then on (I) again.
main microcontroller Flash If error reappears, replace the Control board.
Memory not Force FX Refer to Control Board Replacement on page 7-4.
95
model number
Generator model number in
Troubleshooting
main microcontroller Flash
Memory not Force FX
model number
rem_update_state value number reappears, record the number and call
outside state range the Covidien Service Center.
101
rem_pad_state value outside
102
state range
103
rem_state value in
re_rem_control( ) outside state
104 range
105 rem_state value in
re_non_rem_control( ) outside
state range
110
rem_flash_state value outside
111 state range
rem_led_state value outside
state range
cal_state value in
ca_generator_setup( ) outside
state range
cal_state value in
ca_clock_date_setup( ) outside
state range

cal_mode value in number reappears, record the number and call
ca_clock_date_setup( ) outside the Covidien Service Center.
state range
113
cal_state value in
ca_clock_time_setup( ) outside
114
state range
cal_mode value in
115
ca_clock_time_setup( ) outside
state range
116
cal_state value in
ca_coag_leakage_cal( )
117 outside state range
118 cal_state value in ca_econ_cal(
) outside state range
119 Software malfunction.
econ_cal_state value outside
state range
cal_state value in ca_rem_cal( )
outside state range
rem_cal_state value outside
state range
120 Calibration malfunction. Repeat the failing calibration step. If the alarm
Calibration value(s) outside number reappears, record the number and call
acceptable range the Covidien Service Center.
cal_mode value in number reappears, record the number and call
ca_generator_setup( ) outside the Covidien Service Center.
state range
122 Open circuit REM sense failure Repeat the failing calibration step. If the alarm
number reappears, record the number and call
the Covidien Service Center.

124
to access FEEDBACK_SEM
125
semaphore
126
to access ECON_SEM
semaphore
Troubleshooting
to access KEY_ACTIVE_SEM
semaphore
cal_state value in cs_i_sns_cal( number reappears, record the number and call
) outside state range the Covidien Service Center.
to access FEEDBACK_SEM If error reappears, replace the Control board.
160 Internal component Calibrate the ECON factor. Refer to Calibrating

malfunction. Dosage error test the Generator on page 5-26.
failed. ADC values display at
If the alarm number reappears, refer to Correcting
failure
T_ON ASIC Malfunctions on page 6-22.
170 Watchdog malfunction. Turn the power switch off (O) then on (I) again.
Correct value not sent from If error reappears, replace the Control board.
feedback microcontroller Refer to Control Board Replacement on page 7-4.
Correct value not sent from If error reappears, replace the Control board.
main microcontroller Refer to Control Board Replacement on page 7-4.
172
Watchdog malfunction. Main
microcontroller unable to
access watchdog semaphore
Feedback microcontroller If error reappears, replace the Control board.
unable to access watchdog Refer to Control Board Replacement on page 7-4.
semaphore

which_errors value outside number reappears, record the number and call
state range the Covidien Service Center.
180 Internal diagnostics. Main Turn the power switch off (O) then on (I) again.
microcontroller ST If error reappears, replace the Control board.
Microelectronics RAM check Refer to Control Board Replacement on page 7-4.
failed
181 Internal diagnostics. Feedback Turn the power switch off (O) then on (I) again.
microcontroller ST If error reappears, replace the Control board.
Microelectronics RAM check Refer to Control Board Replacement on page 7-4.
failed
microcontroller dual-port RAM If error reappears, replace the Control board.
check failed Refer to Control Board Replacement on page 7-4.
183
Internal diagnostics. Main
microcontroller Page 0 (zero)
184
Flash Memory CRC test failed
Internal diagnostics. Main
microcontroller Page F Flash
Memory CRC test failed
microcontroller Flash Memory If error reappears, replace the Control board.
CRC test failed Refer to Control Board Replacement on page 7-4.
display_state value outside number reappears, record the number and call

190 Internal diagnostics. Bipolar 1. Turn off, then turn on the generator. Do not
buttons (up arrow, down press buttons or accessory activation devices
arrow, Precise, Standard, and/ during the self-test.
or Macro) may be stuck
191 2. If the alarm number reappears, disconnect all
Internal diagnostics. Cut accessories. Turn off, then turn on the
buttons (up arrow, down generator again.
arrow, Low, Pure, and/or
Blend) may be stuck (button
192 number and call the Covidien Service Center.
shown on terminal using serial
port)
Troubleshooting
Internal diagnostics. Coag
buttons (up arrow, down
193
arrow, Desiccate, Fulgurate,
and/or Spray) may be stuck
(button shown on terminal
194 using serial port)
Internal diagnostics. Recall
button may be stuck (button
195 shown on terminal using serial
port)
Internal diagnostics.
196 Handswitch or Monopolar 1
Footswitch cut pedal may be
stuck
197 Internal diagnostics.
Handswitch or Monopolar 1
Footswitch coag pedal may be
stuck
198
Footswitch cut pedal may be
stuck
Footswitch coag pedal may be
stuck
Handswitch or Bipolar
Footswitch pedal may be stuck
199 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.

200 Internal diagnostics. Main 1. Replace the Control board. Refer to Control
microcontroller SEML line may Board Replacement on page 7-4.
be stuck
201 2. Calibrate the generator. Refer to Calibrating
Internal diagnostics. Feedback the Generator on page 5-26.
microcontroller SEMR line may
be stuck
microcontroller watchdog test If error reappears, replace the Control board.
microcontroller watchdog test If error reappears, replace the Control board.
206
Software malfunction. Turn off, then turn on the generator. If the alarm
doserr_test_state value in number reappears, record the number and call
st_m_doserr_test outside state the Covidien Service Center.
207 range
doserr_test_state value in
st_fb_doserr_test outside state
range
208 Main microcontroller timer 1. Replace the Control board. Refer to Control
interrupt failed Board Replacement on page 7-4.
209
Feedback microcontroller 2. Calibrate the generator. Refer to Calibrating
timer interrupt failed the Generator on page 5-26.
data_type value outside state number reappears, record the number and call
range the Covidien Service Center
211
which_data value outside
state range
212 Generator not calibrated Refer to Calibrating the Generator on page 5-26.
213 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.

215 Internal diagnostics. Real-time 1. Replace the Control board. Refer to Control
clock chip (U1) not compatible Board Replacement on page 7-4.
with firmware
2. Calibrate the generator. Refer to Calibrating
the Generator on page 5-26.
216 Internal memory battery 1. Replace the battery. Refer to Battery

exhausted Replacement on page 7-3.
Troubleshooting
unable to access If error reappears, replace the Control board.
KEY_REQ_SEM semaphore Refer to Control Board Replacement on page 7-4.
221
Feedback microcontroller
unable to access GEN_SEM
semaphore
222 Main microcontroller failed to Turn the power switch off (O) then on (I) again.
copy battery-backed RAM If error reappears, replace the Control board.
data to dual-port RAM in time Refer to Control Board Replacement on page 7-4.
allotted
223
Main microcontroller failed to
complete initialization in time
allotted
224 Internal diagnostics. Turn the power switch off (O) then on (I) again.
Calibration data checksum If error reappears, replace the Control board.
error on feedback Refer to Control Board Replacement on page 7-4.
microcontroller (data in error
shown on terminal using serial
port)
225 Internal diagnostics. Feedback 1. Replace the Control board. Refer to Control
microcontroller CPU test failed Board Replacement on page 7-4.

FEEDBACK_SEM semaphore Refer to Control Board Replacement on page 7-4.
keyed_state value outside number reappears, record the number and call
231
key_req_mode value outside
state range
KEY_ACTIVE_SEM semaphore Refer to Control Board Replacement on page 7-4.
activation_seq value outside number reappears, record the number and call
241
feedback value in
242
do_feedback( ) outside state
range
244
feedback value in
245 do_cal_feedback( ) outside
state range
disable_seq value outside state
range
spark_state value outside state
range
FEEDBACK_SEM semaphore Refer to Control Board Replacement on page 7-4.
247
Feedback microcontroller
unable to access ECON_SEM
semaphore

260 Internal diagnostics. A/D 1. Replace the Control board. Refer to Control
conversion did not complete Board Replacement on page 7-4.
in allowed time
261 Software malfunction. Delay Turn off, then turn on the generator. If the alarm
time out of bounds on main number reappears, record the number and call
Troubleshooting
microcontrollers the Covidien Service Center.
262
Software malfunction. Delay
time out of bounds on
270
feedback microcontroller
Software malfunction. Data
271
type in me_rtc_get_() outside
of the state range
Software malfunction. Data
type in me_rtc_put_() outside
of the state range
451 The internal temperature limit 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.

Correcting T_ON ASIC Malfunctions

Equipment required
Surface mount, quad pack chip extractor
Warning
Electric Shock Hazard To allow stored energy to dissipate after power is disconnected, wait at
least five minutes before replacing parts.
Caution
Important
If you are responding to a specific alarm number, first calibrate the ECON factor as described in
Checking and Adjusting the ECON Factor on page 5-38. If the alarm number reappears after
calibration, complete this procedure.
1. Turn off the generator. Disconnect the power cord from the wall receptacle.
chassis.
3. Remove the Control board.
a. Unlock the connector on the Control board and disconnect the Display board
ribbon cable from the Control board.
b. Carefully slide the Control board straight up through the slots in the heat sinks to
disconnect it from the Power Supply/RF board.
4. On the Control board, verify that the pins on programmable IC U9 are properly seated
in their socket on the Control board.
a. Grip IC U9 with the chip extractor and lift it out of its socket.
b. Align the notch on IC U9 above the notch on the socket and gently press the chip
back into the socket.
5. Install the Control board.

a. Position the Control board over the Power Supply/RF board with the components
facing the rear panel. Fit the edges of the board into the slots on the heat sinks.
Slide the board down, carefully fitting the edge connector into the matching
connector on the Power Supply/RF board.
b. Connect the Display board ribbon cable to the Control board and lock the
connector.
6. Turn on the generator. If the generator successfully completes the self-test, install the
cover (refer to step 11).
7. If the alarm number reappears, replace programmable IC U9.
a. Turn off the generator. Disconnect the power cord from the wall receptacle.
Troubleshooting
b. Remove the Control board (refer to step 3).
c. Grip IC U9 with the chip extractor and lift it out of its socket.
d. Align the notch on the new chip above the notch on the socket and gently press
the chip into the socket.
e. Install the Control board (refer to step 5).
8. Turn on the generator. If the generator successfully completes the self-test, install the
cover (refer to step 11).
9. If the alarm number reappears, replace the Control board.
a. Turn off the generator. Disconnect the power cord from the wall receptacle.
c. Install the new Control board (refer to step 5).
10. Calibrate the generator. Refer to Calibrating the Generator on page 5-26, for
instructions. If the alarm number reappears, record the number and call the Covidien
Service Center.
11. To install the cover, position the cover above the chassis and slide it down. Install the

Correcting Battery-Backed RAM Malfunctions

Equipment required
Surface mount, quad pack chip extractor
Warning
Caution
Notice
battery is replaced. Refer to Calibrating the Generator on page 5-26, for instructions.
chassis.
b. Carefully slide the Control board straight up through the slots in the heat sinks to
Important
All data stored in internal memory (refer to Internal Memory on page 3-3) is lost when the battery
is removed.
4. Replace the battery.
a. Grasp the battery and slide it up and out of the socket.
b. Position the new 3 V button-cell battery above the socket so that the positive side
of the battery is facing out (visible).
c. Slide the new battery down into the socket.

a. Position the Control board over the Power Supply/RF board with the components
facing the rear panel. Fit the edges of the board into the slots on the heat sinks.
Slide the board down, carefully fitting the edge connector into the matching
connector on the Power Supply/RF board.
connector.
6. Calibrate the generator. Refer to Calibrating the Generator on page 5-26, for
instructions. If the calibration is successful, install the cover (refer to step 9).
7. If the alarm number reappears, replace the Control board.
Troubleshooting
a. Turn off the generator.
c. Install the new Control board (refer to step 6).
8. Recalibrate the generator. If the alarm number reappears, record the number and call
the Covidien Service Center.
9. To install the cover, position the cover above the chassis and slide it down. Install the

Chapter 7
Replacement Procedures
Follow the procedures in this section when you need to replace the parts listed
below:
Battery for battery-backed RAM

Control board
Display board and seven-segment LEDs
Fan
Footswitch board
Front panel
Front panel components, including the REM module and power switch
Fuses, including two in the fuse drawer and one on the Power Supply/RF board
Heat sinks (left front, left rear, and right heat sinks) and associated heat sink
components
Low voltage power supply
Power entry module
Power Supply/RF board.
For your reference, this section also includes an electrical cable interconnect
diagram that illustrates all cable connections.
The parts used in these procedures are illustrated in Chapter 9, Service Parts.

Interconnect Diagram
Interconnect Diagram
A block diagram of generator interconnections
6/
BW14

Battery Replacement
Battery Replacement
Equipment required
Warning
Caution
Notice
battery is replaced. Refer to Calibrating the Generator on page 5-26, for instructions.
Important
All data stored in internal memory (refer to Internal Memory on page 3-3) is lost when the battery
is removed.
chassis. Set the cover and screws aside for reinstallation.
3. Locate the battery at the upper left corner of the Control board.
4. Grasp the battery and slide it up and out of the socket.
5. Install the new 3 V button-cell battery (CR2450 or equivalent).
a. Position the battery above the socket so that the positive side of the battery is
facing out (visible).
b. Slide the battery down into the socket until it is firmly seated.
6. Position the cover above the chassis and slide it down. Install the five screws that
secure the cover to the chassis.

Control Board Replacement
Control Board Replacement

Equipment required
Warning
Caution
Notice
Calibrate the generator after you install a new Control board. Otherwise, the default calibration
values are used. Refer to Calibrating the Generator on page 5-26, for instructions.
3. Unlock the connector on the Control board and disconnect the Display board ribbon
cable from the Control board.
4. Carefully slide the Control board straight up through the slots on the heat sinks to
5. Verify that the packaging for the new Control board contains the part number for the
Force FX Electrosurgical Generator C Control board. Do not install any other Control
board.
6. Install the battery in the battery socket (positive side facing up).
7. Position the new Control board over the Power Supply/RF board with the 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.
8. Connect the Display board ribbon cable to the Control board and lock the connector.

Display Board Replacement

Equipment required
Remove the Display Board

Warning
Caution
b. Carefully slide the Control board straight up through the slots on the heat sinks to
disconnect it from the Power Supply/RF board. Set the board aside in an antistatic
container for reinstallation.
4. Disconnect and remove the front panel assembly.
a. Disconnect the power switch from the Power Supply/RF board.
b. Disconnect the two REM connectors from the Power Supply/RF board.
c. Remove the four screws that secure the front panel to the chassis. Save the screws
for reinstallation.
d. Slide the front panel assembly forward, carefully disengaging it from the electrical
contacts on the Power Supply/RF board.
5. Detach and disconnect the Display board from the front panel.
a. Remove the four screws that secure the Display board to the front panel. Save the
screws for reinstallation.
b. Disconnect the CEM switch cable from the Display board.
c. Disconnect the membrane keyboard ribbon cable from the Display board.

d. Disconnect the grounding clips from each side of the bezel by sliding the clips
away from the bezel until they are loose and held only by the Display board.
Install the Display Board

1. Connect and attach the Display board to the front panel.
a. Connect the membrane keyboard ribbon cable to the Display board.
b. Connect the CEM switch cable to the Display board.

c. Connect the grounding clips to each side of the bezel by sliding the clips toward
the bezel until they are snug.
d. Position the Display board over the front panel posts and install the four screws
that secure the board to the front panel.
2. Install the front panel assembly.
a. Position the front panel assembly in front of the chassis and carefully slide it into
the electrical contacts on the Power Supply/RF board.
b. Install the four screws that secure the front panel to the chassis.
c. Connect the power switch cable to J10 on the Power Supply/RF board.
3. Connect the REM wires to the Power Supply/RF board.
a. Connect the white wires with the 2-pin nonlocking connector to J15.
b. Connect the red wires with the 2-pin locking connector to J17.
a. Position the Control board over the Power Supply/RF board with the 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.
connector.

Display Board Seven-Segment LED Replacement
Display Board Seven-Segment LED Replacement

1. Remove the Display board (observe all warnings and cautions). Refer to Display Board
2. Grasp the seven-segment LED and pull it out of the Display board, taking care not to
bend the pins. Note the orientation of pin 1 (the corner with the small 45 chamfer).
3. Verify that the replacement LED is the correct color (green).
4. Install the new seven-segment LED, making sure that the orientation of pin 1
(designated by the small 45 chamfer) is the same as that of the LED you removed.
5. Reinstall the Display board. Refer to Display Board Replacement on page 7-5.
Fan Replacement
1. Remove the Power Supply/RF board and attached heat sinks (observe all warnings
and cautions). Refer to Power Supply/RF Board Replacement on page 7-26.
2. Disconnect the fan connector from the Power Supply/RF board.
3. Turn the Power Supply/RF board over, and remove the four screws and nuts that
secure the fan to the board.
4. Position the new fan on top of the Power Supply/RF board and install the four nuts
and screws that secure it to the board.
5. Connect the fan connector to J4 on the Power Supply/RF board.
6. Reinstall the Power Supply/RF board and attached heat sinks. Refer to Power Supply/
RF Board Replacement on page 7-26.

Footswitch Board Replacement
Footswitch Board Replacement

1. Remove the Power Supply/RF board and attached heat sinks (observe all warnings
and cautions). Refer to Power Supply/RF Board Replacement on page 7-26.
2. Remove the Footswitch board assembly.
a. On the rear panel, remove the six screws that secure the footswitch receptacles to
the rear panel.
b. Inside the rear panel, remove the three screws that secure the Footswitch board
assembly to the rear panel standoffs.
3. Install the new Footswitch board assembly.
a. Position the assembly inside the rear panel and install the three screws that secure
the assembly to the rear panel.
b. On the rear panel, install the six screws that secure the footswitch receptacles to
the rear panel.
4. Reinstall the Power Supply/RF board and attached heat sinks. Refer to Power Supply/
RF Board Replacement on page 7-26.

Front Panel Replacement

Equipment required
Warning
Caution
Remove the Front Panel Assembly

3. Unlock the connector on the Control board and disconnect the Display board ribbon
cable from the Control board.
4. Disconnect the power switch cable from the Power Supply/RF board.
5. Disconnect the two REM connectors from the Power Supply/RF board.
6. Remove the four screws that secure the front panel to the chassis. Save the screws for
reinstallation.
7. Slide the front panel assembly forward, carefully disengaging it from the electrical
Remove and Reinstall the Front Panel Components

If you are replacing the entire front panel assembly, go to Install the Front Panel Assembly
on page 7-10.
or
If you are replacing only the front panel, follow these instructions to remove the
components (Display board, REM module, and power switch) and install them on the
new front panel.
1. Detach and disconnect the Display board from the front panel.
a. Remove the four screws that secure the Display board to the front panel. Save the
screws for reinstallation.
b. Disconnect the CEM switch cable from the Display board.

c. Disconnect the membrane display ribbon cable from the Display board.
d. Disconnect the grounding clips from each side of the bezel by sliding the clips
away from the bezel until they are loose and held only by the Display board.
2. Remove the REM module and reinstall it on the new front panel.
a. Remove the two screws that secure the REM module to the front panel. Then,
remove the bracket that covers the REM module and remove the REM module.
b. From inside the new front panel, insert the REM module into the front panel
opening.
c. Place the bracket over the REM module and install the two screws that secure the
module to the new front panel.
3. Remove the power switch and reinstall it on the new front panel.
a. Inside the front panel, press the four tabs that secure the power switch and push
the switch (and connected cable) out the opening.
b. Outside the new front panel, route the power switch cable through the power
switch opening.
c. Position the power switch with the On (|) switch above the Off (O) switch. Press to
snap the switch into place.
4. Install the Display board on the new front panel.
a. Connect the membrane keyboard ribbon cable to the Display board.
b. Connect the CEM switch cable to the Display board.
c. Connect the grounding clips to each side of the bezel by sliding the clips toward
the bezel until they are snug.
d. Position the Display board over the front panel posts and install the four screws
that secure the board to the front panel.
Install the Front Panel Assembly

1. Position the front panel assembly in front of the chassis and carefully slide it into the
electrical contacts on the Power Supply/RF board.
2. Install the four screws that secure the front panel to the chassis.
3. Connect the REM wires to the Power Supply/RF board.
a. Connect the white wires with the 2-pin nonlocking connector to J15.
b. Connect the red wires with the 2-pin locking connector to J17.
4. Connect the power switch cable to J10 on the Power Supply/RF board.
5. Connect the Display board ribbon cable to the Control board and lock the connector.

Front Panel REM Module Replacement
Front Panel REM Module Replacement

1. Remove the front panel assembly (observe all warnings and cautions). Refer to Front
2. Remove the two screws that secure the REM module to the front panel and remove
the bracket that covers the REM module. Set the bracket and screws aside for
reinstallation.
3. Replace the existing module with a new REM module.
4. Position the bracket over the new REM module and install the two screws that secure
the module to the front panel.
5. Reinstall the front panel assembly. Refer to Front Panel Replacement on page 7-9.

Front Panel Power Switch Replacement
Front Panel Power Switch Replacement

1. Remove the front panel assembly (observe all warnings and cautions). Refer to Front
2. Inside the front panel, press the four tabs that secure the power switch and push the
switch (and connected cable) out the opening.
Removing and disconnecting the power switch
Brown
Tab
Blue
3. Remove the heat shrink from the cables and old switch.
4. Slide a piece of heat shrink tubing (1.0" [2.54 cm] wide; 2.5" [6.35 cm] long) over
the wires.
5. Connect the cable to the new power switch assembly, using the illustration or the
assembly you just removed as a reference.
6. Using a heat gun, shrink the tubing around the electrical connectors on the switch.
Do not allow the heat shrink tubing to cover the plastic tabs on the switch.
7. Outside the front panel, route the power switch cable through the power switch
opening.
8. Position the power switch with the On (|) switch above the Off (O) switch. Press to
snap the switch into place.
9. Reinstall the front panel assembly. Refer to Front Panel Replacement on page 7-9.

Fuse Replacement
Fuse Replacement
Replacing Fuses in the Fuse Drawer

Equipment required
Small flathead screwdriver
Fuse puller
Warning
Disconnect the power cord from the rear panel for easier access to the adjacent fuse
drawer.
2. To release the fuse drawer, insert a small flathead screwdriver into the slot on the
drawer below the power cord receptacle. Then, slide the drawer out.
Replacing fuses in the fuse drawer
3. Use a fuse puller to remove each blown fuse from the fuse drawer.
4. Replace each blown fuse with one of the same type and rating:
For 120 V operation, use 8-amp fuses.
For 240 V operation, use 4-amp fuses.
5. Slide the fuse drawer into its slot until it snaps into place.
6. Connect the power cord to the rear panel.

Fuse Replacement
Replacing the Fuse on the Power Supply/RF Board

Equipment required
Fuse puller
Warning
Caution
3. Locate the fuse at the rear of the Power Supply/RF board, near the power entry
module. Use a fuse puller to remove the blown fuse.
4. Replace the blown fuse with a 6.3-amp fuse.

Left Front Heat Sink and Component Replacement

Equipment required
Warning
Caution
Notice
Component differences may affect output waveforms. Refer to Calibrating the Generator on
page 5-26, for instructions.
Remove the Left Front Heat Sink
chassis. Save the cover and screws for reinstallation.
4. Remove the three screws (one plastic and two metal) that secure the support bracket
to the heat sinks. Save the screws and bracket for reinstallation.
5. On the left side of the chassis, remove the two screws that secure the base of the left
front heat sink to the rail under the Power Supply/RF board. Save the screws for
reinstallation.
6. Lift the heat sink to disconnect it from the Power Supply/RF board.
If you plan to replace one or more components on the existing heat sink, go to Replace
Left Front Heat Sink Components on page 7-16.
or

If you plan to replace the entire left front heat sink assembly, go to
Install the Left Front Heat Sink on page 7-16.
Replace Left Front Heat Sink Components

Replacing left front heat sink components
HVPS Output Diodes
HVPS Secondary Damping Resistor
To replace one or more HVPS (high voltage power supply) output diodes, remove the
screw and shoulder washer that secure the diode to the heat sink. Position the new
diode on the heat sink and reinstall the shoulder washer and screw.
To replace the HVPS secondary damping resistor, remove the screw that secures it to
the heat sink. Position the new resistor on the heat sink and reinstall the screw.
Install the Left Front Heat Sink

1. Inspect the assembly for bent pins. On the left side of the chassis, carefully slide the
heat sink down into the matching connectors on the Power Supply/RF board.
2. Install the two screws that secure the left front heat sink to the rail under the Power
Supply/RF board.
3. Position the support bracket over the heat sinks and install the three screws that
secure the bracket to the left rear heat sink (plastic screw) and to the left front and
right heat sinks (two metal screws).
connector.

Left Rear Heat Sink and Component Replacement

Equipment required
Warning
Caution
Notice
Remove the Left Rear Heat Sink
4. Disconnect the 4-wire heat sink (bridge rectifier) cable from the Power Supply/RF
board.
5. Loosen but do not remove the screw securing the component clip below the bridge
rectifier.
6. On the left side of the chassis, remove the two screws that secure the base of the left
rear heat sink to the rail under the Power Supply/RF board. Save the screws for
reinstallation.
7. Lift the left rear heat sink to disconnect it from the Power Supply/RF board.
Left Rear Heat Sink Components on page 7-18.
or
If you plan to replace the entire left rear heat sink assembly, go to
Install the Left Rear Heat Sink on page 7-18.

Replace Left Rear Heat Sink Components

Components of the left rear heat sink
Bridge Rectifier
HVPS Primary
Damping Resistor
7 5 3 1
RED BROWN
HVPS FETs (4)
BLACK BLUE
To replace the HVPS (high voltage power supply) primary damping resistor, remove
the screw and shoulder washer that secure it to the heat sink. Position the new
resistor on the heat sink and reinstall the washer and screw.
To replace one or more of the four HVPS FETs, remove the screw and shoulder washer
that secure the FET to the heat sink. Position the new FET on the heat sink and
reinstall the washer and screw.
To replace the bridge rectifier, note the orientation of the four wires. Mark them for
reinstallation. Then, detach them from the rectifier.
Remove the screw that secures the rectifier to the heat sink. Position the new bridge
rectifier on the heat sink and reinstall the screw.
Connect the four wires to the appropriate terminal on the rectifier.
Install the Left Rear Heat Sink

1. Position the left rear heat sink over the matching connectors on the Power Supply/RF
board. Slide the components into the connectors.
2. Install the two screws that secure the left rear heat sink to the rail.
3. Connect the 4-wire heat sink (bridge rectifier) cable to J8 on the Power Supply/RF
board.
4. Tighten the screw securing the component clip over the Triac Thermister.

Right Heat Sink and Component Replacement

Equipment required
Warning
Caution
Notice
Remove the Right Heat Sink
5. Disconnect the cable from the tank damping resistor on the right heat sink from J12
on the Power Supply/RF board.
6. On the right side of the chassis, remove the two screws that secure the base of the
right heat sink to the rail under the Power Supply/RF board. Save the screws for
reinstallation.
7. Lift the heat sink to disconnect it from the Power Supply/RF board.

Right Heat Sink Components on page 7-20.
or
If you plan to replace the entire right heat sink assembly, go to
Install the Right Heat Sink on page 7-21.
Replace Right Heat Sink Components

Components of the right heat sink
Power MOSFET
Circuit board
Tank Damping
Resistor
RF Power Diode
Damping Resistor FET
To replace the damping resistor FET, remove the screw and shoulder washer that
secure it to the heat sink. Position the new damping resistor FET on the heat sink and
To replace the RF power diode, remove the screw and shoulder washer that secure
the diode to the heat sink. Position the new RF power diode on the heat sink and
To replace the tank damping resistor, remove the two screws that secure the top and
bottom of the resistor to the heat sink. Position the new tank damping resistor on the
heat sink and reinstall the screws.
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.

Note the orientation of the power MOSFET. Then, remove the two screws that secure
it to the heat sink. Position the new power MOSFET on the heat sink and reinstall the
two screws.
Position the small circuit board over the power MOSFET and reinstall the four screws
that secure the board to the heat sink.
Install the Right Heat Sink

1. On the right side of the chassis, slide the heat sink components down into the
matching connectors on the Power Supply/RF board.
2. Install the two screws that secure the right heat sink to the rail under the Power
Supply/RF board.
3. Connect the right heat sink tank damping resistor cable to J12 on the Power Supply/
RF board.
connector.

Low Voltage Power Supply Replacement

Equipment required
Warning
Caution
Remove the Low Voltage Power Supply

4. Disconnect and remove the low voltage power supply.
a. Disconnect the Power Supply/RF board cables from the low voltage power supply
(red spade lug and 3-pin connector at the rear; 6-pin connector at the front).
Mark the cables for reinstallation.
b. Remove the four screws that secure the low voltage power supply to the Power
Supply/RF board. Save them for reinstallation.
c. Lift the low voltage power supply off the Power Supply/RF board.
Install the Low Voltage Power Supply

1. Place the new low voltage power supply on the Power Supply/RF board and install the
four screws that secure it to the board.
2. Facing the front of the unit, connect the cables from the Power Supply/RF board to
the new low voltage power supply.

Low voltage power supply
3-Pin Cable Connected to J1
Red
Spade
Lug
6-Pin Cable
Connected to
J2
To BW14 on the
Power Supply/RF
Board
To J7 on the Power Supply/RF Board
a. Connect the 3-pin cable to J1 at the rear of the low voltage power supply. Verify
that this cable is connected to J7 on the Power Supply/RF board.
b. Connect the red spade lug with the green and yellow ground wire to the ground
lug on the left rear corner of the low voltage power supply.
c. Connect the 6-pin cable to J2 at the front of the low voltage power supply. Solder
the six wires from the opposing end of this cable to the Power Supply/RF board as
follows:
J2 pin 1 (orange wire) to location BW14 pin 3 on Power Supply/RF board
J2 pin 2 (red wire) to location BW14 pin 1 on Power Supply/RF board
J2 pin 3 (red wire) to location BW14 pin 6 on Power Supply/RF board
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

Power Entry Module Replacement

Equipment required
Warning
Caution
Remove the Power Entry Module

2. Disconnect the power cord from the power entry module.
4. Disconnect the power entry module cable from J6 on the Power Supply/RF board.
5. Remove the two screws that secure the power entry module to the rear panel. Save
the screws for reinstallation.
6. Slide the module out the rear panel until you can access the grounding lug post inside
the rear panel. Then, remove the nut and washer that secure the ground wire ring
terminal to the grounding lug. Save the nut and washer for reinstallation.
7. Slide the ring terminal off the post and remove the power entry module assembly
from the unit.

Install the Power Entry Module

1. Check the cable connections on the new power entry module, using the illustration
or the module you just removed as a reference.
2. Position the new power entry module near the rear panel opening, routing the cable/
ring terminal through the opening.
Cable connections on the power entry module
Molex Connectors Ring Terminal
Green/Yellow
Blue
1 2
(L) (N)
Brown
3. Slide the ground wire ring terminal onto the grounding lug post on the rear panel.
Then, install the washer and nut that secure the ring terminal to the post.
4. Press firmly to snap the power entry module in place. Install the two screws that
secure it to the rear panel.
5. Connect the power entry module cable to J6 on the Power Supply/RF board.
7. Reconnect the power cord to the rear panel.

Power Supply/RF Board Replacement

Equipment required
Warning
Caution
The generator contains electrostatic-sensitive components. When repairing the generator, work at a
static-control workstation. Wear a grounding strap when handling electrostatic-sensitive
nonconductive edges. Use an antistatic container for transport of electrostatic-sensitive components
and circuit boards.
Notice
Calibrate the generator after you install a new Power Supply/RF board. Component differences
may affect output waveforms. Refer to Calibrating the Generator on page 5-26.
Remove the Power Supply/RF Board Assembly

3. Disconnect and remove the front panel assembly.
b. Disconnect the power switch cable from the Power Supply/RF board.
c. Disconnect the two REM connectors from the Power Supply/RF board.
d. Remove the four screws that secure the front panel to the chassis. Save the screws
for reinstallation.
e. Slide the front panel assembly forward, carefully disengaging it from the electrical
4. Disconnect the Footswitch Board ribbon cable from the Power Supply/RF board.
5. Disconnect the power entry module from the Power Supply/RF board.
6. Remove the four screws that secure the rail to the chassis. Also remove the screw in
the center of the Power Supply/RF board (behind the Control board). Save the screws
for reinstallation.
7. Remove the assembly (Power Supply/RF board, heat sinks, Control board, low voltage
power supply, fan) from the chassis.

Remove Components from the Old Board

Important
Save all parts, screws, brackets, etc. for reinstallation.
1. To remove the Control board, carefully slide the Control board straight up to
2. To remove the support bracket, remove the three screws that secure the bracket to
the top of the heat sinks.
3. To remove the left front heat sink, remove the two screws that secure the base of the
heat sink to the rail under the Power Supply/RF board. Lift the heat sink to disconnect
it from the Power Supply/RF board.
4. Remove the left rear heat sink.
a. Disconnect the 4-wire heat sink (bridge rectifier) cable from the Power Supply/RF
board.
b. On the left side of the chassis, remove the two screws that secure the base of the
left rear heat sink to the rail under the Power Supply/RF board. Lift the heat sink to
c. Loosen but do not remove the screw securing the component clip below the
bridge rectifier.
5. Remove the right heat sink.
a. Disconnect the right heat sink cable from the Power Supply/RF board.
b. On the right side of the chassis, remove the two screws that secure the base of
the 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.
6. Remove the low voltage power supply.
a. Disconnect the low voltage power supply cables from the Power Supply/RF board
at J7.
b. Disconnect the 6-pin cable that is connected to J2 on the low voltage power
supply.
c. Remove the four screws that secure the low voltage power supply to the Power
Supply/RF board. Remove the low voltage power supply.
7. Remove the fan.
a. Disconnect the fan control connector from the Power Supply/RF board.
b. Remove the four screws and nuts that secure the fan to the underside of the

Install Components on the New Board

Follow these steps to reinstall the components you removed from the existing board onto
the new Power Supply/RF board.
1. Install the fan on the new Power Supply/RF board.
a. Position the fan on the underside of the Power Supply/RF board and install the
four nuts and screws that secure it to the board.
b. Connect the fan control connector to J4 on the Power Supply/RF board.
2. Install the low voltage power supply on the new board.
a. Place the low voltage power supply on the Power Supply/RF board and install the
four screws that secure it to the board.
b. Connect the 6-pin low voltage power supply cable to J7 on the Power Supply/RF
board.
c. Connect the 6-pin low voltage power supply cable located at BW14 on the Power
Supply/RF board to J2 on the low voltage power supply.
3. Install the right heat sink.
a. On the right side of the Power Supply/RF board, slide the right heat sink
components into the matching connectors.
b. Install the two screws that secure the heat sink to the rail under the board.
c. Connect the right heat sink cable to J12 on the Power Supply/RF board.
4. Install the left rear heat sink.
a. Slide the left rear heat sink components into the matching connectors on the left
rear of the Power Supply/RF Board.
c. Tighten the screw securing the component clip over the Triac Thermister.
d. Connect the 4-wire heat sink (bridge rectifier) cable to J8 on the Power Supply/RF
board.
5. Install the left front heat sink on the new board.
a. Slide the left front heat sink into the matching connectors on the left front of the
7. To install the Control board, position the board over the Power Supply/RF board with
the 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.

Install the Power Supply/RF Board Assembly

1. Position the Power Supply/RF board assembly on the floor of the chassis and install
the four screws that secure the rail to the chassis. Install the screw in the center of the
board (behind the Control board).
2. Connect the power entry module cable to J6 on the Power Supply/RF board.
3. Connect the Footswitch board ribbon cable to J5 on the Power Supply/RF board.
4. Install the front panel assembly.
a. Position the front panel assembly in front of the chassis and carefully slide it into
the electrical contacts on the Power Supply/RF board.
b. Install the four screws that secure the front panel to the chassis.
c. Connect the REM wires to the Power Supply/RF board.
d. Connect the white wires with the 2-pin nonlocking connector to J15.
e. Connect the red wires with the 2-pin locking connector to J17.
f. Connect the power switch cable to J10 on the Power Supply/RF board.
g. Connect the Display board ribbon cable to the Control board and lock the
connector.

Chapter 8
Repair Policy and Procedures
This section contains the following information:
The manufacturers responsibility

Returning the Force FX Electrosurgical Generator C for service
Returning circuit boards
Service centers

Responsibility of the Manufacturer
Covidien is responsible for the safety, reliability, and performance of the generator only
under the following circumstances:
Installation and setup procedures in this manual are followed.
Assembly operation, readjustments, modifications, or repairs are carried out by
persons authorized by Covidien.
The electrical installation of the relevant room complies with local codes and
regulatory requirements, such as the IEC and BSI.
The equipment is used in accordance with the Covidien instructions for use.
For warranty information, refer to the Limited Warranty in this manual.
Returning the Generator for Service

Before you return the generator, call your Covidien Representative for assistance. If you
are instructed to send the generator to Covidien, first obtain a Return Authorization
Number. Then, clean the generator and ship it to Covidien for service.
Obtain a Return Authorization Number

Call the Covidien Customer Service Center for your area to obtain a Return Authorization
Number. Have the following information ready when you call:
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

Clean the Generator
Warning
Electric Shock Hazard Always turn off and unplug the generator before 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.
1. Turn off the generator, and unplug the power cord from the wall outlet.
2. Thoroughly wipe all surfaces of the generator and power cord with a mild cleaning
solution or disinfectant and a damp cloth. Follow the procedures approved by your
institution or use a validated infection control procedure. Do not allow fluids to enter
the chassis. The generator cannot be sterilized.
Ship the Generator

1. Attach a tag to the generator that includes the Return Authorization Number and the
information (hospital, phone number, etc.) listed in Obtain a Return Authorization
Number on page 8-2.
2. Be sure the generator is completely dry before you pack it for shipment. Package it in
its original shipping container, if available.
3. Ship the generator, prepaid, to the Covidien Service Center.
Returning Circuit Boards

Package circuit boards for shipment as follows:
1. Place each circuit board in an electrostatic discharge (ESD) bag or container.
2. Provide a separate packing container for each circuit board.
3. Attach a tag to the container that includes the Return Authorization Number and the
information (hospital, phone number, etc.) listed previously in Obtain a Return
Repair Policy and Procedures
Authorization Number on page 8-2.

4. 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

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.
Replacement ratings and tolerances must be equal to or better than the original.

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)
Serial number (located on the rear panel of the generator)
Part number (for the part you are ordering)
Modification number, if applicable.
If you do not know the part number or if you wish to order spare parts, call the Covidien
Service Center for assistance.

Generator Assembly
Service Parts
Generator Assembly
Generator assembly

Generator Assembly
Generator assemblycontinued

Generator Assembly
Service Parts
Parts List
Item Description Part Number
1 Chassis, lower 1005777
2 Assembly, Footswitch board 1024339

See Footswitch Board Components in this section.
3 Cable assembly, line filter 202 701 890

Includes
Cable, filter line ground 207 500 723
Cable, filter line 207 500 543
Tubing, heatshrink black 1/4 ID 249 001 002
Line filter, 10 amp 251 400 007
Fuse, 4A, 5x20 mm Slow Blow 215 100 074
Sleeving, PVC, clear, 11 awg 249 014 012
4 Handle, collapsible tray 223 300 054
5 Rubber foot 1005706
6 Equipotential ground lug 208 200 141
8 Screw, Phillips M4 x 0.7 x 10 237 050 139
9 Sealant, loctite #222 232 301 148
10 Screw, panhead Phillips M4 x 0.7 x 8 mm 237 050 113
11 Washer, lock internal metric M4 253 300 045
12 Screw, panhead Phillips M3 x 0.5 x 12 zinc 237 050 135
14 Screw, panhead M3 x 0.5 x 8 zinc 237 050 149
15 Lockwasher, M6 ext tooth 253 300 000
16 Nut, hex M6 x 10 brass nickel plated 224 300 000
21 Assembly, front panel 202 701 892

See Front Panel Assembly on page 9-7.
22 Assembly, Control board 1004056

See Control Board Components on page 9-10.

Generator Assembly
23 Cover, upper 1012587
28 Washer, metric M6 253 300 046
Not shown:
Insulator handle 214 100 104
Assembly, Power Supply/RF board 1024313

See Power Supply/RF Board Assembly on page 9-15
and Power Supply/RF Board Components on
page 9-19.
Cover plate 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

Front Panel Assembly
Service Parts
Front panel assembly

Front panel assemblycontinue
17, 18
16
6

Service Parts
Parts List
4 Switch 243 025 037
5 Tubing, heatshrink 1 inch ID 249 001 010
6 Bipolar bracket 223 500 077
7 Tape, foam one-sided 1/16 x 1/4 232 301 185
8 Cable assembly, REM 202 701 854
9 REM retaining plate 223 400 243
12 Assembly, Display board 1024338

See Display Board Components on page 9-10.
13 Screw, thread forming #4-20 0.625 237 050 147
14 Display board spacer 223 400 626
15 Cable assembly, power switch 207 500 213
16 Shroud, bipolar 223 100 998
17 Assembly, CEM switch 202 701 868

Includes
Switch support lever 223 100 975
Lever switch 223 100 974
Spring compression 223 500 076
Assembly, cable switch CEM 202 701 867
18 Adhesive, prism 411 232 301 213
19 Washer, flat M3 253 300 004
Not shown:
Overlay jack 1020029
Keyboard front 1012634
Control panel 223 200 667

Control Board Components
Control Board Components
Reference
Designator Description Part Number
1 Programmed effect mode controller PCB 1001936
BT1 Battery 250 020 028
U9 IC, programmed T_ON ASIC 210 730 249
Display Board Components
Reference
Capacitors
C1, C2 .01 F 20%, 50 V 204 200 456
C3, C4, C5, .1 F 20%, 50 V 204 200 460

C6
C7, C8 47 F 10%, 20 V 204 200 558
LEDs and Lamps
D1 LED, green 0.2 dia. 239 750 063
LP1, LP2, LP3, Lamp 215 200 085

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, 16 5%, 1/2 W 234 014 072

R4

Display Board Components
Service Parts
Reference
R5, R6, R7, 0 234 500 201

R8, R9, R10,
R11, R12
R13, R16 Network 8-pin sip 234 100 184
R14, R15 100 5%, 1/4 W 234 024 039
R17, R18 1 k 2%, 0.12 W SIP 234 100 134
R19, R20, 270 k 5%, 1/4 W 234 024 121

R21
Integrated Circuits
U1 2803A 210 800 002
U2, U3 Bicolor display 239 750 076
U6, U10 Display driver 7218A 210 800 025
Integrated Circuits
U4, U5, U7, LED 7-segment display HDSP560/green 239 750 071
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

Footswitch Board Components
Reference
Capacitors
C1, C2, C12, .01 F 10%, 100 V 204 200 457

C13, C14,
C16, C17,
C18, C21,
C29, C30,
C31, C32,
C33
C3, C4, C5, 0.1 F 10%, 100 V 204 200 509

C6, C7, C8,
C15, C19,
C20, C22,
C23, C24,
C25, C26,
C28, C34,
C36, C37
C9, C10, C27 22 F 20%, 25 V 204 600 063
C11 1 F 20%, 50 V 204 200 464
C35 .022 F 10%, 100 V 204 200 501
C38, C39, .01 F 10%, 500 V 1000293

C40, C41,
C42, C43,
C44, C45,
C46
Diodes
D1, D2 1N4148 239 014 000
Transistors
Q1 FET TN2404KL 239 200 097
Resistors
R1, R2, R3, 10 k 5%, 1/4 W 234 024 087

R4, R7, R9

Service Parts
Reference
R5, R18, R19, 10 k 1%, 1/8 W 234 201 385

R31
R6 6.8 k 5%, 1/4 W 234 024 083
R10 33.2 k 1%, 1/4 W 234 201 435
R8, R15, R22, 2 k 5%, 1/4 W 234 024 070

R23, R26,
R29
R11 432 1%, 1/4 W 234 201 254
R12 Pot, 5 k 236 200 103
R13, R16, 1.4 k 1%, 1/8 W 234 201 303

R20, R24,
R27
R14, R17, 2.15 k 1%, 1/8 W 234 201 321

R21, R25,
R28
R30 19.6 k 1%, 1/8 W 234 201 413
R32 200 k 1%, 1/4 W 234 201 510
R33 5.11 k 1%, 1/8 W 234 201 357
R34 56 k 5%, 1/4 W 234 024 105
R35 100 k 5%, 1/4 W 234 024 111
Integrated Circuits
U1 LM339AN 210 300 015
U2 DC/DC converter HPR107 210 750 007
U3, U4, U5 LM 393 N 210 300 011
U6 LM358AN 210 300 013
U7 Audio amp LM386 210 400 019

Reference
Miscellaneous
ISO1, ISO2, Optoisolator 4N35 239 750 002

ISO3, ISO4,
ISO5
SP1 Speaker, miniature #707 241 003 001
Not shown:
Spacer, footswitch 213 110 583
Cable assembly, Footswitch board 207 500 545
Screw, panhead M3 x 0.5 x 10 zinc 237 050 138
Washer, flat M3.0 253 300 004
Washer, ext. tooth, M3, steel 253 300 022
Nut, hex M3 x 0.5 stl zinc pld 224 300 004
Wire, Teflon, 24 awg wht 255 120 140

Power Supply/RF Board Assembly
Service Parts
Power Supply/RF board assembly

Power Supply/RF board assemblycontinued

Service Parts
Parts List
1 PSRF board 1001860
2 Rail, mount 223 600 190
3 Assembly, fan 202 701 879

Includes
Fan 220 005 011
Terminal 208 191 001
Housing 208 190 035
4 Socket, transistor 208 500 014
5 Power supply, low voltage 207 000 185
6 Socket (for pins with large lead diameter) 208 500 057
7 Socket relay 208 500 089
8 Screw, panhead M3 x 0.5 x 8 zinc 237 050 149
9 Washer, M3 nylon 253 300 042
10 Screw, Phillips M3 x 0.5 x 8 nylon 237 050 126
12 Standoff, hex nylon M3 x 37 F-F 213 110 588
13 Washer, M4 nylon 253 300 041
15 Nut, M4 x 0.7 224 300 040
16 Screw, panhead PHH M4 x 0.7 x 8 mm 1030418

20 Assembly, heat sink, output (right) 1024532

Includes
Cable assembly, resistor 207 500 540
Washer, shoulder 253 200 061
Right heat sink 223 400 675
PCB FET 228 349 000
Screw, pnh phh M4 x 0.7 x 8 mm 237 050 113
Screw, panhead Phillips M3 x 0.5 x 12 zinc 237 050 135
Transistor FET BUZ80A 239 200 020
Transistor FET HI-V N-CH 239 300 044
Diode, ultra fast 30 A, 1000 V 239 850 038
Washer, lock internal metric M4 253 300 045
21 Assembly, heat sink, high voltage (left rear) 1024531

Includes
Cable assembly, rectifier 207 500 212
Left rear heat sink 223 400 674
Resistor, MF 150 5%, 20 W 234 400 251
Screw, panhead Phillips M3 x 0.5 x 12 zinc 237 050 135
Transistor FET N-CH 8 A, 500 V 239 200 022
Diode, bridge 35 A, 400 V 239 700 058
Washer, flat M3.0 253 300 004
Washer, Lock Internal M3 253 300 044
22 Assembly, heat sink, rectifier (left front) 1024533

Includes
Left front heat sink 223 400 673
Resistor, MF 150 5%, 20 W 234 400 251
Screw, panhead Phillips M2.5 x 04.5 x 10 mm zinc 237 050 159
Diode, Fast Recovery 239 850 034
23 Panhead Phillips M4 x 0.7 x 20 mm 237 050 130
24 Fuse holder 1000697
25 Bracket, heat sink support 1030417
28 Screw, panhead Phillips M4 x 0.7 x 8 nylon 237 050 143
30 Wire, TS, 20 awg, yellow 255 058 006
31 Sleeving, PVC clear 11 awg 249 014 012
32 Wire, TS, 20 awg, red 255 058 008
33 Washer, lock internal M3 253 300 044

Power Supply/RF Board Components
Service Parts
34 Tie wire 222 004 001
35 Ties, Cable, wire 222 004 007
Not Shown:
Tubing, heat shrink 3/8 ID 249 001 003
Cable assembly, 6-wire power 1002251
Cable assembly, 3-wire power 207 500 211
Sealant, Locktite 222 232 301 148
Clip relay, 6 pole 213 130 039
Reference
Capacitors
C1, C90 100 pF 5%, 100 V 204 200 452
C2, C43, .01 F 20%, 50 V 204 200 456

C46, C48,
C52, C58,
C65, C71,
C82, C84,
C86, C117,
C118, C156,
C170, C172
C3, C10, 680 F, 400 V 204 500 178

C11, C22

Reference
C4, C12, .01 F 10%, 100 V 204 200 457

C13, C44,
C50, C91,
C93, C94,
C96, C97,
C98, C99,
C102, C132,
C134, C137,
C139, C140,
C141, C144,
C145, C146,
C148
C5, C6, C7, 1000 pF 10%, 100 V 204 200 454

C14, C15,
C16, C17,
C18, C19,
C20, C21,
C23
C8 .22 F 20%, 250 V 204 400 155
C9 33 F 10%, 35 V 1005061
C24, C25, 1 F 20%, 50 V 204 200 464

C26, C39,
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

Service Parts
Reference
C28, C36, .1 F 20%, 50 V 204 200 460

C37, C38,
C45, C47,
C51, C53,
C55, C56,
C57, C59,
C62, C64,
C66, C67,
C72, C74,
C76, C78,
C80, C83,
C85, C88,
C89, C92,
C95, C100,
C101, C103,
C106, C109,
C110, C114,
C115, C116,
C121, C123,
C125, C128,
C131, C133,
C135, C138,
C143, C153,
C173
C29 2 F 10%, 400 V 1000630
C30 180 pF 5%, 100 V 204 200 453
C31, C87 22 F 20%, 25 V 204 600 063
C32 1 F 10%, 250 V 204 400 153
C33, C35 15 F 10%, 200 V 204 400 150
C34 7500 pF 5%, 500 V 204 300 125
C40 18000 pF 5%, 500 V 204 300 134
C41, C60 15000 pF 5%, 500 V 204 300 132
C42 1500 pF 5%, 100 V 204 200 487
C54, C81, .47 F 20%, 50 V 204 200 463

C104
C63, C68 22 pF 5%, 100 V 204 200 450

Reference
C69, C77 .1 F 10%, 100 V 204 200 509
C73, C75 33 pF 5%, 100 V 204 200 451
C79, C107 1000 pF 5%, 100 V 204 200 485
C105, C108 .047 F 20%, 50 V 204 200 517
C119, C126, 6800 pF 5%, 100 V 204 200 495

C129
C150, C151, 3900 pF 5%, 500 V 204 301 044

C158, C159
C152 3300 pF 5%, 500 V 204 105 038
C154, C157 .0047 F 10%, 2000 V 204 200 548
C155, C169 .68 F, 100 V 204 450 016
C171 10 F 20%, 25 V 204 600 067
C174 470 pF 5%, 100 V 204 200 481
Diodes
CR1 1N4007 239 500 013
CR3, CR4, 1N4148 239 014 000

CR5, CR6,
CR7, CR8,
CR12, CR15,
CR17, CR18,
CR25, CR26,
CR27, CR28,
CR34, CR37,
CR39, CR41,
CR47, CR48,
CR49, CR50
CR9 LED, green.2 dia. 239 750 063
CR14, CR16, Schottky.6 A, 40 V 239 700 066

CR29

Service Parts
Reference
CR20, CR21, Zener 1N5240B, 10 V 239 600 001

CR22, CR24,
CR32, CR36,
CR38, CR40,
CR51
CR33, CR42, Zener 1N5233B 239 600 000

CR44, CR45,
CR46, CR52
Fuses
F1, F2, F3 Fuse, sub-mini 1/2 A 215 100 004
F4 Fuse, 5 x 20 mm, 6.3 A 215 100 041
Relays
K1, K3, K4, 12 V 230 013 000

K5, K6, K8,
K9, K10, K11
K2 6 pole 230 017 006
K7 Relay 1005679
K12, K13, Coto-9442 230 017 003

K14, K15,
K16, K17
Transistors
Q2 FET N-CH 14 A, 60 V 239 200 014
Q6, Q8, Q9, FET TN2404KL 239 200 097

Q10
Resistors
R1, R2 9.1 k, 1 W 234 204 003
R3, R38, R69 1 M 5%, 1/4 W 234 024 135
R4 18.2 k 1%, 1/8 W 234 201 410
R5, R6 30 k 5%, 3 W 234 100 180
R7 91 k 5%, 1/4 W 234 024 110

Reference
R8, R169 390 5%, 1/4 W 234 024 053
R9 10 5%, 1 W 234 022 015
R10 63.4 k 1%, 1/8 W 234 201 462
R11, R17, 1 k 5%, 1/4 W 234 024 063

R20, R25,
R39, R75,
R79, R87,
R92, R101,
R106, R144,
R146, R147,
R152, R155,
R170
R12, R18, 51 5%, 1/4 W 234 024 032

R21, R26,
R131, R136,
R140
R13, R14, 10 k 5%, 1/4 W 234 024 087

R15, R45,
R48, R67,
R86, R91,
R93, R99,
R100, R107,
R108, R111,
R112, R122,
R130, R132,
R133, R134,
R137, R142,
R143, R173
R16 4.75 k 1%, 1/8 W 234 201 354
R19, R109 Thermistor, 10 k, 25 C 240 003 006
R22, R23 10 5%, 1/2 W 234 014 068
R24, R34, 100 5%, 1/4 W 234 024 039

R102, R117,
R121, R135
R27 267 1%, 1/8 W 234 201 234

Service Parts
Reference
R28, R54, 4.7 k 5%, 1/4 W 234 024 079

R70, R118,
R119, R125,
R126, R128,
R171
R29 3.32 k 1%, 1/8 W 234 201 339
R30 1.3 k 5%, 1/4 W 234 024 066
R32, R33 Thermistor 240 003 005
R35, R52 100 k 1%, 1/8 W 234 201 481
R36 12.4 k 1%, 1/8 W 234 201 394
R37 10 5%, 1/4 W 234 024 015
R40 7.5 5%, 1/2 W 234 014 065
R41 649 1%, 1/8 W 234 201 271
R42, R55 10 k 1%, 1/4 W 234 201 385
R43, R104 68 k 5%, 1/4 W 234 024 107
R44 5.6 M 5%, 1/4 W 234 024 152
R46 330 5%, 1/4 W 234 024 051
R47 1.6 k 5%, 1/4 W 234 024 068
R49, R53 2.67 k 1%, 1/8 W 234 201 330
R50 511 1%, 1/2 W 234 204 020
R56 200 k 5%, 1/4 W 234 024 118
R57, R66 110 k 5%, 1/4 W 234 024 112
R58 39 k 5%, 1/2 W 234 014 113
R59, R60, 2 k 1%, 1/8 W 234 201 318

R63, R65,
R71, R72,
R73, R85

Reference
R61, R64, 1 k 1%, 1/8 W 234 201 289

R74, R81
R62, R82 499 1%, 1/8 W 234 201 260
R68 510 5%, 1/4 W 234 024 056
R76 100 1%, 2 W 234 400 276
R77 221 1%, 1/8 W 234 100 181
R78 280 1%, 1/8 W 234 201 236
R80 62 k 5%, 1/4 W 234 024 106
R83, R84 249 1%, 1/8 W 234 201 231
R88 6.8 k 5%, 1/4 W 234 024 083
R89 5.1 k 5%, 1/4 W 234 024 080
R90 3.9 k 5%, 1/4 W 234 024 077
R94 56.2 k 1%, 1/8 W 234 201 457
R95, R151, 10 k 1%, 1/8 W 234 201 385

R156, R158,
R162, R163,
R165
R96 Trimpot, 5 k 236 200 078
R97 301 1%, 1/4 W 234 201 239
R98 Thermistor, 1 k /25C 5% 240 003 019
R103 47 5%, 1/4 W 234 024 031
R105, R139, 100 k 5%, 1/4 W 234 024 111

R141
R110 2.15 k 1%, 1/8 W 234 201 321
R113, R114, 820 5%, 1/4 W 234 024 061

R115,
R120 3.40 k 1%, 1/8 W 234 201 340

Service Parts
Reference
R123 270 k 5%, 1/4 W 234 024 121
R124 750 5%, 1/4 W 234 024 060
R127 3.3 k 5%, 1/4 W 234 024 075
R138 15 k 5%, 1/4 W 234 024 091
R145, R154, 5.11 k 1%, 1/8 W 234 201 357

R157, R161,
R167
R148, R149 10 k 1%, 10 W 234 400 275
R150, R153, 4.32 k 1%, 1/8 W 234 201 350

R159, R166,
R168
R160, R164 5.6 M 10%, 2 W 234 204 013
Transformers
T1 Pulse, dual 1025414
T2, T6, T8, Inductor, current sense 251 300 007

T16, T17
T3 Power switching 251 200 105
T4 RF, molded 3F3 core 251 200 107
T7, T10, T11, Square core, REM 1019124

T12
T13 Voltage sense 251 300 044
T14, T15 RF choke 251 100 174
Integrated Circuits
U1 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

Reference
U4 MOSFET driver 210 800 031
U5 PWM controller, high speed 210 720 019
U6 Quad 2 input 4093B 210 250 094
U7 Op-amp Max 492CPA 210 100 035
U8, U10, Dual op-amp AD827 210 400 023

U11, U12,
U23
U14 Multivibrator 74LS221 210 520 094
U15, U16 2803A 210 800 002
U18, U21 Op-amp LF412 210 400 016
U22 Multiplexer DG508 210 800 036
U24 LM319 210 410 001
U25, U31 Op-amp TL052A 210 400 020
U28 Quad analog switch 210 200 041
U29 4081 210 210 081
U30 Inv, hex 74HC14 210 230 004
Miscellaneous
D1 Thermistor, triac AVS 12 CB 239 610 023
J18, J19 Contact, monopolar 223 500 085
J20 Bipolar contact spring 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

Service Parts
Reference
L1 Inductor, 0.75 MH 251 100 167
OPT1, OPT2, Optoisolator, single 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
U17 Oscillator, precision 250 010 036

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Service Manual

Conventions Used in this Guide

ii Force FX Electrosurgical Generator C Service Manual

ForceTriadTM Energy Platform One year from date of shipment

Electrosurgical Generators One year from date of shipment

Cool-tipTM RFA Generator One year from date of shipment

EvidentTM MWA Generator One year from date of shipment

RFG-3CTM Plus Lesion Generator One year from date of shipment

LigaSureTM Vessel Sealing System One year from date of shipment

LigaSureTM Reusable Instruments One year from date of shipment

Mounting Fixtures (all models) One year from date of shipment

Footswitches (all models) One year from date of shipment

RapidVacTM Smoke Evacuator One year from date of shipment

LigaSureTM Sterile Single Use Items Sterility only as stated on packaging

Cool-tipTM Sterile Single Use Items Sterility only as stated on packaging

Sterile Single Use Items Sterility only as stated on packaging

Patient Return Electrodes Shelf life only as stated on packaging

Notwithstanding any other provision herein or in any other document or communication,

Force FX Electrosurgical Generator C Service Manual iii

iv Force FX Electrosurgical Generator C Service Manual

Force FX Electrosurgical Generator C Service Manual v

vi Force FX Electrosurgical Generator C Service Manual

Force FX Electrosurgical Generator C Service Manual vii

viii Force FX Electrosurgical Generator C Service Manual

Force FX Electrosurgical Generator C Service Manual ix

x Force FX Electrosurgical Generator C Service Manual

This manual provides instructions for servicing the Covidien Force FX

Force FX Electrosurgical Generator C Service Manual 1-1

1-2 Force FX Electrosurgical Generator C Service Manual

Force FX Electrosurgical Generator C Service Manual 1-3

Set power levels to the lowest setting before testing an accessory.

Patient Return Electrodes

Fire Hazard Do not use extension cords.

Electric Shock Hazards

1-4 Force FX Electrosurgical Generator C Service Manual

Force FX Electrosurgical Generator C Service Manual 1-5

1-6 Force FX Electrosurgical Generator C Service Manual

Force FX Electrosurgical Generator C Service Manual 2-1

Bipolar controls Cut controls Coag controls

Bipolar Monopolar 1/CEM Monopolar 2

2-2 Force FX Electrosurgical Generator C Service Manual

Precise mode button

Standard mode button

Force FX Electrosurgical Generator C Service Manual 2-3

Bipolar Instrument Receptacle

You can connect either a footswitching or handswitching bipolar instrument to the

2-4 Force FX Electrosurgical Generator C Service Manual

Monopolar Cut Controls

Low mode button

Pure mode button

Force FX Electrosurgical Generator C Service Manual 2-5

Monopolar Coag Controls

Spray mode button

Fulgurate mode button

2-6 Force FX Electrosurgical Generator C Service Manual